Program Industrial Controllers with CODESYS—No Vendor Lock-In
Stop learning proprietary PLC programming languages that trap you with single vendors. PAC Series controllers support IEC 61131-3 international standard with CODESYS runtime—program in 6 languages including Ladder, Function Block, Structured Text, Sequential Function Chart, Instruction List, and Continuous Function Chart. Migrate programs across hardware vendors. Integrate with EtherCAT or Modbus fieldbus systems without protocol converters.
- IEC 61131-3 compliant programming (6 languages: LD, SFC, FBD, ST, IL, CFC)
- CODESYS V3.5 runtime pre-installed (hardware-independent platform)
- EtherCAT or Modbus fieldbus master built-in
- OPC UA Server for SCADA/MES integration (all models)
- Operating temperature: -20°C to 60°C industrial grade
Why Proprietary PLC Programming Creates Long-Term Business Risk
Your factory invested in Brand X PLCs ten years ago. Your senior programmer retires. Replacement candidates want higher salaries due to rare Brand X ladder logic expertise. Meanwhile, competitors deploy flexible IEC 61131-3 systems—hiring from broader talent pool with standard training.
Trapped with Single Hardware Vendor
Programs written in proprietary languages only run on original vendor's hardware. Expansion requires buying same brand controllers at premium prices. Cannot negotiate better deals with alternative suppliers. Vendor discontinues model—forced expensive system replacement.
Scarce Programmers Demand Higher Salaries
Proprietary PLC languages are vendor-specific skills. Fewer engineers trained in niche systems. Hiring requires months-long searches or paying premium salaries. Employee leaves—knowledge walks out the door. Training new staff takes 6-12 months per programmer.
Programs Cannot Migrate to Other Hardware
Company acquired new facility using different PLC brand. Existing control programs cannot transfer. Must rewrite entire logic from scratch in new vendor's language. Testing and commissioning restart from zero. Lost opportunity for standardized multi-site deployment.
Vendor Controls Feature Release Schedule
Industry moves to IIoT, OPC UA, edge computing. Your PLC vendor releases updates on their schedule—often 2-3 years behind market. Cannot integrate with modern cloud platforms without expensive middleware. Competitors deploy faster with open-standard controllers.
Vendor-Specific Training Has No Transferable Value
Invested in vendor-specific programming courses for engineering team. Company switches control systems—training investment becomes worthless. Engineers resist learning yet another proprietary language. Skills don't transfer across projects using different brands.
Different PLC Brands Cannot Share Logic Libraries
Factory has Vendor A PLCs in Building 1, Vendor B in Building 2. Developed PID control library for Vendor A—cannot reuse for Vendor B systems. Maintaining two separate codebases doubles engineering workload. Troubleshooting requires expertise in multiple proprietary languages.
Manufacturing engineers worldwide face these vendor lock-in challenges daily. But what if you could program industrial controllers using an international standard—where code, training, and expertise transfer across hardware vendors—without proprietary language limitations?
IEC 61131-3 Programming Standard with Pre-Installed CODESYS Runtime
PAC Series controllers ship with CODESYS V3.5 runtime pre-configured for immediate programming. Use Ladder Diagram (LD) for relay logic, Function Block Diagram (FBD) for process control, Structured Text (ST) for complex algorithms, Sequential Function Chart (SFC) for state machines, or Instruction List (IL) for time-critical operations. Programs developed in IEC 61131-3 are portable—migrate across hardware vendors without rewriting logic.
6 IEC 61131-3 Languages Supported
Choose programming language based on application requirements—not vendor limitations. Ladder Diagram (LD) for electricians, Function Block Diagram (FBD) for process engineers, Structured Text (ST) for software developers, Sequential Function Chart (SFC) for batch processes, Instruction List (IL) for maximum performance, or Continuous Function Chart (CFC) for complex control flow visualization.
- •Ladder Diagram (LD): Relay logic style
- •Function Block (FBD): Visual process control
- •Structured Text (ST): High-level programming
- •Sequential Function Chart (SFC): State machines
- •Instruction List (IL): Assembly-like performance
- •Continuous Function Chart (CFC): Complex control flow
CODESYS Runtime—Proven on 500+ Controller Brands
CODESYS is leading hardware-independent IEC 61131-3 automation software deployed in millions of controllers worldwide. Programs written in CODESYS run on any compatible hardware—no vendor lock-in. Contec PAC Series includes licensed runtime pre-installed.
- •Hardware-independent IEC 61131-3 platform
- •Used by 500+ automation hardware manufacturers
- •Programs portable across compatible controllers
- •Licensed runtime included—no additional fees
EtherCAT or Modbus TCP Master Function
Connect distributed I/O, servo drives, and sensors without protocol converters. EtherCAT models support real-time control with microsecond synchronization. Modbus TCP models integrate with standard industrial devices. Choose fieldbus based on performance requirements—not vendor restrictions.
- •Up to 65,535 slave devices maximum
- •Microsecond-level synchronization
- •Motion control and high-speed I/O
- •Connect to any Modbus TCP slave device
- •Industry-standard function codes
- •Ethernet-based communication
OPC UA Server Built-In—All Models
Integrate with SCADA, MES, and ERP systems using industry-standard OPC UA protocol. Export controller variables directly to enterprise software platforms—no middleware required. Platform-independent data exchange ensures compatibility with Wonderware, Ignition, LabVIEW, and other OPC UA clients.
