1. Introduction
This manual provides comprehensive instructions for the installation, operation, maintenance, and troubleshooting of your Coolmay Integrated PLC and HMI device. This series combines a Programmable Logic Controller (PLC) and a Human Machine Interface (HMI) into a single unit, offering efficient control and visualization for various industrial automation applications.
The Coolmay Integrated PLC and HMI is compatible with Mitsubishi GX Developer and WORKS 2 software for programming, ensuring broad compatibility and ease of use for engineers familiar with these platforms.
2. Specifications
The Coolmay Integrated PLC and HMI series offers various models with differing specifications. Please refer to the table below for detailed information:
| Feature | EX3G-43HA/HB | EX3G-43(50)KHA/KHB | EX3G-70KHA/KHB | EX3G-100HA/HB |
|---|---|---|---|---|
| General Dimensions | 134*102*30mm | 150*93*32mm | 226*163*35.6mm | 275*194*36mm |
| Cutout Size | 119*93mm | 143*86mm | 218*153mm | 261*180mm |
| Power Consumption | 4-6W | 4-6W/5-7W | 6-7W | 6-8W |
| HMI Specifications | ||||
| Display Features | 60K colors TP | |||
| Display Size | 97*56mm | 97*56/108*65mm | 154*87mm | 222*133mm |
| Resolution (pixels) | 480*272 | 43KHB: 480*272 50KHB: 800*480 |
70KHA: 1024*600 70KHB: 800*480 |
100HA: 1024*600 100HB: 800*480 |
| RAM | HA/KHA: 64MB; HB/KHB: 32MB | HA/KHA: 128MB; HB/KHB: 64MB | ||
| ROM | 128MB | |||
| Operating System | HA/KHA: WINCE 7.0; HB/KHB: without system | |||
| CPU | HA/KHA: CORTEX A8 720MHz-1GHz; HB/KHB: ARM9 216MHz |
HA/KHA: CORTEX A8 720MHz-1GHz; HB/KHB: ARM9 288MHz |
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| HMI COM Ports | 1 TP download port, 1 USB port. 1 RS232 optional (for EX3G-43HA/HB, EX3G-43(50)KHA/KHB). 1 RS485 or RS232 optional (for EX3G-70KHA/KHB, EX3G-100HA/HB). | |||
| HMI Software | CoolMayHMI V5.** (latest version available on coolmay.net) | |||
| PLC Specifications | ||||
| Digital I/O | Up to 12DI/12DO | Up to 30DI/30DO (At most 18 relay outputs) | ||
| I/O Level | MT Output: NPN; MR Output: NO contact; Input: Passive NPN, public terminal isolated | |||
| Output Type | MR/MOS Maximum load: MOS is 2A; MR is 5A |
MR/MT/MRT Maximum load: MT is 500mA; MR is 5A |
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| High-speed Counting | EX3G-HA/KHA: normally 5 single phase 100KHz, 1 channel 20KHz or 2 AB phase 60KHz, 1 channel 10KHz. EX3G-HB/KHB: normally 6 single phase 20KHz or 3 AB phase 10KHz. |
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| High-speed Pulse | EX3G-HA/KHA: normally 8 channels, Y0-Y3 is 100KHz, Y4-Y7 is 10KHz. EX3G-HB/KHB: normally 8 channels 10KHz. |
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| Analog I/O | AI: 0-10V/4-20mA/0-20mA/PT100/K type thermocouple/NTC10K/50K/100K etc. AO: 0-10V/0-5V/0-20mA/4-20mA or mixed. Up to 4AD/2DA (for EX3G-43HA/HB, EX3G-43(50)KHA/KHB). Up to 16AD/8DA (for EX3G-70KHA/KHB, EX3G-100HA/HB). |
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| PLC COM Ports | 2 programming ports (1 MiniB type USB port, 1 RS232 port). 1 RS485 optional (for EX3G-43HA/HB, EX3G-43(50)KHA/KHB). 1 RS485, 1 RS232 or 2 RS485, and CANbus optional (for EX3G-70KHA/KHB, EX3G-100HA/HB). | |||
| PLC Software | Compatible with Mitsubishi GX Developer8.86 and WORKS 2 | |||
Note: '485P/232P' means 485/232 added in PLC; '485H/232H' means 485/232 added in HMI.
For EX3G-70HA/100HA models: If configured with 30DI/30DO, the maximum analog I/O is 5AD/2DA. If configured with 24DI/20DO, the maximum analog I/O is 16AD/8DA.
3. Installation and Setup
3.1 Unpacking and Inspection
Carefully unpack the device and inspect it for any signs of damage during transit. Ensure all components listed in your packing slip are present. If any damage or missing parts are found, contact your supplier immediately.
3.2 Mounting the Device
The Coolmay Integrated PLC and HMI is designed for panel mounting. Refer to the 'Cutout Size' in the specifications table for the precise dimensions required for your chosen model. Ensure adequate ventilation around the device to prevent overheating.
- Cut an opening in the control panel according to the specified cutout dimensions.
- Insert the HMI/PLC unit into the opening from the front.
- Secure the unit using the provided mounting clips or screws from the rear of the panel.
