Coolmay EX3S-8043H-24MT-4AD-PT HMI/PLC All-in-One Instruction Manual

1. Introduction

The Coolmay EX3S-8043H-24MT-4AD-PT is an integrated Human-Machine Interface (HMI) and Programmable Logic Controller (PLC) solution designed for industrial automation. This all-in-one device combines a 4.3-inch touch screen HMI with a powerful PLC, offering a cost-effective and efficient control system.

Key Advantages:

• High Performance: Equipped with a military-grade 32-bit CPU + ASIC dual processor, supporting online monitoring and fast execution speed of basic instructions (0.24µs).
• Enhanced Security: The touch screen and PLC can be encrypted separately to prevent unauthorized access and protect user programs.
• Ample Capacity: The PLC program capacity reaches 30K steps with 12K power-off retention registers, supporting programming in instructions, ladder diagram (LD), and step ladder diagram (SFC).
• Versatile Communication: Supports Delta DVP programming port protocol, Modbus RTU, Modbus ASCII protocol, and free port protocol, enabling easy interconnection and communication with external devices like inverters.
• Advanced Control: Features multiple interrupts (input, timer, communication, high-speed counter, high-speed pulse output), motion positioning, 2 groups of linear and circular interpolation, and CAN bus support for servo control.
• Special Functions: Includes electronic cam, weighing, and G code functionalities.
• Flexible I/O: Supports multiple analog voltage and current mixed inputs and outputs.

2. Specifications

The following table details the technical specifications for the Coolmay EX3S-8043H-24MT-4AD-PT HMI/PLC all-in-one device.

Product Views:

3. Interfaces and Indicator Lights

The Coolmay HMI/PLC features various interfaces and indicator lights for operation and communication.

Indicator Lights:

• POWER: Illuminates when the device is powered on.
• RUN: Indicates PLC running status; lit when the PLC is running.
• COM: Indicates touch screen and PLC communication status; lit when communication is active.

Interfaces:

• Power Terminal: Connect DC24V switching power supply to the DC24V (positive) and 0V (negative) terminals.
• PLC Programming Port: Two ports available (MiniB USB port or Type-C / RS232). PLC programs can be downloaded via a 232 programming line or USB line.
• HMI Programming Port: Used to download touch screen configuration programs.
• USB Interface: Can be directly inserted into a USB flash drive with a FAT32 file system for data transfer.
• SD Card Slot: For inserting an SD card to store historical records and other data.
• Network Port: Supports program downloading or Modbus TCP/IP protocol. Note: PLC and HMI network ports cannot coexist.
• Wireless Network Card: Supports optional WiFi or 4G, occupying the USB download port of the touch screen.

4. Setup and Installation

This section guides you through the physical installation and initial software setup of your HMI/PLC device.

4.1 Physical Installation

The EX3S-8043H-24MT-4AD-PT is designed for snap-on installation. Refer to the dimensional drawing for precise cutout requirements.

4.2 Wiring

Proper wiring is crucial for the safe and correct operation of the device. Ensure all power is disconnected before wiring.

4.2.1 Power Supply Wiring

Connect a DC24V switching power supply to the power terminals on the rear of the device. The positive pole connects to the DC24V terminal, and the negative pole connects to the 0V terminal.

4.2.2 I/O and Analog Wiring

Refer to the detailed wiring diagrams for digital inputs (X), digital outputs (Y), analog inputs (AD), and analog outputs (DA).

Digital Inputs (X0-X13): The device supports 12 digital inputs. Wiring for high-speed contacts and normal contacts are provided in the diagram.

Digital Outputs (Y0-Y11): The device has 10 transistor outputs. Refer to the relay output equivalent circuit and transistor output equivalent circuit for proper connection of loads. For inductive loads, an absorption circuit is recommended.

Analog Inputs (AD0-AD3): The 4 analog inputs support various types including thermocouples (E, K, S, T, J), RTDs (PT100, PT1000), NTCs (10K, 50K, 100K), and voltage/current signals (0-10V, 0-5V, 0-20mA, 4-20mA). Refer to the PLC analog wiring and thermocouple wiring diagrams.

Analog Outputs (DA0-DA1): The device provides 2 analog outputs. Ensure correct wiring for voltage or current output types.

4.2.3 Communication Wiring

Connect your programming PC to the HMI/PLC using the appropriate cables for HMI and PLC programming ports. An example setup is shown below:

4.3 Software Installation

The Coolmay HMI/PLC requires dedicated software for programming both the HMI and PLC components.

4.3.1 HMI Software Installation

The HMI is programmed using CoolMayHMI touch screen software, compatible with Windows XP/7/8/10. If installation issues occur, try running as administrator or reinstalling drivers.

Installation Steps:

1. Run the `Vcool *.exe` installer.
2. Follow the on-screen prompts. A device driver installation wizard may appear.
3. Click 'Next' to install the USB driver.

4.3.2 PLC Software Installation

The PLC is compatible with Vtool PRO programming software. It also supports GX Developer 8.86Q and GX Works2. Ensure you use compatible software versions to avoid incompatibility issues.