- •OPC UA Server pre-configured (all PAC models)
- •Platform-independent data exchange
- •Secure encrypted communication
- •Compatible with SCADA/MES/ERP systems
Business Benefits: No Vendor Lock-In
Strategic Advantages:
- Portable programs across hardware vendors
- Hire from broader talent pool (IEC 61131-3 standard)
- Training investment transferable across brands
- Competitive bidding for future hardware purchases
- Future-proof against vendor technology lag
Technical Advantages:
- 6 programming languages (use what fits application)
- Real-time control with EtherCAT fieldbus
- Standard industrial protocols (Modbus, OPC UA)
- Web-based HMI monitoring built-in
- Industrial temperature range: -20°C to 60°C
PAC Series Integration Architecture
Open-standard IEC 61131-3 platform connecting programming tools, fieldbus networks, and enterprise systems
Open Standard
IEC 61131-3 programming languages work across all CODESYS-compatible controllers
Multi-Vendor Freedom
Connect servo drives, sensors, and field devices from any manufacturer
Enterprise Ready
Built-in OPC UA server for seamless SCADA, MES, and cloud integration
Two Configurations: All-In-One Integrated or Modular Configurable Controllers
Both types support IEC 61131-3 programming with CODESYS runtime and OPC UA Server. Choose Integrated Type for fixed I/O applications with compact installations. Choose Configurable Type for expandable I/O requirements with up to 16 modular I/O modules per controller.
All-In-One Controller with Built-In I/O
Single compact unit with controller CPU and fixed I/O interfaces integrated into one housing. Ideal for machine control applications with known I/O requirements that won't change over time.
Network Communication:
- • LAN: 2 ports (10BASE-T/100BASE-TX)
- • USB: 1 port (USB 2.0 Type-A)
- • RS-232C: 1 port (up to 115.2 Kbps)
- • RS-422A/485: 1 port (EtherCAT model only)
- • SD Card Slot: 1 slot (configuration backup)
Digital I/O:
- • Digital Input: 4 channels (isolated)
- • Digital Output: 4 channels (semiconductor relay)
- • Counter Input: 2 channels (shared with DI)
Analog I/O:
- • Analog Input: 2 channels (current input)
Available Models: 1 Model
• CPS-PC341EC-1-9201: EtherCAT Master + OPC UA
Best For:
- • Machine control with fixed I/O requirements
- • Compact control panel installations
- • Applications not requiring I/O expansion
- • Replacement for proprietary PLC systems
Modular Controller with Expandable I/O Modules
CPU controller module with minimal built-in I/O. Add up to 16 stackable I/O modules based on application needs—analog input, digital output, relay, counter, thermocouple, or serial communication modules.
Network Communication:
- • LAN: 2 ports (10BASE-T/100BASE-TX)
- • USB: 1 port (USB 2.0 Type-A)
- • RS-232C: 1 port (up to 115.2 Kbps)
- • SD Card Slot: 1 slot (configuration backup)
Digital I/O (Built-in):
- • Digital Input: 4 channels (isolated)
- • Digital Output: 4 channels (semiconductor relay)
Expansion Capability:
- • Up to 16 I/O modules stackable
- • 14 different module types available
- • Maximum power: 3.3A total for all modules
Available Models: 3 Models
• CPS-PCS341EC-DS1-1201: EtherCAT Master + OPC UA
• CPS-PCS341MB-DS1-1201: Modbus TCP Master + OPC UA
• CPS-ECS341-1-011: EtherCAT Slave Unit
Best For:
- • Large I/O count requirements (50+ points)
- • Custom I/O mix per application
- • Future expansion planned
- • Distributed control with EtherCAT slaves
| Feature | Integrated Type | Configurable Type |
|---|---|---|
| Form Factor | All-in-one device | CPU module + I/O modules |
| Built-in I/O | 4DI/4DO/2AI/2CNT | 4DI/4DO (CPU base only) |
| I/O Expandability | Fixed (cannot add modules) | Up to 16 modules per controller |
| CODESYS Runtime | Pre-installed | Pre-installed |
| OPC UA Server | Built-in | Built-in |
| EtherCAT Master | Model EC available | Model EC available |
| Modbus TCP Master | Not available | Model MB available |
| EtherCAT Slave Mode | Not available | Slave unit available (CPS-ECS341) |
| Installation Time | Faster (plug-and-play) | Slightly longer (module assembly) |
| Initial Cost | Lower | Higher (CPU + modules) |
| Dimensions (W×D×H) | 44.7×97.4×124.8 mm | 44.7×97.4×124.8 mm + module stack width |
| Best Application | Fixed I/O machine control | Expandable distributed control systems |
Quick decision: If I/O requirements are fixed and fit within 4DI/4DO/2AI, choose Integrated Type for simplicity. If you need diverse I/O types (thermocouples, relays, high-speed counters) or future expansion, choose Configurable Type for flexibility.
EtherCAT vs Modbus TCP Architecture Comparison
Side-by-side comparison of EtherCAT and Modbus TCP fieldbus architectures. See topology differences, performance characteristics (cycle time, jitter, synchronization), maximum network capacity, connected device types, and real-world use cases for each protocol.
8 Reasons Control Engineers Choose Open-Standard PAC Controllers
You could continue with proprietary PLC systems that lock you into single vendors. But forward-thinking manufacturers deploy IEC 61131-3 controllers—here's what open-standard automation delivers.
IEC 61131-3 Compliant Programming
Program using international automation standard adopted worldwide. Ladder Diagram (LD), Function Block (FBD), Structured Text (ST), Sequential Function Chart (SFC), and Instruction List (IL) supported. Engineers trained in IEC 61131-3 work across brands—no vendor-specific retraining.
Verified: 5 programming languages (LD/FBD/ST/SFC/IL)CODESYS V3.5 Runtime Pre-Installed
Industry-leading IEC 61131-3 platform used by 500+ automation hardware manufacturers. Programs developed in CODESYS run on any compatible controller—portable across vendors. Licensed runtime included—no recurring license fees.
Platform: CODESYS V3.5 SP7 Patch 2 or laterEtherCAT Master with Microsecond Sync
Built-in EtherCAT master function for real-time distributed control. Connect up to 65,535 EtherCAT slave devices—servo drives, high-speed I/O, motion controllers. Deterministic communication with microsecond-level synchronization for motion control applications.
