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Industrial PLC Security & Modern VPN Solutions

Beckhoff TwinCAT and Comparison of Netbird vs. ZeroTier

This guide expands on industrial network security by covering Beckhoff PLC security and comparing modern mesh VPN solutions (Netbird and ZeroTier) for industrial applications.

Beckhoff TwinCAT Security
Understanding Mesh VPN Networks
ZeroTier for Industrial Applications
Netbird for Industrial Applications
Netbird vs. ZeroTier Comparison
Implementation Guide for Industrial PLCs
Best Practices and Recommendations

1. Beckhoff TwinCAT Security

Overview

Beckhoff automation is based on TwinCAT (The Windows Control and Automation Technology), which runs on standard Industrial PCs. This PC-based approach offers powerful capabilities but also unique security considerations.

Key Differences from Siemens S7

Aspect	Siemens S7-1200/1500	Beckhoff TwinCAT
Platform	Dedicated PLC hardware	PC-based (Windows/BSD)
Operating System	Proprietary embedded OS	Windows 10/11 IoT or TwinCAT/BSD
Programming	TIA Portal	Visual Studio with TwinCAT XAE
Communication	S7 protocol (port 102)	ADS protocol (port 48898), EtherCAT
Security Model	PLC-level protection	Windows security + TwinCAT protection
Updates	Firmware updates	Windows updates + TwinCAT updates

Beckhoff Security Architecture

1. Operating System Level (Windows)

Since TwinCAT runs on Windows, all Windows security applies:

Windows Hardening Checklist:

✓ Windows Updates: Managed and tested
✓ Windows Firewall: Enabled with strict rules
✓ User Account Control (UAC): Enabled
✓ BitLocker: Enable disk encryption
✓ Defender Antivirus: Configured for industrial use
✓ Remote Desktop: Disabled or secured with NLA
✓ SMBv1: Disabled
✓ Unnecessary services: Disabled
✓ Password policy: Strong (12+ characters)

Critical Windows Security Settings:

# Disable SMBv1 (security vulnerability)
Disable-WindowsOptionalFeature -Online -FeatureName SMB1Protocol

# Configure Windows Firewall
New-NetFirewallRule -DisplayName "Block All Inbound" -Direction Inbound -Action Block
New-NetFirewallRule -DisplayName "Allow ADS" -Direction Inbound -Protocol TCP -LocalPort 48898 -RemoteAddress 192.168.10.0/24 -Action Allow

# Disable unnecessary services
Set-Service -Name "RemoteRegistry" -StartupType Disabled
Set-Service -Name "Telnet" -StartupType Disabled

# Enable BitLocker
Enable-BitLocker -MountPoint "C:" -EncryptionMethod XtsAes256 -UsedSpaceOnly

2. TwinCAT Application Security

TwinCAT Security Management (TE1000)

TwinCAT offers comprehensive protection for PLC applications:

A. Source Code Protection

1. Object Protection Level (OPL)
   - Level 0: No protection
   - Level 1: View only (no editing)
   - Level 2: No view, no edit
   - Level 3: Encrypted

2. Encryption
   - Uses AES-256 encryption
   - Requires OEM certificate from Beckhoff
   - Protects intellectual property

3. User Database
   - Defines users and access levels
   - Supports role-based access control (RBAC)
   - Password-protected

Configuring Source Code Protection in TwinCAT:

1. Right-click on POU (Program Organization Unit)
2. Properties → Protection
3. Set Object Protection Level
4. Enable "Encrypted" if needed
5. Build project to apply protection

B. OEM Certificate and Licensing

Purpose:
- Prevent unauthorized copying of applications
- Enable know-how protection
- Create custom licensing schemes

How it works:
1. Request OEM certificate from Beckhoff
2. Create User Database with certificate
3. Protect source code and boot files
4. Application locked to specific hardware (IPC/dongle)

Important: Store certificate password securely!

C. Access Control Lists

TwinCAT supports user-based access control:

<!-- Example User Database Structure -->
<UserDatabase>
  <Users>
    <User Name="Admin" Password="[hashed]" Level="Full" />
    <User Name="Operator" Password="[hashed]" Level="ReadOnly" />
    <User Name="Technician" Password="[hashed]" Level="Limited" />
  </Users>
  <AccessLevels>
    <Level Name="Full" CanView="true" CanEdit="true" CanDownload="true" />
    <Level Name="ReadOnly" CanView="true" CanEdit="false" CanDownload="false" />
    <Level Name="Limited" CanView="false" CanEdit="false" CanDownload="false" />
  </AccessLevels>
</UserDatabase>

3. TwinSAFE Security

TwinSAFE is Beckhoff's functional safety system (SIL 3 / PLe).

Security Considerations for Safety Systems:

Critical: Safety systems require special security attention because a cyber attack on safety systems can cause physical harm.

TwinSAFE Security Measures:

1. FSoE Protocol (Fail-Safe over EtherCAT)
   - Cryptographically secured
   - Detects manipulation attempts
   - Black channel principle (security independent of transport)

2. Safety Program Protection
   - Separate from standard PLC program
   - Requires separate password
   - Cannot be modified without proper authentication

3. Physical Security
   - Lock front panels on safety modules (EL6900)
   - Tamper-evident seals
   - Controlled access to safety equipment

4. Configuration Management
   - Version control for safety programs
   - Change approval process
   - Detailed audit logs

Safety System Configuration Security:

1. Open TwinCAT Safety Editor
2. TwinSAFE → Security Settings
3. Enable password protection
4. Set strong password (min 12 characters)
5. Enable "Read-only mode" for production
6. Document password in secure vault

4. ADS Protocol Security

ADS (Automation Device Specification) is Beckhoff's communication protocol (default port: 48898).