4.3.3 Initial Programming Notes

Before starting a new project, configure the model settings and communication parameters in the software. This includes specifying the program title, PLC model, and communication settings (e.g., COM port, baud rate).

5. Operation

This section covers the operational aspects of the Coolmay HMI/PLC, including programming, analog I/O, and advanced functions.

5.1 HMI Program Creation and Download

To create a new HMI program:

1. Open the CoolMayHMI software.
2. Create a new project, select the appropriate model (EX3U-8043H for this device), and configure communication protocols.
3. Design your HMI screens.
4. Save the program.
5. Download to HMI: Connect the HMI to your PC via USB, serial, or Ethernet. In the software, go to 'Tools' -> 'Compile' and then 'Download'. Select the appropriate download method and click 'Download'.
6. Upload from HMI: To retrieve a configuration project, event data, or data sampling records from the HMI, use the 'Upload' function in the software.
7. USB Download Steps: For offline updates, export the project to a USB disk from the 'Tools' menu. Insert the USB disk into the HMI and use the 'Project Update' section in 'Touch Screen Parameter Settings' to update.

HMI Operation Demonstration:

5.2 PLC Programming

The PLC supports various programming modes:

• Ladder Diagram Mode: Programs are created using ladder logic. After completion, they must be compiled and converted into instruction code or SFC diagram.
• Instruction Mode: Programs are written using instruction lists. After completion, they must be compiled and converted into ladder diagram or SFC diagram.
• SFC Programming Mode: Programs are created using Sequential Function Charts. These must be converted to instruction code through compilation.

5.3 Analog Input and Output

5.3.1 Analog Input

The EX3S-8043H series HMI/PLC has 4 analog inputs. You can directly read the register values corresponding to each analog quantity.

• Analog Input Types: Voltage (0-10V), Current (0-20mA, 4-20mA).
• Range: 0-4000 for all types.
• Resolution: 2.5mV for voltage, 5uA for 0-20mA current, 4uA for 4-20mA current.
• Accuracy: 1%.
• Register Reading: D[1110]~D[1113] store the output values.
• Sampling: D1377 controls the number of sampling cycles (range 0-7, default 7). D1118 controls filter cycles (range 0-32767).

5.3.2 Analog Output

The analog output setting values range from 0-4000, with 12-bit accuracy. You can use TO instructions or direct register assignment (D8050-D8057) to output 0-10V or 0-20mA analog signals.

5.4 Weighing Function

The EX3S-8043H can be equipped with weighing functions, converting signals into high-precision 24-bit AD for electronic weighing. It supports filtering selection, filtering times, and fault detection.

Weighing Wiring Diagram:

5.5 PID Instruction

The PID (Proportional-Integral-Derivative) instruction is used for closed-loop control, adjusting the output value based on input changes. It is widely used in mechanical, pneumatic, and electronic equipment.

• Instruction Format: PID S1 S2 D (S1: target value, S2: current value, D: output value).
• Parameters: Configured via special registers (S3-S3+20) including sampling time, proportional gain (Kp), integral gain (Ki), differential gain (Kd), and control mode.
• Operation: The PID calculation is performed after the sampling time is reached.

5.6 High-Speed Counter

The device includes both hardware and software high-speed counters. Hardware counters are fast and accurate, while software counters are suitable for less demanding applications.

• Input Allocation: Counters C232-C255 are used for high-speed counting.
• Types: Single-phase (up to 6 channels, 60kHz) and dual-phase (2-3 channels, 200kHz).
• Function Switching: Software settings allow switching between single, double, triple, and quadruple frequency counting modes.

5.7 High-Speed Pulse Output

The HMI/PLC supports various high-speed pulse output applications for precise motion control.

5.7.1 Pulse Output

The device offers 10 channels of high-speed pulse output (Y0-Y11) up to 200KHz, supporting variable speed control. This is used for applications like controlling stepper motors or servo drives.

5.7.2 Pulse Width Modulation (PWM)

The PWM instruction specifies the pulse cycle and ON time for output. It generates a pulse with a defined ON pulse width within a given period.

• Instruction Format: PWM S1 S2 D (S1: pulse output width, S2: pulse output period, D: output pulse soft element).
• Ranges: 0-32767ms for S1/S2.
• Output: Y0-Y3.

5.7.3 Handwheel Pulse Function

The handwheel pulse function is used for manual control, such as setting the origin, fine adjustment, or interruption insertion during processing. It supports servo motors.

• Operation: The handwheel controls the rotation of the motor, with each pulse corresponding to a specific motor movement.
• Wiring: Connect the handwheel to the PLC's X inputs (e.g., X0, X1) and the motor drive to the Y outputs (e.g., Y10, Y11).

5.7.4 G Code Function

The G code function allows the HMI/PLC to act as a CNC controller, supporting 4-axis G code (linked interpolation up to 8 axes). G code files can be generated from CAD software.

• CNC System: The HMI can be used to edit G code and form a CNC system with the PLC.
• Soft Component Functions: Various registers (D1938+) are used to define mechanical parameters, coordinate positions, and control interpolation movements.
• Importing G Code: G code files (e.g., .CNC files) can be imported from a USB drive to the HMI. The file must be in the root directory of the USB drive.

