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TELKOMNIKA Telecommunication, Computing, Electronics and Control

Vol. 18, No. 3, June 2020, pp. 1491~1498
ISSN: 1693-6930, accredited First Grade by Kemenristekdikti, Decree No: 21/E/KPT/2018
DOI: 10.12928/TELKOMNIKA.v18i3.14757  1491

Communication between PLC different vendors

using OPC server improved with application device

Ignatius Deradjad Pranowo, Y. B. Theo Bagastama, Thomas A. F. Wibisono

Politeknik Mekatronika Sanata Dharma, Indonesia

Article Info ABSTRACT

Article history: Many industries often use different devices and controllers in automation
systems. They all face the same difficulty how to exchange data between all
Received Jul 27, 2019 those components. This paper proposed the implementation of OPC Server as
Revised Dec 3, 2019 software interface on communication between two different controllers, PLC
Accepted Dec 21, 2019 Mitsubishi and PLC Omron. The main advantage of the method is
the compatibility and solution for the factory difficulty problem because of
using several driver controller. The compatibility among the different
Keywords: platforms of both controller, PLC Mitsubishi and PLC Omron, can be
reached by use of KEPServerEx6 (OPC server) as a software interface.
Data communication To test the compatibility amongst two different controllers, there was
Different platform developed and implemented two field application devices, bottle unscramble
KEPServerEX6 and bottle filling station. This implementation shows OPC Server technology
OPC server resolving data compatibility issues between different platforms and reducing
PLC development costs. It is envisaged that the method can be very useful to
SCADA realize integration.
This is an open access article under the CC BY-SA license.

Corresponding Author:
Ignatius Deradjad Pranowo,
Politeknik Mekatronika Sanata Dharma,
Yogyakarta, Indonesia.
Email: [email protected]

1. INTRODUCTION
Remote monitoring and control systems are also referred to as supervisory control and data
acquisition (SCADA), the process of collecting data from physical devices to be monitored and applying
commands to control devices. SCADA systems typically consist of a human-machine interface (HMI),
monitoring computer, remote terminal unit (RTU), programmable logic controller (PLC) and communication
infrastructure [1-3]. In a system that uses several different devices and must exchange data such as PLC and
HMI; they must collect, analyse, and display data from various devices using different protocols. This task is
not easy and error-prone. Every device driver requires software from its company. Changes in protocol
specifications result in communication error and adjustments must be made, which are time-consuming and
expensive [4].
OPC (OLE for process control) is a standard data exchange in process control, which provides
a practical method for exchanging data between software configurations based on Windows platforms and
controllers based on field controls [5, 6]. Before OPC became known, to store field control device data,
the software configuration must provide communication drivers for each device. In fact, there are various
types of the field control devices that are constantly being updated, and the communication protocols used
by each control device are also different [4, 7]. OPC technology is a hardware and software interface
standard using client/server mode based on COM (component object model)/DCOM (distributed component

Journal homepage: http://journal.uad.ac.id/index.php/TELKOMNIKA

1492  ISSN: 1693-6930

object model), which offers a general standard mechanism for client’s and server’s data communication,
exchange, and supports the network distributional application procedure communication as well as
the application procedure communication in different platforms [8]. The configuration software can access
the data of the field control device in accordance with the interfaces provided by OPC server without needing
to understand the detailed information of these hardware devices so as to enhance the flexibility, efficiency,
openness and interoperability [9].
Using OPC standard is a good method of communication but still have problems. In
the development of OPC servers, there are problems with how to collect, process data from different OPC
servers, OPC server connections, and read-write from multi OPC servers. Whereas in the OPC client
development work, how to use the application program to create OPC server objects to connect different
OPC servers, OPC objects to collect process data from different OPC server devices [7]. Therefore, both of
these problems deserve to be studied in depth. This paper provides the design and implementation of OPC
server application which connecting between the devices and PLCs. The two prototypes applications of
process control are available for real-time communication between PLC Mitsubishi and PLC Omron based
on OPC technology. The organization of this paper is as follows: section 2 gives an implemented design of
OPC server or method on communication between two different platform devices (PLC Mitsubishi and PLC
Omron). The result and discussion about OPC Server implemented on PLC Mitsubishi and PLC Omron is
provided in section 3. Section 4 gives the conclusions.

