Wednesday, December 2, 2015

Omron PLC USB Protocol used for Communication between Omron PLC and Raspberry Pi




Today, I will share for you about How to make Omron PLC USB Protocol using Python on Raspberry Pi, and used for communication between Omron PLC and Raspberry Pi.
In this case not use RS232 communication, but use USB communication between PLC and Raspberry Pi.
For PLC, I use CP1L-L10 Omron PLC with USB Programming and use standard A-B USB cable,
And for Raspberry Pi, I use Raspberry Pi 2.

Sample Case:
Read D0 memory of Omron PLC by USB Raspberry Pi.
Write D2 memory of Omron PLC by USB Raspberry Pi.
Value from D0 to drive LED on Raspberry Pi
Value from D2 to drive PLC Output

Read Write D memory of Omron PLC by USB Raspberry Pi


Video Demonstration :

Omron PLC USB Protocol and Raspberry Pi




Hardware required for Omron PLC USB Protocol

  1. Omron PLC with USB Programming, I use CP1L-L10DR-A
  2. Standard A-B USB cable
  3. Raspberry Pi, I use Raspberry Pi 2
  4. Optional for testing :
    1. 4 pieces switch
    2. 2 pieces LED
    3. 2 pieces resistors 10K
    4. 2 pieces resistors 220

Hardware for Omron PLC USB Protocol


Connections Hardware for Omron PLC USB Protocol Application

PLC connect to Raspberry Pi

Connect PLC and Raspberry Pi by using standard A-B USB cable

PLC connect to switch

  1. Switch 1 connect to PLC Input I0.00
  2. Switch 2 connect to PLC Input I0.01

Raspberry Pi connect to LED and Switch

Raspberry Pi connect to LED and Switch



Project file for Raspberry Pi

Download Project file for setup Raspberry Pi, click here


Step by step how to setup Raspberry Pi for Access Omron PLC USB Protocol

A. By YouTube video:

Raspberry Pi Setup for Access Omron PLC USB Protocol




B. By Text:


Step 1 :

Copy paste all project file to folder /home/pi on Raspberry Pi

Step 2 :

Raspberry Pi connect to Internet
Open LXTerminal on Raspberry Pi
sudo apt-get install libudev-dev

Step 3 :

cd ~
tar -xvjf libusb-1.0.20.tar.bz2
cd libusb-1.0.20
./configure
make
sudo make install

Step 4 :

cd ~
tar -xvzf pyusb-1.0.0b2.tar.gz
cd pyusb-1.0.0b2
sudo python setup.py install

Step 5:

cd ~
sudo groupadd usbplc
sudo usermod -a -G usbplc pi
sudo nano /etc/udev/rules.d/usbplc.rules
add :
SUBSYSTEMS=="usb", ACTION=="add", ATTRS{idVendor}=="0590", ATTRS{idProduct}=="005b", GROUP="usbplc", MODE="0660"
Press Ctrl+X to exit, Y to save followed by enter twice

STEP 6:

cd ~
sudo crontab -e
Scroll to bottom and add:
@reboot python /home/pi/startup.py
Press Ctrl+X to exit, Y to save followed by enter twice

Step 7 :

cd ~
sudo raspi-config
Select :
Enable Boot to Desktop/Scratch from the menu
and press Enter
Select:
Desktop Login as user pi at the Graphical Desktop.
<Finish> and Enter, then select <Yes> to reboot.


Project File for Omron PLC

Download Project file for CX-Programmer Omron Software, click here
I use CP1L-L10, and for another model click PLC and click Change Model .

This Omron PLC Ladder Programming:

Omron CX PLC Ladder Programming


Python Script for Access Omron PLC by USB

import usb.core
import usb.util
import sys
from random import randint
import RPi.GPIO as GPIO


IDVENDOR = 0x0590
IDPRODUCT = 0x005B


dev = usb.core.find(idVendor=IDVENDOR, idProduct=IDPRODUCT )
if dev is None:        
    raise ValueError('Device not found')