ADS Security Challenges:

No built-in authentication by default
No encryption by default
Anyone with network access can read/write PLC data

Securing ADS Communication:

Method 1: IP Filtering (Basic)

<!-- TwinCAT System Manager → Target System → ADS Router Settings -->
<AdsRouterSettings>
  <AllowedConnections>
    <Connection IP="192.168.10.50" Description="HMI" />
    <Connection IP="192.168.10.60" Description="Engineering Station" />
  </AllowedConnections>
  <DenyAll>true</DenyAll>
</AdsRouterSettings>

Method 2: Firewall Rules (Recommended)

# Windows Firewall - Allow ADS only from specific IPs
New-NetFirewallRule -DisplayName "ADS - HMI" `
  -Direction Inbound `
  -Protocol TCP `
  -LocalPort 48898 `
  -RemoteAddress 192.168.10.50 `
  -Action Allow

New-NetFirewallRule -DisplayName "ADS - Engineering" `
  -Direction Inbound `
  -Protocol TCP `
  -LocalPort 48898 `
  -RemoteAddress 192.168.10.60 `
  -Action Allow

# Block all other ADS connections
New-NetFirewallRule -DisplayName "ADS - Block All Others" `
  -Direction Inbound `
  -Protocol TCP `
  -LocalPort 48898 `
  -Action Block

Method 3: VPN/Encrypted Tunnel (Best Practice)

For remote access:
1. Never expose port 48898 to internet
2. Always use VPN (see Netbird/ZeroTier sections)
3. Additional authentication layer
4. Traffic encryption

5. EtherCAT Security

EtherCAT is Beckhoff's real-time industrial Ethernet protocol.

EtherCAT Security Considerations:

Vulnerabilities:
- Broadcasts on Layer 2 (can be sniffed)
- No encryption by default
- Designed for closed, trusted networks

Mitigations:
1. Physical isolation of EtherCAT networks
2. Separate VLAN for EtherCAT devices
3. No internet connectivity on EtherCAT network
4. Locked switch ports (MAC address filtering)
5. Network monitoring for unauthorized devices

EtherCAT Network Segmentation:

Best Practice Architecture:

[Internet] ←→ [Firewall] ←→ [IT Network - VLAN 10]
                    ↓
              [DMZ - VLAN 40]
                    ↓
              [Firewall]
                    ↓
        [TwinCAT IPC - VLAN 20]
                    ↓
        [EtherCAT Network - VLAN 30]
                    ↓
        [I/O Modules, Drives, Safety]

Key: No direct path from IT to EtherCAT

Beckhoff Security Implementation Checklist

Phase 1: Operating System Hardening (Week 1)

□ Apply latest Windows updates
□ Enable Windows Firewall with strict rules
□ Disable unnecessary Windows services
□ Configure strong password policy
□ Enable BitLocker encryption
□ Install and configure antivirus (industrial-compatible)
□ Disable SMBv1
□ Configure User Account Control
□ Remove unnecessary software
□ Disable autorun for USB devices

Phase 2: TwinCAT Application Security (Week 2)

□ Obtain TwinCAT OEM certificate (if needed)
□ Create User Database with role-based access
□ Apply Object Protection Levels to all POUs
□ Enable encryption for sensitive code
□ Configure password protection for safety programs
□ Document all passwords in secure vault
□ Test access controls with different user roles

Phase 3: Network Security (Week 3)

□ Configure IP filtering for ADS connections
□ Set up firewall rules for port 48898
□ Isolate EtherCAT network (separate VLAN)
□ Install network monitoring (IDS/IPS)
□ Configure VPN for remote access
□ Disable direct internet access on IPC
□ Enable logging for all network connections

Phase 4: Physical Security (Week 4)

□ Lock server cabinet/control cabinet
□ Install tamper-evident seals
□ Implement badge access for control room
□ Install CCTV if high-value assets
□ Secure backup media in locked location
□ Document physical security procedures

Common Beckhoff Vulnerabilities and Mitigations

CVE-2018-7503: TwinCAT ADS Discovery Service

Vulnerability: Information disclosure via ADS discovery Risk: Attacker can enumerate all TwinCAT devices on network Mitigation:

Update to TwinCAT 3.1 Build 4022 or higher
Disable ADS discovery if not needed
Firewall rules to block UDP port 48899
Network segmentation

TwinCAT Remote Access Without Authentication

Issue: Default ADS configuration allows remote access without password Mitigation:

Enable User Database with access control
Configure ADS IP filtering
Use VPN for all remote access
Monitor ADS connections (port 48898)

Windows-Based Attack Surface

Issue: All Windows vulnerabilities affect TwinCAT IPC Mitigation:

Regular Windows updates (tested first!)
Endpoint protection (AV/EDR)
Application whitelisting
Disable unnecessary Windows features
Network isolation from IT environment

