Automation Direct Click PLC Tutorial: Complete Guide to Budget-Friendly PLC Programming

Introduction: Master Click PLC Programming for Budget-Friendly Automation

Click PLC programming has revolutionized automation accessibility for small businesses, machine builders, educational institutions, and cost-conscious engineers across North America. Automation Direct's Click PLC family combines professional-grade functionality with budget-friendly pricing and completely free programming software, making industrial automation achievable for projects previously considered too expensive to automate.

The Click PLC platform stands out in the crowded industrial automation market through Automation Direct's innovative direct sales model that eliminates distributor markup, resulting in PLC hardware costs 50-70% below major brands like Allen-Bradley, Siemens, and Mitsubishi. More importantly, Click programming software is completely free with zero feature limitations, no annual subscriptions, and unlimited installations - saving thousands of dollars compared to commercial PLC programming packages.

This comprehensive Click PLC tutorial covers everything needed to successfully program and deploy Click automation systems. You'll learn Click programming software installation and configuration, ladder logic programming with Click's instruction set, analog I/O scaling and PID control implementation, Modbus RTU and Modbus TCP communication configuration, C-more HMI integration and panel design, and complete real-world application examples with working code.

Automation Direct has established itself as America's premier value automation provider, manufacturing Click PLCs domestically with the same industrial-grade quality found in premium brands. Industries including small manufacturing, machine building, packaging equipment, educational training centers, municipal water systems, and agricultural automation rely on Click PLCs for reliable, cost-effective control solutions backed by exceptional technical support.

Click PLC Product Family: Choosing Your Platform

Click BASIC: Ultra-Budget Entry Level ($79 Starting!)

Revolutionary Entry-Point Pricing: The Click BASIC series represents the most affordable programmable logic controller available in North America, with starter models beginning at just $79 for an 8-point I/O unit. This breakthrough pricing makes PLC automation accessible to hobbyists, educators, and small businesses previously limited to relay logic or Arduino-based solutions.

Click BASIC Specifications:

• 8 to 36 I/O points in compact all-in-one housing
• 24VDC discrete I/O (sinking or sourcing)
• 15K words program memory
• Built-in real-time clock
• RS-232 programming and Modbus slave port
• microsecond program scan times
• FREE Click programming software (full-featured)
• Made in USA quality and reliability

Typical Applications:

• Simple machine control replacing relay logic
• Educational training systems for schools and technical colleges
• Prototype development and proof-of-concept systems
• Small standalone equipment (pumps, conveyors, mixers)
• Home automation and hobby projects
• Low-budget retrofit projects

Key Advantages:

• Unbeatable price-to-performance ratio for budget projects
• Perfect learning platform for PLC programming students
• Same software and programming methods as advanced Click models
• Reliable industrial-grade construction despite low cost
• Exceptional technical support from Automation Direct

Limitations to Consider:

• No analog I/O capability (discrete only)
• Limited communication options (no Ethernet on BASIC)
• Non-expandable I/O (fixed configuration)
• Not suitable for motion control applications

Click PLUS: Expandable Advanced Control

Professional Features at Value Pricing: Click PLUS controllers elevate Click's capabilities with expandable I/O, analog modules, enhanced communication, and advanced instruction set while maintaining Automation Direct's value pricing philosophy. PLUS models serve as the workhorse for small to medium automation systems requiring flexibility and growth potential.

Click PLUS Core Features:

• 6 to 36 I/O points base unit
• Expandable to 220 total I/O with Click I/O expansion modules
• Analog I/O support (voltage and current)
• Modbus RTU master and slave functionality
• RS-232 and RS-485 communication ports
• High-speed counter inputs (50 kHz)
• Pulse train outputs for stepper/servo control
• Advanced math and data handling instructions
• SD card for data logging and program backup
• Real-time clock with battery backup

Communication Capabilities: The PLUS series includes dual serial ports enabling simultaneous HMI communication and Modbus networking. Configure one port for C-more HMI panel connection while using the second port for Modbus RTU device communication, eliminating the need for expensive communication modules.

Expansion Flexibility: Click's modular expansion system allows mixing and matching I/O modules to create custom configurations. Add digital input modules, digital output modules, analog input modules (voltage/current/thermocouple/RTD), analog output modules, and specialty modules as your application requires.

Price Comparison (Click PLUS vs Major Brands):

• Click PLUS 20-point starter: $229
• Siemens LOGO! equivalent: $450
• Allen-Bradley Micro820 equivalent: $525
• Savings: 50%+ on hardware alone

Click PLUS ETHERNET: Built-In Web Server

Advanced Connectivity with Ethernet: Click PLUS ETHERNET models add built-in 10/100 Ethernet communication for Modbus TCP networks, web server functionality, email/text messaging, and remote monitoring capabilities. Ethernet connectivity enables modern IoT integration while maintaining Click's value pricing.

Ethernet-Specific Features:

• Dual Ethernet ports with embedded switch
• Modbus TCP master and slave functionality
• Built-in web server for HMI visualization
• Email and SMS text messaging for alarms
• Remote programming and monitoring
• Time synchronization via NTP servers
• Integration with modern SCADA and MES systems
• Data push to cloud platforms

Web Server Capabilities: The integrated web server allows creating custom HMI screens accessible from any web browser without additional software or licensing. Display real-time data, acknowledge alarms, and control basic functions using tablets, smartphones, or computers - perfect for remote monitoring applications.

Industrial IoT Integration: Click PLUS ETHERNET controllers connect directly to cloud platforms, enabling Industry 4.0 capabilities like remote diagnostics, predictive maintenance, production monitoring, and data analytics without expensive proprietary gateways.

C-more Micro: Integrated PLC + HMI Combo

All-in-One Control and Visualization: C-more Micro panels combine Click PLC functionality with touchscreen HMI in a single integrated package, perfect for applications requiring both control logic and operator interface in space-constrained installations.

C-more Micro Specifications:

• 3.5" to 10" color touchscreen display
• Built-in Click PLC processor (PLUS equivalent)
• 6 to 20 discrete I/O points
• 2 analog inputs standard
• Ethernet and serial communication
• Recipe management and data logging
• Alarm handling with acknowledgment
• USB programming port

Best Applications:

• Panel-mounted machine controls requiring HMI
• Small equipment with limited panel space
• Mobile equipment requiring integrated control
• Educational training panels
• Test equipment and laboratory automation

Product Comparison: Selecting Your Click PLC

| Feature | Click BASIC | Click PLUS | Click PLUS ETHERNET | C-more Micro | |---------|-------------|------------|---------------------|--------------| | Base I/O | 8-36 fixed | 6-36 base | 6-36 base | 6-20 fixed | | Max Total I/O | Fixed | 220 points | 220 points | Fixed | | Analog I/O | No | Yes (expansion) | Yes (expansion) | 2 AI built-in | | Ethernet | No | No | Dual ports | Yes | | Web Server | No | No | Yes | Yes | | Program Memory | 15K words | 20K words | 20K words | 20K words | | HMI Display | No | No | No | Built-in touchscreen | | Price Range | $79-229 | $229-429 | $349-599 | $399-899 | | Best For | Learning/Simple | General purpose | Networking | Integrated HMI |

Why Click PLCs Stand Out From Competition

Free Programming Software: Unlike Siemens TIA Portal ($3,500+), Allen-Bradley Studio 5000 ($10,000+), or even Schneider Electric software ($2,000+), Click programming software is completely free with unlimited installations and no annual subscription fees. This software cost savings alone can exceed hardware costs for small projects.

Made in USA Quality: Click PLCs are designed and manufactured in Automation Direct's Georgia facilities with the same industrial-grade components and quality control processes used by premium brands. Made in USA construction ensures reliable supply chains and consistent quality.

