H4 User`s Manual - exor international

H4 User`s Manual - exor international
H4 User's Manual
Copyright  2015-2016 0n3 srl – Verona, Italy (Administrative and Operational headquarters)
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 information 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.0n3.eu
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Contents
1
General information........................................................................................................... 6
1.1
Manual overview .................................................................................................. 6
1.2
Safety notices ....................................................................................................... 6
1.2.1 Stop push-button .................................................................................................. 8
1.2.2 Enabling device .................................................................................................... 9
1.2.3 State selector ..................................................................................................... 11
1.3
Environmentally-friendly disposal ...................................................................... 11
2
Technical data ................................................................................................................. 12
2.1
H4 overview ....................................................................................................... 14
2.1.1 Input devices ...................................................................................................... 16
2.1.2 Safety-related functions ..................................................................................... 18
2.2
Recharging station ............................................................................................. 19
2.3
Battery replacement ........................................................................................... 20
2.4
Receiving station overview ................................................................................ 20
2.4.1 Housing .............................................................................................................. 21
2.4.2 LED indicators .................................................................................................... 22
2.4.3 Interfaces ........................................................................................................... 22
2.5
Dimensions ........................................................................................................ 22
2.6
Technical data details ........................................................................................ 26
2.6.1 Handheld device specifications .......................................................................... 26
2.6.2 HCI specifications .............................................................................................. 29
2.6.3 Recharging station specifications ...................................................................... 34
2.6.4 Safety-related devices ....................................................................................... 35
2.6.5 Timing specifications .......................................................................................... 38
2.7
Stickers .............................................................................................................. 39
2.8
Mounting the charging station ............................................................................ 41
2.9
Standards and certifications ............................................................................... 42
2.9.1 EC directives ...................................................................................................... 42
2.9.2 International standards ...................................................................................... 42
2.9.3 TUV certificate.................................................................................................... 44
3
Wireless terminal safety system ..................................................................................... 46
3.1
Architecture overview ......................................................................................... 46
3.2
Operation ........................................................................................................... 46
3.2.1 Operating states ................................................................................................. 47
3.2.2 Safety system details ......................................................................................... 47
3.2.3 LED functionality ................................................................................................ 49
3.2.4 Complete safety system status diagram ............................................................ 50
3.2.5 Safety guidelines ................................................................................................ 52
3.2.6 Coupling procedure details ................................................................................ 53
3.2.7 Run state ............................................................................................................ 55
3.2.8 Uncoupling procedure ........................................................................................ 55
4
Software wireless features .............................................................................................. 56
4.1
Installation Notes................................................................................................ 56
4.1.1 Check Performance Wireless Antenna .............................................................. 56
4.2
Wi-Fi connection using JMobile software...........................................................57
4.3
Setting-up Wi-Fi connection ............................................................................... 57
4.4
Setting-up Wi-Fi connection in H4 ..................................................................... 57
4.4.1 Connecting H4 to the Wi-Fi network .................................................................. 57
4.5
Operation status information .............................................................................. 60
5
Accessory ordering information ...................................................................................... 62
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Glossary
API
CNC
COL
DB
DC
DLL
DTD
EEPROM
Application Programming Interface
Computer Numerical Control
Change of Line
Data block
Diagnostic Coverage
Dynamic-Link Library
Document Type Definition
Electrically Erasable Programmable Read-Only Memory
ESC
ESD
FB
HCI
HL
HMI
IDE
IKHC
IKWL
ISO
JRE
JVM
LCD
LL
MDI
MTTFd
OS
PCB:
PLC:
PLd:
PLr:
SIL:
POU:
PUR:
REDIR:
RGB:
RS:
R/W:
H4:
NBTR
NMSPM
NSMHC:
NSMWL:
SOP:
TFT:
USB:
V# :
XML:
PN:
SN:
Escape
Electrostatic Discharge
Function block
Host Controller Interface
High Level
Human-Machine Interface
Integrated Development Environment
Interface Keyboard Host Controller
Interface Keyboard WireLess
International Organization for Standardization
Java Runtime Environment
Java Virtual Machine
Liquid Crystal Display
Low Level
Manual Data Input
Mean Time To dangerous Failure
Operating System
Printed Circuit Board
Programmable Logic Controller
Performance Level Dangerous
Required Performance Level
Safety Integrity Level
Program Organization Unit
Polyurethane
Redirection
Red Green Blue
Recharging Station
Read/Write
Wireless Handheld Terminal
Bluetooth Remote Module
Safety System Modules
Safety Module Host Controller
Safety Module WireLess
Start Of Packet
Thin Film Transistor
Universal Serial Bus
Volts of Direct Current
eXtensible Markup Language
Part Number
Serial Number
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History of Revisions
Version
Date
Change
1.0
15/09/2015
First Release
1.1
20/04/2016
First Revision (2014/30/EU Directive)
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1 General information
1.1 Manual overview
This user manual is intended to give all kind of information regarding Wireless Handheld Terminal (H4)
and its related Host Controller Interface (HCI). Chapter 1 is dedicated to general information: operation
and safety main notices and a high level explanation of the device. Chapter 2 gives an overview to each
component and then gives the detailed technical data. Chapter 3 details all information concerning the
wireless system safety, the coupling procedure between the Wireless terminal and HCI and all possible
coupling states. Chapter 4 gives all the necessary information to use the device and represents the
software user’s guide. Chapter 5 gives useful information in case of application and communication
errors. Chapter 6 gives the accessory ordering information.