LED1_GPIO = 17
LED2_GPIO = 27
SWITCH1_GPIO = 18
SWITCH2_GPIO = 23


GPIO.setmode(GPIO.BCM)
GPIO.setwarnings(False)
GPIO.setup(LED1_GPIO, GPIO.OUT)
GPIO.setup(LED2_GPIO, GPIO.OUT)
GPIO.setup(SWITCH1_GPIO, GPIO.IN, pull_up_down=GPIO.PUD_UP)
GPIO.setup(SWITCH2_GPIO, GPIO.IN, pull_up_down=GPIO.PUD_UP)

GPIO.output(LED1_GPIO, GPIO.LOW)
GPIO.output(LED2_GPIO, GPIO.LOW)


                                                                                       
endpoint_in = dev[0][(0,0)][0]
endpoint_out = dev[0][(0,0)][1]


def USBwrite(msg,revlen):
    x=0
    cnt1=0
    cnt2=0
    data = []
    while(1):        
        try:
            if x==0:
                endpoint_out.write(msg)
                x=1
                
            data += dev.read(endpoint_in.bEndpointAddress, endpoint_in.wMaxPacketSize, timeout = 20)
            if len(data)==revlen:             
                return data
            
        except usb.core.USBError as e:
            
            if e.strerror.find("error sending control message")>=0:
                cnt1+=1
                if cnt1>2:
                    raise ValueError('Over error sending control message')
                x=0
                continue
            
            elif e.strerror.find("Connection timed out")>=0:
                cnt2+=1
                if cnt2>2:
                    raise ValueError('Over Connection timed out')
                continue
            
            else:
                raise ValueError(e.strerror)



def PLC_Run_Monitoring():
    write_array = [0xAB,0x00,0x11,0x80,0x00,0x02,0x00,0x00,0x00,0x00,0x00,0x00]
    write_array.append(randint(1,0xFF))
    write_array +=[0x04,0x01,0xFF,0xFF,0x02]
    sumcheck = sum(write_array)
    sumHi = ((sumcheck >> 8) & 0xFF)
    sumLo = (sumcheck & 0xFF)
    write_array.append(sumHi)
    write_array.append(sumLo)
    res = USBwrite(write_array,19)
    if len(res)==19:
        sum1= res[len(res)-2]<<8 | res[len(res)-1]
        res.pop()
        res.pop()
        sum2 = sum(res)
        if sum1==sum2:
            revc = [171, 0, 16, 192, 0, 2, 0, 0, 251, 0, 0, 0, 4, 1, 0, 0]
            res.pop(12)
            if res==revc:
                print "PLC is Run Monitoring"
            else:
                print "PLC Run Monitoring Error"
        else:
            print "PLC Run Monitoring Error"
    else:
        print "PLC Run Monitoring Error"


def PLC_Run_Mode():    
    write_array = [0xAB,0x00,0x11,0x80,0x00,0x02,0x00,0x00,0x00,0x00,0x00,0x00]
    write_array.append(randint(1,0xFF))
    write_array +=[0x04,0x01,0xFF,0xFF,0x04]
    sumcheck = sum(write_array)
    sumHi = ((sumcheck >> 8) & 0xFF)
    sumLo = (sumcheck & 0xFF)
    write_array.append(sumHi)
    write_array.append(sumLo)
    res = USBwrite(write_array,19)
    if len(res)==19:
        sum1= res[len(res)-2]<<8 | res[len(res)-1]
        res.pop()
        res.pop()
        sum2 = sum(res)
        if sum1==sum2:
            revc = [171, 0, 16, 192, 0, 2, 0, 0, 251, 0, 0, 0, 4, 1, 0, 0]
            res.pop(12)
            if res==revc:
                print "PLC is Run Mode"
            else:
                print "PLC Run Mode Error"
        else:
            print "PLC Run Mode Error"
    else:
        print "PLC Run Mode Error"


def PLC_Program_Mode():
    write_array = [0xAB,0x00,0x10,0x80,0x00,0x02,0x00,0x00,0x00,0x00,0x00,0x00]
    write_array.append(randint(1,0xFF))
    write_array +=[0x04,0x02,0xFF,0xFF]
    sumcheck = sum(write_array)
    sumHi = ((sumcheck >> 8) & 0xFF)
    sumLo = (sumcheck & 0xFF)
    write_array.append(sumHi)
    write_array.append(sumLo)
    res = USBwrite(write_array,19)
    if len(res)==19:
        sum1= res[len(res)-2]<<8 | res[len(res)-1]
        res.pop()
        res.pop()
        sum2 = sum(res)
        if sum1==sum2:
            revc = [171, 0, 16, 192, 0, 2, 0, 0, 251, 0, 0, 0, 4, 2, 0, 0]
            res.pop(12)
            if res==revc:
                print "PLC is Program Mode"
            else:
                print "PLC Program Mode Error"
        else:
            print "PLC Program Mode Error"
    else:
        print "PLC Program Mode Error"


