Monday, June 15, 2015

PLC Application About Ethernet RS232 Using USR-TCP232




How to use Ethernet to RS232 Converter on PLC application?
This article about Ethernet to RS232 converter using USR-TCP232-T.
This PLC application using modbus communication: Serial Modbus RTU
The advantages of using Ethernet communication: Multiple PLC network with Serial Modbus RTU and long distance communication

PLC Application about Ethernet RS232 using USR-TCP232

Video of the testing USR-TCP232 and PLC:


Hardware:
1. USR-TCP232-T module
2. Serial TTL to RS232 Male Connector
3. RS232 PLC Cable
4. PLC with Modbus Support
5. Power Supply DC 3.3V, or use Converter to DC3.3V
6. USB to TTL Serial for USR-TCP232-T Setup

Hardware Connections:

Hardware Connections of Ethernet to RS232 Converter


Download Project File:
1. Project File for Microsoft Visual C#, click here
2. PLC Ladder Programming for Siemens PLC, click here
3. USR-TCP232-T Manual, click here
4. Setup Software for USR-TCP232, click here

Video about USR TCP232 Setup:


Microsoft Visual C#:
using System;
using System.Collections.Generic;
using System.ComponentModel;
using System.Data;
using System.Drawing;
using System.Linq;
using System.Text;
using System.Windows.Forms;
using System.IO;
using System.Net;
using System.Net.Sockets;

namespace USR_TCP232
{
    public partial class Form1 : Form
    {
        byte L0 = 0;
        byte L1 = 0;
        byte L2 = 0;
        byte L3 = 0;
        byte L4 = 0;
        byte L5 = 0;
        byte L6 = 0;
        byte L7 = 0;

        public Form1()
        {
            InitializeComponent();
           
        }


        byte[] Func03(byte Slave_Address, int Starting_Address, int Number_of_Points)
        {
            //Function Code 03 / Read Holding Registers
            //Function 3 request is always 8 bytes
            byte[] message = new byte[8];
            byte Function = 3;
    

            //index0 = Slave Address
            message[0] = Slave_Address;
            //index1 = Function
            message[1] = Function;
            //index2 = Starting Address Hi
            message[2] = (byte)(Starting_Address >> 8);
            //index3 = Starting Address Lo
            message[3] = (byte)Starting_Address;
            //index4 = Number of Points Hi
            message[4] = (byte)(Number_of_Points >> 8);
            //index5 = Number of Points Lo
            message[5] = (byte)Number_of_Points;

            // CRC (Cyclical Redundancy Check) Calculation
            ushort CRC = 0xFFFF;
            byte CRCHi = 0xFF;
            byte CRCLo = 0xFF;
            ushort CRCLSB;

            for (int i = 0; i < (message.Length) - 2; i++)
            {
                CRC = (ushort)(CRC ^ message[i]);

                for (int j = 0; j < 8; j++)
                {
                    CRCLSB = (ushort)(CRC & 0x0001);
                    CRC = (ushort)((CRC >> 1) & 0x7FFF);

                    if (CRCLSB == 1)
                        CRC = (ushort)(CRC ^ 0xA001);
                }
            }
            CRCHi = (byte)((CRC >> 8) & 0xFF);
            CRCLo = (byte)(CRC & 0xFF);

            //index6 = CRC Lo
            message[message.Length - 2] = CRCLo;
            //index7 = CRC Hi
            message[message.Length - 1] = CRCHi;

            return message;
        }


        byte[] Func16(byte Slave_Address, int Starting_Address, short[] values)
        {
            //FUCTION 16
            byte Function = 16;
            int NumberofRegisters = values.Length;
            byte Byte_Count;
            Byte_Count = (byte)(NumberofRegisters * 2);
            byte[] message = new byte[9 + 2 * NumberofRegisters];

            //index0 = Slave Address
            message[0] = Slave_Address;
            //index1 = Function
            message[1] = Function;
            //index2 = Starting Address Hi
            message[2] = (byte)(Starting_Address >> 8);
            //index3 = Starting Address Lo
            message[3] = (byte)Starting_Address;
            //index4 = Number of Registers Hi
            message[4] = (byte)(NumberofRegisters >> 8);
            //index5 = Number of Registers Lo
            message[5] = (byte)NumberofRegisters;
            //index6 = Byte Count
            message[6] = Byte_Count;
            for (int i = 0; i < NumberofRegisters; i++)
            {
                //Data Hi, index7 and index9
                message[7 + 2 * i] = (byte)(values[i] >> 8);
                //Data Lo, index8 and index10
                message[8 + 2 * i] = (byte)(values[i]);
            }

