Xinje ZG3 Series User manual

ZG3 series integrated PLC&HMI
User manual
WUXI XINJE ELECTRIC Co. Ltd.
No. PH C 09 201400902 3.3

This manual includes some basic precautions which you should follow to keep you safe and protect the
products. These precautions are underlined with warning triangles in the manual. About other manuals that
we do not mention please follow basic electric operating rules.
Please follow the precautions. If not, it may lead the control system
incorrect or abnormal, even cause fortune lose.
The models could only be used according to the manual, and an only be
used along with the peripheral equipments recognized or recommended by
XINJE Electronic. They could only work normally in the condition of be
transported, kept and installed correctly, also please operate and maintain
them according to the recommendation.
WUXI XINJE ELECTRIC CO., LTD. Copyright reserved
Without exact paper file allowance, copy, translate or using the manual is not allowed. Disobey this, people
should take the responsibility of loss. We reserve all the right of expansions and their design patent.
Duty Declare
We have checked the manual, its content fits the hardware and software of the products. As mistakes are
unavoidable, we couldn’t promise all correct. However, we would check the data in the manual frequently,
and in the next edition, we will correct the necessary information. Your recommendation would be highly
appreciated.
Correct
Application
Precautions

Catalog
SAFETY NOTES....................................................................................................................................5
1 ZG3 SERIES INTRODUCTION .......................................................................................................1
1-1.INTRODUCTION ...............................................................................................................................1
1-1-1.Characteristics .......................................................................................................................1
1-1-2.Name rule ...............................................................................................................................1
1-2.GENERAL SPECIFICATION ................................................................................................................2
1-2-1. Product specification.............................................................................................................2
1-2-2. Special function .....................................................................................................................4
1-3.PART INTRODUCTION.......................................................................................................................5
1-3-2. Button function ......................................................................................................................6
1-3-3. Download port (COM0) ........................................................................................................7
1-3-4. Communication port AB........................................................................................................7
1-3-5 ． USB download port .............................................................................................................8
1-4.DIMENSION.....................................................................................................................................9
2 I/O AND WIRING.............................................................................................................................10
2-1. INPUT SPEC...................................................................................................................................10
2-2. RELAY OUTPUT.............................................................................................................................12
2-3.TRANSISTOR OUTPUT ...................................................................................................................14
3 PLC AND HMI PROGRAMMING.................................................................................................16
3-1. PLC PROGRAMMING ....................................................................................................................16
3-2．INSTRUCTION LIST .....................................................................................................................16
3-2-1. Basic instructions ................................................................................................................16
3-2-2. Application instructions.......................................................................................................18
3-2-3. Special instructions .............................................................................................................22
3-2-4. Soft component ....................................................................................................................23
3-3. HMI PROGRAMMING....................................................................................................................24
APPENDIX 1SPECIALAUXILIARY REGISTER .........................................................................................27
APPENDIX 2SPECIAL DATA REGISTERS ................................................................................................34
APPENDIX 3SPECIAL FLASH REGISTER ...............................................................................................49

Preface
Thank you for purchasing XINJE ZG3 series integral industrial controller, please read the manual
before operating.
This manual applies to the ZG3 series integral industrial controller.
XINJE provides user with press document and tele-document:
User CD
Contained software, manual and application examples
XINJE website
Welcome to www.XINJE.com to download center to find
electronic document.
If you have any questions, please contact us.
Tel: [phone]
Fax: [phone]
Address: 4th Floor, Building 7, Originality Industrial Park, Liyuan
Development Zone, Wuxi City, Jiangsu province, China
Manual purpose
This manual provides user with the guide of using and operating our product, it
includes the product characteristics, spec explanation, using method, etc.
This manual contains product summarization, exterior layout, PLC program,
and HMI editing. The details please refer to XD series PLC manual and TG series
HMI manual.
Summarization: introduce the product characteristics, specs, dimension,
installation.
Exterior layout: introduce the product power spec, in-out layout.
PLC program: introduce how to program in PLC.
HMI picture: introduce how to edit picture in TG.
Exterior extension: introduce extension ability of the product.
Suitable people
This manual aims to below users:
Terminal user
Debugging person
Technology support person
Make sure you have read the safety notice before operating.
Scope
Tele-document
Contact us