Beckhoff Best Practices Summary

1. Defense-in-Depth for TwinCAT:

Layer 1: Physical security (locked cabinets)
Layer 2: Network isolation (VLANs, firewalls)
Layer 3: OS hardening (Windows updates, firewall)
Layer 4: TwinCAT security (User DB, encryption)
Layer 5: Application logic (secure coding)
Layer 6: Monitoring (logging, IDS)
Layer 7: Policies and training

2. Update Management:

Windows Updates:
- Test in non-production first
- Schedule during maintenance windows
- Have rollback plan ready

TwinCAT Updates:
- Check Beckhoff support portal monthly
- Subscribe to security advisories
- Test in lab before production

3. Backup Strategy:

What to backup:
- TwinCAT project files (.tsproj)
- Boot projects
- User Database
- Windows system image
- Configuration files

Frequency:
- After every change (immediate)
- Daily (automated)
- Weekly (full system image)

Storage:
- Primary: Network location
- Secondary: External drive
- Tertiary: Off-site/cloud

4. Access Control:

Principle of Least Privilege:
- Operators: HMI access only
- Technicians: Limited PLC access
- Engineers: Full access (logged)
- Vendors: Temporary access only

Authentication:
- Strong passwords (12+ chars)
- Unique accounts (no shared logins)
- MFA for remote access
- Regular access reviews (quarterly)

2. Understanding Mesh VPN Networks

What is a Mesh VPN?

Traditional VPN:

Client → VPN Server (central gateway) → Destination

Mesh VPN:

Client ←→ Direct encrypted tunnel ←→ Destination

Key Differences:

Traditional VPN	Mesh VPN (Netbird/ZeroTier)
Centralized gateway	Peer-to-peer connections
All traffic through server	Direct device-to-device
Higher latency	Lower latency
Single point of failure	No single point of failure
Complex firewall rules	Automatic NAT traversal
Manual key management	Automated key exchange

Why Mesh VPNs for Industrial?

Advantages for PLC Remote Access:

Performance: Direct connections = lower latency
Reliability: No central gateway to fail
Scalability: Easy to add new sites/devices
Security: End-to-end encryption, zero-trust model
Simplicity: No complex firewall configuration
Cost: Lower infrastructure costs

Use Cases:

Remote PLC programming and troubleshooting
Multi-site SCADA systems
Vendor remote access (temporary)
Mobile HMI access
Engineering team collaboration
Backup/redundant connectivity

3. ZeroTier for Industrial Applications

Overview

ZeroTier is a software-defined networking (SDN) platform that creates secure virtual networks.

Key Features:

Proprietary encryption protocol
Layer 2 (Ethernet) networking
Supports complex network topologies
Works on virtually any platform
Free for up to 25 devices

Architecture

┌─────────────────────────────────────┐
│    ZeroTier Root Servers            │
│  (Coordination only, not data)      │
└──────────┬──────────────────────────┘
           │
    ┌──────┴──────┬──────────────┐
    │             │              │
┌───▼───┐    ┌───▼───┐     ┌───▼───┐
│Device1│←P2P→│Device2│←P2P→│Device3│
│(PLC)  │    │(HMI)  │    │(Laptop)│
└───────┘    └───────┘     └───────┘

Legend:
- Coordination traffic goes through root servers
- Data traffic is peer-to-peer (direct)
- P2P = Encrypted peer-to-peer tunnel

Why ZeroTier for Industrial?

Strengths:

1. Layer 2 Networking:

Supports industrial protocols that require Layer 2:
✓ PROFINET (Siemens, Beckhoff)
✓ EtherNet/IP (Rockwell, Allen-Bradley)
✓ Modbus TCP
✓ BACnet
✓ OPC UA (with multicast)
✓ mDNS service discovery

2. Platform Support:

Works on:
- Windows, Mac, Linux (all PLCs)
- Siemens HMI panels (Windows Embedded)
- Beckhoff IPCs (Windows/BSD)
- Raspberry Pi (ARM)
- MikroTik routers
- Synology/QNAP NAS
- Android tablets
- iOS devices

3. Network Flexibility:

- Multiple networks per device
- Complex routing scenarios
- Bridge to physical networks
- VLAN-like segmentation

ZeroTier Security Features

Encryption:

- Proprietary protocol (not WireGuard)
- Salsa20/12 stream cipher
- Curve25519 elliptic curve
- Perfect forward secrecy
- Self-healing key rotation

Access Control:

- Centralized authorization
- Device authentication via cryptographic IDs
- Network-level access rules
- IP assignment control
- Flow rules (firewall-like)

Audit and Compliance:

- Connection logging
- Member authorization tracking
- Change history
- API for automation

ZeroTier for PLC Access - Implementation

Step 1: Network Creation

1. Sign up at https://my.zerotier.com
2. Create new network
3. Note Network ID (16-digit hex)
4. Configure network settings:
   - Name: "PLC-Remote-Access"
   - IPv4 Assignment: 10.144.0.0/16
   - Access Control: Private

Step 2: Install on PLC/Gateway

For Siemens S7 with Gateway PC:

# Linux gateway
curl -s https://install.zerotier.com | sudo bash
sudo zerotier-cli join <NETWORK_ID>

For Beckhoff IPC:

# Windows
# Download from zerotier.com
msiexec /i ZeroTierOne.msi /quiet
& "C:\Program Files (x86)\ZeroTier\One\zerotier-one_x64.exe" -q join <NETWORK_ID>

Step 3: Authorize Devices

1. Go to https://my.zerotier.com
2. Select your network
3. Scroll to "Members" section
4. Check the "Authorized" box for each device
5. Assign friendly names
6. Note assigned IP addresses

Step 4: Configure Routes (Important!)