2. METHOD
2.1. Conventional communication system
Conventional communication works by communicating every each end connection. Every
end-to-end connection required a custom driver to facilitate communications between specific endpoints. For
example, if an HMI needed to communicate with a PLC, it required a custom HMI driver written for
the specific protocol used by the PLC. Figure 1 shows the use of custom drivers between every endpoint
meant that even a small number of devices and applications quickly involved the use of many drivers. Each
driver establishes its own connection to the device or controller that it is designed to communicate with.
These things bring the problems of custom drivers in conventional communication.

2.2. OPC communication system

In software network as a central controller, each device are connected to the central controller with the
help of standard protocols [10]. OPC is used to answer one of the automation industry’s biggest challenges: how
to communicate between devices, controllers, and/or applications without getting caught up in the usual custom
driver-based connectivity problems. OPC abstracts the data source (e.g., PLC) and data sink (e.g., application
device) implementation details from each side so data can be exchanged between them without requiring them
to know anything about each other’s native communication protocol and internal data organization [9].
Figure 2 shows that OPC acts as an abstraction layer that sits between the data source and the data sink,
allowing them to exchange data without knowing anything about each other. The OPC device abstraction is
realized by using two, specialized OPC components called an OPC client and OPC server [4]. What is important
to note is that just because the Data Source and Data Sink can communicate with each other via OPC does not
mean their respective native protocols are no longer necessary or have been replaced by OPC. Instead, these
native protocols and/or interfaces are still present, but only communicate with one of the two OPC components.

Figure 1. Configuration of conventional communication

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Figure 2. OPC client/server architecture [4]

2.3. PLC device and application device

PLC used is Omron CP1E and Mitsubishi FX3U. PLC Omron is used to control the bottle filling
process, and PLC Mitsubishi is used to control the bottle unscramble process. Each PLC uses a software
driver from its manufacturer; PLC Omron uses CX Programmer while PLC Mitsubishi uses GX Work3.
The application device used in this project is two prototypes which consist of the bottle unscramble station
controlled by PLC Mitsubishi, and the bottle filling station controlled by PLC Omron. The two applications
were made with operational functions the processes as they represented. Actually, the two applications only
needed to show the working of communication system using OPC Server control two different PLC platforms.

2.4. The proposed system

This work was proposed the use of OPC Server to achieve the integration and communication
between two PLC different vendors. OPC abstracts the data source (i.e., PLC) and data sink
(i.e., application device) implement details from each side so data can be exchanged between them without
requiring them to know each other’s native communication protocol. The composition of real-time
communication developed in the system is shown in Figure 3. Systematic basic hardware items are displayed
as follows: PC (personal computer) equipped with ordinary parts. In addition, A PC-Adapter which is used to
convert PC’s RS232 interface to the PLC interface is furnished. The CX Programmer software can be
downloaded to the PLC Omron with the PC-Adapter. Also, the GX Work3 software can be downloaded to
the PLC Mitsubishi. The systematic basic software items are shown as follows: Windows 10 Professional,
The KEPServerEX6 is a 64-bit OPC Server application program, CX Programmer and GX Work3 it issued to
program both PLCs.

Figure 3. The configuration of communication between different PLC using OPC server

Communication between PLC different vendors using OPC server ... (Ignatius Deradjad Pranowo)
1494  ISSN: 1693-6930

GX Work3 connects the OPC server through OPC interfaces and accesses the data of PLC Omron
device register units by accessing the item object in the OPC server. Because group-object provides
the interfaces to PLC Omron CP1E, the PLC Omron CP1E exchanges data with group-object but not
item-object. The interfaces use the RS232 to realize. The OPC interfaces can connect OPC server after
configuring the OPC server object, the group object and the item object. When the OPC interfaces are
opened, the OPC customer’s application programming will access the OPC server and realize the access to
PLC Omron CP1E.
Both application devices, the bottle unscramble and the bottle filling, can communicate with each
other through OPC Server software configuration settings. Through this arrangement, the process of filling
water into a bottle will only do if it is getting bottles sent from the bottle unscramble process that have been
arranged on position (the bottle’s hole is above). This information is obtained because the controller of
the bottle filling process reads the data released from the sensor as a result of the detection of the presence of
the bottles sent from the bottle unscramble process. Meanwhile, the bottle unscramble process will stop, if
the queue of bottles in the bottle filling process is still long, and it will reactivate if the queue is empty or
depends on the desired PLC program. This information is received by the bottle unscramble process because
it reading of data information from the bottle filling process. Since both PLC are not on the same platform, to
be able to communicate with requires the OPC Server as software interface.

