0N3 X5 System User manual

MANUGENX5 - Version 1.01 24.03.2021
© 2021 0N3 s.r.l. - Subject to change without notice 1
X5 System
User Manual

MANUGENX5 - Version 1.01 24.03.2021
© 2021 0N3 s.r.l. - Subject to change without notice 2
Copyright © 0N3 s.r.l. – Bari, Italy
Subject to change without notice
The information contained in this document 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.

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Table of Contents
Introduction 5
Safety notices 5
Safety guidelines 6
1 Overview 8
2 Safety Link 9
2.1 Network conguration 9
2.2 Network SSID 9
2.3 Pairing and Unpairing Procedure with PairingAPP 10
2.3.1 Pairing Lamp 11
2.3.2 Auxiliary Unpairing Input 11
2.3.3 Add a new Base Station 12
2.3.4 Wi-Fi Connection 12
2.3.5 Pairing procedure 12
2.3.6 Unpairing - Delete 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 specications 23
4.1 Safety parameters 23
4.1.1 General Safety parameters 23
4.1.2 Safety functions parameters 23
4.2 Proof test frequency 24
4.3 Lifetime 24
5 Wireless Handheld 25
5.1 Overview 25
5.2 Technical data 27
5.3 Handheld device chemical resistance 28
5.3.1 Test results 29
5.4 Status Indicators 31
5.5 ON/OFF keys 31
5.6 Input Devices 32
5.6.1 Potentiometers 32

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5.6.2 Handwheel 32
5.6.3 Keypad 32
5.7 Battery 33
5.7.1 Battery Disposal 33
5.8 Mechanical dimensions 34
5.9 Maintenance 34
5.10 Product Identication 34
6 Base Station 35
6.1 Overview 35
6.2 Technical data 36
6.3 Status Indicators 37
6.4 Power supply 37
6.5 Mechanical dimensions 38
6.6 Product Identication 38
6.7 Maintenance 39
7 Charging Station 40
7.1 Overview 40
7.2 Technical Data 41
7.3 Status Indicators 42
7.4 Mechanical dimensions 43
7.5 Product Identication 44
8 Installation Guidelines 45
8.1 Installation 45
8.2 Conguration 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 52
8.3.6 X8 Serial Port 53
9 Environmentally-friendly disposal 54
10 Standards and Certications 55
10.1 EC directives 55
10.2 International standards 56
11 Special Instruction for Use 58
12 Unpacking and Packing Instructions 59

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Introduction
This document is the Hardware User Manual of X5 System and provides technical information regarding product’s
functionalities, installation and use of Wireless Handheld and its related Base Station and Charging Station.
This User Manual is intended to give the following information:
CHAPTERS 1 -2 -3
overview to each component, connectivity, pairing and 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 certications
CHAPTER 11 - 12
accessory ordering information
Safety notices
All safety notices in this manual are specied as follows:
iINFORMATION
Respecting guidelines and regulations avoids errors
CAUTION!
Respecting guidelines and regulations avoids injuries or damage to material
!WARNING!
Respecting guidelines and regulations avoids severe injuries or damage to material
!DANGER!
Respecting guidelines and regulations avoids life-risks

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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 qualied personnel, so by persons who are familiar with transport, mounting,
installation, commissioning and operation of the product and who have the appropriate qualications.
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

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iINFORMATION
• All the instructions contained in this manual ensuring user safety must be taken in consideration. Each
non-conformity could cause the safety functions integrated in the Wireless Handheld terminal not to
work properly.
• Wireless Handheld and Base Station have been designed, developed, and manufactured for conventional
use in industry. They were not designed, developed, and manufactured for any use involving serious
risks or hazards that could lead to death, injury, serious physical damage, or loss of any kind without
the implementation of exceptionally stringent safety precautions. Such risks and hazards include the
use of X5 System in the following applications:
- nuclear reactions monitoring in nuclear power plants;
- flight control systems;
- flight safety;
- mass transit control systems;
- medical life support systems;
- control of weapon systems.
• 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 storage
of the devices.
• Two main considerations must be done in order to prevent damages during transport:
- always use the original packaging;
- always keep the right environmental conditions as explained in the technical data.
• Installation must take place according to the documentation and using suitable equipment and tools.
!WARNING!
• It is important that the Indicators shall be clearly visible and the operator instructed that he can rely
on the Emergency Stop Button only when the Indicator is steady ON.
• If the application software allows controlling more than one machinery at the time, then the safety
circuits on the plant should be wired in such a way that the Emergency Stop Button will halt all the
machinery that could be involved.