Capacity: Up to 65,535 EtherCAT slave devices maximum-20°C to 60°C Continuous Operation
Industrial-grade controllers designed for harsh factory environments. Fanless passive cooling—no moving parts to fail. Operate continuously in unheated warehouses, near heat sources, or cold storage facilities without thermal shutdowns.
Tested: Continuous operation at temperature extremesOPC UA Server Built-In—All Models
Integrate with SCADA, MES, and ERP systems using industry-standard OPC UA protocol. Platform-independent data exchange—compatible with Wonderware InTouch, National Instruments LabVIEW, and any OPC UA client software. Secure encrypted communication with authentication.
Standard: OPC UA Server pre-configured (no middleware)CONPROSYS HMI Built-In Web Server
Monitor controller variables via web browser—no dedicated HMI software required. Access from desktop PCs, tablets, or smartphones. Create custom monitoring screens with 20+ pre-built display components (gauges, trends, alarms, tables).
Feature: Web HMI accessible from any browserUp to 16 Stackable I/O Modules
Configurable Type controllers support modular expansion with 14 different I/O module types. Slide modules onto DIN rail—no wiring harnesses required. Mix analog input, digital output, relay, thermocouple, or serial communication modules based on application needs.
Expansion: 14 module types, maximum 3.3A total power1.6ns Ladder Logic Execution Speed
ARM Cortex-A8 600MHz processor with optimized CODESYS runtime. Basic Ladder Diagram (LD) instruction executes in 1.6 nanoseconds. Structured Text (ST) instruction in 5.8ns. Scan time 74 microseconds for 20,000 program steps—fast enough for real-time control.
Performance: 250,000 steps maximum program sizeZero Vendor Lock-In—Maximum Flexibility
Portable Programs
IEC 61131-3 code runs on any compliant controller. Migrate programs across hardware vendors without rewriting logic.
Broader Talent Pool
Hire engineers trained in IEC 61131-3 international standard. No vendor-specific expertise required.
Lower Total Cost
Competitive bidding for hardware purchases. Training investment transferable. No recurring license fees.
IEC 61131-3 Programming Languages Comparison
Interactive comparison of 6 standard programming languages supported by PAC Series controllers. See learning curves, execution speeds, target audiences, and real-world applications for each language.
PAC Series Model Selection Decision Tree
Interactive flowchart to help you select the appropriate PAC Series model based on fieldbus requirements (EtherCAT vs Modbus TCP), I/O configuration needs (Integrated vs Configurable), and system architecture. Covers all 7 models including EtherCAT slave units.
Choose Your PAC Controller: Integrated, Configurable, or EtherCAT Slave Unit
All PAC Series models include CODESYS V3.5 runtime pre-installed, IEC 61131-3 programming support (5 languages), and OPC UA Server for enterprise integration. Select controller based on I/O requirements, fieldbus protocol, and expansion needs.
Single compact unit with controller CPU, communication interfaces, and fixed I/O integrated into one housing. Ideal for machine control applications with known I/O requirements.
PAC Controller with EtherCAT Master—Integrated Type
All-in-one programmable automation controller with built-in EtherCAT master function. Program using IEC 61131-3 languages (Ladder, Function Block, Structured Text, SFC, IL). Connect up to 65,535 EtherCAT slave devices for distributed real-time control.
Programming Environment:
- • CODESYS V3.5 SP7 Patch 2 or later
- • 5 IEC 61131-3 languages (LD/SFC/FBD/ST/IL)
- • Maximum program size: 250,000 steps
- • Basic instruction execution: 1.6ns (LD), 5.8ns (ST)
- • Scan time: 74μs (at 20,000 steps)
Controller Hardware:
- • CPU: ARM Cortex-A8 (600 MHz)
- • Memory: 512MB DDR3 SDRAM
- • ROM: 32MB NOR-flash (OS), 1MB (programs)
- • Operating temperature: -20°C to 60°C
- • Cooling: Fanless (passive cooling)
Communication Interfaces:
- • LAN: 2 ports (10BASE-T/100BASE-TX)
- • USB: 1 port (USB 2.0 Type-A)
- • RS-232C: 1 port (up to 115.2 Kbps)
- • RS-422A/485: 1 port (isolated)
- • SD Card Slot: 1 slot (SDHC compatible)
Built-In I/O (Fixed):
- • Digital Input: 4 channels (isolated, 24V DC)
- • Digital Output: 4 channels (semiconductor relay)
- • Analog Input: 2 channels (4-20mA current)
- • Counter Input: 2 channels (max 100 kHz)
EtherCAT Master Function:
- • Maximum slave devices: 65,535 units
- • Real-time synchronization (microsecond-level)
- • Motion control and high-speed I/O support
• Built-In OPC UA Server (Pre-configured)
Platform-independent data exchange with SCADA, MES, and ERP systems. Secure encrypted communication with authentication. Compatible with Wonderware, Ignition, LabVIEW, and any OPC UA client software.
Physical Specifications:
• Dimensions (W×D×H): 44.7 × 97.4 × 124.8 mm
• Mounting: 35mm DIN rail
• Weight: Approximately 300g
• Power Supply: 24V DC (0.3A controller only)
• Power Consumption: Approx. 7.2W
• Protection Rating: IP20 (for control panel installation)
• Standards: VCCI Class A, FCC Class A, CE marking
Best Use Cases:
PAC Controller with Modbus TCP Master—Integrated Type
All-in-one programmable automation controller with built-in Modbus TCP master function. Program using IEC 61131-3 languages (Ladder, Function Block, Structured Text, SFC, IL). Connect to standard industrial Modbus TCP slave devices without protocol converters.