3. RESULT AND DISCUSSION

3.1. Conviguration of variable and connection
The purpose of configuration connection is to set up a connection between the OPC Server and
the client, and includes two following respects specifically [11, 12]. The first is hardware configuration. There are
two purposes of PLC hardware system configuration for both PLC Omron CP1E and PLC Mitsubishi FX3U. One
is to set basic parameter communication and the program addresses between PLC and PC which are used by OPC
Server, the other is to open the memory and data section which the PC need to access and download the basic data
and program to the PLC. Do run ‘KepServerEx6’ application, then complete both PLC hardware configuration of
CP1E and FX3U, DI/DO modules, OPC Server and setting of the basic parameters of the system. Then, choose the
communication port from the setting the PC Interface of the OPC Server, the COM port address and
communication speed between PC-Adapter and PC. The second is OPC server configuration. Configuration should
be finished in the COM before starting the OPC Server. Firstly, choose the network communication device and set
its relational parameters by utilizing ‘Setting the PC Interface’ application in the KEPServerEX6. Secondly, run the
Runtime application in KEPServerEX6 and set COM configuration parameter. In the end, enter the OPC
parameter setting of the OPC Server, set communication requiring cycle, and select connection as a
communication protocol between PC and PLC. The purpose of configuration variable is to set up
the communication data variable between the OPC Server and PLC Omron CP1E / PLC Mitsubishi FX3U.
Variable and parameter setting in KEPServerEX6 [13] are briefly presented in Table 1.

3.2. PLC program and KEPServerEX6

We can realize the real-time communication between PLC and process devices through command way.
Before we design the real-time communication program between PLC and process devices, the two things
should be finished [11]. First, the OPC Foundation offers a set of core components to browse other computers
and communicate with them which do not be installed. Secondly, in order to set up a connection between object
and OPC server object, we should configure the distributed COM environment between OPC server and OPC
customer. The program of both PLC (Mitsubhisi and Omron) are as in Table 2.
We can get communication data between bottles unscramble and bottle filling from the process record
of the KEPServerEX6 feature. Table 3 shows sample data transfer of one cycle when the PLC Mitsubishi and
PLC Omron communicate with each other (TX = to write the data; and RX = to read the data). At 13: 28:
39,416 the PLC Mitsubishi sends data to the PLC Omron; with details 13 data length and data content there are
a series of numbers. PLC Omron receives data twice, the first at (time) 13: 28: 39,436 with details of data length
32 and the second at (time) 13: 28: 39,462 with details of data length 11, with each containing a series of data
according to the length of the data. Reading of the data from this communication will be better understood
through the display in the KEPServerEX6 window of each device (PLC Omron and PLC Mitsubishi), as shown
in Figures 4-7.
In the bottle filling application (controlled by PLC Omron CP1E), it is programmed to fill 5 times for
one process cycle. The counter value will decrease according to the process that has occurred, and the process
will stop when the counter value has been fulfilled (the setting value is 5, and will stop if the value is 0). As
shown in Figure 4, the bottle filling has a value of 2, which means that 3 filling processes have been fulfilled
and 2 remaining filling processes. In Figure 5, the counter will decrease according to the process from 2 to 1

TELKOMNIKA Telecommun Comput El Control, Vol. 18, No. 3, June 2020: 1491 - 1498
TELKOMNIKA Telecommun Comput El Control  1495

from the setting value 5. Communication between the two PLCs with each different program can provide data
to each other with the help of KEPServerEX6 (OPC server).
Figure 6 shows the Counter value is 0 (zero) it shows that the filling process has been fulfilled, and the
value of the Stop communication is 1 (one) or active which will cause the process to stop. Figure 7 shows the
Reset value is 1 which means that the Reset button has been activated. The counter returns to value 5 and will
start for new process for refilling bottles five times. If the Stop button on the bottle unscramble is activated, it
will cause the whole process of bottle unscramble and bottle filling to be stopped. This shows that the
communication between the two is fulfilled (successfully sending and receiving data). Vice versa, if the
emergency button on the bottle filling is pressed (activated), both processes will stop (communication is
fulfilled; sending and receiving data is successful).