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1 Overview
The X5 System consists of three devices: Wireless Handheld, Base Station and Charging Station battery charger.
The Wireless Handheld provides all the features of an advanced HMI panel and the potential of an on-board controller that
can interface with the most modern PLCs, all within a compact, lightweight and ergonomic design. Wireless connection
with certication for Safety Controls makes this product the ideal solution for industrial applications. Integrated devices
(Keypad, Potentiometers, Handwheel) can be fully 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 LED, on Base Station by a light device installed on board the machine
and by a status LED.
All conguration and control commands selected through the Keypad or the Touchscreen Display, the Handwheel and
the Potentiometers status, the Emergency Stop Button, Enabling Button and Selector status are sent by the Wireless
Handheld to the Base Station.
Wireless Handheld
Wireless Link
Base Station
Charging Station

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2 Safety Link
Safety Link is a Wi-Fi point-to-point connection between a Wireless Handheld and a Base Station.
The same Wi-Fi link is used to exchange Safety and Application data.
2.1 Network conguration
The Wi-Fi link is based on a Private Network where only two devices can be connected at a time: Base Station and
Wireless Handheld.
Network Conguration
Band 2.4GHz / 5GHz, user congurable
Channel Manual selection
SSID Fixed
Password Yes, user congurable
For all details regarding how to setup Network Conguration refer to JMobile Studio User Manual.
2.2 Network SSID
The Network SSID is xed and based on Base Station Unique Identication (SAFETY UID), hardcoded in the device.
User can get Base Station SAFETY UID using System Settings (refer to JMobile Studio User Manual for details) or from
device label.

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2.3 Pairing and Unpairing Procedure with PairingAPP
PairingAPP is a pre-installed application on the Wireless Handheld that allows you to perform the pairing between the
device and any Base Station available for operation. The Wi-Fi link between a Wireless Handheld and a Base Station is
dynamic; the devices can be connected and disconnected over the time according the Pairing/Unpairing procedure.
The PairingAPP is opened at every power-up of the Wireless Handheld, but it can be resumed in any moment by press-
ing K1 and K4 keys simultaneously.
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 the pairing
lamp), answer correctly to the questions, complete the procedure in a denite time (30 sec every step).
• The pairing procedure is guided by the application but requires the intervention of the operator to iden-
tify the Base Station and the conrmation on display of the required information. It is the operator’s
responsibility to complete each step of the procedure within the timeframe provided (30sec each step).

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2.3.1 Pairing Lamp
The functions of the pairing lamp are:
• Support to the pairing procedure for the identication of the Base Station
• Verication of the pairing status of the Base Station
Pairing Lamp Status Description
ON PAIRED
OFF UNPAIRED
BLINK LINK LOSS
In addition to the pairing lamp, the status of the security Safety Link is indicated 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 the flashing status of the pairing lamp.
2.3.2 Auxiliary Unpairing Input
The auxiliary unpairing input can be used as an alternative recovery procedure to reset the state of Base Station to IDLE
when the device is in SAFE State.

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2.3.3 Add a new Base Station
Press Add button
Enter Base Station UID, Password (if required)
and Base Station Description
Press Save
2.3.4 Wi-Fi Connection
Select a Base Station from the list and
press Connect button
Wait for Wi-Fi connection
CAUTION!
• It is recommended to select “Connect 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 ashes
in a random range from 1 to 5
Insert the answers
(number of flashes, Lamp ON, Lamp OFF)
while looking at the status of the Pairing Lamp
Answer if the pairing lamp is ON or OFF
The YES/NO buttons will appear in random positions
Press and release the Emergency Stop Button
Press Exit button

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The pairing procedure can fail for the following reasons:
• Required by user with “Abort” button
• Wrong answers
• Timeout (User not entering response within the predened 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 Xbutton
2.3.7 Unpairing procedure
Press the Unpair button and conrm the operation by
pressing the Yes button