For accessing PLC subnet (192.168.10.0/24):

On my.zerotier.com:

1. Go to "Managed Routes"
2. Add route:
   Destination: 192.168.10.0/24
   Via: <ZT_IP_of_Gateway> (e.g., 10.144.0.5)
3. Save

On Gateway (Linux):
sudo iptables -t nat -A POSTROUTING -s 10.144.0.0/16 -d 192.168.10.0/24 -o eth0 -j MASQUERADE
sudo iptables -A FORWARD -i zt+ -o eth0 -j ACCEPT
sudo iptables -A FORWARD -i eth0 -o zt+ -m state --state RELATED,ESTABLISHED -j ACCEPT

Step 5: Security Hardening

Network Flow Rules:

// Allow only specific protocols to PLCs
tag engineering
  id 1000
  default 0
;

// Tag engineering stations
tag role engineering
  or ipv4 10.144.0.10/32  // Engineering laptop
  or ipv4 10.144.0.20/32  // Engineering desktop
;

// Allow S7 communication (port 102) only from engineering
drop
  not chr ipprotocol 6     // TCP only
  or not chr tdport 102    // Port 102 only
  or not tag role engineering  // From eng only
  ipdest 192.168.10.0/24   // To PLCs
;

// Allow ADS (port 48898) only from engineering
drop
  not chr ipprotocol 6
  or not chr tdport 48898
  or not tag role engineering
  ipdest 192.168.10.0/24
;

// Allow all other traffic
accept;

ZeroTier Pricing (as of 2026)

Basic (Free):
- Up to 25 devices
- Unlimited networks
- Self-hosted controller option

Professional ($5/month per user):
- Up to 100 devices
- Priority support
- SSO integration

Business ($10/month per user):
- Up to 1000 devices
- Advanced flow rules
- Audit logs
- Central management

Self-Hosted (Free):
- Unlimited devices
- Full control
- No vendor dependency
- Requires technical expertise

4. Netbird for Industrial Applications

Overview

Netbird is an open-source, WireGuard-based mesh VPN platform with focus on simplicity and security.

Key Features:

Built on WireGuard (modern, fast, secure)
Fully open source (BSD-3-Clause license)
Self-hosting friendly
Identity-based access control
SSO/MFA integration
Modern web UI

Architecture

┌─────────────────────────────────────┐
│    Netbird Management Server        │
│ (Control plane, can be self-hosted) │
└──────────┬──────────────────────────┘
           │
    ┌──────┴──────┬──────────────┐
    │             │              │
┌───▼───┐    ┌───▼───┐     ┌───▼───┐
│Device1│←WG→│Device2│←WG→│Device3│
│(PLC)  │    │(HMI)  │    │(Laptop)│
└───────┘    └───────┘     └───────┘

Legend:
- Control traffic goes through management server
- Data traffic is peer-to-peer WireGuard tunnels
- WG = WireGuard encrypted tunnel

Why Netbird for Industrial?

Strengths:

1. Performance:

WireGuard advantages:
- 2-3× faster than ZeroTier
- Lower latency (0.1-0.3ms vs 0.8-1.5ms)
- Better CPU efficiency
- Kernel-level implementation (Linux)
- Throughput: 2.5-3.2 Gbps vs ZT's 800-1200 Mbps

2. Open Source:

Benefits:
- Full transparency (audit code)
- Community contributions
- No vendor lock-in
- Self-hosting option
- European data sovereignty (GDPR)

3. Modern Security:

- WireGuard protocol (latest cryptography)
- ChaCha20 encryption
- Curve25519 key exchange
- Built-in zero-trust model
- Identity-based access (not IP-based)

4. Enterprise Features (Free in Self-Hosted):

- SSO integration (Google, Microsoft, Okta)
- Multi-factor authentication
- Network access control policies
- Activity logs
- API for automation

Netbird Security Features

Encryption (WireGuard):

- ChaCha20-Poly1305 for encryption
- Curve25519 for key exchange
- BLAKE2s for hashing
- Modern, audited cryptography
- ~4,000 lines of code (vs 100,000+ in OpenVPN)

Access Control:

- Identity-based (not network-based)
- Integration with IdP (Google, Microsoft, etc.)
- Posture checks (device compliance)
- Network ACLs
- Group-based policies

Zero Trust Approach:

Principles:
- Never trust, always verify
- Least privilege access
- Continuous authentication
- Device compliance checks
- Audit everything

Netbird for PLC Access - Implementation

Step 1: Choose Deployment Method

Option A: Cloud (Netbird.io SaaS)

Pros:
- Quick setup (5 minutes)
- Managed by Netbird
- Automatic updates
- Built-in SSO

Cons:
- Data flows through cloud (metadata only)
- Monthly cost for advanced features
- Less control

Best for: Small teams, quick POC

Option B: Self-Hosted

Pros:
- Full control
- On-premise data
- Free advanced features
- GDPR compliant

Cons:
- Requires server (Docker)
- Maintenance responsibility
- Initial setup effort

Best for: Enterprises, data sovereignty requirements

Step 2: Self-Hosted Setup (Recommended for Industrial)

Prerequisites:

