Step‑by‑Step Guide to Setting Up FortiOS Open‑Source ICS Training Environment

 4 min read

YouTube video ID: CCj9iW4KJvU

Source: YouTube video by Fortiphyd Logic IncWatch original video

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Introduction

This article walks you through the complete process of installing and configuring the FortiOS open‑source Industrial Control System (ICS) training environment using VirtualBox. By following the steps, you can have a fully functional simulation of a chemical plant, PLCs, SCADA, and a pfSense firewall without needing to watch the original video.

Prerequisites

  • A computer running Windows, macOS, or Linux.
  • At least 8 GB of RAM (16 GB recommended) and 30 GB of free disk space.
  • Administrative rights to install software and create network adapters.

1. Download and Install VirtualBox

  1. Visit the VirtualBox download page.
  2. Choose the latest version for your operating system.
  3. Run the installer and accept all default options.
  4. After installation, launch VirtualBox.

2. Obtain the Pre‑Built VM Images

You can either build the VMs from source or, much easier, download ready‑made images from the FortiOS GitHub repository. 1. Open the repository’s Download VMs section. 2. Click each link (five VMs total) and download the .ova files.

3. Create Two Host‑Only Network Adapters

  1. In VirtualBox, go to Tools → Host Network Manager → Create.
  2. Adapter 1: set IP = 192.168.95.111, Netmask = 255.255.255.0, enable DHCP.
  3. Adapter 2: set IP = 192.168.90.111, Netmask = 255.255.255.0, enable DHCP.
  4. Note that VirtualBox may assign different names (e.g., VirtualBox Host‑Only Ethernet Adapter). Use the adapter that matches the IP address, not the name.

4. Import the VM Appliances

For each downloaded .ova file: 1. Click File → Import Appliance. 2. Browse to the .ova location. 3. Keep default settings, optionally change the destination folder. 4. Click Import. Repeat until all five VMs (PLC, SCADA‑BR, Chemical Plant, Workstation, pfSense) are imported.

5. Attach Host‑Only Adapters to the VMs

PLC VM

  • Settings → Network → Adapter 1 → Enable.
  • Attach to Host‑Only Adapter → select the adapter with IP 192.168.95.111.
  • Advanced → Promiscuous Mode: Allow VMs.
  • Adapter type: Paravirtualized Network (or the closest option).

SCADA‑BR VM

  • Same as PLC, but attach to the adapter with IP 192.168.90.111.

Chemical Plant VM

  • Disable Adapter 1.
  • Enable Adapter 2 and attach it to the 192.168.95.111 host‑only adapter.

Workstation VM

  • Enable Adapter 1 and attach it to the 192.168.95.111 adapter.

pfSense VM

  • Enable Adapter 1 → attach to 192.168.95.111.
  • Enable Adapter 2 → attach to 192.168.90.111.
  • Keep the same promiscuous and adapter‑type settings as above.

Tip: After configuring adapters, a system reboot may be required for the host‑only networks to work correctly.

6. Initial pfSense Configuration

  1. Start the pfSense VM and wait for the console.
  2. When prompted, answer No to VLAN setup.
  3. Choose the WAN interface (e.g., vtnet0 or em0).
  4. Choose the LAN interface (e.g., vtnet1 or em1).
  5. Confirm with Y and wait for the configuration to finish.
  6. Once the console shows Enter an option, you can safely close the VM window.

7. Power Up All VMs

  • Select each VM and click the Start arrow.
  • Allow a few minutes for each machine to finish booting.

8. Verify the Environment

  1. Open a web browser on your host and navigate to http://192.168.95.10. You should see the Web Visualization of the chemical plant.
  2. Access the SCADA‑BR HMI by opening the address shown on its console. Log in with admin / admin.
  3. If you see a small triangle with an exclamation mark, the HMI cannot reach the PLC – double‑check network assignments.
  4. In the Workstation VM, open a terminal and run ping 192.168.95.2. A successful ping confirms proper connectivity.

9. Troubleshooting Common Issues

  • Incorrect Adapter Assignment – Verify each VM is attached to the correct host‑only adapter (match IP addresses, not names).
  • DHCP Not Working – Ensure the DHCP server checkbox is enabled for both host‑only adapters.
  • Promiscuous Mode – The setting must be Allow VMs; otherwise traffic may be blocked.
  • Adapter Type Mismatch – Some hosts require Intel PRO/1000 MT Desktop instead of Paravirtualized.
  • Restart Required – If adapters appear inactive, reboot the host machine.

Conclusion

By following this guide you will have a fully operational FortiOS open‑source ICS training lab, complete with a simulated chemical plant, PLCs, SCADA, and a pfSense firewall. The environment is ready for hands‑on practice with network security, intrusion detection, and incident response in an industrial setting.

You can now run a complete FortiOS ICS training lab locally, enabling realistic practice without any additional hardware or video tutorials.

Frequently Asked Questions

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