No Minimum Orders: Buy a single PLC at the same price as thousand-unit orders. Automation Direct's direct sales model eliminates distributor minimum order requirements, making Click ideal for prototype development and small production runs.

Industry-Leading Technical Support: Free unlimited technical support via phone and email from actual engineers who understand your application. No expensive support contracts or premium hotline fees required.

Lifetime Warranty: Click PLCs include lifetime warranty coverage against manufacturing defects, demonstrating Automation Direct's confidence in product reliability and quality.

Click Programming Software: Free and Full-Featured

Software Download and Installation

Obtaining Click Programming Software: Visit AutomationDirect.com and navigate to the Support section where Click programming software is available as a free download for Windows operating systems. No registration, licensing, or payment information required - simply download and install immediately.

System Requirements:

• Windows 7, 8, 10, or 11 (32-bit or 64-bit)
• 2GB RAM minimum (4GB recommended)
• 500MB available disk space
• USB port for PLC connection
• Internet connection for software updates (optional)

Installation Process: Download the Click programming software installer package, run the setup executable with administrator privileges, accept the license agreement and select installation directory, wait for automatic installation to complete (typically 2-3 minutes), and launch Click programming software from desktop icon or start menu. No activation codes, dongles, or online verification required.

Software Updates: Automation Direct regularly releases free software updates adding features, improving stability, and supporting new hardware. Update notifications appear automatically when new versions are available, maintaining your software investment with zero ongoing costs.

Project Creation and Hardware Configuration

Starting a New Project: Launch Click programming software and select "New Project" from the File menu. The Project Wizard guides you through initial configuration including project name and description, PLC model selection (BASIC, PLUS, or PLUS ETHERNET), I/O configuration for base unit and expansion modules, and communication port settings.

Hardware Configuration Interface: The Hardware Configuration screen displays a graphical representation of your Click PLC with drag-and-drop module placement. Select your base Click unit from the product catalog, add expansion modules by dragging to expansion slots, configure I/O types (sinking/sourcing) and operating modes, set up communication ports (baud rate, parity, data bits), and verify total I/O count and memory usage.

I/O Address Assignment: Click PLCs use straightforward addressing conventions that make programming intuitive. Discrete inputs use X addresses (X001-X220), discrete outputs use Y addresses (Y001-Y220), analog inputs use XD addresses (XD1-XD32), analog outputs use YD addresses (YD1-YD32), internal control relays use C addresses (C1-C2000), and timers use T addresses (T1-T500).

Programming Interface Overview

Main Screen Layout: The Click programming environment provides an intuitive ladder logic editor with familiar relay logic representation. Key interface components include the instruction toolbar containing common instructions, project tree showing program organization, ladder editor workspace for logic development, status bar displaying cursor position and scan information, and output window showing compile results and diagnostics.

Instruction Palette: Click programming software organizes instructions into logical categories for easy access. Available instruction groups include basic relay instructions (contacts, coils, set/reset), timer and counter instructions, comparison and math operations, data movement and conversion, communication instructions, PID control functions, and specialty functions (high-speed counter, pulse output).

Drag-and-Drop Programming: Create ladder logic programs by dragging instructions from the palette directly to the ladder rungs. This intuitive approach eliminates memorization of instruction mnemonics while maintaining professional ladder logic conventions.

Multiple Editor Views: Switch between ladder logic view for intuitive programming, instruction list view for text-based editing, and address view for tag-based programming. Each view represents the same program logic with different visualization options.

Ladder Logic Programming Fundamentals

Basic Ladder Logic Structure: Click ladder logic programs consist of rungs evaluated from left to right, top to bottom in each scan cycle. Each rung begins with input conditions (contacts) on the left side and concludes with output instructions (coils) on the right side, following traditional relay logic conventions.

Contact Instructions: Normally open contacts (examine if closed) allow logic continuity when the referenced address is ON. Normally closed contacts (examine if open) allow logic continuity when the referenced address is OFF. Use contacts to test input states, output states, internal relay states, timer/counter status, and comparison results.

Coil Instructions: Standard output coils energize when logic continuity exists. Set coils latch an address ON and remain ON until reset. Reset coils turn an address OFF. Positive transition coils pulse for one scan when logic goes true. Negative transition coils pulse for one scan when logic goes false.

Programming Best Practices: Organize programs into logical sections with descriptive comments. Use meaningful tag names instead of raw addresses when possible. Document rung logic with clear descriptions. Avoid overly complex rungs (break into multiple simpler rungs). Test programs thoroughly using simulator mode before downloading to hardware.

Simulator Mode: Test Without Hardware

Integrated Simulation Environment: Click programming software includes a powerful simulator that executes ladder logic on your computer without requiring connected PLC hardware. This invaluable feature enables program development, testing, and debugging before hardware availability, significantly reducing commissioning time and field troubleshooting.

Starting Simulation: Click the "Simulate" button in the toolbar to enter simulation mode. The software compiles your ladder logic and begins executing scan cycles just as real PLC hardware would. Watch rung logic highlight as it evaluates, force inputs and outputs to specific states, monitor timer and counter values in real-time, and step through program execution one rung at a time.

Simulation Capabilities: Force input states to simulate sensor conditions, toggle internal relays to test different logic paths, modify timer/counter presets and observe behavior, inject faults to verify error handling logic, verify communication instruction operation, and test analog scaling calculations without hardware.

Debugging Tools: Set breakpoints to pause execution at specific rungs. Single-step through logic to observe detailed execution flow. Watch windows display real-time address values. Data table view shows entire memory map. Cross-reference tools locate all uses of specific addresses.

Ladder Logic Programming with Click PLCs

Click Instruction Set Overview

Basic Relay Instructions: Click PLCs implement standard relay logic instructions found in all major PLC brands, ensuring programmers familiar with other platforms can immediately apply existing knowledge. Basic instructions include examine if closed (normally open contact), examine if open (normally closed contact), output energize (standard coil), set (latch ON), reset (latch OFF), positive transition (one-shot rising), and negative transition (one-shot falling).

Timer Instructions: Click provides three timer types for different application needs. On-delay timers (TON) energize output after preset time delay expires, commonly used for motor start delays and settling times. Off-delay timers (TOF) energize output immediately and hold after input goes false for preset time. Retentive timers (TONR) accumulate time across multiple ON periods until preset value reached.

Timer Resolution: Click timers support millisecond, 0.01 second, 0.1 second, and 1 second time bases, enabling applications from high-speed events to long-duration processes. Select appropriate time base for each timer to optimize precision and memory usage.

Counter Instructions: Up counters (CTU) increment on each input transition until reaching preset value. Down counters (CTD) decrement from preset value to zero. Up/down counters (CTUD) count in both directions based on separate increment and decrement inputs. All counter types include reset inputs for initialization.

High-Speed Counters: Click PLUS and PLUS ETHERNET models provide hardware high-speed counter inputs capable of 50 kHz input frequencies, perfect for encoder feedback, flow measurement, and rapid event counting beyond standard PLC scan rates.

Math and Comparison Operations

Arithmetic Instructions: Click PLCs perform standard math operations on integer and floating-point values. Addition, subtraction, multiplication, and division instructions process 16-bit or 32-bit numbers with overflow detection. Advanced functions include square root, absolute value, logarithms, trigonometric functions, and modulo operations.

Comparison Instructions: Logic decisions require comparison operations testing relationships between values. Available comparisons include equal, not equal, greater than, greater than or equal, less than, and less than or equal. Compare integers, floating-point values, analog readings, or calculated results.