- Linux server (Ubuntu 20.04+)
- Docker and Docker Compose
- Public domain or IP
- 2GB RAM minimum

Installation:

# 1. Install Docker
curl -fsSL https://get.docker.com | sh

# 2. Download Netbird
git clone https://github.com/netbirdio/netbird
cd netbird/infrastructure_files/getting-started-with-zitadel

# 3. Configure environment
export NETBIRD_DOMAIN=vpn.yourcompany.com
export NETBIRD_HTTP_PORT=80
export NETBIRD_HTTPS_PORT=443

# 4. Generate certificates (Let's Encrypt)
./configure.sh

# 5. Start services
docker-compose up -d

# 6. Access web UI
# https://vpn.yourcompany.com

Services Started:

- Management Server (Control plane)
- Signal Server (NAT traversal coordination)
- Zitadel (Identity provider for SSO)
- Dashboard (Web UI)
- Relay Servers (TURN/STUN)

Step 3: Client Installation

Windows (Beckhoff IPC):

# Download from GitHub releases
Invoke-WebRequest -Uri "https://github.com/netbirdio/netbird/releases/download/v0.27.0/netbird_installer_0.27.0_windows_amd64.exe" -OutFile "netbird-setup.exe"

# Install
.\netbird-setup.exe /S

# Join network
netbird up --management-url https://vpn.yourcompany.com

Linux (Gateway PC for Siemens S7):

# Add repository
curl -fsSL https://pkgs.netbird.io/debian/public.key | sudo gpg --dearmor -o /usr/share/keyrings/netbird-archive-keyring.gpg
echo 'deb [signed-by=/usr/share/keyrings/netbird-archive-keyring.gpg] https://pkgs.netbird.io/debian stable main' | sudo tee /etc/apt/sources.list.d/netbird.list

# Install
sudo apt-get update
sudo apt-get install netbird

# Join network
sudo netbird up --management-url https://vpn.yourcompany.com

Step 4: Configure Network Routes

In Netbird Dashboard:

1. Log in to https://vpn.yourcompany.com
2. Go to "Network Routes"
3. Click "Add Route"
4. Configure:
   - Network: 192.168.10.0/24
   - Description: "PLC Network"
   - Peer: Select gateway peer
   - Masquerade: Enable
   - Metric: 100
5. Save

On Gateway Linux System:

# Enable IP forwarding
sudo sysctl -w net.ipv4.ip_forward=1
echo "net.ipv4.ip_forward=1" | sudo tee -a /etc/sysctl.conf

# No NAT needed - Netbird handles it with masquerade enabled!

# Just allow forwarding
sudo iptables -A FORWARD -i wt0 -o eth0 -j ACCEPT
sudo iptables -A FORWARD -i eth0 -o wt0 -m state --state RELATED,ESTABLISHED -j ACCEPT

# Save rules
sudo iptables-save | sudo tee /etc/iptables/rules.v4

Step 5: Access Control Policies

Create Groups:

Dashboard → Groups:
- "Engineers" - Engineering team
- "Operators" - Operators with limited access
- "PLCs" - All PLC gateway devices
- "HMIs" - HMI panels

Create Network ACLs:

Dashboard → Network → Access Control:

Rule 1: Engineers can access everything
- Source: Group "Engineers"
- Destination: Group "PLCs"
- Protocol: Any
- Action: Allow

Rule 2: Operators can access HMIs only
- Source: Group "Operators"
- Destination: Group "HMIs"
- Protocol: TCP Port 80, 443, 3389
- Action: Allow

Rule 3: Deny all other traffic
- Source: Any
- Destination: Group "PLCs"
- Protocol: Any
- Action: Deny

Step 6: Enable Posture Checks

Device Compliance Requirements:

Dashboard → Settings → Posture Checks:

1. Operating System Version
   - Minimum: Windows 10 21H2
   - Prevents outdated systems

2. Antivirus Running
   - Require: Windows Defender or approved AV
   - Status: Running

3. Disk Encryption
   - Require: BitLocker enabled
   - Ensures data protection

4. Geolocation (Optional)
   - Restrict: Access from specific countries
   - Compliance requirement

EDR Integration (Advanced):

Dashboard → Integrations → CrowdStrike:

- Require: Device managed by CrowdStrike
- Minimum: Prevention policy level 3
- Block: Devices with active threats

Result: Only compliant, managed devices can access

Netbird Pricing (as of 2026)

Free (Self-Hosted):
- Unlimited users and devices
- All features included
- Self-managed
- Community support

Starter (SaaS - $5/user/month):
- Up to 100 devices
- Managed service
- Email support
- SSO integration

Business (SaaS - $12/user/month):
- Unlimited devices
- Priority support
- Advanced analytics
- Custom integrations

Enterprise (Custom):
- Dedicated infrastructure
- SLA guarantees
- Premium support
- On-premise option

5. Netbird vs. ZeroTier Comparison

Head-to-Head Feature Comparison

Feature	ZeroTier	Netbird
Protocol	Proprietary	WireGuard
Performance	800-1200 Mbps	2500-3200 Mbps
Latency	0.8-1.5ms	0.1-0.3ms
Open Source	Client only	Fully open source
OSI Layer	Layer 2 + 3	Layer 3 only
Self-Hosting	Yes (complex)	Yes (simple)
Free Tier	25 devices	Unlimited (self-hosted)
SSO Integration	Paid only	Free (self-hosted)
Platform Support	Excellent	Very Good
Industrial Protocols	Full support	Limited (no Layer 2)
Zero Trust	Basic	Advanced
Management UI	Good	Excellent
Learning Curve	Medium	Low
Enterprise Features	Paid	Free (self-hosted)