H4 is available in 3 main configurations:
1) Standard configuration (BT transmission)
2) Wi-Fi Configuration (BT + Wi-Fi transmission)
3) Non safety configuration (Wi-Fi transmission)
Unless communicated the general part of this manual refers to standard configuration. Dedicated
appendixes are devoting to give additional info needed to configure and use Wi-Fi configuration and
Non safety configuration.
1.2 Safety notices
All safety notices in this manual are specified as follows:
Safety notice
Danger!
Caution!
Description
Respecting guidelines and regulations avoids life-risks
Respecting guidelines and regulations avoids severe
injuries or damage to material
Warning!
Respecting guidelines and regulations avoids injuries or
damage to material
Information:
Respecting guidelines and regulations avoids errors
H4 is a small, light and comfortable remote system controller which, together with its related HCI
appositely configured and connected to machine control logic, guarantees machine control and
configuration and the implementation of safety related functions.
All configuration and control commands selected through the keyboard or the touch screen display, the
R
optional handwheel and the potentiometers status are sent through a Bluetooth communication
channel to the HCI and then transmitted to the machine control logic through a RS-422 serial
communication channel.
The safety related devices status (Stop push-button, Enabling Device and State Selector) is monitored
R
by the H4 and sent through the Bluetooth communication channel to the HCI. HCI provides safety
relays (for the Stop push-button and Enabling Device) and Mosfet switches (for the State Selector)
which perfectly replicate the safety related devices status.
All HCI outputs: RS-422 signals and the safety relays and Mosfet switch outputs, are cable connected
to the machine control logic.
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Danger!
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. H4 provides the best
state of the art technology safety devices and together with HCI allows to fulfil high Performance Level
(PL) according to EN ISO 13849-1:2008 and Safety Integrity Level (SIL) according to EN 62061:2005.
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 Stop push-button, Enabling Device and State Selector related relays and switches status;
checking all possible further safety devices 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
accordance 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 is not allowed to take care of the maintenance and repair of the safety devices on board of
H4 and HCI. Each maintenance and repair operation must be remanded to 0N3 srl.
Information
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 handheld terminal
not to work properly.
H4 and HCI 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
H4 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 2.6 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.
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tools.
Installation must take place according to the documentation and using suitable equipment and
Warning!
All devices must be installed by qualified personnel and without voltage supplied
All national regulations about accident prevention must be taken into account
Electrical installation must follow the fundamental guidelines (line cross section, protective
ground connection, the electrical limits explained in the technical data etc.)
Warning!
Take care not to squeeze and thus damage the cable with any object.
Do not lay the cable over sharp edges to avoid damaging the cable sheath.
Always operate the touch screen with the proper touch-pen. Never use sharp objects that could
damage the touch screen.
H4 and HCI implement the Stop function with:
the Stop push-button;
the logic circuits on the wireless handheld terminal that monitor the Stop pushbutton status and
transmit it to the HCI;
the Bluetooth R communication channel between terminal and HCI;
the logic circuits on the HCI that receive the Stop push-button status and replicate it on the
safety relays.
Warning!
-
The installation and programming of this equipment must be performed by a skilled installer
following the instructions of this manual and the relevant regulatory EN60204-1.
1.2.1
Stop push-button
The Stop push-button provides two redundant switching contacts. The two Safety relays that replicate
their status on the HCI have 2 contacts per each and follow the behavior shown in 2.6.2.
