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Connect to PLC ( Ethernet/IP, PROFINET)

This guide shows you how to connect your OV80i camera to industrial PLCs using EtherNet/IP or PROFINET protocols. These connections enable real-time communication for triggering inspections, receiving results, and integrating vision inspection into your automated production systems.

When to Use PLC Communication: When you need to integrate vision inspection with automated production lines, trigger inspections from PLC signals, send pass/fail results to PLCs, or coordinate vision inspection with other automation equipment.

Prerequisites​

  • OV80i camera system set up and connected to network
  • PLC system with EtherNet/IP or PROFINET capability
  • Network infrastructure connecting camera and PLC
  • Access to PLC programming software (Studio 5000, TIA Portal, etc.)
  • Basic understanding of industrial networking concepts

Understanding PLC Communication Protocols​

EtherNet/IP​

  • Used by: Allen-Bradley/Rockwell Automation PLCs primarily
  • Benefits: High-speed communication, widely supported, explicit and implicit messaging
  • Applications: ControlLogix, CompactLogix, and other Rockwell platforms
  • Data Exchange: Cyclic I/O and message-based communication

PROFINET​

  • Used by: Siemens and other European manufacturers
  • Benefits: Real-time deterministic communication, advanced diagnostics
  • Applications: Siemens S7 PLCs, various industrial automation systems
  • Data Exchange: Cyclic I/O with real-time performance

Part 1: EtherNet/IP Connection​

Step 1: Configure OV80i for EtherNet/IP​

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1.1 Access Industrial Ethernet Settings​

  1. Open the OV80i web interface
  2. Navigate to "Industrial Ethernet" in the left menu
  3. You'll see the Industrial Ethernet configuration page

1.2 Enable EtherNet/IP Protocol​

  1. In the Industrial Ethernet menu, select "EtherNet/IP" protocol
  2. Click "Enable" to activate EtherNet/IP communication
  3. Note your camera's network settings in the Device Information window

1.3 Configure Network Settings​

  1. Set Static IP Address (recommended for production)
    • Go to System Settings > Network
    • Configure static IP in same subnet as your PLC
    • Example: Camera: 192.168.1.100, PLC: 192.168.1.50
  2. Configure Subnet Mask (typically 255.255.255.0)
  3. Set Gateway if required for your network

1.4 Configure EtherNet/IP Device Settings​

  1. Device Name: Set a meaningful name for your camera
  2. Assembly Configuration: Configure input/output data structures
  3. Connection Parameters: Set appropriate timeout and RPI (Requested Packet Interval) values
  4. Click "Save" to apply EtherNet/IP settings

Step 2: Configure PLC Recipe Settings​

2.1 Enable PLC Triggering (Optional)​

  1. Navigate to Recipe Editor > Imaging Setup
  2. In Photometric Control, set Trigger Mode to "PLC Trigger"
  3. Important: Once PLC Trigger is enabled, manual triggering is disabled

2.2 Configure Pass/Fail Output​

  1. Navigate to Recipe Editor > IO Block
  2. Ensure your inspection logic ends with "Final Pass/Fail" node
  3. This sets the Inspection Pass bit in the EtherNet/IP assembly

Step 3: Configure PLC Side (Allen-Bradley Example)​

3.1 Install EDS File​

  1. Download EDS file from Overview.ai support or camera interface
  2. In Studio 5000, go to Tools > EDS Hardware Installation Tool
  3. Browse and select the OV80i EDS file
  4. Follow the installation wizard to complete EDS installation

3.2 Add OV80i Module to PLC Project​

  1. In Studio 5000, open your PLC project
  2. Go to I/O Configuration in the project tree
  3. Right-click on Ethernet module and select "New Module"
  4. Search for "OV80i" or "Overview" in the module catalog
  5. Select the OV80i module and click "Create"

3.3 Configure Module Properties​

  1. Name: Enter descriptive name for the camera
  2. IP Address: Enter the OV80i's IP address (e.g., 192.168.1.100)
  3. RPI (Requested Packet Interval): Set to 100ms or as required
  4. Connection Parameters: Configure input/output data sizes
  5. Click "OK" to create the module

