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MANUGENX5 - Version 1.01 24.03.2021

© 2021 0N3 s.r.l. -  Subject to change without notice

6

Safety guidelines

!

DANGER!

•  The following guidelines shall be strictly complied in order to operate in a safe environment.

• 

User is responsible for the correct system installation and interfacing to the machine control logic.

• 

User is responsible for implementing the machine safety related functions.

• 

User should implement the safety related functions according to the application safety level determined 

in a previous risk analysis.

• 

User, during machine control logic implementation, is responsible for considering all conditions related 
to the machine motion: checking the Emergency Stop Button, Enabling Button and Selector related 
relays and switches status; checking all possible further Safety Modules available on board of the 
machine: safety fences, optical barriers and so on.

• 

User is responsible for considering all further safety and accident prevention guidelines related to the 

particular working environment in addition and independently to this document.

• 

User is responsible for observing all safety precautions applying to industrial control systems in ac

-

cordance with national and international regulations.

• 

User is responsible for observing that all installation, commissioning and maintenance tasks must 
be carried out only by qualified personnel, so by persons who are familiar with transport, mounting, 
installation, commissioning and operation of the product and who have the appropriate qualifications. 
Furthermore is suggested to follow all national accident prevention guidelines.

• 

All safety guidelines, cabling schemes, mechanical and electrical limit values listed in the technical 

data must be read before installation and commissioning and strictly respected.

• 

User shall be aware which machinery or group of machinery is controlling.

• 

User shall be aware if the Wireless Handheld terminal is enabled and connected to the machinery that 

is supposed to control.

• 

User is not allowed to take care of the maintenance and repair of the X5 System Modules. Each main

-

tenance and repair operation must be remanded to 0N3 srl

Содержание X5 System

Страница 1: ...MANUGENX5 Version 1 01 24 03 2021 2021 0N3 s r l Subject to change without notice 1 X5 System User Manual ...

Страница 2: ...ument is provided for informational purposes only While efforts were made to verify the accuracy of the infor mation contained in this documentation it is provided as is without warranty of any kind Third party brands and names are the property of their respective owners www exorint com Software available in these products is based on OpenSource Visit oss exorint net for more details ...

Страница 3: ...lete Base Station 13 2 3 7 Unpairing procedure 13 3 Safety Controls 14 3 1 Emergency Stop Button 14 3 2 Enabling Button 15 3 3 Selector 18 3 4 Safety State Diagram 19 3 4 1 Wireless Handheld 20 3 4 2 Base Station 20 3 5 Safety Outputs 21 3 6 Safety reaction time 22 4 Safety specifications 23 4 1 Safetyparameters 23 4 1 1 General Safety parameters 23 4 1 2 Safety functions parameters 23 4 2 Proof t...

Страница 4: ...Station 40 7 1 Overview 40 7 2 Technical Data 41 7 3 Status Indicators 42 7 4 Mechanical dimensions 43 7 5 Product Identification 44 8 Installation Guidelines 45 8 1 Installation 45 8 2 Configuration and programming 46 8 3 Base Station connectors and cables 47 8 3 1 General Connection Diagram 48 8 3 2 X1 Power Supply 49 8 3 3 X5 Auxiliary I O 50 8 3 4 X6 Safety Outputs 51 8 3 5 X7 Selector Outputs...

Страница 5: ...nd unpairing procedures and safety functions CHAPTERS 4 5 6 7 general information detailed technical data high level explanation of the devices installation CHAPTERS 8 9 10 useful information on safety and certifications CHAPTER 11 12 accessory ordering information Safety notices All safety notices in this manual are specified as follows i INFORMATION Respecting guidelines and regulations avoids e...

Страница 6: ...ted to the particular working environment in addition and independently to this document User is responsible for observing all safety precautions applying to industrial control systems in ac cordance with national and international regulations User is responsible for observing that all installation commissioning and maintenance tasks must be carried out only by qualified personnel so by persons wh...