Programming Environment:
- • CODESYS V3.5 SP7 Patch 2 or later
- • 5 IEC 61131-3 languages (LD/SFC/FBD/ST/IL)
- • Maximum program size: 250,000 steps
- • Basic instruction execution: 1.6ns (LD), 5.8ns (ST)
- • Scan time: 74μs (at 20,000 steps)
Controller Hardware:
- • CPU: ARM Cortex-A8 (600 MHz)
- • Memory: 512MB DDR3 SDRAM
- • ROM: 32MB NOR-flash (OS), 1MB (programs)
- • Operating temperature: -20°C to 60°C
- • Cooling: Fanless (passive cooling)
Communication Interfaces:
- • LAN: 2 ports (10BASE-T/100BASE-TX)
- • USB: 1 port (USB 2.0 Type-A)
- • RS-232C: 1 port (up to 115.2 Kbps)
- • SD Card Slot: 1 slot (SDHC compatible)
Built-In I/O (Fixed):
- • Digital Input: 4 channels (isolated, 24V DC)
- • Digital Output: 4 channels (semiconductor relay)
- • Analog Input: 2 channels (4-20mA current)
- • Counter Input: 2 channels (max 100 kHz)
Modbus TCP Master Function:
- • Industry-standard function codes supported
- • Connect to any Modbus TCP slave device
- • Ethernet-based communication (no RS-485 wiring)
- • Multiple slave device support
• Built-In OPC UA Server (Pre-configured)
Platform-independent data exchange with SCADA, MES, and ERP systems. Secure encrypted communication with authentication. Compatible with Wonderware, Ignition, LabVIEW, and any OPC UA client software.
Physical Specifications:
• Dimensions (W×D×H): 44.7 × 97.4 × 124.8 mm
• Mounting: 35mm DIN rail
• Weight: Approximately 300g
• Power Supply: 24V DC (0.3A controller only)
• Power Consumption: Approx. 7.2W
• Protection Rating: IP20 (for control panel installation)
• Standards: VCCI Class A, FCC Class A, CE marking
Best Use Cases:
Compare All 5 PAC Models—Find Perfect Match for Your Application
All models include CODESYS runtime, IEC 61131-3 programming (5 languages), and OPC UA Server. Main differences: fieldbus protocol (EtherCAT vs Modbus), I/O configuration (Integrated vs Configurable), and programming capability (Controller vs Slave Unit).
| Specification | CPS-PC341EC-1-9201 (Integrated EtherCAT) | CPS-PC341MB-ADSC1-9201 (Integrated Modbus) | CPS-PCS341EC-DS1-1201 (Config EtherCAT) | CPS-PCS341MB-DS1-1201 (Config Modbus) | CPS-ECS341-1-011 (EtherCAT Slave) |
|---|---|---|---|---|---|
| PROGRAMMING | |||||
| CODESYS Runtime | V3.5 SP7 Patch 2 | V3.5 SP7 Patch 2 | V3.5 SP7 Patch 2 | V3.5 SP7 Patch 2 | No programming |
| IEC 61131-3 Languages | 5 (LD/SFC/FBD/ST/IL) | 5 (LD/SFC/FBD/ST/IL) | 5 (LD/SFC/FBD/ST/IL) | 5 (LD/SFC/FBD/ST/IL) | Slave unit only |
| Maximum Program Size | 250,000 steps | 250,000 steps | 250,000 steps | 250,000 steps | N/A |
| HARDWARE | |||||
| CPU | ARM Cortex-A8 600MHz | ARM Cortex-A8 600MHz | ARM Cortex-A8 600MHz | ARM Cortex-A8 600MHz | N/A (I/O only) |
| Memory (RAM) | 512MB DDR3 SDRAM | 512MB DDR3 SDRAM | 512MB DDR3 SDRAM | 512MB DDR3 SDRAM | N/A |
| Operating Temperature | -20°C to 60°C | -20°C to 60°C | -20°C to 60°C | -20°C to 60°C | -20°C to 60°C |
| FIELDBUS | |||||
| EtherCAT Master | Up to 65,535 slaves | Not available | Up to 65,535 slaves | Not available | Slave only |
| Modbus TCP Master | Not available | Multiple slaves | Not available | Multiple slaves | Slave only |
| OPC UA Server | Built-in | Built-in | Built-in | Built-in | Controlled by master |
| BUILT-IN I/O | |||||
| Digital Input | 4 channels (24V DC) | 4 channels (24V DC) | 4 channels (24V DC) | 4 channels (24V DC) | 4 channels (24V DC) |
| Digital Output | 4 channels (semiconductor) | 4 channels (semiconductor) | 4 channels (semiconductor) | 4 channels (semiconductor) | 4 channels (semiconductor) |
| Expandable I/O Modules | Fixed I/O only | Fixed I/O only | Up to 16 modules | Up to 16 modules | Up to 16 modules |
EtherCAT vs Modbus TCP
EtherCAT Models (EC suffix):
- • Real-time motion control (microsecond sync)
- • Up to 65,535 slave devices maximum
- • High-speed I/O and servo drive control
- • Deterministic communication timing
Modbus TCP Models (MB suffix):
- • Standard industrial device connectivity
- • Wide device compatibility (any Modbus slave)
- • Ethernet-based (no RS-485 wiring)
- • Process control and monitoring
Integrated vs Configurable
Integrated Type (PC341 prefix):
- • Fixed built-in I/O (4DI/4DO/2AI/2CNT)
- • Compact single-unit design
- • No expansion capability
- • Lower initial cost
- • Faster installation (plug-and-play)
Configurable Type (PCS341 prefix):
- • Minimal built-in I/O (4DI/4DO base)
- • Up to 16 expandable I/O modules
- • 14 different module types available
- • Custom I/O mix per application
- • Future-proof expansion capability
Controller vs Slave Unit
Controller Models (PC/PCS prefix):
- • CODESYS V3.5 runtime pre-installed
- • 5 IEC 61131-3 programming languages
- • 250,000 program steps maximum
- • Independent control logic execution
- • OPC UA Server for SCADA integration
Slave Unit (ECS prefix):
- • No programming capability (I/O only)
- • Controlled by EtherCAT master PAC
- • Distributed I/O expansion function
- • Up to 16 I/O modules per slave
- • Lower cost for remote I/O
Quick Selection Guide
STEP 1: Choose Fieldbus Protocol
├─ Need real-time motion control? → Choose EtherCAT models (EC suffix)
└─ Need standard device connectivity? → Choose Modbus TCP models (MB suffix)
STEP 2: Determine I/O Requirements
├─ Fixed I/O (≤10 points, known requirements)? → Choose Integrated Type (PC341 prefix)
├─ Expandable I/O (50+ points, future growth)? → Choose Configurable Type (PCS341 prefix)
└─ Remote distributed I/O only? → Choose EtherCAT Slave Unit (ECS341)
STEP 3: Verify Programming Need
├─ Need independent control logic? → Choose Controller models (PC/PCS prefix)
└─ Just need remote I/O expansion? → Choose Slave Unit (ECS prefix)
6 Industries Using Open-Standard PAC Controllers for Real-Time Control
From factory automation to smart agriculture, control engineers deploy IEC 61131-3 programmable controllers where vendor-neutral programming and hardware flexibility matter. Here's how different industries benefit from open-standard automation.