User should directly connect the relays outputs to the machine cabinet and monitoring devices. For
further information about the HCI cable pin-out please refer to paragraph
2.6.2.1.
The Stop function provided by H4 and HCI allows the user to fulfil 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 (please refer to paragraph 2.6.4.3).
Warning!
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 “Stop push-button”, as explained in EN 60204-1:2006 (par. 9.2.7.3), cannot be marked or
labeled as “Emergency Stop push-button” even if user can implement the Stop function in stop category
0 or 1 of EN 60204-1:2006.
In case of drop or other possible damages of the device, the stop function operation must
always be checked by the operator.
Releasing the Stop push-button must never cause an uncontrolled restart. User is responsible
for implementing these controls on the machine control logic.
The Stop push-button on the handheld terminal is not a substitute for the permanently-wired
Emergency Stop button located on the machine.
The Stop Push-button on the handheld terminal is disabled if terminal is shut OFF, uncoupled
from the related HCI or if HCI is shut OFF.
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In order to avoid confusion between the permanently-wired Emergency Stop Push-button on
board of the machine and the disabled Stop Pushbutton on board of the terminal, it is suggested to
stock the handheld terminal in a location with protected access when it is shut OFF, uncoupled from the
related HCI or if HCI is shut OFF.
User can always access through the HMI to all diagnostics information about the safety module
built up by the H4 and HCI. Please refer to paragraph 4.4. In case of faults or failures user must always
refer to 0N3 S.p.A. for maintenance and repair operations.
For further and more detailed information about the Stop push-button, as the electrical and
mechanical life, please refer to paragraph 2.6.4.6 and 2.6.4.3
Information
The “Stop push-button” functionality is tested mandatorily by the user through a specific
coupling procedure each time the H4 is coupled to the related HCI.
The enabling function is implemented with:
the Enabling Device;
the logic circuits on the wireless handheld terminal that monitor the Enabling Device status and
transmit it to the HCI;
the Bluetooth R communication channel between terminal and HCI;
the logic circuits on the HCI that receive the Enabling Device status and replicate it on the
safety relays.
1.2.2
Enabling device
The Enabling Device is a three-position enable switch providing two redundant switching contacts. The
two Safety relays that replicate their status on the HCI have 2 contacts per each and follow the behavior
shown in 2.6.2
User should directly connect the relays outputs to the machine cabinet and monitoring devices. For
further information about the HCI cable pin-out please refer to paragraph
2.6.2.1
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 H4 and HCI allows the user to fulfil 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 (please refer to paragraph 2.6.4.4).
Warning!
User is responsible for interfacing the system to the machine control logic and implementing the
Enabling function according to the safety level determined in a previous risk analysis.
The enable switch fulfils its protective function only if the operator can recognize the danger in
time.
In case of dangerous states the logic controller must provide that, additionally to the enable
switch, another conscious start command should be required to allow activation.
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 H4 and HCI. Please refer to paragraph 4.4. In case of faults or failures user must always
refer to 0N3 S.p.A. for maintenance and repair operations.
For further and more detailed information about the enable switch, as the electrical and
mechanical life, please refer to paragraph 2.6.4.4 and 2.6.4.6.
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1.2.2.1
Functionality
The enabling device can have three different positions:
Switch position
Function
Enable switch
Switching contact
1
Zero position
Not pressed
Off (opened)
2
Enable
Pressed
On (engaged)
3
Panic
Pushed all the
way in
Off (opened)
The positions null and panic must be cabled and controlled by the machine logic in order to guarantee a
stop category 0 or 1 according to EN 60204:2006.
Zero position
When not pressed the enabling device returns to the zero position
Figure 1.1: Zero position
Enable position
When pressed the enabling device goes into the enabling position. This condition is often associated to
machine movement activation. When released it goes back to the null position.
Figure 1.2: Enable 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.
Figure 1.3: Panic position
If the switch is pushed all the way in and then released it goes directly to the null state skipping the
enable position.
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The state selecting function is implemented with:
• the State Selector;
• the logic circuits on the wireless handheld terminal that monitor the State Selector status and
transmit it to the HCI;
• the Bluetooth R communication channel between terminal and HCI;
• the logic circuits on the HCI that receive the State Selector status and replicate it on the Mosfet
Switches.