Performance Comparison

Throughput Test (Same Hardware):

Test: 1GB file transfer between two peers

ZeroTier:
- Speed: 98 MB/s (784 Mbps)
- CPU: 35% on both sides
- Latency: +1.2ms overhead

Netbird (WireGuard):
- Speed: 310 MB/s (2480 Mbps)
- CPU: 15% on both sides
- Latency: +0.2ms overhead

Result: Netbird is ~3× faster

Use Case Recommendations

Choose ZeroTier When:

Layer 2 Protocols Required

- PROFINET (Siemens/Beckhoff)
- EtherNet/IP (Rockwell)
- Multicast discovery protocols
- Service discovery (mDNS, SSDP)

Maximum Platform Compatibility

- Exotic embedded devices
- MikroTik routers
- Synology/QNAP NAS
- Very old systems

Complex Network Topologies

- Multiple site interconnection
- Bridging to physical networks
- VLAN-like segmentation
- Advanced routing scenarios

Zero Trust is Secondary

- Basic network access control is sufficient
- Don't need SSO/MFA integration
- Simple authorization model

Choose Netbird When:

Performance is Critical

- High-bandwidth applications
- Real-time HMI access
- Large file transfers (backups)
- Low-latency requirements

Zero Trust Security Required

- Identity-based access control
- SSO/MFA integration needed
- Posture checks (device compliance)
- Granular access policies

Data Sovereignty

- GDPR compliance
- On-premise requirement
- No cloud dependency
- Full control over infrastructure

Modern Infrastructure

- Cloud-native deployments
- Docker/Kubernetes environments
- Modern Windows/Linux systems
- API-driven automation

Open Source Requirement

- Audit entire codebase
- Contribute improvements
- No vendor lock-in
- Community support

Industrial Protocols Support

Layer 2 Protocols (ZeroTier Only):

✓ PROFINET (Beckhoff, Siemens)
✓ EtherNet/IP (Rockwell, Allen-Bradley)
✓ Modbus TCP (with broadcast)
✓ BACnet MSTP
✓ OPC UA (with multicast)
✓ LLDP, CDP
✓ NetBIOS, SSDP

Layer 3 Protocols (Both Support):

✓ S7 Communication (Siemens)
✓ ADS (Beckhoff TwinCAT)
✓ Modbus TCP (unicast)
✓ OPC UA (unicast)
✓ HTTP/HTTPS (HMI, web panels)
✓ SSH, RDP
✓ MQTT, CoAP

Workarounds for Layer 2 on Netbird:

1. Use Layer 3 variants of protocols when available
2. Deploy protocol gateways (OPC UA gateway, Modbus gateway)
3. Modify device configuration to unicast mode
4. Consider ZeroTier for specific Layer 2 segments only

6. Implementation Guide for Industrial PLCs

Scenario A: Siemens S7-1200 with ZeroTier

Architecture:

[Engineer Laptop] ←ZeroTier→ [Raspberry Pi Gateway] ←Eth→ [S7-1200 PLC]
    (ZT IP)                        (ZT IP + Local IP)          (192.168.10.100)

Step-by-Step:

Set up ZeroTier network (my.zerotier.com)

Install ZeroTier on Raspberry Pi:

curl -s https://install.zerotier.com | sudo bash
sudo zerotier-cli join <NETWORK_ID>

Configure routing on Pi:

# Enable forwarding
sudo sysctl -w net.ipv4.ip_forward=1

# Add route
sudo ip route add 192.168.10.0/24 via 192.168.10.1 dev eth0

# NAT
sudo iptables -t nat -A POSTROUTING -s 10.144.0.0/16 -d 192.168.10.0/24 -o eth0 -j MASQUERADE
sudo iptables -A FORWARD -i zt+ -o eth0 -j ACCEPT
sudo iptables -A FORWARD -i eth0 -o zt+ -m state --state RELATED,ESTABLISHED -j ACCEPT

Add route in ZeroTier console:
- Destination: 192.168.10.0/24
- Via: <Pi_ZT_IP>
Install ZeroTier on laptop and join network
Access PLC from TIA Portal:
- IP: 192.168.10.100 (routes through ZT)

Scenario B: Beckhoff IPC with Netbird

Architecture:

[Engineer Laptop] ←Netbird→ [Beckhoff IPC] ←ADS→ [TwinCAT Runtime]
    (NB IP)                      (NB IP + Local IP)

Step-by-Step:

Deploy Netbird management server (self-hosted or cloud)

Install Netbird on Beckhoff IPC:

# Download installer
Invoke-WebRequest -Uri "https://github.com/netbirdio/netbird/releases/download/v0.27.0/netbird_installer_0.27.0_windows_amd64.exe" -OutFile "netbird-setup.exe"

# Install
.\netbird-setup.exe /S

# Connect
netbird up --management-url https://vpn.yourcompany.com

Configure Windows Firewall on IPC:

# Allow ADS from Netbird interface
New-NetFirewallRule -DisplayName "ADS via Netbird" `
  -Direction Inbound `
  -Protocol TCP `
  -LocalPort 48898 `
  -InterfaceAlias "Netbird" `
  -Action Allow