Table 1. Variable and parameter setting in KEPServerEX6

no variable setting parameter to be set
connectivity | add channel wizard: CJ1 for PLC Omron
select the channel FX for PLC Mitsubishi
PLC Omron for channel 1
specify the object
PLC Mitsubishi for channel 2
1 channel
select the hardware device type for communication COM port
specify port number port 1 for Omron & port 2 for Mitsubishi
baud rate 9600
diagnostic capture enable
channel | add device wizard: PLC Omron for device 1 r
specify the object PLC Mitsubishi for device 2
CJ1 for PLC Omron
2 device model
FX for PLC Mitsubishi
ID 0.0.0
data collection enable
connectivity | property editor :
tag name: add all input item (start, stop, etc.)
channel 1 | device 1 (omron)
tag tag name: add all input item (start, stop, etc.)
channel 2 | device 2 (mitsubishi)
address
addressed tag name: start, stop, etc. for Omron start: X002; stop: X003 … etc
addressed tag name: start, stop, etc. for Mitsubishi start: M000; stop: M001 … etc

communic
ation: change average tag to be link tag
average tag
advanced link the item with the corresponding one
tags

Communication between PLC different vendors using OPC server ... (Ignatius Deradjad Pranowo)
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Table 2. Main program of both PLC Mitsubishi and PLC Omron

PLC OMRON PLC Mitsubishi
(filling station) (unscramble station)
LD 200.00 ‘continued ‘’continued LD X002
OR 200.03 AND W0.05 TIM 005 #8 OUT M1
OUT W0.00 OUT W0.06 LD W0.14 LD M1
LD 200.01 TIM 000 #10 CNT 006 #5 OUT M5
OR 200.04 LD T000 LD C006 LD X000
OUT W0.01 AND W0.06 OR 200.07 OUT M2
LDNOT 0.00 OUT W0.07 ANDNOT W0.14 LD M2
OUT 200.09 LD W0.03 OUT 200.07 OUT M6
LD 0.02 OR W0.08 LD W0.05 LD M3
OUT W0.02 AND W0.07 ANDNOT W0.06 OUT M7
LD LR OUT W0.08 OR W0.13 LD M5
OUT W0.03 TIM 001 #20 OUT 100.00 OR M8
LD 0.04 LD T001 LD W0.07 ANDNOT M6
OUT W0.04 OR W0.09 ANDNOT W0.12 ANDNOT M7
LD 0.01 AND W0.08 OUT 100.01 ANDNOT M10
OUT 200.05 OUT W0.09 LD W0.12 OUT M8
LD 200.02 TIM 002 #60 ORNOT W0.07 LD M8
OR 200.05 LD T002 OUT 100.02 OUT Y000
OUT W0.14 OR W0.10 LD W0.08 LD M8
OR W0.15 AND W0.09 ANDNOT W0.11 OUT Y001
ANDNOT W0.01 OUT W0.10 OUT 100.03 LD M8
ANDNOT 200.07 TIM 003 #60 LD W0.11 ANDNOT M0
ANDNOT 200.09 LD T003 ORNOT W0.08 ANDNOT M9
OUT W0.15 OR W0.11 OUT 100.04 OUT Y002
LD W0.15 AND W0.10 LD W0.09 @LD X001
AND W0.04 OUT W0.11 ANDNOT W0.10 OR M0
OR W0.05 TIM 004 #20 OUT 100.05 ANDNOT T001
ANDNOT T005 LD T004 OUT M0
ANDNOT W0.01 OR W0.12 TIM 000 #10
ANDNOT 200.07 AND W0.11 LD M0
ANDNOT 200.09 OUT W0.12 OR M9
OUT W0.05 LD W0.04 AND T000
LD W0.04 AND W0.12 OUT M9
@AND W0.02 OUT W0.13 TIM 001 #15
OR W0.06 ‘’continued LDNOT M0
‘continued OR M9
OUT Y003