Safety notes
Read the manual carefully before operating. Be aware of the safety and correct operation. The
content below is focus on ZG3 series products only.
Please safekeeping the manual, put in somewhere easy to get and read and give the manual to final
user.
●Do not put the wire close to cable, keep 10cm distance at least.
●Do not change the inside module of product or it may cause fault, error action, loss,
fire.
●When it smelly or noisy, cut the power immediately (short tweet after power on is
normal).
●Do not press the screen with pen, screwdriver or other sharp tools, it may cause screen
break or error.
●For installing the product, tighten the screws to avoid loose.
●Transport, install, store, assemble and maintain the product accurately to avoid
breaking.
●Confirm the power voltage and wire connection before turn on the power in order to
avoid breaking
●Do not touch the connection point to avoid getting an electric shock
●Do not open the back cover board
●Cut all the power before installation and take-down to avoid error and fault
●Please use in the surrounding the manual stated to avoid accident
●Do not use the product under the condition of high frequency radiation, strong
magnetic field to avoid interference
◎Notice items ◎
ATTENTION
DANGEROUSNESS

ZG3 series
1
1ZG3 series introduction
1-1. Introduction
1-1-1. Characteristics
Integrated logical control, analog I/O, HMI in one unit
Digital input: 16 points, optical isolation, high speed optical coupling please refer to 1-2-2.
Digital output: 14 points, relay output/transistor output/relay & transistor output
Analog extension: under development
HMI screen is easy to edit, rich function, support touch screen
LCD: 800*480 pixels, 7 inches, 16000000 colors, use life up to 50000 hours
Support high speed count, high speed pulse, external interruption
Front panel waterproof level is IP65
1-1-2. Name rule
1：
Series name
ZG：16 million colors touch screen
2：
PLC type
3：XD3 series
3：
I/O points
30：16 input 14 output
4：
Output type
NPN type R：relay output
T：transistor output
PNP type PR：relay output
PT: transistor output
model
Input point
(DC24V)
Output point
(R, T)
DC source
Relay output
Transistor output
NPN
ZG3-30R
ZG3-30T
16 points
14 points
PNP
ZG3-30PR
ZG3-30PT
16 points
14 points

The models include Z-3AD3PT-BD, Z-4AD2DA-A-BD. Please refer to Z series expansion BD
manual.
1-2. General specification
1-2-1. Product specification
Item
Spec
Electrical
Input voltage
DC24V
Rated frequency
~26.4V
Allowable momentary
power failure time
10ms DC24V
Withstanding voltage
10A DC26.4V
Insulation resistor
About 10MΩ, DC500V (signal and ground)
Environment
Operation temperature
0～50℃
Storage temperature
–10～60℃
Ambient humidity
20~85% (no condensation)
Vibration resistance
10~25Hz (X, Y, Z each direction is 30 minutes 2G)
Interference immunity
Voltage noise: 1000Vp-p
Ambient air
No corrosive gas
Protection
IP65 for the front cover
Structure
Cooling
Natural air cooling
Dimension
200.4*146.9*49.0
Installation dimension
192.0*138.5
Interface
Download port
RS-232/USB
Communication port
RS-232/ RS-485
Item
Spec
Screen
Type
16 million colors LCD
LCD size
7 inches
Use life
50000 hours, 24 hours run under the ambient temperature 25℃
Display area
800*480
Contrast
adjustable
Extension BD board
Electrical spec
HMI spec

ZG3 series
3
Language
Chinese, English, Spanish, Korean and so on
Font
Any font and size
Touch mode
4-wire resistance touch mode
Memory
Screen
128MB
Item
Spec
Program execution mode
Cyclic scan
Programming mode
Instruction, ladder chart, visual C
Operation speed
0.05µs
Latched
Flash ROM and Li-battery
User program capacity※1
128KB
I/O points
Input 16 points; output 14 points
Internal coil (X)
1048point：X0~X2027
Internal coil (Y)
1048point：Y0~Y1037
Internal coil (M、HM）
11008 point
M0~M7999【HM0~HM959】※5
Special use※6 SM0~SM2047
Flow (S)
1152 point
S0~S1023【HS0~HS127】
Timer (T)
Points
704 points
T0~T575 【HT0~HT95】
Precise timer ET0~ET31
Spec
100ms timer: 0.1~3276.7 s
10ms timer: 0.01~327.67 s
1ms timer: 0.001~32.767 s
Counter
(C)
Points
704 points
C0~C575【HC0~HC95】
High speed counter HSC0~HSC31
Spec
16-bit counter: 0~32767
32-bit counter: -2147483648~＋2147483647
Data register (D)
11548 words
D0~D7999【HD0~HD999】※5
Special use※6 SD0~SD2047
Special use※6 HSD0~HSD499
FlashROM register (FD)
8144 words
FD0~FD6143
Special use※6 SFD0~SFD1999
High speed functions
High speed count, pulse output, external interruption
Scheduled scan time
0~99ms
Password protection
6-bit ASCII
Self diagnosis
Power-on self test, monitoring timer, grammar check
※1: The max capacity in encrypting download mode
※2 : I/O numbers means the input and output terminal numbers.
※3：X means input relay，the X points over input terminals can be mediate relay.
※4：Y means output relay，the Y points over output terminal can be mediate relay.
※5：【】means power failure area ,cannot change.
PLC spec