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3 Safety Controls
The Wireless Handheld and the Base Station are designed to provide Safety Controls that are enabled only when the
two devices are paired to each other over a safety link.
The Safety Controls are: Emergency Stop Button, Enabling Button and Selector.
When the Wireless Handheld and the Base Station are paired, the state of Safety Controls are replicated on the Base
Station as Safety Outputs.
3.1 Emergency Stop Button
The Emergency Stop Button provides two redundant switching contacts. The two safety relays 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 full high PL (according to EN ISO 13849-1:2008) and SIL (according to
EN 62061:2005) for the safety function once it is interfaced with the machine control logic.
• The Emergency Stop Button is a Safety Control with internal illumination.
• It becomes illuminated only when the Safety link Wireless Handheld/Base Station is active.
• The device is associated to two relay contacts present on the Base Station and it behaves as reported
Emergency Stop Button Relay Contacts (Base Station)
PULL Closed
PUSH Open

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CAUTION!
• User is responsible for interfacing the system to the machine control logic and implementing the Stop
function according to the safety level determined in a previous risk analysis.
• The Emergency Stop Button cannot be marked or labelled as “Emergency Stop Button” even if user
can implement the Stop function in stop category 0 or 1 of EN 60204-1:2006.
• The Emergency Stop Button must not to be used to enable power line of the machinery.
• In case of drop or other possible damages of the device, the stop function operation must always be
checked by the operator.
• Releasing the Emergency Stop Button must never cause an uncontrolled restart. User is responsible
for implementing these controls on the machine control logic.
• The Emergency Stop Button on the Wireless Handheld is not a substitute for the permanently-wired
Emergency Stop Button located on the machine.
• The Emergency 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.
iINFORMATION
• The Emergency Stop Button and its related relays are Safety Modules, subject to internal functional
tests. In case of hardware failure the Safety State Diagram enters Emergency state.
3.2 Enabling Button
The Enabling Button is a three-position switch providing two redundant switching contacts. User should directly connect
the relays Outputs to the machine cabinet and monitoring devices. Respecting the standard EN60204-1, two positions,
Null and Panic, represent off condition while only the Enable position allows activation. The enabling function provided
by Wireless Handheld and Base Station allows the user to full high PL (according to EN ISO 13849-1:2008) and SIL
(according to EN 62061:2005) for the safety function once it is interfaced with the machine control logic.

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The control is associated to two relay contacts present on the Base Station and it behaves as reported:
Enabling Button (Wireless Handheld) Relay Contacts (Base Station)
Zero Open
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 which corresponds to the same contact condition
as the zero state.

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If the switch is pushed all the way in and then released it goes directly to the Null state skipping the Enable position.
CAUTION!
• User is responsible for interfacing the system to the machine control logic and implementing the En-
abling function according to the safety level determined in a previous risk analysis.
• The enable switch fulls its protective function only if the operator can recognize the danger in time.
• The Enabling Button and its related relays are Safety Modules, subjected to internal functional tests.
In case of hardware failure the Safety 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 Handheld and Base Station. In case of faults or failures user must always refer to
0N3 S.r.l for maintenance and repair operations.
iINFORMATION
• The enabling function is implemented with:
-the Enabling Button;
-the logic circuits on the Wireless Handheld that monitor the Enabling Button status and transmit
it to the Base Station;
-the logic circuits on the Base Station that receive the Enabling Button status and replicate it on
the safety relays.

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3.3 Selector
This is a 16 positions rotary switch with binary Outputs.
When the Wireless Handheld device is paired to a Base Station, the status of the Selector is replicated to the Base
Station as Safety Outputs (24Vdc High Side driver).
CAUTION!
• User is responsible for interfacing the system to the machine control logic and implementing the State
Selecting function according to the safety level determined in a previous 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 the safety module built
up by the Wireless Handheld and Base Station. In case of faults or failures user must always refer to
0N3 S.r.l. for maintenance and repair operations.
• In order to avoid false fault detection the User must provide power supply to Selector Safety Output
even if they are not used.

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3.4 Safety State Diagram
This paragraph provides a description of Safety State Machine for the X5 System, including one Wireless Handheld
and one Base Station. For both devices the States are:
Legend
OFF The device is switched OFF
IDLE The device is switched ON, the status is UNPAIRED
RUN The device is switched ON, the status is PAIRED
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 dened 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)
LINK-LOSS Loss of Wi-Fi Link
LINK-REC Recovery of Wi-Fi Link
PAIR-LOSS* Loss of PAIRED Status
FAIL System Failure
*Note: PAIR-LOSS can be caused by a device fault or hardware reset when the device is in RUN or SAFE-P States

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3.4.1 Wireless Handheld
Event
Safety FSM OFF ON PAIR UNPAIR LINK-LOSS LINK-REC PAIR-LOSS FAIL
OFF -IDLE - - - - - -
IDLE OFF -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