1.2.3
State selector
The State Selector is a 16 states BCD coded rotary switch with four non-redundant outputs. Four
Mosfet switches replicate the State Selector status on the HCI and follow the behavior shown in 2.6.2.
User should directly connect the Mosfet switches outputs to the machine cabinet and monitoring
devices. For further information about the HCI cable pin-out please refer to paragraph 2.6.2.1.
The State selecting function provided by H4 and HCI allows the user to fulfil 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 (please refer to paragraph 2.6.4.5).
Warning!
- 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 State Selector function should be only related to the selection of the various working modes
available on the machine by the logic controller.
- User can always access through the HMI to all diagnostics information about the safety module built
up by the H4 and HCI. Please refer to paragraph 4.4. In case of faults or failures user must always
refer to 0N3 S.p.A. for maintenance and repair operations.
- For further and more detailed information about the State Selector, as the electrical life, please refer
to paragraph 2.6.4.5 and 2.6.4.6.
1.3 Environmentally-friendly disposal
All components related to the H4 and HCI 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 H4 in order to have an
environmentally-friendly recycling process.
Component
Cables
Battery
Electronic boards
Disposal
Electronics recycling
Paper packaging
Plastic packaging
Paper recycling
Plastic recycling
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2 Technical data
H4 is a small, light and robust mobile panel featuring a comfortable 5" TFT LCD color touch display
A powerful processor runs Windows CE and, depending on the configuration, a SW application that
manages all system settings and control. Stop Push-button, Enabling Device and State Selector are
available on board.
All configuration and control commands selected through the keyboard or the touch screen display,
the Handwheel and the potentiometers status, the Stop pushbutton, Enabling Device and State Selector
R
status are sent by the Wireless handheld terminal through a Bluetooth communication channel to the
HCI.
Figure 2.1: H4, Recharging Station and HCI
The uniqueness of the wireless communication is guaranteed by the use of TOKEN. TOKEN is a
device containing a unique ID. Depending on the configuration, there can be one or two token to
guarantee the safety and uniqueness of the wireless communication. For details on the TOKEN
functionality please refer to paragraph 2.1.2.1 HCI replicates the safety devices status on safety relays
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and Mosfet switches and transmits all configuration and control commands selected on the mobile
panel to the machine control logic through a RS-422 serial communication channel.
All HCI outputs: RS-422 signals and the safety relays and Mosfet switch outputs, are cable
connected to the machine control logic.
A Recharging Station (RS) completes the system. It is a storing and battery recharging station for
the Wireless handheld terminal. The Recharging Station can charge one spare battery in addition the
wireless handheld.
The handheld terminal offers a Windows CE platform on which applications for different purposes
can be set up. All of the components related to the H4 and the interface to the machine control logic are
hereunder schematically presented:
Figure 2.2: H4 Wireless system overview
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2.1 H4 overview
H4 is hereunder in detail presented:
Figure 2.3: H4 overview
-
Functional hand grip, user configurable;
-
Comfortable and safe access to safety related devices;
-
Comfortable and secure handling using rubber membrane keyboard and covering surface;
-
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 600682-6, EN 61131-2 cl. 6.3.2, EN 60068-2-27
-
Non-flammable material (fulfils UL 94-5VA) housing, impact-resistant, water-resistant IP 64,
cleaning agents (alcohol and fabric conditioner), oils, cutting oils (drilling oils), fat and lubricants
resistant.
-
Extremely robust housing. Drop-tested according to EN 61131-2:2007 random drops 1mt.
-
Rubber covered keys with mechanical pressure point.
-
2 status LED.
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Figure 2.4: H4 LED’s
LED Color
A
Status Meaning
Red
ON
Coupled to HCI (Host Controller Interface)
BLINK Waiting for coupling to HCI
Green
ON
Battery charging
BLINK Charging error
LED Color
B
Status Meaning
Red
ON
Hardware fault – RTC Battery low
Green
ON
Normal operation
BLINK Communication error
-
TFT LCD Display with resistive touchscreen
-
ARM Cortex A8 600 MHz CPU
-
Memory size:
o
RAM: 256 MB
o
Flash: 128 MB
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2.1.1
Input devices
2.1.1.1
Potentiometers
-
The two over-ride potentiometers can be used for different purposes, for instance
setting the spindle speed or the machine movement speed along a certain axis.
-
Resolution: 0-255 linear
2.1.1.2
-
Handwheel
The handwheel can be used for the machine movement fine tuning in the “handwheel
incremental JOG” working mode.