※6：Special register cannot use for other purposes .
※7：Input coil and output relay/transistor number is octal number system, other is decimal system.
※8：I/O which is not linked with outside facilities can be used for fast internal relay.
1-2-2. Special function
1. High speed count
ZG3-30T/R
Incremental mode
AB phase mode
HSC0
HSC2
HSC4
HSC6
HSC8
HSC10
HSC12
HSC0
HSC2
HSC4
HSC6
HSC8
Max
frequency
80K
10K
10K
80K
10K
10K
4-time
frequency
2/4
2/4
2/4
Count
interruption
√
√
√
√
√
√
X000
U
A
X001
B
X002
Z
X003
U
A
X004
B
X005
Z
X006
U
A
X007
B
X010
Z
X011
2.High speed pulse output
ZG3-30T: Y0, Y1, max speed is 200kHz
ZG3-30R: not support
3. External interruption
Input
pointer
Suppress
interruption
Rising
interruption
Falling
interruption
X2
I0000
I0001
SM050
X3
I0100
I0101
SM051
X4
I0200
I0201
SM053
X5
I0300
I0301
SM054
X6
I0400
I0401
SM055
X7
I0500
I0501
SM056

ZG3 series
5
X10
I0600
I0601
SM056
X11
I0700
I0701
SM057
X12
I0800
I0801
SM058
X13
I0900
I0901
SM059
Notes:
1. the details please refer to XD3 series PLC manual.
2. the external interruption will not execute after suppress interruption coil is ON.
4. Frequency measurement
Model
X ID
Max frequency
ZG3
series
30 points
X0
80KHz
X3
10KHz
X6
10KHz
1-3. Part introduction
1-3-1. Structure
Touch area

1-3-2. Button function
1. Power supply terminal
Power supply：DC24V
0V
24V
FG
2. I/O terminals
1 2 3 4
24V 0V FG
1 2 3 4
ABSG COM0
S/ N: N20140825028
MODE: ZG3-30R
XINJE
WUXI XINJE ELECTRIC CO.,LTD
Power
supply
Input terminals
Output terminals
RS485
Communication port
DIP switch
USB-B port
PLC
Download
port COM0

ZG3 series
7
1-3-3. Download port (COM0)
The download port COM0 accords to RS232. It can download PLC program.
Pin
Function
Pin2
PRG
Pin4
RxD
Pin5
TxD
Pin6
VCC
Pin8
GND
Please use XINJE company programming cable, if no cables, make it by yourself according to the
below diagram:
3
45
1
2
6
87
15
9 6
Mini Din 8 Core plug (needle) DB9 plug (hole)
Notes: do not change the communication parameter of COM0 (PLC port1), otherwise PLC cannot
connect to the PC.
1-3-4. Communication port AB
ZG3 integrated communication port is PLC communication port, RS485 (Serial port2).
Under factory setting, you can use this port to download and upload PLC program. It can also
communicate with external sensors, instrumentation and other equipments.
Here are the port diagram:
Communication parameters:
Station number
Modbus station 1~254, 255(FF) is free format
345
12
68
7

communication
Baud rate
300bps~115.2Kbps
Data bit
8 data bits, 7data bits
Stop bit
2 stop bits, 1 stop bit
Checking
Even, odd, no parity
Note:
1. For ZG3 hardware version below v3.1.1, when using RS485 to communicate with other device,
it cannot change the communication parameters, please only use the default parameters.
The default parameters: station no.1, baud rate 19200bps, 8 data bits, 1 stop bit, even parity.
2. For ZG3 hardware version up v3.1.1, the RS485 communication parameters can be changed.
1-3-5．USB download port
ZG3 integrated controller USB-B download port is only for HMI to download, it can be very
fast, reaching 480Mbps.
Under special environment, the HMI cannot download or it cannot reveal after download.
Please force download.
Instructions ：
（1）Please make ZG3 power off, turn on switch 2.
（2）Please make ZG3 power on, linking with USB to download the program.
（3）when it finished, turn off switch 2, re-power on the ZG3.
4-bits DIP switch is shown as below:
Switch
Switch1
Switch2
Switch3
Switch4
function
State
ON
OFF
OFF
OFF
Not defined
OFF
ON
OFF
OFF
Force download
OFF
OFF
ON
OFF
System menu: time calibration, touch
calibration
OFF
OFF
OFF
ON
Internal inspection mode (not recommended)
1 2 3 4
ON
OFF