Data Type Handling: Click supports multiple data types including 16-bit signed integers (-32,768 to +32,767), 32-bit signed integers, 32-bit floating-point numbers for analog values and calculations, binary-coded decimal (BCD), and ASCII strings for communication and display.

Example Program: Conveyor Control System

Application Requirements: Design a simple conveyor control system demonstrating fundamental Click programming concepts. The system includes a conveyor motor controlled by start and stop pushbuttons with safety interlocks, photo eye sensor detecting package presence for downstream equipment, emergency stop circuit with safety relay integration, hour meter tracking total runtime for maintenance scheduling, and package counter displaying total throughput.

I/O Assignment:

Inputs:
X1 - Start pushbutton (NO, momentary)
X2 - Stop pushbutton (NC, maintained)
X3 - Emergency stop (NC, maintained)
X4 - Safety relay feedback (NO)
X5 - Photo eye sensor (NO, active high)
X6 - Reset pushbutton (NO, momentary)

Outputs:
Y1 - Conveyor motor contactor
Y2 - Run indicator light (green)
Y3 - Stop indicator light (red)
Y4 - Fault indicator light (amber)

Internal Memory:
C1 - Motor run control relay
C2 - Start seal-in relay
T1 - Hour meter timer (retentive)
CTU1 - Package counter

Ladder Logic Program:

Rung 1: Start/Stop Control with Safety Interlocks
|---] [---] [---] [---]/[----------(C1)---|
    X1    C2    X2    X3

Rung 2: Seal-In Contact
|---] [---------------------------------(C2)---|
    C1

Rung 3: Safety Relay Verification
|---] [---] [----------------------(Y1)---|
    C1    X4

Rung 4: Run Indicator Light
|---] [---------------------------------(Y2)---|
    Y1

Rung 5: Stop Indicator Light
|---]/[---------------------------------(Y3)---|
    Y1

Rung 6: Hour Meter (Retentive Timer)
|---] [--[TONR T1, Preset: 36000]----|
    Y1

Rung 7: Package Counter Increment
|---] [----[CTU CTU1, Preset: 9999]----|
    X5

Rung 8: Counter Reset
|---] [------[RST CTU1]----------------|
    X6

Rung 9: Fault Detection
|---]/[---]/[----------------------(Y4)---|
    X2    X3

Program Operation: Pressing the start button (X1) energizes control relay C1 when stop button (X2) and emergency stop (X3) are both closed. Control relay C1 seals itself in through contact C2 for maintained operation. Motor contactor Y1 energizes only when C1 is ON and safety relay feedback X4 confirms proper safety circuit operation. Retentive timer T1 accumulates runtime hours for maintenance scheduling. Photo eye sensor X5 increments counter CTU1 on each package detection. Fault light Y4 illuminates when stop or emergency stop circuits are open.

Memory Organization and Addressing

Click Memory Map: Understanding Click's memory structure enables efficient program development and troubleshooting. The memory map includes discrete I/O areas (X001-X220 inputs, Y001-Y220 outputs), analog I/O areas (XD1-XD32 analog inputs, YD1-YD32 analog outputs), internal control relays (C1-C2000 general purpose), system control relays (SC special function bits), timer memory (T1-T500), counter memory (CT1-CT250), data registers (DS 16-bit signed integers, DD 32-bit signed integers, DF 32-bit floating-point), and text/string memory for communication.

Tag-Based Addressing: While direct addressing works perfectly for simple programs, Click software supports tag-based programming where you assign meaningful names to addresses. Instead of remembering Y5 controls the conveyor motor, create a tag "ConveyorMotor" linked to Y5. Tags improve program readability and simplify troubleshooting.

Indirect Addressing: Advanced programs use pointer-based addressing where the target address is stored in a variable. This powerful technique enables array operations, recipe management, and dynamic memory access without hardcoding specific addresses.

Analog I/O Programming and Scaling

Understanding Click Analog Modules

Analog Input Module Types: Click analog input modules accept various signal types to interface with industrial sensors and transmitters. Voltage input modules accept 0-10VDC or -10 to +10VDC signals from analog sensors. Current input modules accept 0-20mA or 4-20mA signals from process transmitters. Thermocouple modules directly interface with Type J, K, T, E, N thermocouples for temperature measurement. RTD modules accept Pt100 and Pt1000 resistance temperature detectors.

Analog Output Module Types: Analog output modules control variable speed drives, control valves, and analog instrumentation. Voltage output modules provide 0-10VDC signals for devices requiring voltage control. Current output modules provide 0-20mA or 4-20mA signals for industrial actuators and positioners.

Resolution and Accuracy: Click analog modules use 12-bit resolution providing 4096 distinct values across the input/output range. For a 0-10VDC signal, resolution equals approximately 2.4mV per count. This resolution proves sufficient for most industrial applications including temperature control, pressure monitoring, and flow regulation.

Raw Value Scaling Techniques

Understanding Raw Analog Values: Click PLCs store analog input values as raw integers from 0 to 4095 (12-bit resolution). For useful program logic, convert these raw values to engineering units representing actual process variables like temperature, pressure, flow rate, or level.

Linear Scaling Formula: The basic linear scaling equation converts raw analog values to engineering units:

Scaled Value = ((Raw Value - Raw Min) × (Eng Max - Eng Min)) / (Raw Max - Raw Min) + Eng Min

Example Scaling Calculation: Scale a 4-20mA pressure transmitter (0-100 PSI range) connected to Click analog input:

• Raw value at 4mA (0 PSI): 819 counts
• Raw value at 20mA (100 PSI): 4095 counts
• Formula: PSI = ((Raw - 819) × (100 - 0)) / (4095 - 819) + 0
• Simplified: PSI = (Raw - 819) × 0.03055

Click Scaling Instruction: Click programming software includes built-in scaling instructions that simplify analog conversion. The SCALE instruction automatically performs linear interpolation given raw minimum, raw maximum, engineering minimum, and engineering maximum values.

Scaling Instruction Example:

Rung 1: Scale Analog Input to Engineering Units
|----[SCALE]--------------------------|
     Source: XD1 (raw analog input)
     Raw Min: 819
     Raw Max: 4095
     Eng Min: 0.0
     Eng Max: 100.0
     Destination: DF1 (pressure in PSI)

PID Control Implementation

PID Loop Basics: Proportional-Integral-Derivative (PID) control maintains process variables at desired setpoints by continuously calculating error values and applying corrective actions. Click PLCs include dedicated PID instructions for temperature control, pressure regulation, flow control, and level management.

PID Instruction Parameters: Configure Click PID loops with process variable input (analog input address), setpoint value (desired target), output address (analog output for control), proportional gain (Kp), integral time (Ki), derivative time (Kd), loop update time, output limits (minimum and maximum), and auto/manual mode selection.

Temperature Control Example: Implement a simple oven temperature control system using Click PID:

Application: Maintain oven temperature at 350°F
Analog Input XD1: Thermocouple (0-600°F)
Analog Output YD1: Electric heater control (0-100%)

Rung 1: PID Temperature Control
|----[PID]------------------------------|
     PV Input: DF1 (scaled temperature)
     Setpoint: DF2 (target = 350.0)
     Output: DF3 (heater control 0-100)
     Kp: 2.0
     Ki: 0.5
     Kd: 0.1
     Update Time: 1.0 seconds
     Output Min: 0.0
     Output Max: 100.0

PID Tuning Guidelines: Start with conservative gains and adjust incrementally. Increase proportional gain until system oscillates, then reduce by 50%. Add integral action to eliminate steady-state error. Add derivative action for fast-changing processes requiring damping. Monitor system response and adjust parameters based on observed performance.