Factory Automation—EtherCAT Motion Control
Assembly line requires synchronized multi-axis motion control with microsecond-level timing accuracy. Previous proprietary PLC system limited to single vendor's servo drives—expensive and restrictive.
Deploy CPS-PCS341EC-DS1-1201 (EtherCAT Master PAC). Program motion sequences using IEC 61131-3 Structured Text. Connect any EtherCAT-compatible servo drives (Yaskawa, Delta, Panasonic). Achieve deterministic control with microsecond synchronization.
• Reduced servo drive costs (multi-vendor bidding)
• Portable control programs (not locked to hardware)
• Faster commissioning (CODESYS standard tools)
• Easier troubleshooting (IEC 61131-3 programmers available)
Recommended Model: CPS-PCS341EC-DS1-1201 (EtherCAT Master + Expandable I/O)
Smart Agriculture—Climate Control System
Plant factory requires precise temperature, humidity, CO2, and lighting control across 12 growing zones. Legacy PLC limited programming languages—difficult to implement complex control algorithms.
Deploy CPS-PCS341MB-DS1-1201 (Modbus TCP Master PAC). Add thermocouple I/O modules for temperature sensing. Program PID control loops using Structured Text (ST) for readability. Connect Modbus humidity sensors and CO2 monitors. Visualize data via built-in Web HMI.
• Complex algorithm implementation (ST language support)
• Mixed sensor types (modular I/O flexibility)
• Remote monitoring (Web HMI built-in)
• Scalable to additional zones (add I/O modules)
Recommended Model: CPS-PCS341MB-DS1-1201 (Modbus Master + Thermocouple Modules)
Equipment Manufacturing—Packaging Machine OEM
OEM manufactures packaging machines sold globally. Customers request different PLC brands (Siemens, Mitsubishi, Omron). Maintaining separate code versions per brand doubles engineering workload.
Standardize on CPS-PC341EC-1-9201 (Integrated EtherCAT PAC). Develop single IEC 61131-3 codebase portable across deployments. Train customers on CODESYS standard tools (not proprietary). Offer upgrade path—customers keep existing programs when upgrading hardware.
• Single codebase maintenance (IEC 61131-3 standard)
• Lower customer training costs (CODESYS standard)
• Competitive advantage (no vendor lock-in)
• Higher customer satisfaction (program portability)
Recommended Model: CPS-PC341EC-1-9201 (Compact Integrated Type)
Water Treatment—Municipal Plant Automation
Water treatment plant requires real-time monitoring from central SCADA system. Existing PLCs use proprietary protocols—expensive middleware needed for SCADA integration. IT department demands OPC UA standard.
Deploy CPS-PC341MB-ADSC1-9201 (Integrated Modbus PAC). Connect Modbus flow meters, pressure sensors, and valve actuators. Export all variables via built-in OPC UA Server—no middleware required. SCADA software reads data directly using OPC UA client.
• Eliminated middleware costs (OPC UA built-in)
• IT-approved standard protocol (OPC UA)
• Secure encrypted communication (authentication)
• Platform-independent (works with any SCADA)
Recommended Model: CPS-PC341MB-ADSC1-9201 (Integrated Modbus + OPC UA)
Distributed Control—Multi-Site Manufacturing Campus
Manufacturing campus spans 5 buildings across 2km area. Running individual I/O cables from central control room to remote sensors impractical—expensive wiring and voltage drop issues.
Deploy 1x CPS-PCS341EC-DS1-1201 (Master PAC) in central control room. Install 5x CPS-ECS341-1-011 (EtherCAT Slave Units) in remote buildings—connected via fiber optic Ethernet. Each slave unit supports up to 16 I/O modules. Single CODESYS program controls entire campus.
• Reduced wiring costs (Ethernet instead of I/O cables)
• Scalable architecture (add slave units as needed)
• Centralized control logic (single program)
• Real-time communication (EtherCAT synchronization)
Recommended Model: 1× Master PAC + 5× EtherCAT Slave Units
Automotive Testing—Engine Test Bench Control
Engine test bench requires high-speed data acquisition (temperature, pressure, RPM, torque) with precise timing. Previous system used LabVIEW with expensive DAQ hardware— difficult to integrate with production PLCs.
Deploy CPS-PCS341EC-DS1-1201 with high-speed counter and thermocouple I/O modules. Program test sequences using Sequential Function Chart (SFC) for clear state machine visualization. Export real-time data to LabVIEW via OPC UA Server—no proprietary drivers needed.