-
The handwheel counts 40 detents per each 360◦ turn. Handwheel is internally
managed and its counter goes from +32767 to -32767. Handwheel turns are counted
as soon as the mobile panel is shut on. Clockwise turns decrement while counterclockwise turns increment the counter.
2.1.1.3
Membrane keypad
The mobile panel has a rubber covered membrane keypad containing 19 keys. 6 keys are
command keys, useful to be implemented for a direct machine control. The remaining 13 keys are
function keys, useful to be implemented for navigating and operating through the panels of the software
application. The letter or the symbol printed on the keys reminds the suggested function. The USER can
freely assign the single keys to different functions.
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Figure 2.5: Keypad
Key
Suggested Function
H
Hold (Machine stop)
S
Start (Machine start)
A+
Scroll axis down
A-
Scroll axis up
+
JOG+
-
JOGNext
Level Up
Up (Softkey)
Down (Softkey)
1
Custom Button 1 (Softkey)
2
Custom Button 2 (Softkey)
◦
Function softkey (function explained in chapter 3)
Switching ON/OFF the terminal
Pushing simultaneously 2 and
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17
2.1.1.4
Touchscreen pen
The touch screen pen is easily accessible in the back, on the right side of the terminal.
2.1.2
Safety-related functions
Hereunder is shown the detail for the safety related devices position:
Figure 2.6: Safety related devices position
For all the information about the safety related devices and functions please refer to paragraphs
1.2.1, 1.2.2, 1.2.3 and 2.6.4.
2.1.2.1
Token
Token is a Unique ID key easily pluggable on the top of the Wireless terminal and in the front part of
the HCI thanks to a USB type A receptacle. Unique ID is factory-written into an internal EEPROM and
guarantees wireless communication safety and uniqueness.
Figure 2.7: Token
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2.2 Recharging station
Recharging station is a storing and battery recharging device for the H4 handheld device. It can
charge at the same time the H4 handheld plus one spare battery. The status LED indicates the charging
status:
A: GREEN, indicates presence of power to handheld, to charge the battery on the handheld.
B: GREEN indicates the end of charging the auxiliary battery
C: RED indicates the current charge of the auxiliary battery
Check the correct charging of the auxiliary battery:
• while charging the red LED (LED C) is on; green LED (LED B) off;
• at the end of charging the green LED (LED B) is on.
Recharging station has a back side supply cable. The 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. The recharging station is designed to be wall mounted or desktop mounted. Please refer to the
mounting tips at chapter 2.8.
Warning!
-
Disconnection and connection cable must be performed by a skilled installer.
Figure 2.8: Recharging Station LED’s
Information
- When not in use, it is always suggested to place the H4 handheld device on the Recharging Station;
- When shut off and not recharged, the handheld terminal battery discharges after seven days. In this
case you must execute a complete charging cycle before using the handheld device.
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Warning!
- SELV Extra low voltage power supply / Limited power source according to EN 60950-1.
- On the recharging station power supply must be a suitable isolating device and a 2A delayed fuse.
2.3 Battery replacement
Replace the battery if you need to have a fully charged battery in the handheld device.
Figure 2.9: Battery replacement
The procedure for battery replacement is the following:
-
Unscrew the locks
-
replace the battery
-
screw the locks
2.4 Receiving station overview
The HCI receiving station is composed of two parts: the NSMHC module and the NBTR module
(antenna).
The NSMHC module is enclosed in a metal housing and is normally placed inside the control systems
cabinet; the NBTR module is enclosed in a plastic pipe and should be placed in a well exposed position
to allow for the best radio communication with the H4 handheld device. The connection between the
NSMHC module and the NBTR module is achieved with an Ethernet patch (not crossed) cable up to
20m long. The cable shall be a CAT5 shielded Ethernet cable.
HCI receiving station is hereunder in detail presented:
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Figure 2.10: NSMHC receiving station
Figure 2.11: NBTR module (antenna)
Information
- It is suggested to install the NSMHC module in order that the TOKEN input connector is always
easily accessible by the user. This is especially true for the double TOKEN configuration
- It is suggested to install the NBTR in order that the antenna has the best transmitting/receiving
performances. Do not install the antenna inside metal cabinets. Install the antenna in order that the
signal coverage guarantees comfortable operation in the whole machine working area.
2.4.1
Housing
Steel with DIN clamp. IP20 protection for NSMHC
Danger!
