Air-Gapped PLC Remote Access:
Troubleshoot Machines Without the Flight
Bypass restrictive IT firewalls safely without compromising corporate LAN security. Our solution delivers secure PLC remote access via air-gapped 4G VPN gateways, letting you diagnose and reprogram globally while reducing warranty travel by up to 90%.
Explore Remote Architecture ↓The Nightmare of On-Site Commissioning
The Factory IT Blockade
End-users will not let your machine onto their corporate LAN. Trying to get an IP address or port-forwarding rule from their IT department takes weeks of red tape and compliance audits.
“Bricking” the PLC
Using cheap consumer routers leads to dropped packets. A single connection loss during a Siemens TIA Portal or Allen-Bradley logic download can corrupt the controller entirely.
Blind Spots in Peripherals
The PLC only knows what it’s wired to. If a remote pump trips or a cabinet door is left open, you have zero visibility without flying a tech on-site for a simple visual check.
Our Strategy: Air-Gapped Cellular Tunnels
1. Independent 4G Cellular Backhaul
Provide your own internet using your local SIM or global roaming IoT cards. An air-gapped cellular gateway establishes a dedicated connection, creating a complete physical air-gap from the customer’s corporate network. Zero LAN conflicts, zero IT friction, and complete isolation from factory internal threats.
2. Rock-Solid VPN Encrypted Tunnels
Support for self-hosted OpenVPN/IPsec servers or the Valtoris Secure Cloud ensures that your PLC remote access path from TIA Portal or Studio 5000 directly to the machine is strictly encrypted (AES-256) and TCP-stable. No dropped downloads, no exposed IP addresses.
3. Out-of-Band Peripheral Monitoring (Modbus TCP)
Don’t waste expensive PLC I/O points. Use an edge I/O module to passively monitor cabinet temperatures, fluid levels, or external alarms over Ethernet, independent of the main controller’s operating cycle.
Remote Diagnostics Topology
Click the nodes to see how we bypass firewalls and establish direct control.
Node Info
The OEM Remote Ready Stack
* Designed specifically for industrial control panels. Features DIN-rail mounting, 24V DC power inputs, and a wide operating temperature range to survive harsh factory environments.
| Component | Role in Remote Architecture | Recommended Hardware |
|---|---|---|
| The Secure Gateway | Provides cellular internet, manages OpenVPN/IPsec tunnels, and establishes reliable PLC remote access by handling port-forwarding to internal controllers. | Valtoris VT-LTE400 → |
| Peripheral Monitor | Modbus TCP/RTU I/O block (DI/DO/AI). Monitors cabinet doors, external pump limits, and triggers remote alarms without touching PLC logic. | Valtoris 4CH-IO-ETH → |
Download the PLC Remote Routing Cheat Sheet
Stop guessing IP configurations. Get our engineer-to-engineer PDF guide on setting up static routes, OpenVPN certs, and port forwarding for Siemens S7 and Allen-Bradley environments.
VPN_Routing_Guide_PLC.pdf
✓ Practical routing tables, no sales pitch.
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