• High-speed data acquisition (500kHz counters)
• Mixed signal types (thermocouples + digital)
• LabVIEW integration (OPC UA standard)
• Clear program structure (SFC visual programming)
Recommended Model: CPS-PCS341EC-DS1-1201 (EtherCAT + Special Function Modules)
| Industry | Primary Challenge | PAC Series Advantage | Recommended Model |
|---|---|---|---|
| Factory Automation | Vendor lock-in, expensive servo drives | Multi-vendor EtherCAT support, IEC 61131-3 | CPS-PCS341EC |
| Smart Agriculture | Complex control algorithms | Structured Text programming, modular I/O | CPS-PCS341MB + modules |
| Equipment Manufacturing | Multiple customer PLC brand preferences | Portable IEC 61131-3 code, CODESYS standard | CPS-PC341EC |
| Water Treatment | SCADA integration middleware costs | Built-in OPC UA Server, no middleware | CPS-PC341MB |
| Distributed Control | Expensive long-distance I/O wiring | EtherCAT distributed architecture, slave units | Master + Slave units |
| Automotive Testing | High-speed DAQ + PLC integration | Fast counters, OPC UA for LabVIEW/SCADA | CPS-PCS341EC + modules |
What All These Applications Share
Every successful deployment avoided proprietary PLC vendor lock-in by choosing IEC 61131-3 international standard programming. Engineers write control logic once—programs run on any CODESYS-compatible hardware. Training investment transfers across projects. Talent pool expands beyond vendor-specific experts. Future hardware upgrades don't require code rewrites.
This is why forward-thinking manufacturers deploy open-standard PAC controllers.
3 Steps from Unboxing to Running Your First IEC 61131-3 Program
No complex initialization procedures or vendor-specific tools required. PAC Series controllers ship with CODESYS runtime pre-installed. Mount hardware, download free CODESYS IDE, write program in your preferred IEC 61131-3 language—start controlling equipment in under 30 minutes.
I/O Expansion Architecture Diagram
Visualize modular I/O expansion architecture for PAC Series Configurable Type controllers with detailed DIN-rail stacking layout, power distribution, and installation workflow.
Mount PAC Controller and Connect Power/Communication
Time Required: 10 minutes
1.1 Mount Controller on DIN Rail
a) Snap PAC controller onto standard 35mm DIN rail
- Position controller in control panel enclosure
- Ensure adequate ventilation (fanless passive cooling)
- Leave 50mm clearance on sides for heat dissipation
- Operating temperature: -20°C to 60°C (no active cooling required)
b) For Configurable Type: Attach I/O modules
- Slide I/O modules onto DIN rail adjacent to CPU module
- Modules connect via daisy-chain (no wiring harness)
- Maximum 16 modules per controller (23.4mm width each)
- Total system width: CPU (44.7mm) + (23.4mm × module count)
Single Controller: 44.7mm (W) × 97.4mm (D) × 124.8mm (H)
With 8 I/O Modules: 231.9mm (W) total
With 16 I/O Modules: 419.1mm (W) total
1.2 Connect 24V DC Power Supply
a) Wire 24V DC power supply to controller
- Voltage: 24V DC ±10% (21.6V - 26.4V acceptable)
- Current requirement (Controller only): 0.3A (7.2W)
- Current requirement (With 16 I/O modules): 3.6A (86.4W max)
- Use appropriate wire gauge (AWG 16 or larger for high current)
b) Verify power LED indicators
- PWR LED: Solid green (normal operation)
- RUN LED: Blinking green (ready for program download)
- ERR LED: Off (no hardware errors)
Ensure proper grounding to prevent electrical noise interference. Use shielded cables for analog signals and high-speed counters.
1.3 Connect Ethernet Cable for Programming
a) Connect Ethernet cable from PC to PAC controller
- Use LAN Port 1 or Port 2 (both 10/100 Mbps)
- Default IP address: 192.168.1.1 (check label on controller)
- Subnet mask: 255.255.255.0
- Configure PC network adapter to same subnet (e.g., 192.168.1.100)
b) Verify network connectivity
- Open Command Prompt (Windows) or Terminal (Mac/Linux)
- Type: ping 192.168.1.1
- Expected result: Reply from 192.168.1.1 (connection successful)
| Parameter | Default Value | Notes |
|---|---|---|
| IP Address | 192.168.1.1 | Check controller label for actual IP |
| Subnet Mask | 255.255.255.0 | Standard Class C subnet |
| Gateway | 192.168.1.254 | Configure if internet access required |
| CODESYS Port | 1217 | TCP port for programming communication |
| OPC UA Server Port | 4840 | Standard OPC UA port |
Solution: Check Ethernet cable connection, verify PC IP in same subnet (192.168.1.x), disable PC firewall temporarily
Solution: Verify 24V DC power supply voltage with multimeter, check polarity (+ and - terminals), ensure wire connections secure
Solution: Power cycle controller, check I/O module connections (Configurable Type), verify total I/O current under 3.3A limit
Download CODESYS IDE and Install Target Runtime
Time Required: 15 minutes
2.1 Download CODESYS V3 Development System (FREE)
a) Visit CODESYS Store website
- URL: https://store.codesys.com
- Register free account (email + password)
- Download "CODESYS Development System V3" (latest version)
- License: FREE for programming (no cost for development)
- File size: Approx. 500MB
- Compatible OS: Windows 7/8/10/11 (64-bit)
b) Install CODESYS Development System
- Run installer as Administrator
- Accept license agreement
- Choose installation directory (default: C:\Program Files\CODESYS 3.5)
- Installation time: 5 minutes
- Restart PC after installation
No license fees for development software. PAC Series controllers include runtime license pre-installed—you only pay for hardware once.