3.4 Map I/O Data​

  1. Input Data: Inspection results, status bits, camera ready signals
  2. Output Data: Trigger commands, recipe change requests, control signals
  3. Create tags in your PLC program to map to the I/O data
  4. Example Input Tags:
    • Camera_InspectionPass: BOOL
    • Camera_Ready: BOOL
    • Camera_Busy: BOOL
  5. Example Output Tags:
    • Camera_Trigger: BOOL
    • Camera_RecipeSelect: INT

Input Assembly (OV80i → PLC)

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Output Assembly (PLC → OV80i)

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Step 4: Test EtherNet/IP Communication​

4.1 Verify Connection Status​

  1. In Studio 5000, check module status in I/O Configuration
  2. Green checkmark indicates successful connection
  3. Red X indicates communication issues

4.2 Test Basic Communication​

  1. Monitor input data from camera in PLC program
  2. Toggle output signals to camera and verify response
  3. Check diagnostic information for any error codes

4.3 Test Trigger and Response​

  1. Enable PLC trigger output to camera
  2. Monitor inspection results in PLC input data
  3. Verify pass/fail status updates correctly
  4. Check timing of trigger and response cycles

Part 2: PROFINET Connection​

Step 1: Configure OV80i for PROFINET​

1.1 Access Industrial Ethernet Settings​

  1. Open the OV80i web interface
  2. Navigate to "Industrial Ethernet" in the left menu
  3. Select "PROFINET" protocol from the options

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1.2 Enable PROFINET Protocol​

  1. Click "Enable PROFINET" to activate protocol
  2. Note: PROFINET manages camera IP address when enabled
  3. Camera IP settings may be overridden by PLC configuration

1.3 Configure PROFINET Device Settings​

  1. PROFINET Device Name: Set unique name for camera
    • Example: "OV80i_Line1_Station2"
    • Must be unique if multiple cameras on same PLC
  2. Device Configuration: Note the device capabilities and data structure
  3. Click "Save" to apply PROFINET settings

Step 2: Configure PLC Recipe Settings​

2.1 Enable PLC Triggering (Optional)​

  1. Navigate to Recipe Editor > Imaging Setup
  2. Set Trigger Mode to "PLC Trigger" if needed
  3. Warning: Manual triggering disabled when PLC trigger is active

2.2 Configure Pass/Fail Logic​

  1. Navigate to Recipe Editor > IO Block
  2. Ensure inspection logic concludes with "Final Pass/Fail" node
  3. This sets the Inspection Pass bit in PROFINET input assembly

Step 3: Configure PLC Side (Siemens Example)​

3.1 Install GSDML File​

  1. Download GSDML file from Overview.ai support
  2. In TIA Portal, go to Options > Manage general station description files (GSD)
  3. Click "Install GSD file" and select the OV80i GSDML file
  4. Complete the installation process

3.2 Add OV80i to Hardware Configuration​

  1. In TIA Portal, open Device & Networks view
  2. From the Hardware catalog, expand Other field devices > PROFINET IO
  3. Locate OV80i device and drag it to the network view
  4. Connect the OV80i to your PLC's PROFINET interface

3.3 Configure Device Properties​

  1. Device Name: Set same name as configured in camera
  2. IP Address: Configure IP address (may be managed by PLC)
  3. Update Time: Set cycle time (default 128ms recommended)
  4. I/O Data: Configure input/output data modules as needed

3.4 Assign IP Address and Device Name​

  1. Compile hardware configuration
  2. Go online with PLC
  3. Assign IP address to OV80i device
  4. Assign device name matching camera configuration

Step 4: Test PROFINET Communication​

4.1 Verify Device Status​

  1. In TIA Portal, check device status in Device & Networks
  2. Green status indicates successful communication
  3. Red status indicates communication problems

4.2 Test Data Exchange​

  1. Monitor input data from camera in PLC program
  2. Control output data to camera and verify response
  3. Check diagnostic buffers for any error messages

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4.3 Test Inspection Cycle​

  1. Activate PLC trigger to camera
  2. Monitor inspection results in PLC input data
  3. Verify pass/fail status transmission
  4. Check cycle timing meets application requirements

Step 5: Troubleshooting PLC Communication​

5.1 Common EtherNet/IP Issues​

ProblemSymptomsSolution
Connection timeoutModule shows red X in Studio 5000Check IP addresses, network connectivity, firewall settings
Data not updatingI/O data remains staticVerify EDS file version, check assembly configuration
Trigger not workingCamera doesn't respond to PLC triggerCheck trigger bit mapping, verify PLC output is active
Slow responseDelayed inspection resultsAdjust RPI timing, check network load

