In the world of industrial automation, having an intuitive and powerful programming environment is key. OpenPLC Editor, combined with CONTROLLINO, brings a seamless IEC 61131-3 programming experience, simulation capabilities, and Modbus communication to the table. Here’s how you can install and get started with OpenPLC Editor, including support for CONTROLLINO boards.

Why Choose OpenPLC Editor with CONTROLLINO?

• Rich IEC 61131-3 Programming IDE: Enjoy programming in Ladder, Structured Text (ST), Instruction List (IL), Function Block Diagram (FBD), and Sequential Function Chart (SFC).
  “Nice and mature IDE for IEC 61131-3 programming.”
• Simulation Capabilities: Test your program before uploading it to the CONTROLLINO.
  “You can simulate your program before uploading to CONTROLLINO.”
• Modbus RTU, Serial, and TCP/IP: Full support for RS485 communication on CONTROLLINO MAXI and MEGA.

Step 1: Download and Install OpenPLC Editor

1. Download: Visit the OpenPLC download page and choose the appropriate version for your operating system.
2. Install: Follow the standard installation process after downloading the setup file.

Step 2: Update OpenPLC Editor for CONTROLLINO Boards Support

• Open the Editor: After installation, launch the OpenPLC Editor.
• Check for Updates: Navigate to File -> Check for updates... as shown below:

• Apply Updates: If updates are available, accept them and restart OpenPLC Editor to finalize the installation.
• Checking Controllino’s Boards: Check that is possible to select our boards in the Arduino upload dialog.

Tip: CONTROLLINO support might already be included in your version, but it’s always good practice to check for updates.

Step 3: Start a New Project with OpenPLC Editor

1. Create or Open a Project: Click on the Open icon in the toolbar to start a new project or load an existing one.

1. Explore the Example Project: Use the predefined programs and structures (e.g., inputs, outputs, and control) to understand the flow of your automation logic.
2. Write Your Code: Develop your automation project using Ladder Logic or any of the supported programming languages.

Advantages of CONTROLLINO Boards with OpenPLC

• Arduino-Compatible Hardware: CONTROLLINO is based on Arduino, making it familiar and developer-friendly.
• Industrial-Grade Quality: Designed for real-world applications with robust build quality and excellent communication interfaces.
• Seamless Integration: Direct support in OpenPLC Editor ensures a smooth experience from programming to deployment.

By following these steps, you can harness the power of OpenPLC Editor and CONTROLLINO to develop, simulate, and deploy industrial automation projects efficiently. Embrace the future of automation with this powerful combination!

How to get and open examples

• Install git and clone the examples repository.
• Open the link below and download the examples folders or execute on local git app the following command:
  • git clone https://github.com/CONTROLLINO-PLC/OpenPLC_examples.git

This tutorial explains how to implement an automatic water reserve control system using a CONTROLLINO PLC and OpenPLC. The system monitors the water levels of a cistern (minimum level) and an elevated tank (minimum and maximum levels) to control a pump that transfers water from the cistern to the elevated tank. Additionally, manual pump control is possible using start and stop buttons.

Prerequisites

Before starting, ensure you have the following:

• OpenPLC software installed.
• A CONTROLLINO PLC (any model) or a compatible PLC.
• Sensors for water level detection:
• Minimum level sensor for the cistern.
• Minimum and maximum level sensors for the elevated tank.
• Two buttons for manual control (Start and Stop).
• Basic knowledge of ladder logic programming.

Step-by-Step Guide

Step 1: Install and Set Up OpenPLC

1. Download OpenPLC:

• Visit the OpenPLC official website and download the software.
• Follow the installation instructions for your operating system.

1. Set Up the OpenPLC Environment:

• Open the OpenPLC editor.
• Configure the device by selecting your CONTROLLINO model in Settings > Device.
• Assign the correct COM port for communication with the PLC.

Step 2: Configure System Inputs and Outputs

Define the following inputs and outputs in your ladder logic program:

Step 3: Program the Ladder Logic

1. Automatic Mode:

• The pump (Water_Pump) is activated automatically when:
  • The cistern is above its minimum level (Pool_Low_Level_Sensor is active).
  • The tank is below its minimum level (Tank_Low_Level_Sensor is active).
• The pump is deactivated when:
  • The tank reaches its maximum level (Tank_High_Level_Sensor is active).
  • The cistern falls below its minimum level (Pool_Low_Level_Sensor is inactive).

1. Manual Mode:

• The pump can be directly controlled using the buttons:
  • The Start Button (Start_Button) activates the pump.
  • The Stop Button (Stop_Button) deactivates the pump.
• The switch (Automatic_Manual_Switch) must be in manual mode to enable this functionality.

1. Switching Between Modes:

• The Automatic_Manual_Switch toggles between automatic and manual modes.
• In manual mode, sensor readings do not affect the pump operation.

Step 4: Connect the Hardware

1. Wiring:

• Connect the level sensors to the respective input pins.
• Connect the Start and Stop buttons to other input pins.
• Connect the water pump to the assigned output pin.