2.2 Install CONPROSYS PAC Series Target Package
a) Download target package from Contec website
- Navigate to: www.contec.com → Products → CONPROSYS → PAC Series
- Download "CODESYS Target Support Package" (ZIP file)
- File size: Approx. 50MB
- Package includes: Device description, I/O configuration tools, sample programs
b) Install target package in CODESYS
- Open CODESYS Development System
- Menu: Tools → Package Manager
- Click "Install" button
- Browse to downloaded .package file
- Click "Open" to install
- Restart CODESYS IDE after installation
- Verify: Tools → Device Repository → Search "CONPROSYS PAC"
2.3 Create Your First CODESYS Project
a) Start new CODESYS project
- Menu: File → New Project
- Select "Standard Project" template
- Project Name: "MyFirstPACProgram"
- Location: Choose directory (e.g., C:\Projects)
b) Configure device target
- Device: Select "CONPROSYS CPS-PC341EC" (or your model)
- Communication Settings:
- Protocol: TCP/IP
- IP Address: 192.168.1.1 (your controller IP)
- Port: 1217 (default CODESYS port)
- Click "OK" to create project
c) Add Program Organization Unit (POU)
- Right-click "Application" → Add Object → POU
- Name: "PLC_PRG" (main program)
- Type: "Program"
- Language: Choose from 5 options:
- LD - Ladder Diagram (for relay logic engineers)
- FBD - Function Block Diagram (for process engineers)
- ST - Structured Text (for software developers)
- SFC - Sequential Function Chart (for state machines)
- IL - Instruction List (for assembly-like programming)
| Language | Best For | Learning Curve | Use Case Example |
|---|---|---|---|
| LD | Electricians, relay logic veterans | Easy | Simple on/off control |
| FBD | Process control engineers | Easy | PID loops, analog control |
| ST | Software developers, algorithms | Medium | Complex math, data parsing |
| SFC | Batch processes, state machines | Medium | Sequential operations |
| IL | Performance-critical applications | Hard | Time-critical loops |
Write Control Logic and Download to PAC Controller
Time Required: 5-10 minutes
3.1 Create "Hello World" LED Blink Program
(* Simple LED Blink Program - Ladder Diagram *)
(* Toggles Digital Output 1 every 500ms *)
Network 1: Timer for 500ms pulse
|--[TON]--Timer_Blink--|
IN: TRUE
PT: T#500ms
Q: Timer_Blink.Q
Network 2: Toggle output on timer
|--[Timer_Blink.Q]--[F_TRIG]--Trigger--|
|--[Trigger.Q]------[Output1]----------|
(* Output1 connected to DO1 (Digital Output Channel 1) *)(* Simple LED Blink Program - Structured Text *)
PROGRAM PLC_PRG
VAR
Timer_Blink: TON; // Timer instance
Output_State: BOOL := FALSE; // Output toggle state
END_VAR
// Timer counts to 500ms
Timer_Blink(IN:= TRUE, PT:= T#500ms);
// Toggle output when timer completes
IF Timer_Blink.Q THEN
Output_State := NOT Output_State; // Toggle state
Timer_Blink(IN:= FALSE); // Reset timer
END_IF;
// Assign to physical output
DO1 := Output_State; // Digital Output 1- Creates 500ms timer (toggles every half second)
- Toggles boolean variable on timer completion
- Outputs state to Digital Output channel 1 (DO1)
- Result: LED or relay connected to DO1 blinks at 1 Hz
3.2 Map Program Variables to Physical I/O
a) Open I/O Configuration window
- Double-click "Device (CONPROSYS PAC)" in device tree
- Navigate to I/O Mapping tab
- View available I/O channels:
- Digital Inputs: DI1, DI2, DI3, DI4
- Digital Outputs: DO1, DO2, DO3, DO4
- Analog Inputs: AI1, AI2 (if Integrated Type)
- Counter Inputs: CNT1, CNT2 (if Integrated Type)
b) Assign variables to physical I/O
- Method 1: Drag variable from program to I/O channel
- Method 2: Use AT notation in variable declaration
Example: Output1 AT %QX0.0 : BOOL; // Digital Output 1
Input1 AT %IX0.0 : BOOL; // Digital Input 1
c) For Configurable Type: Add I/O modules
- Right-click device → Add Device → Select module type
- Choose from 14 module types (DI, DO, AI, AO, TC, RTD, etc.)
- Configure module parameters (voltage range, current range, filter settings)
- Modules appear in I/O tree automatically
| I/O Type | Addressing Format | Example | Description |
|---|---|---|---|
| Digital Input | %IX0.n | %IX0.0 (DI1) | Bit input, channel n |
| Digital Output | %QX0.n | %QX0.0 (DO1) | Bit output, channel n |
| Analog Input | %IW0.n | %IW0.0 (AI1) | Word input (16-bit) |
| Analog Output | %QW0.n | %QW0.0 (AO1) | Word output (16-bit) |
| Counter Input | %ID0.n | %ID0.0 (CNT1) | Double word (32-bit) |
3.3 Compile, Download, and Run Program
a) Build (Compile) project
- Menu: Build → Build (or press F11)
- Check Messages window for errors
- Expected result: "Build complete - 0 errors, 0 warnings"
- If errors: Double-click error message to jump to problem line
b) Login to controller
- Menu: Online → Login (or press Alt+F8)
- CODESYS scans network for controller at 192.168.1.1
- Click "Login" when controller found
- If prompted: "Application differs. Download?" → Click "Yes"
- Program downloads to controller (takes 3-5 seconds)
c) Start program execution
- Click "Start" button (green play icon) or press F5
- Controller enters RUN mode
- RUN LED on controller blinks green rapidly
- Program executes continuously (scan cycle)
d) Monitor variables in real-time
- Right-click variable in program → "Toggle Breakpoint"
- Watch window shows variable values updating live
- Force values: Right-click variable → "Write Value"
- Verify DO1 output toggles every 500ms (LED blinks)
- RUN LED: Blinking green (scan cycle active)
- ERR LED: Off (no runtime errors)
- CODESYS status: "Running" (online mode)
- DO1 output: Toggles every 500ms (measure with multimeter or LED)
- Scan time: Under 1ms for simple programs (view in Watch window)
Installation Complete Checklist
Next Steps - Advanced Configuration
- EtherCAT Network: Add EtherCAT slave devices (servo drives, remote I/O) to fieldbus network
- OPC UA Server: Configure SCADA or HMI software to read variables via OPC UA protocol
- Web HMI: Create custom dashboards using built-in web visualization tools
- Data Logging: Enable SD card logging for historical data collection (CSV format)
- Email Alerts: Configure SMTP settings for email notifications on alarm conditions
- User Management: Add additional user accounts with role-based access control
Complete Software Ecosystem: CODESYS IDE, Web HMI, OPC UA, and Enterprise Integration
PAC Series controllers integrate with industry-standard software tools—no proprietary platforms required. Program in CODESYS IDE (free download), visualize data via built-in Web HMI, connect to SCADA systems using OPC UA Server, and exchange data with ERP/MES platforms using standard protocols.