Communication Capabilities

Modbus RTU Communication

Modbus Protocol Support: Click PLUS and PLUS ETHERNET models function as both Modbus master (initiating communication) and Modbus slave (responding to requests) on RS-232 or RS-485 networks. This flexibility enables Click PLCs to interface with HMIs, SCADA systems, variable frequency drives, remote I/O, and third-party devices using the industry-standard Modbus protocol.

RS-485 Network Wiring: Modbus RTU networks typically use RS-485 two-wire or four-wire connections supporting up to 32 devices across 4,000 feet. Proper wiring requires twisted pair cable (Belden 9841 or equivalent), 120-ohm termination resistors at network endpoints, proper shield grounding at one point only, and consistent polarity (A/B or +/-) across all devices.

Modbus Master Configuration: Configure Click as Modbus master to read/write data from slave devices like VFDs, remote I/O modules, and instrumentation. Define slave addresses, function codes (read coils, read registers, write registers), starting addresses, data length, timeout values, and retry counts. Click automatically handles message formatting, CRC calculation, and error detection.

Modbus Slave Configuration: Configure Click as Modbus slave to respond to SCADA/HMI requests. Map Click memory addresses to Modbus register addresses, configure slave ID (1-247), set baud rate and communication parameters, and enable Modbus slave functionality on desired communication port.

Complete Modbus Example: Read motor speed from VFD (Modbus slave address 1) and write speed setpoint:

Rung 1: Read VFD Speed (Function Code 3, Register 8192)
|---[MOD_READ]-------------------------|
    Slave Address: 1
    Function Code: 3 (Read Holding Registers)
    Starting Register: 8192
    Quantity: 1
    Destination: DS100 (motor speed RPM)
    Port: Port 2

Rung 2: Write VFD Speed Setpoint (Function Code 6, Register 0)
|---[MOD_WRITE]------------------------|
    Slave Address: 1
    Function Code: 6 (Write Single Register)
    Register: 0
    Value: DS200 (speed setpoint)
    Port: Port 2

Modbus TCP Ethernet Communication

Ethernet Network Configuration: Click PLUS ETHERNET models include dual Ethernet ports for industrial networking. Configure IP address (static or DHCP), subnet mask, default gateway, and DNS servers through programming software. The built-in Ethernet switch enables daisy-chain topology reducing network infrastructure requirements.

Modbus TCP vs RTU: Modbus TCP encapsulates Modbus protocol in TCP/IP packets for Ethernet networks. While register addressing and function codes remain identical to Modbus RTU, Modbus TCP eliminates baud rate configuration, enables higher data rates (10/100 Mbps), supports unlimited network nodes, and simplifies network diagnostics using standard IT tools.

Modbus TCP Programming: Click Modbus TCP instructions mirror RTU functionality with Ethernet-specific parameters. Specify target device IP address instead of slave ID, use same function codes and register addressing, configure connection timeout and retry parameters, and monitor connection status for diagnostic purposes.

Email and Text Messaging

Built-In Notification Capabilities: Click PLUS ETHERNET models send email and SMS text messages directly from ladder logic, enabling automated alarm notifications, production reports, and remote monitoring alerts without external gateways or special hardware.

Email Configuration: Configure SMTP server settings (Gmail, Outlook, corporate mail servers), authentication credentials, sender and recipient addresses, and message formatting options. Email instructions trigger from ladder logic conditions sending custom messages with variable data.

Practical Application:

Rung 1: High Temperature Alarm Email
|---] [---]/[---[EMAIL]----------------|
    High_Temp  Alarm_Sent

    To: maintenance@company.com
    Subject: "Oven High Temperature Alarm"
    Body: "Oven temperature exceeded 400F at " + DATETIME$

Practical Application Examples

Example 1: Small Packaging Machine Control

Application Description: Design an automated packaging machine for small production runs requiring product counting, pneumatic cylinder sequencing, safety interlocking, and basic HMI interaction. This example demonstrates typical small business automation using Click PLUS with C-more Micro HMI.

Machine Operation Sequence:

1. Operator presses start button on HMI
2. Product sensor detects item entering packaging station
3. Stop cylinder extends, holding product in position
4. Packaging material dispenser activates for preset time
5. Heat sealer activates sealing package
6. Stop cylinder retracts, releasing packaged product
7. Product counter increments
8. Sequence repeats until stop button pressed or count target reached

I/O Assignment:

Inputs:
X1 - Product sensor (photo eye, NO)
X2 - Stop cylinder extended limit switch
X3 - Stop cylinder retracted limit switch
X4 - Safety gate closed (NC)
X5 - Air pressure switch (NO)

Outputs:
Y1 - Stop cylinder solenoid (extend)
Y2 - Material dispenser valve
Y3 - Heat sealer output
Y4 - Machine ready lamp (green)
Y5 - Cycle active lamp (amber)
Y6 - Fault lamp (red)

HMI Tags:
C10 - Start command from HMI
C11 - Stop command from HMI
C12 - Reset command from HMI
DS10 - Product count setpoint
DS11 - Current product count
DS12 - Dispenser time setpoint (0.1 sec)
DS13 - Sealer time setpoint (0.1 sec)

Ladder Logic Program:

Rung 1: Machine Ready Conditions
|---] [---] [---] [-------------------( C20 )---|
    X4    X5    C12  (Safety OK)

Rung 2: Start Cycle Logic
|---] [---] [---] [---]/[----------( C21 )---|
    C10   C20   X1    C22  (Start if ready and product detected)

Rung 3: Stop Cylinder Extend
|---] [----------------------------( Y1 )---|
    C21

Rung 4: Wait for Cylinder Extended
|---] [---] [---[TON T1, 0.5s]----( C23 )---|
    C21   X2  (Timeout if cylinder doesn't extend)

Rung 5: Material Dispenser Control
|---] [---[TON T2, DS12]-----------( Y2 )---|
    C23

Rung 6: Heat Sealer Control
|---] [---[TON T3, DS13]-----------( Y3 )---|
    T2.DN

Rung 7: Retract Cylinder After Sealing
|---]/[----------------------------( Y1 )---|
    T3.DN

Rung 8: Cycle Complete Detection
|---] [---] [---[P_TRAN]----------( C22 )---|
    T3.DN  X3  (Pulse when retracted)

Rung 9: Increment Product Counter
|---] [---[CTU DS11, DS10]--------|
    C22

Rung 10: Reset Counter
|---] [---[RST DS11]---------------|
    C12

Rung 11: Machine Ready Lamp
|---] [----------------------------( Y4 )---|
    C20

Rung 12: Cycle Active Lamp
|---] [----------------------------( Y5 )---|
    C21

Rung 13: Fault Detection
|---]/[---]/[---] [---------------( Y6 )---|
    X4    X5    T1.DN  (Safety or timeout fault)

Example 2: Environmental Control System

Application Description: Implement a greenhouse environmental control system maintaining temperature and humidity using Click PLUS with analog I/O. System controls exhaust fans, heating, misting system, and provides data logging to SD card.

System Components:

• Temperature sensor (0-10VDC = 32-122°F)
• Humidity sensor (0-10VDC = 0-100% RH)
• Exhaust fan with VFD (4-20mA speed control)
• Electric heating (analog output 0-100%)
• Misting solenoid valve (discrete output)
• Data logging to SD card (every 15 minutes)

Control Logic: Temperature control uses PID algorithm modulating exhaust fan speed and heating output to maintain 72°F setpoint. Humidity control activates misting when humidity drops below 60% and deactivates above 75%. All sensor readings log to SD card with timestamp for historical analysis.