ZG3 series
9
1-4. Dimension
Product dimension (unit: mm)
200.4
146.9
24V 0V FG
1234
ABSG
138.5
192.0
COM0
S/ N: N20140825028
MODE: ZG3-30R
XINJE
49.0
190.0
136.5
WUXI XINJE ELECTRIC CO.,LTD

2I/O and wiring
2-1. Input spec
DC power
R3
R4
R2
R1
X*7
X*0
COM
supply
Input signal voltage
DC24V±10%
Input signal current
7mA/DC24V
Input ON current
Above 4.5mA
Input OFF current
Below 1.5mA
Input response time
About 10ms
Input signal format
Point input or NPN
collector open
transistor
Circuit insulation
Optical coupling
insulation
Input action display
LED is ON when
input ON
Basic unit
Input wiring

ZG3 series
11
The input current of ZG3 series is supplied by internal 24V power supply. If using external power
supply to drive the optical-electricity sensor, the supplier should be DC24V±4V. The output
transistor of sensor should be NPN open collector.
Input points
Connect input point and com point with non-voltage point or NPN open collector transistor to
turn on the input.
Input loop
The first loop and the second loop are insulated by optical coupler, the second loop has C-R
filter which can prevent wrong action caused by industry noise or input points oscillation. As
the result, there will be a response delay for 10ms to the input points. There is digital filter in
the input points.
Input sensitivity
Input current is DC 24V 7mA. To make the input reliable, the ON current should be above
3.5mA, the OFF current should be below 1.5mA.
DC power
DC24V
power supply
R3
R4
R2
R1
X*7
X*0
COM
+5V
R5R6
LED
I=7mA
sensor
supply
Typical wiring
Input connection

2-2. Relay output
Output points
Relay output has 4 common points. Different units can drive the loader of different power-
voltage systems.
Loop insulation
It is electric insulated between relay output point and outside load circuit.
Action indication
Relay output coil produces close sound when it is on.
Response time
The response time is about 10ms transferring the ON or OFF signal from relay output coil to
Power supply
Below AC250V, DC30V
Circuit insulation
Machinery insulation
Max loader
Resistance load
3A
Inductance load
80VA
Lamp load
100W
Min loader
DC5V 2mA
Response
time
OFF→ON
10ms
ON→OFF
10ms
Relay output spec
Relay output circuit

ZG3 series
13
the output connection.
Output current
Output current is 3A per point to drive resistance load for voltage below AC250V.
Inductance load is below 80VA(AC100V or AC200V) and lamp load is below 100W (AC100V
or AC200V).
Open leakage current
There is no leakage current when output point is OFF, it can drive neon light.
Use life of relay output point
The standard life of inductance load such as contactor, solenoid valve: according to our
experiment results, 20VA load is about 3 million times, 35VA load is about 1 million times,
80VA load is about 0.2 million times. However, the life will extend if parallel connect surge
absorber with the load.
Note: T type (Y0, Y1) has no relay output, do not connectAC220V, or the product will be broken.
◆For DC inductance load, please parallel connect with commutate diode. If not connect with the
commutate diode, the point’s life will be decreased greatly. Please choose the commutate diode
which allow inverse voltage endurance up to 5~10 times of the load’s voltage, ordinal current
exceeds load current.
◆Parallel connect AC inductance load with surge absorber can reduce noise and extend useful
life of the points.
+24V
circuit
drive
relay
Y*3
Y*2
Y*1
Y*0
M
5A～10A
Load ～AC power
<AC250V
Relay output
To avoid burning PLC basic circuit
set a fuse every 4 points
supply
Typical output wiring
Output circuit construction

2-3. Transistor output
use suitable fuse for the load
To avoid burning PLC basic circuit
DC power
DC5~30V
Load
Load
Load
Load
1A
circuit
drive
photo-electricity
Y*4
Y*5
Y*6
Y*7
supply
DC load
AC load
High speed pulse output