Страница 7: ...s Electrical components that are vulnerable to electrostatic discharge ESD must be handled accordingly DANGER Do not touch the connector contacts do not touch the contact tips when removing the protection covers All kind of environmental temperature aggressive atmospheres humidity and mechanical stresses over the accepted limits explained in this User Manual must be avoided during transport and st...

Страница 8: ...ully programmed assuring a quick use with your automation project Wireless Handheld is fully programmable with JMobile The safety Wireless link between the Wireless Handheld and the Base Station can be activated deactivated dynamically through a dedicated pairing procedure The activation status of the safety link is indicated on Wireless Handheld by the illuminated emergency button and by a status...

Страница 9: ...wo devices can be connected at a time Base Station and Wireless Handheld Network Configuration Band 2 4GHz 5GHz user configurable Channel Manual selection SSID Fixed Password Yes user configurable For all details regarding how to setup Network Configuration refer to JMobile Studio User Manual 2 2 Network SSID The Network SSID is fixed and based on Base Station Unique Identification SAFETY UID hard...

Страница 10: ...imultaneously The Pairing Application let user to Manage a list of Base Station devices Verify the Wi Fi signal and battery levels Manage Pairing and Unpairing Procedure with a single Base Station CAUTION The pairing procedure wants to assure the user is aware about the Base Station he wants to establish a safety connection For this reason it is required for user to look at the Base Station e g th...

Страница 11: ...ted by a local LED of the Base Station The positioning of the pairing lamp must ensure an easy association between the lamp and the machine as well as facilitate its display at a distance for the implementation of the pairing procedure CAUTION If a Base Station paired with a Wireless Handheld is subjected to a power cycle the link status is not restored automatically but the event is reported by t...

Страница 12: ... automatically checkbox if user wants to use the Wireless Handheld with the same Base Station This option speeds up the Wi Fi link setup 2 3 5 Pairing procedure Press Start pairing button Look at Pairing Lamp on the Base Station of the machine under control Count the number of flashes in a random range from 1 to 5 Insert the answers number of flashes Lamp ON Lamp OFF while looking at the status of...

Страница 13: ...r with Abort button Wrong answers Timeout User not entering response within the predefined time 30 seconds In case of failure the procedure must be repeated 2 3 6 Unpairing Delete Base Station Select a Base Station from the list and press the red X button 2 3 7 Unpairing procedure Press the Unpair button and confirm the operation by pressing the Yes button ...

Страница 14: ...ays that replicate their status on the Base Station have two contacts per each and follow the behavior shown in the table below User should directly connect the relays Outputs to the machine cabinet and monitoring devices The Stop function provided by Wireless Handheld and Base Station allows the user to fulfil high PL according to EN ISO 13849 1 2008 and SIL according to EN 62061 2005 for the saf...

Страница 15: ...ency Stop Button on the Wireless Handheld terminal is disabled if terminal is shut OFF unpaired from the related Base Station or if Base Station is shut OFF User can always access through the HMI to all diagnostics information about the safety module built up by the Wireless Handheld and Base Station User must always refer to 0N3 S r l for maintenance and repair operations i INFORMATION The Emerge...

Страница 16: ... Enable Closed Panic Open Zero position When not pressed the Enabling Button returns to the zero position Enable position When pressed the Enabling Button goes into the enabling position This condition is often associated to machine movement activation When released it goes back to the null position Panic position When the enabling device is pushed all the way in it goes to the panic position whic...

Страница 17: ...afety FSM enters Emergency state In case of dangerous states the logic controller another conscious start command should be required to allow activation additionally to the enable switch The only person permitted in the dangerous area is the person activating the enable switch User can always access through the HMI to all diagnostics information about the safety module built up by the Wireless Han...

Страница 18: ...vious risk analysis The Selector function should be only related to the selection of the various working modes available on the machine by the logic controller The Selector and its related Outputs are Safety Modules subjected to internal functional tests In case of hardware failure the Safety State Diagram Emergency state User can always access through the HMI to all diagnostics information about ...