Key Program Elements:

Rung 1: Scale Temperature Input (XD1 to 32-122°F)
|---[SCALE XD1, 0, 4095, 32.0, 122.0, DF1]---|

Rung 2: Scale Humidity Input (XD2 to 0-100%)
|---[SCALE XD2, 0, 4095, 0.0, 100.0, DF2]---|

Rung 3: Temperature PID Control
|---[PID DF1, 72.0, DF10, Kp:2.0, Ki:0.5, Kd:0.1]---|

Rung 4: Map PID Output to Fan Speed (4-20mA)
|---[SCALE DF10, 0.0, 100.0, 819, 4095, YD1]---|

Rung 5: Humidity Control - Misting ON
|---] [----------------------------( Y10 )---|
    DF2 < 60.0

Rung 6: Humidity Control - Misting OFF
|---]/[----------------------------( Y10 )---|
    DF2 > 75.0

Rung 7: Data Logging Timer (15 minutes)
|---[TON T10, 900s]---[P_TRAN]----( C50 )---|
                      T10.DN

Rung 8: Write Data Log Entry
|---] [---[SD_WRITE]----------------|
    C50   File: "DATALOG.CSV"
          Data: DATETIME$, DF1, DF2, DF10

Example 3: Tank Level Monitoring with Email Alerts

Application Description: Monitor water tank level using ultrasonic sensor, control fill pump automatically, and send email alerts for high/low level alarms. Click PLUS ETHERNET provides Modbus communication with remote SCADA and email notification capabilities.

System Requirements:

• Ultrasonic level sensor (4-20mA = 0-10 feet)
• Fill pump control (discrete output)
• High level alarm (email notification)
• Low level alarm (email notification)
• Remote monitoring via Modbus TCP
• HMI display showing current level

Control Strategy: Automatically start fill pump when level drops below 3 feet, stop pump when level reaches 8 feet. Send high level alarm email if level exceeds 9 feet. Send low level alarm email if level drops below 2 feet. Publish current level via Modbus TCP for SCADA integration.

Implementation:

Rung 1: Scale Level Sensor (4-20mA to 0-10 feet)
|---[SCALE XD1, 819, 4095, 0.0, 10.0, DF1]---|

Rung 2: Pump Start Logic (Level < 3 feet)
|---] [---] [-------------------( C30 )---|
    DF1<3.0  Y1  (Seal-in)

Rung 3: Pump Stop Logic (Level > 8 feet)
|---]/[----------------------------( C30 )---|
    DF1>8.0

Rung 4: Pump Output
|---] [----------------------------( Y1 )---|
    C30

Rung 5: High Level Alarm Detection
|---] [---]/[---[P_TRAN]----------( C31 )---|
    DF1>9.0  C32  (Pulse on alarm)

Rung 6: Send High Level Email
|---] [---[EMAIL]------------------|
    C31   To: "ops@company.com"
          Subject: "Tank High Level Alarm"
          Body: "Level: " + STRING(DF1) + " feet"

Rung 7: Set High Alarm Sent Flag
|---] [----------------------------( C32 )---|
    C31

Rung 8: Reset High Alarm Flag (Level drops)
|---]/[----------------------------( C32 )---|
    DF1<8.5

Rung 9: Low Level Alarm Detection
|---] [---]/[---[P_TRAN]----------( C33 )---|
    DF1<2.0  C34  (Pulse on alarm)

Rung 10: Send Low Level Email
|---] [---[EMAIL]------------------|
    C33   To: "ops@company.com"
          Subject: "Tank Low Level Alarm"
          Body: "Level: " + STRING(DF1) + " feet"

C-more Micro HMI Integration

C-more Panel Selection

Panel Size Options: C-more Micro panels combine Click PLC functionality with integrated touchscreen HMI in various screen sizes. 3.5" panels suit compact machines and tight spaces. 4.3" panels balance screen real estate with space constraints. 7" panels provide comfortable viewing and interaction. 10" panels offer maximum screen space for complex visualization.

Integrated vs Standalone: C-more Micro panels include built-in Click PLC processor eliminating separate PLC hardware, perfect for applications requiring both control and visualization. Alternatively, connect standalone C-more EA9 touchscreens to existing Click PLUS or PLUS ETHERNET controllers via Ethernet or serial communication.

Panel Specifications: All C-more Micro panels feature color TFT touchscreen displays, LED backlight with adjustable brightness, built-in Click PLUS equivalent PLC processor, discrete and analog I/O points, Ethernet and serial communication, USB programming port, recipe management with 32 recipes, data logging to SD card or USB, alarm management with acknowledge/reset, and trend graphs displaying up to 8 variables.

Creating C-more HMI Screens

C-more Programming Software: Download free C-more programming software from AutomationDirect.com providing complete HMI development capabilities. The graphical development environment includes drag-and-drop screen design, extensive object library (buttons, indicators, numeric displays, bar graphs, trends), animation and graphics support, multi-language capability, and integrated simulator for testing.

Screen Development Process: Create new C-more project selecting panel model. Design main overview screen showing key process variables. Add navigation buttons linking to detail screens. Create alarm summary screen with acknowledge functionality. Design trending screens for historical data viewing. Configure recipes for product changeover. Build user login and security access screens.

Common HMI Objects: Numeric displays show real-time process values from Click PLC tags. Selector switches control mode selection and enable/disable functions. Momentary buttons trigger discrete actions (start, stop, reset). Indicator lamps display status conditions color-coded for quick recognition. Bar graphs visualize analog values as percentage scales. Trend graphs plot historical data over time. Text fields display messages and alarm descriptions.

Tag Database Linking

Direct Memory Mapping: C-more Micro panels with integrated Click PLC processor access PLC memory directly using standard Click addressing (X, Y, C, DS, DF). No communication configuration required - HMI objects link directly to PLC addresses providing real-time data display and control.

Standalone C-more to Click Communication: External C-more EA9 panels communicate with Click PLCs via Ethernet (Modbus TCP) or serial (Modbus RTU). Configure communication driver specifying Click PLC IP address or serial parameters. Import Click tag database into C-more project for simplified object linking.

Tag-Based Programming: Use meaningful tag names instead of raw addresses improving HMI clarity. Create tag "TankLevel" linked to DF1. Create tag "PumpRunning" linked to Y1. Create tag "Setpoint" linked to DS10. HMI objects reference tag names making screen logic readable and maintainable.

Alarms and Trending

Alarm Configuration: Define alarm conditions monitoring process variables for out-of-range situations. Configure high alarms (temperature >400°F), low alarms (pressure <10 PSI), discrete alarms (safety gate open), and system alarms (communication loss, memory errors). Specify alarm priority (critical, warning, information), alarm message text, and acknowledge requirements.

Alarm Display: C-more alarm summary screen shows active alarms sorted by priority and timestamp. Operators acknowledge alarms by touching alarm entry, clearing display after condition normalizes. Alarm history logs maintain 1000+ alarm events with date, time, description, and acknowledgment information.

Trend Configuration: Historical trends visualize process behavior over time aiding troubleshooting and optimization. Configure sample rate (1 second to 60 minutes), time span displayed (1 hour to 30 days), auto-scaling or fixed scale, multiple pen colors for different variables, and touch-to-query for specific value inspection.

Data Logging: Log process data to SD card or USB drive for long-term analysis. Configure logging intervals, variable list, file format (CSV for Excel compatibility), and automatic file rollover preventing memory overflow. Export logged data for analysis in Excel, database applications, or statistical software.

Cost Analysis: Click vs Major Brand PLCs

Complete System Cost Comparison

Sample Project: 32 I/O Control System Compare total project costs for small manufacturing application requiring 32 discrete I/O points, 4 analog inputs, 2 analog outputs, Ethernet communication, HMI touchscreen, and programming software.