def D_Write(D_number,D_value):
    write_array = [0xAB,0x00,0x16,0x80,0x00,0x2,0x00,0x00,0x00,0x00,0x00,0x00]
    rdm = randint(1,0xFF)
    write_array.append(rdm)
    write_array +=[0x01,0x02,0x82]
    write_array.append(D_number >> 8);
    write_array.append(D_number & 0xFF);
    write_array +=[0x00,0x00,0x01]    
    write_array.append(D_value >> 8);
    write_array.append(D_value & 0xFF);
    sumcheck = sum(write_array)
    sumHi = ((sumcheck >> 8) & 0xFF)
    sumLo = (sumcheck & 0xFF)
    write_array.append(sumHi)
    write_array.append(sumLo)    
    res = USBwrite(write_array,19)
    if len(res)==19:
        val1=res.pop()
        val2=res.pop()
        sum1 = val2<<8 | val1
        sum2 = sum(res)
        if sum1==sum2:            
            rdm2= res.pop(12)
            if rdm==rdm2:
                revc = [171, 0, 16, 192, 0, 2, 0, 0, 251, 0, 0, 0, 1, 2, 0, 0]
                if res==revc:
                    return 1
                else:
                    return 0
            else:
                return 0
        else:
            return 0
    else:
        return 0

def D_Read(D_number):
    write_array = [0xAB,0x00,0x16,0x80,0x00,0x2,0x00,0x00,0x00,0x00,0x00,0x00]
    rdm = randint(1,0xFF)
    write_array.append(rdm)
    write_array +=[0x01,0x04,0x07,0x00,0x00,0x00,0x82]
    write_array.append(D_number >> 8);
    write_array.append(D_number & 0xFF);
    write_array +=[0x00]
    sumcheck = sum(write_array)
    sumHi = ((sumcheck >> 8) & 0xFF)
    sumLo = (sumcheck & 0xFF)
    write_array.append(sumHi)
    write_array.append(sumLo)    
    res = USBwrite(write_array,24)
    if len(res)==24:
        val1=res.pop()
        val2=res.pop()
        sum1 = val2<<8 | val1
        sum2 = sum(res)
        if sum1==sum2:
            rdm2= res.pop(12)
            if rdm==rdm2:
                val1=res.pop()
                val2=res.pop()
                value = val2<<8 | val1
                val1=res.pop()
                val2=res.pop()
                revc = [171, 0, 21, 192, 0, 2, 0, 0, 251, 0, 0, 0, 1, 4, 0, 0, 7]
                if res==revc:
                    return (1,value)
                else:
                    return (0,0)
            else:
                return (0,0)
        else:
            return (0,0)
    else:
        return (0,0)

        
        
#PLC_Run_Monitoring()  
PLC_Run_Mode()
#PLC_Program_Mode()


       
while(1):
    #Read Value from D0 CP1l-L10 Omron PLC to Raspberry Pi
    val = D_Read(0)
    if val[0]:
        
        if (val[1] & 1):
            GPIO.output(LED1_GPIO, GPIO.HIGH)
        else:
            GPIO.output(LED1_GPIO, GPIO.LOW)

        if ((val[1]>>1)&1):
            GPIO.output(LED2_GPIO, GPIO.HIGH)
        else:
            GPIO.output(LED2_GPIO, GPIO.LOW)
            
    else:
        print "Read Error"


    #Write Value from Raspberry Pi to D2 CP1L-L10 Omron PLC
    valw=0
    if not GPIO.input(SWITCH1_GPIO):
        valw = valw | 1<<0
    if not GPIO.input(SWITCH2_GPIO):
        valw = valw | 1<<3

    c = D_Write(2,valw)
    if not c:
        print "Write Error"


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