Страница 19: ... SAFE The device is switched ON the status is UNPAIRED SAFE P The device is switched ON the status is PAIRED EMG The device is switched ON the status is PAIRED The transition among Safety States are defined by the following Events Legend OFF Switch OFF ON Switch ON PAIR Pairing procedure Wireless Handheld UNPAIR Unpairing procedure Wireless Handheld AUX REC Auxiliary unpairing Input Base Station L...

Страница 20: ...FF RUN EMG RUN OFF IDLE SAFE P SAFE EMG SAFE OFF IDLE EMG SAFE P OFF IDLE RUN SAFE EMG EMG OFF 3 4 2 Base Station Event Safety FSM OFF ON PAIR UNPAIR AUX REC LINK LOSS LINK REC PAIR LOSS FAIL OFF IDLE SAFE IDLE OFF RUN EMG RUN OFF IDLE SAFE P SAFE EMG SAFE OFF RUN IDLE EMG SAFE P OFF IDLE RUN SAFE EMG EMG OFF When powered up the device enters Safe State if previously switched off in Safe State ...

Страница 21: ...Closed Z High Impedance Wireless Handheld State Base Station State OFF IDLE RUN SAFE SAFE P EMERGENCY OFF ESo O EDo O SSo Z ESo O EDo O SSo Z ESo O EDo O SSo Z ESo O EDo O SSo Z IDLE ESo C EDo O SSo SS ESo C EDo O SSo SS ESo C EDo O SSo SS ESo C EDo O SSo SS RUN ESo ESi EDo EDi SSo SSi SAFE ESo O EDo O SSo SS ESo O EDo O SSo SS ESo O EDo O SSo SS ESo O EDo O SSo SS SAFE P ESo O EDo O SSo SS EMERGE...

Страница 22: ...ion time The table provides reaction timing for the Safety Outputs caused by any changing of the status of the Safety Controls Safety Outputs Condition Typ ms Max ms Emergency STOP Closed to Open 75 350 Open to Closed 125 Enabling Closed to Open 75 350 Open to Closed 125 Selector All Directions 75 350 ...

Страница 23: ...erations indicated in the previous table cannot be exceeded because the declared PFHd is guaranteed only if this number is respected 4 1 2 Safety functions parameters The following parameters apply Safety function Safety function mode SIL IEC 61508 PFHd IEC 61508 Performance level EN 13849 1 Safe Stop High demand or continuous mode SIL3 6 10 8 1 h PLd Cat 3 Enabling Device Push Button High demand ...

Страница 24: ...op push button must be released and the operator must verify that the machine remains stopped until the standard Reset Start sequence is executed on its console Part 2 proof test of the Safe Enable function The Enabling Device push button must be set in central position starting from the released position The operator must verify that the machine is enabled in this condition Then the Enabling Devi...

Страница 25: ... Handheld 5 1 Overview TOP 1 Emergency Stop Button 2 Enabling Button 3 USB 4 Selector 5 Potentiometer 2 6 Potentiometer 1 7 Handwheel 1 2 3 4 5 6 7 FRONT 8 Status LED 1 9 Status LED 2 10 Keypad 9 8 10 BACK 11 Touchscreen pen 12 Hanging magnets 11 12 BOTTOM 13 USB 14 Battery charging contact 13 14 ...

Страница 26: ...Keypad and covering surface Rubber covered keys with mechanical pressure point Comfortable handling also using gloves thanks to well designed command key spacing Clear display user configurable brightness Vibration and shock resistant according to EN 61131 2 2007 EN 61131 2 cl 6 3 1 EN 60068 2 6 EN61131 2 cl 6 3 2 EN 60068 2 27 Non flammable material fulfils UL 94 5VA housing impact resistant wate...

Страница 27: ...y Switch Emergency Stop Button Yes illuminated Enabling Button 3 positions Status Indicators 2 bi colour LED Keys 19 user programmable Sensors 3 axis Accelerometer Temperature internal Buzzer Vibrator Yes Interface Wireless IEEE Std 802 11a b g n USB 2 Host V2 0 250mA max NFC Yes Ratings Power Supply Rechargeable Battery BATT3V74A401 Battery capacity 4400 mAh 6h of autonomy typ Charging Station Ye...

