Raspberry PI based, fully modular PLC for home and industrial automation.

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In the past, I've had some experience with PLC's from different vendors (Siemens, Rockwell Automation, WAGO e.t.c.).
It's respected manufacturers and they made great products. But also their products have some imperfections for me:
1. Price. It's expensive.
2. Programming environments are different for products from different vendors and not so simple to understand.
3. Size. Most of those products I can't install it in the electrical cabinet (standard electrical cabinet for the home created for 58 mm height DIN rail products)
4. Restrictions. Most vendors using own cloud services which don't have features you can find in Amazon AWS for example.
5. In - Out voltage. I can't connect inexpensive 3.3 or 5-volt sensors without level shifters.

So, I thought a little, and IOTON MICRIO idea was born.

Now I have 19 different modules.
I will write a separate article about each module.
Stay tuned!

IOTON MICRIO MPU Quick Start and Hello World

This video is about very basic IOTON MICRIO functionality. How to connect devices, program system via  EDITOR, control it via USER DASHBOARD and via E-mail messages.


Some modules (not all).

Before I start the project description let me introduce the first industrial project on IOTON MICRIO equipment.  

My old school friend is the CEO of company produced bioreactors. For one of his projects he asked me to make a system to control 3 big fans (on/off by schedule) and one pump motor. RPM for this pump motor must depend on atmospheric pressure and temperature, and calculated with the interesting formula (I can't post it here because of NDA). I solved this problem in one day. IOTON MICRIO MPU takes atmospheric pressure and temperature data from the INTERNET and control motor by MODBUS protocol (RS485 PHY).  On this moment system works around 3 months w/o any problems. The schematic is simple:


Please, excuse me for any errors in the text, English writing is not so simple for me.

Base principles:

At first, I identified five base principles for the whole system:

1. Any input or output must be galvanically, optically or mechanically isolated from the Microprocessor Unit (MPU)
2. Keep the size as small as possible.
3. Keep it simple, stupid.
4. Reliability is more important than functionality.
5. All modules must be cross interchangeable.

Programming environment:

Luckily I found Node-Red from IBM guys. It's a really great and simple programming environment for the IOT devices. It works flawlessly on Raspbian and has great support from developers on their forum.


It was not so challenging for me. I have enough experience in it. Also, I have experience with repair different models of PLCs so I know base principles for safety, reliability, and functionality. 
A little challenge was to find the solution for RS485 and 1-wire galvanic isolation. I used an isolated DC-DC converter and Analog Devices transformer isolators.

... Read more »



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  • 250 × Too much components....

  • Let's add some POWER

    Andrey V09/12/2019 at 14:04 0 comments

    Today I'm trying to install Banana Pi M2 zero instead Raspberry Pi Zero W. 

    Here a quick comparison:

    I've tested real speed in different applications and found that Banana PI M2 zero is around 2 times faster than Raspberry PI Zero W.

    But M2 has one problem, it dissipates much more heat than PI Zero....

    My enclosure is small therefore I need a big heatsink for M2 processor and memory cooling, also I need to create special profile on the bottom of the heatsink (because of some components more height than the processor and memory). 

    So I found old heatsink from the computer PSU, cut piece from it, machine bottom on the CNC and glued it right on processor and memory ICs. 

    The whole sandwich looks like this:  

    Now it's time for the temperature tests. I will tell about the results next time. Stay tuned)

  • IOTON MICRIO - Fifth element of a successful IIoT project

    Andrey V09/09/2019 at 09:52 0 comments

    Four elements are required to build a successful Industrial Internet of Things (IIoT) project:

    • Inputs/Outputs are wired directly to sensors and devices and translate between the electrical signals devices use and the digital ones and zeros computers understand. Inputs/Outputs brings data from the physical world and sends instructions out for controlling equipment.
    • Logic in software processes data from I/O and determines what automated actions to take. Logic sends I/O the instructions to control equipment and processes.
    • Visualization presents data to human. GUI allows human to control the system manually.
    • Data collection and analysis for the process optimization and predictive maintenance.  

    IOTON MICRIO combine all of these, like in movie.


    Andrey V09/04/2019 at 12:59 0 comments

    As you can see all of the enclosures in my project have holes (for the USB, LAN, Antenna or GPIO connectors).

    I did some special tools which allow me to cut holes with good precision and repeatability. 

    It's also saving me a huge amount of time. Because after installing the fixing tool I can quickly change the enclosures for milling.