Click PLC System:

• Click PLUS ETHERNET 20-point base: $349
• 16-point input expansion module: $119
• 8-point analog input module: $169
• 2-point analog output module: $139
• C-more EA9-T7CL 7" touchscreen: $499
• Programming software (Click + C-more): FREE
• Ethernet cables and mounting: $50
• Total Click System Cost: $1,325

Allen-Bradley Micro850 System:

• Micro850 24-point controller: $525
• 16-point expansion module: $295
• Analog combination module: $425
• PanelView 800 7" HMI: $1,195
• Connected Components Workbench: FREE (for Micro800)
• Cables and mounting: $75
• Total Allen-Bradley Cost: $2,515

Siemens LOGO! System:

• LOGO! 8 12/24 RCE: $385
• Digital expansion modules (2×): $380
• Analog modules (2×): $520
• KTP700 Basic HMI: $875
• LOGO! Soft Comfort + WinCC Basic: $350
• Cables and mounting: $60
• Total Siemens Cost: $2,570

Cost Savings Summary: Click system saves $1,190 (47%) compared to Allen-Bradley and $1,245 (48%) compared to Siemens for equivalent functionality. These savings multiply across multiple machines for OEM builders or facilities with multiple control points.

Software Licensing Savings

Click Software Investment: $0 Automation Direct provides completely free programming software with unlimited installations, no annual fees, free updates forever, no feature limitations, and free technical support. Install on office computers, shop floor stations, and customer sites without licensing restrictions.

Major Brand Software Costs: Allen-Bradley Studio 5000 Standard Edition costs $10,725 with $2,145 annual support fees. Siemens TIA Portal Professional costs $3,500+ with annual updates at $700+. Schneider Electric EcoStruxure costs $2,000+ depending on features. Mitsubishi GX Works costs $1,500+ with update fees.

Lifetime Software Savings: Over a typical 10-year equipment lifecycle, Click's free software saves $5,000-$15,000+ per programming station compared to major brands requiring software purchases and maintenance contracts. Multiple programming stations multiply savings proportionally.

Training Cost Comparison

Click Learning Curve: Click's intuitive programming environment and excellent documentation enable self-directed learning with minimal formal training investment. Free online resources include video tutorials, application examples, webinars, and user forums. Most engineers become proficient with Click programming within 1-2 weeks of self-study.

Major Brand Training: Professional training courses for Siemens, Allen-Bradley, and Schneider Electric typically cost $1,500-$3,000 per student for 3-5 day classes. Advanced courses add additional costs. Factor in travel expenses, hotel accommodations, and lost productivity during training weeks.

Training ROI: Click's simplified programming model and free learning resources eliminate training course requirements for most applications, saving thousands of dollars per engineer while achieving productivity faster than major brand training schedules.

Total Cost of Ownership

5-Year TCO Analysis (Small Manufacturer with 10 Control Points):

Click Platform:

• Hardware (10 systems): $13,250
• Software licenses: $0
• Annual software maintenance: $0
• Training: $0 (self-directed)
• Technical support: $0 (included free)
• Spare parts inventory: $1,000
• 5-Year TCO: $14,250

Major Brand Platform (Average):

• Hardware (10 systems): $25,000
• Software licenses (2 stations): $8,000
• Annual software maintenance: $3,500 ($700/year × 5)
• Training (2 engineers): $6,000
• Technical support contracts: $2,500
• Spare parts inventory: $2,000
• 5-Year TCO: $47,000

Savings Calculation: Click platform saves $32,750 (70%) over 5 years for this small manufacturer example. Larger facilities with more control points see proportionally higher savings, potentially reaching six figures for plant-wide deployments.

Return on Investment Example

Small Business Automation Project: A small packaging company currently using relay logic considers automating a production line. Initial automation investment includes PLC hardware, HMI, programming time, and installation labor.

Project Costs:

• Click system hardware: $1,500
• Installation labor (16 hours × $75/hr): $1,200
• Programming/commissioning (20 hours × $100/hr): $2,000
• Total Investment: $4,700

Annual Benefits:

• Reduced scrap (2% improvement × $50k material): $1,000
• Increased throughput (5% improvement × $200k revenue × 15% margin): $1,500
• Reduced labor (0.5 operator hours/day × 250 days × $25/hr): $3,125
• Reduced maintenance (better monitoring): $500
• Total Annual Savings: $6,125

ROI Calculation: Payback period = $4,700 ÷ $6,125 = 9.2 months. First-year ROI = 30%. Five-year total return = $26,000+ on $4,700 investment.

The accessible pricing of Click PLCs makes automation economically viable for small businesses and applications previously unable to justify major brand control systems.

When to Choose Click PLC

Ideal Click PLC Applications

Budget-Constrained Projects: Click PLCs excel when project budgets limit automation spending but programmable control provides significant value over relay logic or Arduino-based solutions. Small businesses, startups, non-profits, and educational institutions benefit most from Click's low total cost of ownership.

Small to Medium Automation Systems: Projects requiring up to 220 I/O points with moderate complexity perfectly match Click capabilities. Typical applications include packaging machinery, material handling, environmental control, machine tools, test equipment, municipal infrastructure, and agricultural automation.

Educational Training Platforms: Schools, technical colleges, and training centers choose Click for automation curriculum due to free software, affordable hardware for multiple training stations, and industry-relevant programming environment. Students gain transferable skills applicable to major brand PLCs.

OEM Machines (Cost-Sensitive Markets): Machine builders serving price-sensitive markets or developing countries utilize Click PLCs to maintain competitive pricing while delivering reliable programmable control. The lifetime warranty and Made in USA quality ensure end-user satisfaction.

Prototype and Proof-of-Concept Development: Engineers developing new automation concepts use Click for rapid prototyping without large upfront investment. Quick testing validates concepts before committing to production hardware purchases.

Standalone Equipment Control: Individual machines requiring local control without complex networking or high-speed motion control benefit from Click's simplicity and value. Examples include mixers, pumps, HVAC, conveyors, and production workstations.

When Major Brand PLCs Suit Better

Mission-Critical Applications: Systems where downtime costs exceed $10,000/hour or where safety-critical applications require SIL-rated PLCs should use major brand platforms with proven field track records in critical applications. Examples include pharmaceutical processing, primary metals, power generation, and oil/gas.

Complex Multi-Axis Motion Control: Applications requiring more than 4 coordinated servo axes, advanced motion profiles, CNC-style programming, or robotics integration exceed Click motion capabilities. Choose specialized motion controllers from Siemens, Allen-Bradley, Beckhoff, or Delta AS series.

Large Distributed Systems (>500 I/O): Facilities with thousands of I/O points distributed across extensive geographical areas benefit from major brand redundant processors, distributed I/O architectures, and advanced networking capabilities beyond Click's design scope.

Proprietary Ecosystem Requirements: Projects requiring integration with existing Allen-Bradley, Siemens, or Schneider Electric networks may necessitate staying within those ecosystems for communication protocol compatibility and engineering efficiency.

Advanced Safety Integration: Applications requiring integrated safety PLCs with safety-rated I/O, safety over EtherNet/IP, and certified safety function blocks need major brand safety platforms (GuardLogix, S7-1500F, Modicon Safety).

High-Speed Process Control: Ultra-fast scan times (<1ms), complex PID loops, model predictive control, or advanced process algorithms may require high-performance major brand processors beyond Click capabilities.