Страница 28: ...d off and the box will be closed immediately afterwards for 24 hours The test will be performed at environmental temperature about 20 C Test 2 Very strict The units under test UUT are fully and thoroughly wet by solvent then will be closed into a closable box 120 x 85 x 65 mm for 24 h Approximately 5 ml solvent will be sprayed over the UUT The box will be closed and the UUT will remain in the clos...

Страница 29: ...housing housing gets doughy Blu Diesel Rubber Keypad Handles Terminal housing Rubber cap Rubber lateral cover Handles Terminal housing Rubber cap Rubber lateral cover Test 2 Rubber Keypad rubber gets doughy Silicone spray Rubber Keypad Handles Terminal housing Rubber cap Rubber lateral cover Rubber Keypad Terminal housing Rubber cap Rubber lateral cover Test 2 Handles loss of colour Kluber KONSTAN...

Страница 30: ...sion 1 01 24 03 2021 2021 0N3 s r l Subject to change without notice 30 Touchscreen test results Test passed with the following solvents Unleaded Gasoline Denatured Ethyl Alcohol Diesel Kluber KONSTANT OY 32 Acetone ...

Страница 31: ...F GREEN BLINKING Battery charging COMPLETED GREEN ON Battery charging ON LED 2 Colour Status Description RED ON CPU Error GREEN ON CPU Run CAUTION In case of errors contact supplier 5 5 ON OFF keys To switch on or off the Wireless Handheld press the F2 and F5 keys simultaneously for a few seconds The boot of the system is indicated by the red and the green indicators switching on in sequence Befor...

Страница 32: ...55 linear 5 6 2 Handwheel Counter goes from 0 to 32767 Clockwise turns increment while counter clockwise turns decrement the counter 5 6 3 Keypad The mobile panel has a rubber covered membrane keypad with 19 keys 12 keys are named Function Keys F1 6 K1 6 7 keys are named dots keys All of them are user programmable by software application ...

Страница 33: ...ull charge cycle requires about 3h when the battery is completely discharged The battery is fixed on the rear side of the device via two locks The procedure for battery replacement is the following Unscrew the locks Replace the battery Screw the locks The battery charge status can be checked dynamically in several ways System Settings Pairing App System variable available from App WARNING Use only...

Страница 34: ...ssed in mm 5 9 Maintenance Verification of safety devices as described in Chapter 4 5 10 Product Identification Wireless Handheld is labelled with a sticker nameplate that allows unique identification showing Model Name Product Part Number Product Version Product Serial Number Production Date yy mm Manufacturer Name and Address CE MARK ...

Страница 35: ...ase 1 programmable Serial Port RS232 485 422 1 USB Host 2 0 port 1 SD Card connector Support expansion modules plug ins Safety Devices relay outputs for emergency key and enabling device Outputs for Selector The device is equipped with dual band Wi Fi interface 2 4 5GHz compatible IEEE 802 11a b g n on SMA connector for external antenna 1 Serial Port 2 Power Supply 3 Ethernet Port 1 4 Ethernet Por...

Страница 36: ...DO Safety Auxiliary functions Interface Wireless IEEE Std 802 11a b g n Safety Link Ethernet Port 2 port 0 10 100 port 1 10 100 USB Port 1 Host v 2 0 max 500 mA Serial Port 1 RS232 422 485 sw programmable SD Card Yes Expansion 1 slot for plug in modules Ratings Power Supply 24 Vdc 10 to 32 Vdc Current Consumption 0 4 A max at 24 Vdc Input Protection Electronic Environment Conditions Operating Temp...

Страница 37: ... 6 3 Status Indicators L2 L4 L3 L1 LED Colour Description L1 RED CPU Error L2 GREEN CPU Run L3 RED Base Station Paired L4 GREEN Power Supply 6 4 Power supply The device requires a nominal power supply 24Vdc SELV Class 2 according to UL Standards with Ground connection Functional Ground ...

Страница 38: ...ical dimensions All dimensions are expressed in mm 6 6 Product Identification Base Station is labeled with a sticker nameplate that allows unique identification showing Model Name Product Part Number Product Version Product Serial Number Production Date yy mm Manufacturer Name and Address CE MARK ...