1. Pin Mapping:

• Ensure that the variable names in OpenPLC match the physical connections.

Step 5: Test the System

1. Load the Program:

• Save your project in the OpenPLC editor.
• Connect your CONTROLLINO PLC to the computer and upload the program.

1. Test Automatic Mode:

• Ensure the cistern is above its minimum level.
• Lower the water level in the tank below its minimum.
• Observe how the pump automatically activates and fills the tank until it reaches the maximum level.

1. Test Manual Mode:

• Switch to manual mode using the Automatic_Manual_Switch.
• Press the Start Button to activate the pump and the Stop Button to deactivate it.

Ladder Logic Explanation

Automatic Mode

1. Automatic Activation:

• When both Pool_Low_Level_Sensor and Tank_Low_Level_Sensor are active, the pump (Water_Pump) turns on.

1. Automatic Deactivation:

• The pump turns off when either:
  • Tank_High_Level_Sensor is active (tank full).
  • Pool_Low_Level_Sensor is inactive (cistern empty).

Manual Mode

1. Manual Control:

• Pressing Start_Button turns on the pump manually.
• Pressing Stop_Button turns off the pump manually.

Troubleshooting

1. Check Wiring:

• Ensure sensors and buttons are connected to the correct input pins.
• Verify the pump is connected to the correct output pin.

1. Verify Variables:

• Check that the variable names in OpenPLC match the physical connections.

1. Debugging:

• Use the OpenPLC debugging tools to monitor the state of inputs, outputs, and signals.

Conclusion

Congratulations! You have successfully implemented a water reserve control system with both automatic and manual modes. This system is ideal for efficiently managing water levels in elevated tanks and cisterns. You can further customize the system by adding additional sensors or modifying the logic to suit specific requirements.

This tutorial demonstrates how to create an automatic staircase lighting system using OpenPLC and a CONTROLLINO PLC. The system uses two push buttons for manual control and a PIR sensor for automatic activation. The light toggles manually with button presses or turns on automatically when motion is detected, staying on for 20 seconds before turning off if no further motion occurs.

Prerequisites

Before you begin, ensure you have the following:

• OpenPLC software installed.
• A CONTROLLINO PLC (any model) or compatible PLC.
• A Passive Infrared (PIR) motion sensor.
• Two push buttons (for manual control).
• Basic knowledge of ladder logic programming.

Step-by-Step Guide

Step 1: Install and Configure OpenPLC

1. Download OpenPLC:

• Visit the OpenPLC website and download the software.
• Follow the installation instructions for your operating system.

1. Set Up the OpenPLC Environment:

• Open the OpenPLC Editor.
• Configure the environment for your CONTROLLINO PLC by selecting the correct model in Settings > Device.
• Assign the appropriate COM port for communication.

Step 2: Define System Inputs and Outputs

Configure the following inputs and outputs in your ladder logic program:

Timers:

• TOF0 (Off Delay Timer): Controls the light timeout after motion detection.
• Duration: T#20s.

Step 3: Create the Ladder Logic Program

1. Manual Light Control:

• When either control_button_down or control_button_up is pressed, the lights_buttons_state toggles the stairs_light.
• This allows manual on/off control of the staircase light.

1. Automatic Light Control:

• When the stairs_pir_sensor detects motion, it activates the timer TOF0.
• The light (stairs_light) remains on while the timer is active or as long as motion is detected.

1. Light Timeout:

• When no motion is detected for 20 seconds, the TOF0 timer deactivates.
• The light turns off automatically unless toggled manually.

Step 4: Connect the Hardware

1. Wiring:

• Connect the PIR sensor output to a digital input pin (e.g., DI0).
• Connect the downstairs push button to another input pin (e.g., DI1).
• Connect the upstairs push button to a separate input pin (e.g., DI2).
• Connect the staircase light to a digital output pin (e.g., DO0).

1. Pin Mapping:

• Assign the corresponding input and output variables in OpenPLC:
  • stairs_pir_sensor → %IX0.0
  • control_button_down → %IX0.1
  • control_button_up → %IX0.2
  • stairs_light → %QX0.0

Step 5: Load and Test the Program

1. Upload the Program:

• Save your ladder logic project in the OpenPLC Editor.
• Connect your CONTROLLINO PLC to your computer and upload the program.

1. Test Manual Light Control:

• Press the upstairs (control_button_up) or downstairs (control_button_down) push button.
• Confirm that the light toggles on and off with each press.

1. Test Automatic Light Control:

• Walk near the PIR sensor to simulate motion detection.
• Observe the light turning on and staying active for 20 seconds after the motion stops.
• Ensure the light turns off automatically after the timer expires.

Ladder Logic Explanation (Detailed)

Manual Light Control

1. Toggling the Light:

• Each button press (control_button_up or control_button_down) changes the state of lights_buttons_state.
• The state of lights_buttons_state determines whether stairs_light is turned on or off.