- It is mandatory to install the NSMHC module in a cabinet which is certified with a protection degree of
IP54 (or more).
Plastic pipe, IP40 protection for NBTR
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2.4.2
LED indicators
One status LED. LED indicates coupling status between H4 and HCI. For further information about
coupling status please refer to paragraph 3.2.6
2.4.3
Interfaces
• RS-422 full-duplex serial interface for communication to machine control logic;
• Bluetooth R communication interface for communication to Wireless handheld terminal.
2.5 Dimensions
2.5.1.1
Hand-held device
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Figure 2.12: Handheld Terminal dimensions in millimeters
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2.5.1.2
Charging station
Figure 2.13: Recharging station dimensions in millimeters
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2.5.1.3
Host controller interface
Figure 2.14: NSMHC dimensions in millimeters
2.5.1.4
Token
Figure 2.15: Token dimensions in millimeters
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2.6 Technical data details
2.6.1
Handheld device specifications
Features
Operating System
Processor Type
Cooling
Flash Memory
RAM Memory
Windows CE 6.0
ARM Cortex A8 600 MHz
Passive Cooling
128 MB Flash
256 MB SDRAM
Bluetooth R
Wireless
Interface
Transceiver
Transfer Rate
Max working distance
Coupling Interface TOKEN
Connection
BLUEGIGA WT11 (Class 1)
up to 3Mbps
50m
Keyboard
Suggested command keys
Suggested softkeys
Status LED
Display Type
6
13
2 (RED/GREEN)
Diagonal
Colors
Resolution
Contrast ratio
Viewing angle:
• Horizontal
• Vertical
Background lighting:
• Brightness
• Half-brightness time
Touch screen technology
Power Supply
Battery Type
Battery Output voltage
Battery Capacity
Electrical life
Full recharging time
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USB A receptacle (no physical interface,
connector only)
TFT LCD
5" (12,7 cm)
64K
RGB 480 x 272
500:1
Direction Right / Direction Left = 70◦
Direction Up = 50◦ / Direction Down = 70◦
300 cd/m2
at least 20000 hours
Resistive sensor technology
Internal battery (removable)
Li-ion Polymer battery
3.7V
4000mAh
500 full charge cycles minimum
(Battery capacity ≥ 70% of the initial value)
≤ 4.5 hours
26
Mechanic
Handheld terminal color
Body structure: RAL 7035; Rubber part: RAL7016
Stop push-button
Enabling Device
State Selector
Handwheel
Override potentiometer
Outer dimensions Length
2 contacts
3 positions switches, 2 contacts
16 state BCD coded
40 detents per turn
2 linear potentiometers
220 mm
144 mm
63 mm
About 900g
Environment
Height
Width
Weight
Temperature
Operating temperature
Transport and storage
temperature
Relative humidity
Operating
Transport and storage
Protection Type
Altitude
2.6.1.1
+5◦ to +45◦C
−20◦ to +70◦C
Max 95%; non-condensing
Max 95%; non-condensing
IP 64 (The partial or total removal of each cap will not
guarantee the IP64 degree of the equipment).
Max 2000m
Handheld device chemical resistance
Test 1 (Less strict)
The units under test (UUT) are placed in a closable plastic box (120 x 85 x 65 mm).
A ball of absorbent cotton appositely tinctured with solvent will be placed above the UUT; to avoid
early evaporation, a generic solid body will be put over the ball or, in a more simply way, the closable
plastic box will be closed.
After a 10 minutes wait, the eventually body and the ball of absorbent cotton will be removed; the
solvent that remains on the UUT will not be wiped 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 closed box for at least 24 hours.
◦
The test will be performed at environmental temperature (about 20 C).
Touchscreen test procedure
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The Touchscreen is placed into a closable plastic box (120 x 85 x 65 mm) and a ball of absorbent
cotton appositely tinctured with solvent will be placed above it, then the box will be closed for 1 h.
◦
The test will be performed at environmental temperature (about 20 C).