Страница 39: ... interventions by the user for the maintenance part except Periodic verification of safety devices In case of malfunction X5 System devices must not be opened or repaired by the user otherwise the warranty will be void and the functional safety certificates will be violated The failed device shall be returned to the manufacturer using the RMA procedure ...

Страница 40: ...tice 40 7 Charging Station 7 1 Overview Charging Station is a docking and battery charging device for the Wireless Handheld device It can charge at the same time the Wireless Handheld plus one spare battery Ø 5mm holes Vertical Surface Mount Ø 4mm holes Horizontal Surface Mount ...

Страница 41: ...otection Type Voltage Input Protection from polarity inversion over voltage and under voltage Current Input Protection from overload current Voltage Output Internally regulated Environment Conditions Operating Temp 5 to 45 C Storage Temp 20 to 70 C Operating Storage Humidity 5 95 RH non condensing Protection Class IP64 not UL evaluated Flame resistant Fulfils UL 94V 0 HB 1 16 Dimensions and Weight...

Страница 42: ...skilled installer can disconnect the power cable from the side and connect it to bottom side maintaining the same cap where the cable is already inserted CAUTION Disconnection and connection cable must be performed by a skilled installer SELV Extra low voltage Power Supply Limited power source according to EN 60950 1 and Class 2 according to UL Standards i INFORMATION When not in use it is always ...

Страница 43: ...MANUGENX5 Version 1 01 24 03 2021 2021 0N3 s r l Subject to change without notice 43 7 4 Mechanical dimensions All dimensions are expressed in mm ...

Страница 44: ...without notice 44 7 5 Product Identification Charging Station is labeled with a sticker nameplate that allows unique identification showing Model Name Product Part Number Product Version Product Serial Number Production Date yy mm Manufacturer Name and Address CE MARK ...

Страница 45: ...em with a Wi Fi signal below 80dBm a notch It is recommended to implement at the application level of the passive monitoring mechanisms for the radio signal in order to promptly inform the user of any limit situations via buzzer vibrator pop up DANGER It is mandatory to install the Base Station module in a cabinet which is certified with a protection degree of IP54 or more The position of the exte...

Страница 46: ...re required Definition of location in accordance with regional directives Choice of Wi Fi channel Definition of a Safety Link password optional Auxiliary functions for Pairing Unpairing procedure Pairing Lamp Auxiliary Unpairing Input 8 2 Configuration and programming The Wireless Handheld and Base Station devices must be configured and programmed for use For all details refer to JMobile Studio Us...

Страница 47: ...WG20 unshielded TP X2 SD Card X3 Ethernet 0 RJ45 plug with latch S FTP Cat5e shielded X4 Ethernet 1 RJ45 plug with latch S FTP Cat5e shielded X5 Auxiliary I O Weidmüller 1277460000 AWG20 shielded X6 Safety Outputs Weidmüller 1727560000 AWG20 shielded X7 Selector Outputs Weidmüller 1727500000 AWG20 shielded X8 Serial Port Weidmüller 1727570000 AWG24 20 shielded X9 USB Port USB A USB 2 0 shielded X1...

Страница 48: ...hange without notice 48 8 3 1 General Connection Diagram 1 2 3 1 2 3 4 1 2 3 4 5 6 1 2 3 4 5 6 7 8 X1 X5 X7 X6 X4 X3 X10 Antenna Ethernet Ethernet A1 A2 B1 B2 C1 C2 D1 D2 OUT B0 OUT B1 OUT B2 OUT B3 Pairing Lamp Unpair Switch Earth Connection BASE STATION 24 Vdc ...

Страница 49: ...X5 Version 1 01 24 03 2021 2021 0N3 s r l Subject to change without notice 49 8 3 2 X1 Power Supply Pin Description 1 L 2 M 3 Power Supply Limits Min Typ Max Absolute maximum 35 V 35 V Operating 10 V 24 V 32 V ...