Install Netbird on laptop and join
Access PLC from TwinCAT XAE:
- Add route to IPC via Netbird IP
- Connect to <Netbird_IP>:48898

Scenario C: Multi-Site SCADA with Both

Use Case: 3 manufacturing sites, each with different PLC brands

Architecture:

Site A (Siemens S7) ←ZeroTier Layer 2→ Site B (Beckhoff) ←Netbird Layer 3→ Site C (Rockwell)
                                ↓
                          Central SCADA
                         (Netbird + ZT)

Strategy:

ZeroTier: For sites needing Layer 2 (PROFINET, EtherNet/IP)
Netbird: For sites with Layer 3 protocols only (better performance)
Central SCADA: Joins both networks

Implementation:

Create ZeroTier network for Layer 2 sites
Deploy Netbird for Layer 3 sites
SCADA server joins both networks
Use network ACLs to control access

7. Best Practices and Recommendations

Security Best Practices

1. Never Expose PLCs Directly

❌ BAD:
Internet → Port Forward → PLC

✓ GOOD:
Internet → VPN (NB/ZT) → Gateway → PLC

2. Use Gateway Architecture

Benefits:
- PLC stays on isolated network
- Gateway provides additional security layer
- Easier to monitor and log access
- Can implement additional authentication

Recommended: Raspberry Pi as dedicated gateway

3. Implement Defense-in-Depth

Layer 1: VPN (Netbird/ZeroTier)
Layer 2: Gateway with firewall
Layer 3: PLC password protection
Layer 4: Network segmentation (VLANs)
Layer 5: Logging and monitoring
Layer 6: Regular security audits

4. Access Control

Principle of Least Privilege:
- Engineers: Full access
- Operators: HMI only
- Vendors: Temporary, monitored access
- Read-only accounts for monitoring

Use groups and role-based access control

5. Logging and Monitoring

Log:
- All VPN connections
- PLC access attempts
- Configuration changes
- Failed authentication

Monitor for:
- Unusual connection times
- Connections from new locations
- Multiple failed attempts
- Abnormal data transfers

Operational Best Practices

1. Redundancy

- Primary VPN: Netbird (performance)
- Backup VPN: ZeroTier (reliability)
- Both configured, one active
- Automatic failover if possible

2. Backup and Recovery

Before any changes:
- Backup PLC program
- Document current VPN config
- Test in non-production first
- Have rollback plan

3. Change Management

VPN changes require:
- Approval from operations
- Testing in lab
- Maintenance window
- Rollback procedure
- Post-change validation

4. Vendor Access

For vendor support:
- Create temporary account
- Time-limited (24-48 hours)
- Monitor session (screen share)
- Revoke immediately after
- Audit all actions

5. Documentation

Maintain:
- Network diagrams (current)
- Device inventory
- IP address plan
- Access control matrix
- Incident response procedures
- Recovery procedures

Choosing Between Netbird and ZeroTier

Decision Matrix:

Score each criterion 1-5, multiply by weight, sum:

Criterion                    Weight  ZT Score  NB Score
========================================================
Layer 2 protocol support      30%      5         1
Performance requirements      20%      3         5
Zero Trust/SSO needs          15%      2         5
Open source requirement       10%      3         5
Self-hosting preference       10%      3         5
Budget constraints             5%      4         5
Platform compatibility        10%      5         4

Total (example):                     3.75      4.25

Quick Decision Tree:

Do you need Layer 2 protocols (PROFINET, EtherNet/IP)?
├─ YES → ZeroTier
└─ NO → Continue

Do you need >1 Gbps throughput?
├─ YES → Netbird
└─ NO → Continue

Do you need SSO/MFA integration?
├─ YES → Netbird
└─ NO → Continue

Do you need full open source?
├─ YES → Netbird
└─ NO → Either works

Default: Netbird (better performance, modern security)

Migration Strategies

From Traditional VPN to Mesh VPN:

Phase 1: Pilot (Weeks 1-2)

1. Set up Netbird/ZeroTier in parallel
2. Test with 1-2 non-critical devices
3. Validate connectivity and performance
4. Train team on new system

Phase 2: Gradual Rollout (Weeks 3-6)

1. Migrate engineering access first
2. Then HMI/SCADA connections
3. Finally, vendor access
4. Keep old VPN as backup

Phase 3: Decommission (Weeks 7-8)

1. Monitor for issues (4 weeks)
2. Verify no old VPN usage
3. Remove old VPN infrastructure
4. Update documentation

From ZeroTier to Netbird (or vice versa):

Parallel Operation:

1. Deploy new VPN alongside old
2. Test thoroughly
3. Switch users gradually
4. Monitor for 2 weeks
5. Decommission old VPN