    You can see the whole process on video:

    0:00 Tool for fix the enclosure for the side holes milling
    0:10 Setting XY zero by the template
    0:17 Changing the template to the new enclosure 
    0:35 Setting Z and side holes milling
    1:16 Changing fixing tool for USB and LAN holes milling
    1.36 Setting XY zero by the template
    1:43 LAN hole milling
    2:30 USB holes milling
    2:53 Changing fixing tool for the antenna hole milling
    3:10 Setting zero and the antenna hole milling

    Final result:

    Read more »


    Andrey V09/04/2019 at 09:24 0 comments

    It's the part of the mini-hotel automation system project (SIEMENS to IOTON replacement).

    I think I finished the main control enclosure wiring and test.

    Totally I have 143 wires in it. 

    Now it looks like this:

    Read more »


    Andrey V09/02/2019 at 17:36 0 comments

    So far so good...

    Today I made some wirings for the mini-hotel automation system.

    I think it was a very good decision to combine 4 inputs or outputs in one group because to connect one group I need one UTP cable. Now wiring is as easy as possible.

    Read more »

  • Replacement SIEMENS to IOTON.

    Andrey V08/30/2019 at 06:18 0 comments

    One of my friends is an owner of 3 mini-hotels. 

    He renews one of it and wants to add an automation system. It's not so large building (3 floors, 26 rooms).

    Initially, the project was made on Siemens equipment, but after a quick conversation with him and his system integrator, the decision to replace Siemens was made. Preliminary money savings on equipment is around 3 times.

    Initially, he is planning to equip only one floor(8 rooms) to reduce risks (my equipment is very new). And if it will work w/o problems, to scaling it for all his buildings and connecting in one grid.

    Basic functionalities:
    1. Illumination control
    2. Heating control
    3. Doors status
    4. Several sensors (move, temp, humidity)
    5. Connection to power meters
    6. Control dashboard for personnel
    7. Database for future statistics

    It will be 1 main control box, 1 power box(for HV equipment) and two small mixed boxes.

    The main control box will look like this:

    I think, I will start wiring for test next week. Also, some radio interfaces will be added for real life test reasons.

  • Family portrait

    Andrey V08/28/2019 at 08:24 0 comments

    Andrey V

    "Dad and son calmly lie next to each other without noticing a predatory snake creeping up behind"

    Silicium and Stannum. Painted in Shchelkovo 2017-2019. Louvre long gallery.

    In fact, MICRIO predecessor was a huge disaster for me. I made many critical errors in concept and design. I spent a huge amount of time and got an expensive and inflexible product. It was so hard to start a new project after that.

    Some words I can say to developers who younger than I:

    A big part of our life experience was received from mistakes and disasters. It's the truth of our life. In theory, only one man didn't make any mistakes - who did absolutely nothing. 

    So never give up, be strong and move on!

  • IOTON DOino

    Andrey V08/28/2019 at 06:45 0 comments

    Today I've started a new product development.

    It will be a controller for real-time applications with extra interface and wireless possibilities.

    This module will able to work flawlessly with the next IOTON extension modules:

    • DI8.1, DI8.2 (universal input modules)
    • DO8.1, DO8.2 (output modules)
    • DIO4.1, DIO4.2 (universal input/output modules)
    • RLY4.1, RLY4.2, RLY4.3, RLY4.4 (relay modules)
    • DIM4.1, DIM4.2 (dimmer modules)
    • SSR4.1, SSR4.2 (Solid State Relay modules)
    • ADC4 (16bit ADC for 0-10V or 4.20ma)

    What will be onboard:

    1. ATmega32U4 microcontroller.
    2. ESP8266 module (option)
    3. UART radio extender up to 3000m(option)
    4. Two micro USB ports for ATmega32U4 and ESP8266 programming
    5. 24V PSU
    6. RS485 isolated port(option)
    7. SMA connector for antenna

    I think I will get working prototype in around two months(PCB manufacturing, components order and delivery takes some time).


    Andrey V08/27/2019 at 16:23 0 comments

    I think my work with user manuals is near to the end.

    You can find the draft versions in the files section.

    Only Russian language now because I haven't any friends who can translate it.

    If somebody can help me with it please, write to me!

  • Schematics

    Andrey V08/27/2019 at 16:04 0 comments

    Now, you can find the schematics for all modules and interfaces in the files section) 

    Files are in the DXF format, I did it for convenience when I will start work with the service manual. Just no time for it right now.

    You can open it with any online .dxf viewer.


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VASILIS VORRIAS wrote 06/25/2020 at 09:14 point

Excellent project. A lot of work done. The idea of using NODE RED adds value to your project. We have a similar idea (M10CUBE) but it has a different concept. Being in Automation for more that 35 years I can appreciate your design and the work done. The DIN rail  approach is very good indeed for using it  in industrial enclosures.
I am trying the pdf files but all are in Russian? Is anything in English?
Our idea M10CUBE  tries to cover both worlds in an practical package. Please join us to exchange ideas.

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