Decision Matrix

Use this matrix to evaluate Click PLC suitability for your project:

| Criteria | Click Excellent Fit | Consider Major Brand | |----------|---------------------|----------------------| | Budget | <$5,000 total system | >$10,000 total system | | I/O Count | <220 points | >500 points | | Motion Axes | 0-4 axes simple positioning | >4 axes coordinated | | Downtime Cost | <$1,000/hour | >$10,000/hour | | Networking | Modbus RTU/TCP sufficient | Proprietary protocols required | | Safety Rating | Standard control only | SIL-rated safety required | | Engineer Experience | Learning or multi-brand | Single-brand specialist | | Support Model | Self-sufficient or phone support | On-site factory support needed | | Timeline | Quick deployment (<3 months) | Long-term project (>1 year) |

The Sweet Spot: Click PLCs perfectly serve the vast middle market of small-to-medium automation projects where reliability, functionality, and cost matter more than brand prestige or advanced enterprise features. This represents 60-70% of automation applications worldwide.

Best Practices for Click PLC Programming

Program Organization Strategies

Logical Program Structure: Organize Click programs into clear functional sections improving readability and maintenance. Recommended structure includes initialization section (first-scan setup, system defaults), input conditioning section (debouncing, scaling, conversions), main control logic section (sequencing, interlocking, safety), output driver section (final output control, safety overrides), communication section (Modbus, HMI, networking), and diagnostics section (fault detection, troubleshooting aids).

Using Subroutines Effectively: Click software supports subroutines (separate ladder logic sections called from main program) for repeated logic sequences, complex calculations executed conditionally, and maintaining manageable rung counts per section. Subroutines improve program organization and troubleshooting efficiency.

Descriptive Commenting: Document programs thoroughly with rung comments explaining logic purpose, section headers dividing program functionality, I/O descriptions identifying physical devices, setpoint notes documenting adjustment ranges, and revision history tracking program changes over time.

Tag Naming Conventions: Establish consistent naming standards like PascalCase for tag names (TankLevelSetpoint), descriptive prefixes (btn_Start, ind_Running, val_Temperature), meaningful abbreviations (Temp not T, Press not P), and avoiding cryptic shorthand that confuses future maintenance.

Documentation Requirements

Hardware Documentation: Maintain accurate records including electrical schematics showing I/O connections, panel layout drawings identifying component locations, wiring diagrams with wire numbers and termination points, bill of materials listing all components, and configuration settings for all network devices.

Software Documentation: Document all programming elements including ladder logic program with comprehensive comments, tag database with descriptions of every address, Modbus mapping showing register assignments, HMI screen documentation explaining operator interface, and revision history tracking changes and reasons.

Operational Documentation: Create user-friendly materials including operator instructions for normal operation, startup and shutdown procedures, troubleshooting guides for common issues, maintenance schedules for routine service, and emergency procedures for fault conditions.

Backup Procedures

Regular Program Backups: Establish backup routines protecting against program loss. Upload PLC program to computer regularly, save backups with date-stamped filenames (ClickProgram_2025-12-11.zip), store backups in multiple locations (local computer, network drive, cloud storage), include HMI programs in backup procedures, and verify backup integrity by test restores periodically.

Version Control: Implement simple version control tracking program evolution. Number program versions (v1.0, v1.1, v2.0), document changes in revision notes, maintain previous versions for rollback capability, include version number in program comments, and update documentation to match current version.

On-Machine Backup: Store backup copies on equipment using Click SD card slot for program storage, printed ladder logic diagrams in electrical cabinet, laminated quick reference guides, spare PLC with backup program loaded, and documented backup/restore procedures for maintenance personnel.

Panel Design Tips for Click PLCs

Mounting and Clearances: Install Click PLCs per manufacturer specifications ensuring proper ventilation clearances (minimum 2" above/below), DIN rail mounting with secure end clips, vertical orientation preferred for natural convection cooling, separation from heat-generating components, and accessibility for programming cable connection.

Power Supply Sizing: Size power supplies with adequate capacity accounting for PLC internal consumption (typically 50-100mA), all I/O current draw (8mA per input, 500mA per output typical), expansion module requirements, communication device power, and 20% safety margin for reliability.

Wire Management: Professional panel construction includes wire duct organizing I/O wiring, numbered wires matching schematics, proper wire gauge for current requirements, ferrule terminations for stranded wire, and separation of high-voltage and low-voltage wiring preventing noise coupling.

Electrical Noise Protection: Minimize electrical interference through proper grounding practices, shielded cable for analog signals (grounded one end only), transient suppressors on inductive loads, physical separation from VFDs and welders, and surge protection on incoming power.

Frequently Asked Questions

Is Click PLC programming software free?

Yes, Click programming software is completely free with no limitations, no license keys, no annual fees, and unlimited installations. Download from AutomationDirect.com and install on as many computers as needed. All features included with no paid upgrades required. This represents thousands of dollars in savings compared to Siemens, Allen-Bradley, or Schneider Electric programming software requiring expensive licenses and annual maintenance contracts.

Free C-more HMI programming software is also available for designing touchscreen interfaces. Complete automation projects without any software licensing costs, making Click the most economical PLC platform for budget-conscious applications.

How much does a Click PLC cost?

Click PLC pricing starts at just $79 for entry-level Click BASIC models with 8 I/O points, making them the most affordable industrial PLCs available in North America. Click PLUS models range from $229-$429 depending on I/O count and features. Click PLUS ETHERNET models with built-in networking range from $349-$599.

Complete 32 I/O systems with analog capabilities typically cost $600-$800 including expansion modules, representing 50-70% savings compared to equivalent Allen-Bradley, Siemens, or Mitsubishi systems. C-more Micro integrated PLC/HMI panels range from $399-$899 depending on screen size.

Automation Direct's direct sales model eliminates distributor markup and minimum order quantities, allowing single-unit purchases at same prices as bulk orders. Free shipping on orders over $49 further reduces project costs.

Can Click PLC do Modbus?

Yes, Click PLUS and Click PLUS ETHERNET models fully support both Modbus RTU (serial) and Modbus TCP (Ethernet) protocols. Click PLCs function as Modbus master devices (initiating communication with slave devices) or Modbus slave devices (responding to requests from SCADA/HMI systems).

Modbus RTU operates over RS-232 or RS-485 serial connections supporting up to 247 slave devices on a single network. Modbus TCP operates over Ethernet networks with unlimited device connections. Click implements standard Modbus function codes for reading and writing coils, discrete inputs, holding registers, and input registers.

Built-in Modbus instructions in Click programming software simplify configuration with parameters for slave address, function code, register address, data length, and timeout settings. Modbus capability enables integration with variable frequency drives, remote I/O, instrumentation, and third-party automation equipment.

Is Click PLC made in USA?

Yes, Click PLCs are designed and manufactured in the United States at Automation Direct's facilities in Cumming, Georgia. American manufacturing ensures consistent quality control, reliable supply chains free from international shipping delays, compliance with domestic electrical standards, and support for American jobs and economy.

Made in USA construction uses industrial-grade components meeting UL508, CE, and RoHS standards for safety and environmental compliance. Quality manufacturing processes result in Click's lifetime warranty against defects, demonstrating confidence in American production quality.

Domestic manufacturing also provides faster delivery times (typically 1-2 day shipping within USA) and simplified technical support with American-based engineers available during US business hours.

What is the difference between Click BASIC and PLUS?

Click BASIC represents the entry-level platform with fixed I/O configuration (8-36 points, discrete only), limited to discrete I/O (no analog capability), RS-232 communication only, 15K word program memory, and ultra-budget pricing starting at $79. BASIC models excel for simple control applications replacing relay logic or serving educational purposes.

Click PLUS adds expandable I/O (up to 220 total points), analog I/O support (voltage, current, thermocouple, RTD), RS-232 and RS-485 communication, Modbus master and slave capability, high-speed counter inputs (50 kHz), pulse outputs for motion control, SD card slot for data logging, 20K word program memory, and advanced instruction set. PLUS models handle small to medium automation projects requiring flexibility and analog control.