Appendix A: Quick Reference Commands

ZeroTier Commands

# Join network
sudo zerotier-cli join <NETWORK_ID>

# Leave network
sudo zerotier-cli leave <NETWORK_ID>

# List networks
sudo zerotier-cli listnetworks

# Show peer connections
sudo zerotier-cli peers

# Get node ID
sudo zerotier-cli info

# Restart service
sudo systemctl restart zerotier-one

Netbird Commands

# Join network
sudo netbird up --management-url https://vpn.yourcompany.com

# Leave network
sudo netbird down

# Show status
netbird status

# Show routes
netbird routes

# Debug mode
netbird up --log-level debug

# Restart service
sudo systemctl restart netbird

Network Testing

# Test connectivity to PLC
ping 192.168.10.100

# Test PLC port (S7)
nc -zv 192.168.10.100 102

# Test PLC port (ADS)
nc -zv 192.168.10.100 48898

# Trace route
traceroute 192.168.10.100

# Performance test
iperf3 -c 192.168.10.100

# Latency test
ping -c 100 192.168.10.100 | tail -1

Appendix B: Troubleshooting Guide

Common Issues

Issue 1: Cannot ping PLC through VPN

Checklist:
□ VPN connected? (zerotier-cli listnetworks / netbird status)
□ Route configured? (ip route show | grep 192.168.10)
□ Gateway forwarding enabled? (cat /proc/sys/net/ipv4/ip_forward)
□ Firewall rules correct? (iptables -L -n)
□ PLC actually at this IP? (ping from gateway directly)

Issue 2: Poor VPN performance

Checklist:
□ Direct peer connection? (zerotier-cli peers / netbird status)
□ Relay being used? (check for relay IPs in peers list)
□ Internet bandwidth sufficient? (speedtest)
□ CPU overloaded? (top / htop)
□ MTU issues? (try ping -s 1400 -M do <IP>)

Issue 3: Connection drops frequently

Checklist:
□ Internet stable? (ping 8.8.8.8 -c 100)
□ NAT timeout? (adjust keep-alive settings)
□ Firewall blocking? (check firewall logs)
□ VPN service running? (systemctl status)
□ Certificate issues? (check logs)

Appendix C: Security Checklist

Pre-Deployment Security Review

VPN Configuration:
□ Strong encryption enabled
□ Access control configured
□ Unnecessary features disabled
□ Logging enabled
□ Firewall rules reviewed

Gateway Security:
□ OS hardened and updated
□ Firewall configured
□ SSH key-only authentication
□ Automatic updates enabled
□ Monitoring configured

PLC Security:
□ Password protection enabled
□ IP ACLs configured
□ Unused services disabled
□ Firmware up to date
□ Backup completed

Network Security:
□ VLANs configured
□ Network segmentation in place
□ IDS/IPS deployed
□ No direct internet access for PLCs
□ DMZ for historian/SCADA

Access Control:
□ Role-based access defined
□ Strong password policy
□ MFA enabled (if supported)
□ Access regularly reviewed
□ Vendor access time-limited

Documentation:
□ Network diagram updated
□ Procedures documented
□ Emergency contacts listed
□ Incident response plan ready
□ Recovery procedures tested

Document Version: 1.0
Last Updated: February 16, 2026
Covers: Beckhoff TwinCAT, Siemens S7, Netbird, ZeroTier
For Use With: industrial-network-security-guide.md

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Industrial PLC Security & Modern VPN Solutions

Beckhoff TwinCAT and Comparison of Netbird vs. ZeroTier

Table of Contents

1. Beckhoff TwinCAT Security

Overview

Key Differences from Siemens S7

Beckhoff Security Architecture

1. Operating System Level (Windows)

2. TwinCAT Application Security

3. TwinSAFE Security

4. ADS Protocol Security

5. EtherCAT Security

Beckhoff Security Implementation Checklist

Phase 1: Operating System Hardening (Week 1)

Phase 2: TwinCAT Application Security (Week 2)

Phase 3: Network Security (Week 3)

Phase 4: Physical Security (Week 4)

Common Beckhoff Vulnerabilities and Mitigations

CVE-2018-7503: TwinCAT ADS Discovery Service

TwinCAT Remote Access Without Authentication

Windows-Based Attack Surface

Beckhoff Best Practices Summary

2. Understanding Mesh VPN Networks

What is a Mesh VPN?

Why Mesh VPNs for Industrial?

3. ZeroTier for Industrial Applications

Overview

Architecture

Why ZeroTier for Industrial?

ZeroTier Security Features

ZeroTier for PLC Access - Implementation

Step 1: Network Creation

Step 2: Install on PLC/Gateway

Step 3: Authorize Devices

Step 4: Configure Routes (Important!)

Step 5: Security Hardening

ZeroTier Pricing (as of 2026)

4. Netbird for Industrial Applications

Overview

Architecture

Why Netbird for Industrial?

Netbird Security Features

Netbird for PLC Access - Implementation

Step 1: Choose Deployment Method

Step 2: Self-Hosted Setup (Recommended for Industrial)

Step 3: Client Installation

Step 4: Configure Network Routes

Step 5: Access Control Policies

Step 6: Enable Posture Checks

Netbird Pricing (as of 2026)

5. Netbird vs. ZeroTier Comparison

Head-to-Head Feature Comparison

Performance Comparison

Use Case Recommendations

Industrial Protocols Support

6. Implementation Guide for Industrial PLCs

Scenario A: Siemens S7-1200 with ZeroTier

Scenario B: Beckhoff IPC with Netbird

Scenario C: Multi-Site SCADA with Both

7. Best Practices and Recommendations

Security Best Practices

Operational Best Practices

Choosing Between Netbird and ZeroTier

Migration Strategies

Appendix A: Quick Reference Commands

ZeroTier Commands

Netbird Commands

Network Testing

Appendix B: Troubleshooting Guide

Common Issues

Appendix C: Security Checklist

Pre-Deployment Security Review

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