5.8 Communication Port Instructions

The HMI/PLC offers multiple communication ports for various protocols.

5.8.1 MODBUS Communication

When the PLC acts as a master, it supports MODRW (read/write), MODRD (read), and MODWR (write) instructions.

• MODRD (Read Data): Reads data from a slave device. S1 specifies slave station number, S2 specifies target address, 'n' is the number of registers to read.
• MODWR (Write Data): Writes data to a slave device. S1 specifies slave station number, S2 specifies target address, 'n' is the number of registers to write.
• MODRW (Read/Write Data): Reads and writes data simultaneously.

5.8.2 RS232 and RS485 Communication

The device includes RS232 (COM1) and RS485 (COM2/COM3) ports. These ports support Delta DVP programming port protocol, free port protocol, and MODBUS RTU/ASCII protocol.

• Settings: Communication parameters like baud rate, data length, parity, and stop bits can be configured via special registers (e.g., D1120, D1109).
• Master/Slave Operation: The PLC can operate as a master or slave station.

5.8.3 Network Communication

The device can be equipped with an optional network port for program downloading and Modbus TCP/IP protocol. Network card status and settings are managed via specific registers (M1504, M1505, D1954, etc.).

6. Maintenance

To ensure the longevity and optimal performance of your Coolmay HMI/PLC, follow these maintenance guidelines:

• Environmental Conditions: Operate the device within the specified temperature (-20°C to 60°C) and humidity (20% to 90% non-condensing) ranges. Avoid freezing conditions.
• Cleaning: Regularly clean the HMI screen and the device's exterior with a soft, dry cloth. Do not use abrasive cleaners or solvents.
• Ventilation: Ensure adequate ventilation around the device to prevent overheating. Keep vents clear of dust and obstructions.
• Wiring Integrity: Periodically check all wiring connections for tightness and signs of wear or damage. Loose connections can lead to intermittent operation or faults.
• Software Updates: Keep your HMI and PLC programming software updated to the latest versions to benefit from new features, bug fixes, and improved compatibility.
• Data Backup: Regularly back up your HMI projects and PLC programs to an external storage device (e.g., USB flash drive, PC) to prevent data loss.

7. Troubleshooting

This section provides solutions to common issues you might encounter with your HMI/PLC device.

• Device Not Powering On: Check the DC24V power supply connection and ensure it is providing the correct voltage. Verify the POWER indicator light.
• PLC Not Running: If the RUN indicator is off, check your PLC program for errors. Ensure the PLC is not in STOP mode.
• Communication Issues (PC to HMI/PLC):
  • Verify that the correct USB/serial drivers are installed on your PC.
  • Check Device Manager to ensure the COM ports are recognized and assigned correctly.
  • Ensure the correct communication port (COM1, COM2, etc.) and baud rate are selected in your programming software.
  • Try using a different USB cable or port.
  • If using Ethernet, verify IP address settings and network cable connection.
• HMI Screen Unresponsive: Perform a touch screen calibration if the screen is not responding accurately.
• PID Control Instability:
  • If the user parameter settings exceed the range, the system will use the left and right limits.
  • Ensure the PID measured value (PV) is stable before PID calculation actions.
  • The maximum difference of sampling time (Ts) should be within -(1 scan cycle + 1ms) to +(1 scan cycle). Adjust scan cycle or use time interrupt subroutine if errors occur.
• Flying Shear/Chasing Shear Not Starting: Ensure that 'ECAM_Withe' is downloaded to the device. If the download fails, restart the host computer software and reconfigure before attempting to download again.
• Handwheel Pulse Function Errors:
  • If abnormalities occur after adjusting gear ratio, turn off M1743, assign 0 to the following axis number (D1816), then change it back and restart M1743.
  • Pulse display values (D1336, D1338) cannot be cleared directly. If clearing is necessary, follow the specific steps in the manual to avoid safety risks.
• Network Card Function Canceled: If the network cable is disconnected, the network card function may be canceled. Reconnect the cable and reconfigure if necessary.

8. User Tips

Here are some helpful tips from experienced users and common inquiries:

• Leverage High-Speed Functions: The device's high-speed pulse output and encoder support are very powerful. Explore these features for precise motion control applications.
• Software Availability: The programming software (CoolMayHMI, Vtool PRO, GX Developer, GX Works2) and manuals are typically available for free download from the manufacturer's website. Contact the sales team for direct download links if needed.
• Communication Troubleshooting: If you encounter issues with PC-to-HMI/PLC communication, especially after installing drivers, double-check your Device Manager for proper port recognition. Sometimes, trying a different USB port, cable, or ensuring the correct COM port and baud rate are selected in the software can resolve the problem.
• Backup Your Work: Always back up your HMI projects and PLC programs regularly. This is crucial for preventing data loss and ensuring a smooth recovery process if any issues arise.

9. Further Documentation

For more detailed information, including comprehensive programming guides and advanced functionalities, please refer to the official user manual:

• CoolmayEX3U-80 Series HMI/PLC all-in-one Programming Manual (PDF)