Price difference typically $150-$200 between equivalent BASIC and PLUS models, justified when applications require analog I/O, expandability, or Modbus communication. Choose BASIC for simple discrete control and PLUS for more sophisticated automation requirements.

Can Click PLC control servos?

Yes, Click PLUS and PLUS ETHERNET models provide high-speed pulse outputs (up to 100 kHz) capable of controlling stepper motors and pulse-commanded servo drives. Click supports simple point-to-point positioning, velocity control, and basic 2-axis interpolation suitable for pick-and-place, material handling, and simple machine tool applications.

Built-in positioning instructions include pulse output control, position move (absolute and relative), velocity mode control, home sequence programming, and position compare functions. Click handles up to 4 motion axes simultaneously for basic coordinated motion.

However, Click PLCs are not designed for advanced motion control requiring high-speed coordinated motion (>4 axes), complex cam profiles, electronic gearing, or CNC-style applications. For sophisticated motion control, consider Delta AS series, Siemens S7-1500T, Allen-Bradley CompactLogix with motion, or specialized motion controllers.

Does Click PLC support Ethernet?

Click PLUS ETHERNET models include built-in dual Ethernet ports supporting 10/100 Mbps communication with embedded switch functionality for daisy-chain topology. Ethernet capabilities include Modbus TCP master and slave, built-in web server for browser-based HMI, email and SMS text messaging for notifications, time synchronization via NTP servers, and remote programming over Ethernet.

Standard Click BASIC and Click PLUS (without ETHERNET designation) do not include built-in Ethernet ports but connect to Ethernet networks using external Ethernet-to-serial gateway devices if needed. For projects requiring native Ethernet communication, specify Click PLUS ETHERNET models.

Click Ethernet implementation follows standard TCP/IP networking protocols, integrating easily with corporate networks, industrial switches, and Ethernet infrastructure using standard Cat5e/Cat6 cabling and RJ45 connectors.

How reliable are Automation Direct PLCs?

Automation Direct Click PLCs provide industrial-grade reliability comparable to major brand PLCs despite lower pricing. Manufactured in USA using quality components meeting UL508 standards, Click PLCs operate in harsh industrial environments with wide temperature ranges (-20°C to +60°C), electrical noise immunity per IEC 61000-4 standards, and vibration resistance per IEC 60068-2-6.

Automation Direct backs Click PLCs with lifetime warranty against manufacturing defects, demonstrating confidence in long-term reliability. Field installations spanning 10+ years verify Click durability in demanding industrial applications including manufacturing, water treatment, material handling, and building automation.

Independent user reviews consistently rate Automation Direct PLCs highly for reliability while noting exceptional value. Most failures result from installation errors, improper power supply, or electrical surges rather than inherent PLC defects. Following proper installation practices ensures decades of reliable Click PLC operation.

Can I use Click PLC in industrial applications?

Absolutely, Click PLCs are fully qualified for industrial automation applications meeting UL508, CE marking, FCC Class A, and RoHS compliance standards. Suitable industries include small manufacturing (packaging, assembly, material handling), food and beverage processing, water and wastewater treatment, HVAC and building automation, agricultural automation, machine tools and metalworking, and municipal infrastructure.

Click PLCs handle typical industrial environmental conditions including temperature extremes (-20°C to +60°C operating range), electrical noise from VFDs and welding equipment, vibration and shock per IEC standards, and dusty or humid atmospheres (NEMA Type 1 enclosure required).

The primary limitation is application scale and complexity rather than industrial capability. Click suits small to medium systems (<220 I/O) without requirements for mission-critical redundancy, advanced safety integration, or high-speed coordinated motion exceeding Click specifications. Within these parameters, Click provides reliable industrial control at exceptional value.

What programming languages does Click support?

Click PLCs primarily use ladder logic programming, the most common PLC programming language worldwide resembling electrical relay logic schematics. Click's ladder logic implementation supports standard relay instructions (contacts, coils, set/reset), timers and counters (TON, TOF, TONR, CTU, CTD), comparison and math operations, data movement and conversion, communication instructions (Modbus, email), PID control loops, high-speed counter functions, and pulse output control.

Click software does not currently support IEC 61131-3 programming languages including structured text (ST), function block diagram (FBD), or sequential function chart (SFC). However, ladder logic handles 95%+ of small to medium automation applications effectively, and most PLC programmers worldwide have ladder logic experience.

The visual ladder logic representation makes programs easy to understand and troubleshoot even for electricians and technicians without computer programming backgrounds, contributing to Click's appeal for small businesses and educational institutions.

How does Click compare to Allen-Bradley?

Click PLCs compete directly with Allen-Bradley Micro800 and MicroLogix series in functionality while offering significant cost advantages. Hardware costs run 50-60% less for equivalent Click systems, software is completely free (vs Allen-Bradley software ranging from free Connected Components Workbench for Micro800 to $10,000+ Studio 5000 for ControlLogix), and technical support is free (vs Allen-Bradley support contracts).

Functionally, Click PLUS matches or exceeds Micro800 capabilities for most small automation applications. Both support Modbus communication, analog I/O, basic motion control, and HMI integration. Allen-Bradley advantages include larger ecosystem with extensive third-party support, proprietary protocols (EtherNet/IP, DeviceNet), stronger brand recognition, and scalability to very large systems.

For small businesses, machine builders, and budget-constrained applications not requiring Allen-Bradley ecosystem integration, Click provides better value. For facilities with existing Allen-Bradley infrastructure or requiring proprietary Rockwell protocols, staying within the Allen-Bradley ecosystem may prove more practical despite higher costs.

Where can I buy Click PLCs?

Purchase Click PLCs directly from AutomationDirect.com online store or by phone (1-800-633-0405). Automation Direct's direct sales business model eliminates distributors and industrial supply houses, passing savings to customers through lower prices and no minimum order requirements.

Online ordering provides immediate pricing transparency, detailed product specifications, application examples, user manuals, and customer reviews. Create a free account to track orders, access purchase history, and receive technical bulletins. Most orders ship within 24 hours via UPS or FedEx with free shipping on orders over $49.

International customers outside USA can purchase through authorized Automation Direct distributors in their countries or order directly from AutomationDirect.com with international shipping. Some countries have local Automation Direct entities providing regional support and warehousing.

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Next Steps: Start Your Click PLC Journey

Now that you understand Click PLC programming fundamentals, value proposition, and application examples, you're ready to implement budget-friendly automation solutions. Download free Click programming software from AutomationDirect.com and explore simulator mode without hardware investment. Review Automation Direct's extensive application examples, video tutorials, and user manuals available free online. Consider purchasing a Click BASIC starter kit ($79) for hands-on learning and experimentation. Connect with the Automation Direct user community through forums and social media for peer support.

For related automation topics, explore these comprehensive tutorials: Free PLC Programming Software covering all available no-cost PLC tools including Click software details, Delta PLC Programming Tutorial for another budget-friendly PLC option popular internationally, Modbus RTU Protocol Tutorial for mastering industrial communication used extensively with Click PLCs, and HMI Programming Tutorial covering C-more and other HMI platforms for operator interface development.

Click PLCs democratize industrial automation, making professional programmable control accessible to small businesses, students, and cost-conscious engineers previously unable to justify major brand systems. With completely free software, exceptional technical support, Made in USA quality, and pricing 50-70% below competitors, Click represents the smartest choice for budget-friendly automation projects.

Start programming today and discover why thousands of engineers, machine builders, and manufacturers trust Click PLCs for reliable, affordable industrial control.