5.2 Common PROFINET Issues​

ProblemSymptomsSolution
Device not foundCamera not visible in TIA PortalCheck GSDML file installation, verify device name
IP address conflictsCommunication errorsEnsure unique IP addresses, check subnet configuration
Cycle time errorsWatchdog timeoutsIncrease cycle time, check network performance
Data format errorsIncorrect I/O dataVerify GSDML version, check data structure mapping

5.3 Network Diagnostics​

  1. Ping test between camera and PLC
  2. Check network switches and cable integrity
  3. Monitor network traffic for bandwidth issues
  4. Verify firewall settings don't block communication

Step 6: Performance Optimization​

6.1 Timing Considerations​

  • EtherNet/IP RPI: Start with 100ms, adjust based on application needs
  • PROFINET Cycle Time: Use 128ms default, reduce only if required
  • Inspection Time: Consider total inspection time in cycle planning
  • Network Latency: Account for network delays in timing calculations

6.2 Data Efficiency​

  • Minimize data size in I/O assemblies
  • Use appropriate data types (BOOL vs INT vs REAL)
  • Avoid unnecessary data in cyclic communication
  • Use explicit messaging for non-critical data

6.3 Network Management​

  • Use managed switches for better diagnostics
  • Implement redundancy for critical applications
  • Monitor network utilization to prevent congestion
  • Plan IP address ranges for scalability

Success! Your PLC Communication is Established​

Your OV80i camera can now:

✅ Communicate with PLCs using industrial protocols

✅ Receive trigger signals from automation systems

✅ Send inspection results to PLC control logic

✅ Integrate seamlessly with production line automation

✅ Support remote recipe changes and system coordination

Best Practices​

Production Deployment​

  • Use static IP addresses for consistent communication
  • Document all network settings and device configurations
  • Test thoroughly before production deployment
  • Plan for maintenance and troubleshooting procedures

Security Considerations​

  • Segment industrial networks from office networks
  • Use managed switches with appropriate security features
  • Monitor network access and device communications
  • Keep firmware updated on all network devices

Maintenance​

  • Regular network health checks and diagnostics
  • Monitor communication statistics for performance trends
  • Update device drivers and configuration files as needed
  • Maintain documentation of all network configurations

Next Steps​

After establishing PLC communication:

  1. Develop PLC control logic for your specific application
  2. Create operator interfaces for monitoring and control
  3. Set up data logging for production tracking
  4. Implement alarm handling for system fault management
  5. Plan system backup and disaster recovery procedures

📥 Download Files​

Download these essential files for PLC integration (compatible with both OV20i and OV80i systems):

EtherNet/IP Configuration​

  • OV80i EDS File - Electronic Data Sheet for Allen-Bradley Studio 5000
    • Required for configuring OV80i module in ControlLogix/CompactLogix systems

PROFINET Configuration​

  • OV80i GSDML File - Device description for Siemens TIA Portal
    • Required for configuring OV80i device in PROFINET networks

Sample PLC Code (Universal)​

  • Recipe Switch Routine - Ladder logic for recipe switching

    • Complete Allen-Bradley routine for changing camera recipes via PLC
    • Works with both OV20i and OV80i systems

  • Camera Trigger Routine - Ladder logic for triggering inspections

    • Complete Allen-Bradley routine for triggering camera and handling results
    • Works with both OV20i and OV80i systems

File Usage Notes:​

  • EDS Files: Import into Studio 5000 via Tools → EDS Hardware Installation Tool
  • GSDML Files: Import into TIA Portal via Options → Manage GSD Files
  • L5X Files: Import ladder logic directly into your Allen-Bradley project
  • Camera-Specific: Use OV80i EDS/GSDML files for OV80i systems, sample code is compatible across models
  • Reference: EtherNet/IP Assembly Maps & Timing Diagrams
  • Reference: PROFINET GSDML & Network Limits
  • How-To: Digital Input Trigger Setup
  • How-To: System Settings (Network/Time/Logs)
  • Troubleshooting: Camera to PLC Communication Fails