CODESYS V3 Development System
FREE Programming SoftwareIndustry-leading IEC 61131-3 development environment used by 500+ automation hardware manufacturers worldwide. Write control programs in 5 standardized languages, debug with powerful breakpoint tools, and simulate logic before hardware deployment.
- • Ladder Diagram (LD)
- • Function Block (FBD)
- • Structured Text (ST)
- • Sequential Function Chart (SFC)
- • Instruction List (IL)
- • Real-time variable monitoring
- • Breakpoint support
- • Force values for testing
- • Execution flow visualization
- • Test programs without hardware
- • Validate logic before deployment
- • Reduce commissioning time
- • Git integration built-in
- • Track program changes
- • Team collaboration support
- • Diff/merge capabilities
- • Pre-built control algorithms
- • PID, motion, communication
- • Drag-and-drop reusable code
- • Custom library creation
- • Visual I/O module setup
- • Fieldbus configuration wizard
- • Network topology scanner
- • Automatic device detection
8 Questions Engineers Ask Before Switching to Open-Standard PAC Controllers
Considering migration from proprietary PLCs to IEC 61131-3 controllers? Here are answers to technical, commercial, and support questions based on real deployment experience from control engineers worldwide.
SHORT ANSWER:
IEC 61131-3 is international programming standard—portable across hardware vendors, wider talent pool, no vendor lock-in. Proprietary languages trap you with single supplier.
DETAILED EXPLANATION:
Business Benefits:
- Portable programs: Code runs on any IEC 61131-3 compliant controller—not locked to original hardware vendor. Company acquired? Merge control systems without rewriting programs.
- Broader talent pool: Hire engineers trained in international standard. No need to pay premium salaries for rare vendor-specific expertise.
- Training investment transferable: Engineers learn IEC 61131-3 once—skills apply across projects, brands, industries. Proprietary training becomes worthless if you switch vendors.
- Competitive hardware bidding: Not locked into single supplier means negotiate better prices. Competition drives innovation and cost reduction.
Technical Benefits:
- 5 standardized languages: Choose best language per task (Ladder for relay logic, Structured Text for algorithms, SFC for batch processes). Proprietary systems often limited to 1-2 languages.
- Hardware-independent platform: Programs developed in CODESYS run on 500+ controller brands worldwide. Future-proof investment.
- Modern features: IEC 61131-3 includes object-oriented programming, advanced data structures, integrated simulation. Many proprietary systems lag behind standard.
Risk Mitigation:
- Vendor discontinues product: With IEC 61131-3, migrate to alternative hardware without code rewrite. Proprietary systems force expensive emergency replacement.
- Vendor bankruptcy or acquisition: International standard protects your investment—programs survive hardware vendor changes.
- Technology obsolescence: IEC committee updates standard regularly with modern features. Proprietary vendors control update schedule.
Real-World Example:
Equipment manufacturer standardized on IEC 61131-3 controllers. Customers in 15 countries deploy machines—some sites prefer Brand A hardware, others Brand B. Single codebase serves all installations. Previously maintained 3 separate proprietary codebases—engineering cost reduced significantly.
Stop Paying Proprietary PLC Premiums—Switch to Open-Standard IEC 61131-3 Control
Your factory invested thousands in proprietary PLC systems that trap you with single vendors. Engineers spend months learning vendor-specific languages that become obsolete when brands discontinue products. Meanwhile, competitors deploy IEC 61131-3 controllers—hiring from broader talent pools, bidding hardware across multiple suppliers, and migrating programs without vendor restrictions.
How much longer will you accept vendor lock-in?
Choose best language per task: Ladder, Function Block, Structured Text, SFC, or Instruction List. Proprietary systems force single vendor's language.
CODESYS IDE free download. Runtime license included with hardware. OPC UA Server built-in. Web HMI pre-installed. Zero ongoing software costs.
Scale from single machine to factory-wide distributed control. Real-time motion synchronization. Connect any EtherCAT-compatible servo drives and I/O.
Portable Programs Across Hardware Brands
IEC 61131-3 code runs on any compliant controller. Migrate programs when upgrading hardware—no vendor lock-in. Future acquisitions? Standardize control systems without rewriting logic.
Hire from Broader Engineering Talent Pool
Stop paying premium salaries for rare proprietary PLC experts. IEC 61131-3 is international standard taught in engineering schools worldwide. Faster hiring, lower costs, transferable skills.
Reduce Total Cost of Ownership
Eliminate expensive IDE software licenses, HMI runtime fees, OPC middleware costs. Bid hardware across multiple vendors—competition drives prices down. Free CODESYS software forever.
Need Technical Consultation? Contact Our Engineers
Every month you delay switching to IEC 61131-3 controllers, competitors gain advantage with portable programs, lower engineering costs, and vendor-neutral flexibility.
Don't wait for your current PLC vendor to discontinue products and force emergency replacement at premium prices.
Start migration today—download datasheet and see why 500+ automation manufacturers worldwide trust CODESYS open-standard platform.