Table 3. Sample of data transfer between PLC Mitsubishi and Omron using KEPServerEX6
PLC Mitsubishi
time event length data
13:28:39.416 TX 13 02 45 30 30 38 38 30 30 32 03 44 41
13:28:39.447 RX 8 02 32 32 30 31 03 43 38
PLC Omron
time event length data
13:28:39.436 RX 32 40 30 30 46 41 30 30 43 30 … … … … … … 30 30 30 30 30 31
13:28:39.462 RX 11 30 30 30 30 35 33 33 2A 0D

Figure 4. The counter counts the value 2 of 5 Figure 5. The counter counts the value 1 of 5

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TELKOMNIKA Telecommun Comput El Control  1497

Figure 6. Stop communication is active, valued 1 Figure 7. Reset is active, valued 1

3.3. Discussion
In several previous papers on OPC Server, the usefulness of OPC Server was discussed. Among
them are papers written by Zhang [5], Şahin [14], and Li [15] which use OPC Server to monitor PLC, but
only one manufacturer is used. Furthermore when there is a demand to integrate two or more different PLC
manufacturers, it still needs to be considered. Other paper, Toyland [1] and Wenyan [16] apply the OPC
Server for the application of water systems. In the example this application provides instructions on how
OPC Server can be used in applications, consequently the usefulness of OPC Server becomes less optimal if
only for this purpose. The use of web-based OPC Server in [2] and [8] has provided alternative solutions, but
this is quite difficult if applied because it demands a reliable cloud system. Lieping [17] and Zhang [18] offer
the real-time communication between MATLAB and PLC, for the use of OPC we must make a program
using Visual Basic 6,0 [7] or using MATLAB [19]. Another paper proposed the OPC connectivity-based
approach to remote monitoring and control [20] and [21]. Vadi & Bayindir [22] developed an OPC and PLC
based remote-access laboratory. Zhu, et.al. [23] used OPC to design the information acquisition for field
equipment. Mahmoud, et.al. [24] using OPC to support in advanced process control. Data communication is
one of the significant part where the nodes send data towards the destination, some are based on real-time
and some are on normal data communication [25]. The use of KEPServerEX6 provides a relatively easy
solution for integrator technician who will combine the controls of several other PLCs so that can
communicate each other without difficulty with factory driver problems.
In this paper OPC Server has been designed and developed for integration of controls between two
PLCs from different manufacturers to communicate. The OPC Server used in this study came from
the KEPWARE, namely KEPServerEX6 [13]. KEPServerEX6 is an application program that uses OPC
Server technology. With the help of KEPServerEX6, integration issues two or more different control
platforms can be overcome from different manufacturers can be communicated together. So that the ability
and capacity of the OPC Server can be used more leverage than just to control one device or one
PLC manufacturer.
The obstacle is that in KEPServerEX6 there is no choice for HMI Omron etc. Furthermore the PLC
that we use is limited since does not have a serial port. Therefore the mini-USB connection can only be used
for one RS232 connection to USB-PC. By the way, this will be easily overcome if the choice of PLC used
considers the existence of the ports needed for RS232 and serial connections. The rest of the use of
KEPServerEX6 is quite strong and meets the needs of integrating two or more PLCs (controllers)
different platform.

4. CONCLUSION
The objective of this study was tried to answer the question how to communicate among different
devices and controllers in industrial process. The implementation of OPC Server technology has concluded
that communication between PLC Mitsubishi and PLC Omron can be done even though both have its own
driver software for controlling the field application devices. The observation from this study finds that using
the KEPServerEX6 (OPC server), PLC Mitsubishi and PLC Omron can communicate each other by send
and/or receive the data. This work has come up with the finding by using KEPServerEX6 (OPC server) it is
possible to realize the integration among the different devices and controllers which is commonly find in
the industrial processes. Further work needs to be done to establish the human machine interface in this
system, so that the integration and communication among the controller can be monitor and operate easily.

Communication between PLC different vendors using OPC server ... (Ignatius Deradjad Pranowo)
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