Страница 50: ...rbed by auxiliary Input 1 2 Operating Over operating temperature range and voltage ranges 20 mA 20 mA Input voltage sensed as Auxiliary input is OFF 1 2 Operating 32 V 5V Input voltage sensed as Auxiliary input is ON 1 2 Operating 15 V 32 V Voltage on the Output in the high impedance state 4 Operating 0 V 32 V DIAG_OUT current 4 Operating 0 A 0 5 A Voltage drop between DIGITAL_OUT and the supply g...

Страница 51: ... Stop Button contact 2 4 RELAY_B2 Safety contact B2 Emergency Stop Button contact 2 5 RELAY_C1 Safety contact C1 Enabling Button contact 1 6 RELAY_C2 Safety contact C2 Enabling Button contact 1 7 RELAY_D1 Safety contact D1 Enabling Button contact 2 8 RELAY_D2 Safety contact D2 Enabling Button contact 2 Parameter Power Supply Limits Min Typ Max Voltage across the safety output Absolute maximum 35 V...

Страница 52: ...uts 3 SS_OUT_B0 Output Selector OUT B0 4 SS_OUT_B1 Output Selector OUT B1 5 SS_OUT_B2 Output Selector OUT B2 6 SS_OUT_B3 Output Selector OUT B3 Parameter Pin Power Supply Limits Min Typ Max Supply voltage applied for contact 1 2 Absolute maximum 35 V 35 V Supply voltage applied for contact 3 4 5 6 Operating 10 V 24 V 32 V Current coming out from safety output in the low impedance state 3 4 5 6 Ope...

Страница 53: ...ice 53 8 3 6 X8 Serial Port RS 422 RS 485 Pin Description 1 CHB 2 CHA 3 CHB 4 CHA 5 5V Output at 100 mA max 6 GND 7 8 SHIELD RS 232 Pin Description 1 RX 2 TX 3 CTS 4 RTS 5 5V Output at 100 mA max 6 GND 7 8 SHIELD To operate in RS 485 pins 1 2 and 4 3 must be connected externally ...

Страница 54: ...on are designed to respect the environment and reduce as much as possible the impact on pollution It is important to specify how to dismiss the different components of the X5 System in order to have an environmentally friendly recycling process Component Disposal Cables Battery Electronic boards Electronic recycling Paper packaging Paper recycling Plastic packaging Plastic recycling ...

Страница 55: ...nd Certifications 10 1 EC directives Directive Description 2006 42 EC Machine Directive 2014 30 EU Electromagnetic Compatibility Directive EMC 2014 53 EU Harmonisation of the laws of the Member States re lating to the making available on the market of radio equipment and repealing Directive 1999 5 EC ...

Страница 56: ...s Immunity to conducted disturbances induced by radio frequency fields EN 61000 4 8 2013 Electromagnetic compatibility EMC Part 4 8 Testing and measurement tech niques Power frequency magnetic field immunity test EN 61000 4 29 2000 Electromagnetic compatibility EMC Part 4 29 Testing and measurement tech niques Voltage dips short interruptions and voltage variations on d c input power port immunity...

Страница 57: ...trollers Part2 Equipment requirements and tests 5 3 3 Shock according EN 60068 2 27 Emergency Stop Button conforming to EN 60947 5 1 2004 A1 2009 Low voltage switchgear and controlgear EN 60947 5 5 1997 A11 2013 Low voltage switchgear and controlgear EN 13850 2015 Safety of machinery Emergency stop Principles for design EN 60204 1 2010 Safety of machinery Electrical equipment of machines Enabling ...

Страница 58: ... Care shall be taken not to allow layers of dust to form on the graphic panel in a way that might cause the accumu lation of static charges Keep the faceplate of the HMI device clean the equipment must be cleaned only with a soft cloth and neutral soap product Do not use solvents This device should not be used for purposes and methods other than indicated in this document and in the docu mentation...

Страница 59: ...MANUGENX5 Version 1 01 24 03 2021 2021 0N3 s r l Subject to change without notice 59 12 Unpacking and Packing Instructions Unpacking To repack the units please follow the instructions backwards ...

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