3.3 Wiring Connections
All wiring should be performed by qualified personnel, adhering to local electrical codes and safety standards. Ensure the power supply is disconnected before making any connections.
- Power Supply: Connect a 24V DC power supply to the designated terminals. Refer to Figure 2 for the 'Power supply' input location.
- Digital Inputs/Outputs: Connect your sensors and actuators to the 'Digital input' and 'Digital output' terminals as per your application's logic.
- Analog Inputs/Outputs: For models with analog capabilities, connect analog sensors (e.g., 0-10V, 4-20mA) to the 'Analog input' terminals and analog actuators to the 'Analog output' terminals.
- RS485 Communication: If your model includes an RS485 port, connect it for serial communication with other devices.
- PLC Programming Port (RS232/RS485): Use this port to connect to your PC for PLC program download and debugging.
- HMI Programming Port (USB): Use the MiniB type USB port to connect to your PC for HMI screen design and download.
- Run Switch: This switch controls the operational state of the PLC.
For detailed wiring diagrams and pin assignments, please refer to the specific model's documentation, such as the Coolmay HMI/PLC All-in-on Programming Manual and HMI/PLC All-in-one User Manual.
3.4 Software Installation
To program the PLC and design the HMI interface, you will need the following software:
- PLC Programming: Mitsubishi GX Developer8.86 or WORKS 2.
- HMI Design: CoolMayHMI V5.** (latest version available from the official Coolmay website).
Install these software packages on your computer following their respective installation guides.
4. Operation
4.1 Powering On and Initial Boot
Once all connections are secure, apply power to the device. The HMI screen should illuminate, and the system will boot up. The 'RUN', 'COM', and 'PWR' indicators on the device will show its status.
4.2 Programming the PLC
- Connect your PC to the PLC programming port using the appropriate cable (RS232 or MiniB USB).
- Open Mitsubishi GX Developer8.86 or WORKS 2.
- Create or load your PLC program.
- Configure communication settings in the software to match the PLC port.
- Download the program to the PLC.
- Switch the 'Run switch' to the 'Run' position to execute the PLC program.
4.3 Designing and Uploading HMI Screens
- Connect your PC to the HMI programming port (USB).
- Open CoolMayHMI V5.** software.
- Design your HMI screens, linking elements to PLC registers as needed.
- Configure communication settings in the HMI software.
- Upload the HMI project to the device.
4.4 Interacting with the HMI
The HMI provides a touch-sensitive interface for monitoring and controlling your industrial process. Use the touch screen to navigate between screens, input data, and activate controls as designed in your HMI project.
5. Maintenance
5.1 Cleaning
Regularly clean the HMI screen and the device's exterior with a soft, damp cloth. Do not use abrasive cleaners or solvents, as these can damage the screen or casing. Ensure the device is powered off before cleaning.
5.2 Environmental Considerations
Ensure the operating environment remains within the specified temperature and humidity ranges. Avoid exposing the device to excessive dust, moisture, or corrosive gases, which can lead to malfunction or damage.
5.3 Firmware and Software Updates
Periodically check the Coolmay official website for firmware updates for the HMI/PLC and software updates for CoolMayHMI. Keeping your device and software updated ensures optimal performance and access to new features or bug fixes.
6. Troubleshooting
This section addresses common issues you might encounter with your Coolmay Integrated PLC and HMI.
| Problem | Possible Cause | Solution |
|---|---|---|
| Device does not power on. | No power supply or incorrect voltage. | Check 24V DC power connection and ensure correct voltage. |
| HMI screen is blank or unresponsive. | HMI program not loaded or corrupted; hardware issue. | Re-upload the HMI project. If issue persists, contact support. |
| PLC program not running. | 'Run switch' in 'Stop' position; program error; communication issue. | Ensure 'Run switch' is in 'Run'. Check PLC program for errors. Verify communication settings. |
| Communication error between HMI and PLC. | Incorrect communication settings; wiring issue. | Verify communication parameters (baud rate, parity, data bits) in both HMI and PLC software. Check wiring for continuity and correct connections. |
| Digital I/O not responding. | Incorrect wiring; faulty sensor/actuator; PLC program logic error. | Check wiring to I/O terminals. Test sensors/actuators independently. Review PLC program logic. |
If you encounter problems not listed here or if the suggested solutions do not resolve the issue, please consult the detailed Coolmay HMI/PLC All-in-on User Manual or contact Coolmay technical support.
7. User Tips
- Backup Your Projects: Always back up your PLC programs and HMI projects regularly to prevent data loss.
- Test Thoroughly: Before deploying your system in a production environment, thoroughly test all PLC logic and HMI functionalities.
- Cable Quality: Use high-quality shielded cables for communication and I/O connections to minimize electrical noise interference.
- Grounding: Ensure proper grounding of the device and associated equipment to enhance stability and reduce electrical interference.
8. Warranty and Support
Coolmay products are designed for reliability and performance. For information regarding product warranty, technical support, and service, please refer to the official Coolmay website or contact your authorized distributor.
Additional detailed documentation, including the Coolmay HMI/PLC All-in-on Programming Manual and CoolMay HMI User Manual, can be found on the manufacturer's website.