            // CRC (Cyclical Redundancy Check) Calculation
            ushort CRC = 0xFFFF;
            byte CRCHi = 0xFF;
            byte CRCLo = 0xFF;
            ushort CRCLSB;

            for (int i = 0; i < (message.Length) - 2; i++)
            {
                CRC = (ushort)(CRC ^ message[i]);

                for (int j = 0; j < 8; j++)
                {
                    CRCLSB = (ushort)(CRC & 0x0001);
                    CRC = (ushort)((CRC >> 1) & 0x7FFF);

                    if (CRCLSB == 1)
                        CRC = (ushort)(CRC ^ 0xA001);
                }
            }
            CRCHi = (byte)((CRC >> 8) & 0xFF);
            CRCLo = (byte)(CRC & 0xFF);

            //index11= CRC Lo
            message[message.Length - 2] = CRCLo;
            //index12 = CRC Hi
            message[message.Length - 1] = CRCHi;

            return message;
        }

        private bool CRCResponseCheck(byte[] message)
        {

            //CRC Response Check:
            byte[] CRC = new byte[2];
            ushort CRCFull = 0xFFFF;
            byte CRCHigh = 0xFF, CRCLow = 0xFF;
            ushort CRCLSB;

            for (int i = 0; i < (message.Length) - 2; i++)
            {
                CRCFull = (ushort)(CRCFull ^ message[i]);

                for (int j = 0; j < 8; j++)
                {
                    CRCLSB = (ushort)(CRCFull & 0x0001);
                    CRCFull = (ushort)((CRCFull >> 1) & 0x7FFF);

                    if (CRCLSB == 1)
                        CRCFull = (ushort)(CRCFull ^ 0xA001);
                }
            }
            CRCHigh = (byte)((CRCFull >> 8) & 0xFF);
            CRCLow = (byte)(CRCFull & 0xFF);

            if (CRCLow == message[message.Length - 2] && CRCHigh == message[message.Length - 1])
                return true;
            else
                return false;
        }

        private static bool IPCheck(string IPServer, int PortServer, int TimeOutConnectMS)
        {
            Socket socket = null;
            try
            {
                socket = new Socket(AddressFamily.InterNetwork, SocketType.Stream, ProtocolType.Tcp);
                socket.SetSocketOption(SocketOptionLevel.Socket, SocketOptionName.DontLinger, false);


                IAsyncResult result = socket.BeginConnect(IPServer, PortServer, null, null);
                bool success = result.AsyncWaitHandle.WaitOne(TimeOutConnectMS, true);

                return socket.Connected;
            }
            catch
            {
                return false;
            }
            finally
            {
                if (null != socket)
                    socket.Close();
            }
        }

        private void timer1_Tick(object sender, EventArgs e)
        {
            if (!IPCheck(ip_server.Text, Convert.ToInt32(port_server.Text), 500))
            {
                Status.Text = "IP=" + ip_server.Text + " and Port=" + port_server.Text + " Not Ready";
                return;
            }
           
            try
                {
                    TcpClient IPClient = new TcpClient(ip_server.Text, Convert.ToInt32(port_server.Text));
                    IPClient.SendTimeout = 100;
                    IPClient.ReceiveTimeout = 100;
                    NetworkStream NS = IPClient.GetStream();
                    NS.ReadTimeout = 100;
                    NS.WriteTimeout = 100;

                    byte[] readBuffer;
                    short[] values;
                    int numberOfBytesRead;

                    values = new short[1];
                    values[0] = (short)((L0 * 1) + (L1 * 2));
                    values[0] += (short)((L2 * 4) + (L3 * 8));
                    values[0] += (short)((L4 * 16) + (L5 * 32));
                    values[0] += (short)((L6 * 64) + (L7 * 128));
                  
                    byte[] ModbusSend = Func16(1, 0, values);
                    try
                    {
                        NS.Write(ModbusSend, 0, ModbusSend.Length);
                        readBuffer = new byte[IPClient.ReceiveBufferSize];
                        numberOfBytesRead = NS.Read(readBuffer, 0, readBuffer.Length);
                        if (readBuffer[1] == 16)
                        {
                            if (CRCResponseCheck(readBuffer)) Status.Text = "Modbus Run";
                        }
                    }
                    catch
                    {
                        Status.Text = "Modbus Error";
                        NS.Close();
                        IPClient.Close();
                        return;
                    }