Automatic Light Control

1. PIR Sensor Activation:

• When the stairs_pir_sensor detects motion, the timer TOF0 starts.
• The stairs_light remains on while motion is detected or while the timer is active.

1. Light Timeout:

• The TOF0 timer turns off the light 20 seconds after the PIR sensor stops detecting motion.

Combining Manual and Automatic Control

• The light can be manually toggled on or off at any time using the push buttons.
• Automatic activation by the PIR sensor operates independently, ensuring flexibility.

Troubleshooting

1. Verify Wiring:

• Ensure all sensors and buttons are correctly connected to the appropriate input pins.
• Confirm the light is connected to the correct output pin.

1. Check Variable Assignments:

• Double-check that the input and output variables in OpenPLC match your physical connections.

1. Debugging:

• Use the OpenPLC debugging tools to monitor the state of variables and timers.

Conclusion

Congratulations! You have successfully implemented an automatic staircase lighting system using OpenPLC and a CONTROLLINO PLC. This system combines manual and automatic control for optimal flexibility and convenience. Experiment with different timer durations or additional sensors to customize the system further.

This tutorial explains how to create a PWM-based light intensity control system using OpenPLC software and a CONTROLLINO Micro PLC. The system adjusts the brightness of a light through a single push button, using a digital output. Each button press decreases the brightness until it cycles back to full intensity. This project showcases ladder logic programming to control light intensity using PWM.

Prerequisites

Before you begin, ensure you have the following:

• OpenPLC software installed.
• A CONTROLLINO Micro PLC.
• Basic knowledge of ladder logic and PWM.
• Hardware setup ready, including a connected push button and light output.

Step-by-Step Guide

Step 1: Install and Configure OpenPLC

1. Download OpenPLC from the official OpenPLC website.
2. Install the software on your computer.
3. Open the OpenPLC Editor and configure the environment for your CONTROLLINO Micro PLC:

• Navigate to Settings > Device and select “CONTROLLINO Micro” from the list.
• Ensure the correct COM port is selected.

Step 2: Create the Ladder Logic Program

1. Define Variables:
   Open the OpenPLC editor and define the variables listed below: Name Type Description Control_button BOOL Push button input to control brightness cycling. Light_output BOOL PWM output controlling the light intensity. Light_bright INT Tracks the current brightness level. Pulse_regulator TIME Timing variable for PWM modulation. Light_on_state BOOL Indicates whether the light is currently on. Reset_state BOOL Resets the brightness level to maximum. Flag_cicle BOOL Controls PWM signal cycling. Full_bright BOOL Indicates the full brightness state.

1. Draw the Ladder Diagram:

• Implement the logic as described in the Ladder Logic Explanation section below.
• Use counters (CTU), timers (TP and TOF), and comparators (EQ, GT) to create the control logic.

Step 3: Understanding the Ladder Logic

Button Press and Brightness Cycling

1. Counter (CTU0):

• Each button press increments the counter.
• The counter cycles through brightness levels (0, 1, 2, 3) and resets to 0 after reaching the maximum level.

1. Brightness Level Comparison:

• Use comparators to determine the brightness level (Light_bright) and adjust the PWM pulse width accordingly.

1. PWM Signal Generation:

• Use timers to control the on/off duration of the PWM signal based on the current brightness level.

1. Light Output Control:

• The variable Pulse_regulator adjusts the Light_output signal to modulate light intensity.

Step 4: Connect the Hardware

1. Wiring:

• Connect the push button to a digital input pin (e.g., CONTROLLINO_D0).
• Connect the light output to a PWM-capable pin (e.g., CONTROLLINO_Q0).

1. Pin Mapping:

• Assign the Control_button variable to the input pin connected to the push button.
• Assign the Light_output variable to the output pin connected to the light.

Step 5: Load and Run the Program

1. Upload the Program:

• Save your ladder logic project.
• Use the OpenPLC Editor to upload the program to your CONTROLLINO Micro.

1. Test the System:

• Power on the CONTROLLINO Micro.
• Press the push button and observe the light cycling through brightness levels.

Ladder Logic Explanation (Detailed)

Counter (CTU0):

• Tracks the number of button presses and increments the Light_bright variable.
• Resets to 0 after reaching the maximum brightness level.

Reset and Cycling:

• When the brightness reaches the lowest level, the Reset_state variable resets the system to the maximum brightness level.

Brightness Control:

• Use comparators (EQ, GT) to map the brightness level to a PWM duty cycle.
• Timers (TP0, TOF0) generate the PWM signal by controlling the on/off duration of Light_output.

Troubleshooting

1. Verify the wiring between the push button, light, and CONTROLLINO.
2. Ensure that the correct input and output pins are assigned to the variables.
3. Check for errors in the ladder logic program using the OpenPLC debugger.

Conclusion

You have successfully implemented a PWM-based light intensity control system using a CONTROLLINO Micro and OpenPLC. By integrating ladder logic and PWM, this project demonstrates an efficient way to control light brightness with a single push button. Experiment with the timing variables and additional functionality to customize the system further.