                    byte[] ModbusRead = Func03(1, 0, 1);
                    NS.Write(ModbusRead, 0, ModbusRead.Length);
                    readBuffer = new byte[IPClient.ReceiveBufferSize];
                    numberOfBytesRead = NS.Read(readBuffer, 0, readBuffer.Length);
                    if (readBuffer[1] == 3)
                    {
                        if (CRCResponseCheck(readBuffer))
                        {
                            byte registers = (byte)(readBuffer[2] / 2);
                            values = new short[registers];
                            for (int i = 0; i < registers; i++)
                            {
                                values[i] = readBuffer[2 * i + 3];
                                values[i] <<= 8;
                                values[i] += readBuffer[2 * i + 4];
                                if ((values[i] & 1) == 1) { button0.Image = Properties.Resources.on; button0.Tag = 1; } else { button0.Image = Properties.Resources.off; button0.Tag = 0; }
                                if ((values[i] & 2) == 2) { button1.Image = Properties.Resources.on; button1.Tag = 1; } else { button1.Image = Properties.Resources.off; button1.Tag = 0; }
                                if ((values[i] & 4) == 4) { button2.Image = Properties.Resources.on; button2.Tag = 1; } else { button2.Image = Properties.Resources.off; button2.Tag = 0; }
                                if ((values[i] & 8) == 8) { button3.Image = Properties.Resources.on; button3.Tag = 1; } else { button3.Image = Properties.Resources.off; button3.Tag = 0; }
                                if ((values[i] & 16) == 16) { button4.Image = Properties.Resources.on; button4.Tag = 1; } else { button4.Image = Properties.Resources.off; button4.Tag = 0; }
                                if ((values[i] & 32) == 32) { button5.Image = Properties.Resources.on; button5.Tag = 1; } else { button5.Image = Properties.Resources.off; button5.Tag = 0; }
                                if ((values[i] & 64) == 64) { button6.Image = Properties.Resources.on; button6.Tag = 1; } else { button6.Image = Properties.Resources.off; button6.Tag = 0; }
                                if ((values[i] & 128) == 128) { button7.Image = Properties.Resources.on; button7.Tag = 1; } else { button7.Image = Properties.Resources.off; button7.Tag = 0; }
                            }
                        }
                        else
                        {
                            Status.Text = "Modbus CRC Error";
                        }
                    }

                    NS.Close();
                    IPClient.Close();
                }
                catch (Exception err)
                {
                    //Status.Text = err.Message;
                    Status.Text = err.StackTrace;
                }

        }

        private void button0_Click(object sender, EventArgs e)
        {
            if (Convert.ToUInt16(button0.Tag) == 0) { L0 = 1; } else { L0 = 0; }
            button0.Image = null;
        }

        private void button1_Click(object sender, EventArgs e)
        {
            if (Convert.ToUInt16(button1.Tag) == 0) { L1 = 1; } else { L1 = 0; }
            button1.Image = null;
        }

        private void button2_Click(object sender, EventArgs e)
        {
            if (Convert.ToUInt16(button2.Tag) == 0) { L2 = 1; } else { L2 = 0; }
            button2.Image = null;
        }

        private void button3_Click(object sender, EventArgs e)
        {
            if (Convert.ToUInt16(button3.Tag) == 0) { L3 = 1; } else { L3 = 0; }
            button3.Image = null;
        }

        private void button4_Click(object sender, EventArgs e)
        {
            if (Convert.ToUInt16(button4.Tag) == 0) { L4 = 1; } else { L4 = 0; }
            button4.Image = null;
        }

        private void button5_Click(object sender, EventArgs e)
        {
            if (Convert.ToUInt16(button5.Tag) == 0) { L5 = 1; } else { L5 = 0; }
            button5.Image = null;
        }

        private void button6_Click(object sender, EventArgs e)
        {
            if (Convert.ToUInt16(button6.Tag) == 0) { L6 = 1; } else { L6 = 0; }
            button6.Image = null;
        }

        private void button7_Click(object sender, EventArgs e)
        {
            if (Convert.ToUInt16(button7.Tag) == 0) { L7 = 1; } else { L7 = 0; }
            button7.Image = null;
        }

    }
}



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