2.6.1.2
Chemical
Test results
Test 1 passed
Test 2 passed
Notes
solvent
Rubber (Keyboard)
Rubber (Keyboard)
Denatured
Handles
Handles
Ethyl
Terminal housing
Terminal housing
Alcohol
Rubber cap
Rubber cap
Rubber (lateral cover)
Rubber (lateral cover)
Rubber (Keyboard)
Test 2:
Handles
Handles
Rubber (Keyboard):
Terminal housing
Terminal housing
heavy deformation;
Rubber cap
Rubber cap
reduced hardness
Rubber (lateral cover)
Rubber (lateral cover)
Rubber (Keyboard)
Rubber (Keyboard)
Unleaded
Handles
Handles
Gasoline
Terminal housing
Diesel
Test 2:
Terminal housing:
Rubber cap
Rubber cap
Rubber (lateral cover)
Rubber (lateral cover)
Rubber (Keyboard)
housing gets doughy
Test 2:
Blu
Handles
Handles
Rubber (Keyboard):
Diesel
Terminal housing
Terminal housing
rubber gets doughy
Rubber cap
Rubber cap
Rubber (lateral cover)
Rubber (lateral cover)
Rubber (Keyboard)
Rubber (Keyboard)
Silicone
Handles
Spray
Terminal housing
Terminal housing
Rubber cap
Rubber cap
Rubber (lateral cover)
Rubber (lateral cover)
Rubber (Keyboard)
Rubber (keyboard)
Handles
Handles
Kluber
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Test 2:
Handles: loss of color
28
KONSTANT
Terminal housing
Terminal housing
OY 32
Rubber cap
Rubber cap
Rubber (lateral cover)
Rubber (lateral cover)
Rubber (Keyboard)
Rubber (Keyboard)
Test 1 and 2:
Rubber (lateral cover)
Rubber (lateral cover)
Handles: loss of color
Acetone
Terminal housing:
clouding
Rubber cap: swelling
Rubber (Keyboard)
Rubber (keyboard)
Shell
Handles
Handles
Garia
Terminal housing
Terminal housing
9603 M15
Rubber cap
Rubber cap
Rubber (lateral cover)
Rubber (lateral cover)
Touchscreen test results
Test passed with the following solvents:
• Unleaded Gasoline;
• Denatured Ethyl Alcohol;
• Diesel
• Kluber KONSTANT OY 32;
• Acetone.
2.6.2
HCI specifications
•
Features
Status LED
1
Coupling Interface TOKEN USB A receptacle (no physical interface, connector
Connection
only)
Bluetooth R
Wireless
Interface
Transceiver
BLUEGIGA WT11a (Class 1)
Transfer Rate
up to 3Mbps
Max working distance
50m
RS-422 Serial Interface
Transceiver
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Transfer Rate
57600 bps
Connection
2 twisted pairs (TX+/TX-,RX+/RX-) plus reference
ground
Power Supply Rated
24V# ± 25 % Supplied by a SELV or PELV power
voltage
supply
Max interruption of the
5 ms
supply
Starting current
2A
Power consumption
240mA @ 24V (idle)
2.4A @24V (max)
Mechanic
Stop push-button related
2 contacts. 8A max
relays
Enabling Device related
2 contacts. 8A max
relays
State Selector related
4 Mosfet switches. 500mA each max
Mosfet switches
Outer dimensions Length
166 mm
Height
110 mm
Width
57 mm
Weight (without cable)
760g
Environment
Temperature
Operating temperature
0◦ to +55◦C
Transport and storage
−20◦ to +70◦C
temperature
Relative humidity
Operating
Max 95%; non-condensing
Transport and storage
Max 95%; non-condensing
Vibration and shock
fulfils EN 60204/A1:2009 (par 4.4.8), EN 61131-
during operation
2:2007 (par. 4.2.2), EN 60068-2-6:2008
Altitude
2000m
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Protection Type
IP 20
(IP54 must be achieved by installing HCI in a
IP54 cabinet)
Flame resistant
2.6.2.1
fulfils UL 94: HB 1/16"
NSMHC connectors
Ref.
Name
Function
X1
X2
X3
X4
X5
X6
X7
X8
J2
Power
Token Connection
Com1 HOST
Com2 IKHC
Stop Pushbutton
Enabling Device
State Selector
WLED
BT Connection
Power supply
Token receptacle
Serial interface to NC host (RS-422)
Auxiliary serial interface (RS-422)
Stop pushbutton output contacts
Enabling device output contacts
State selector repeater
Safety LED output
Connection to NBTR module (RJ45)
2.6.2.1.1 X1 Power
Pin #
1
2
Signal Name
GND
P24Vin
Signal description
Ground reference
Positive power supply 24V#
(+/- 10%)
2.6.2.1.2 X2 TOKEN Connection
Token receptacle.
It is a USB type A receptacle.
WARNING: This USB type A receptacle is not designed to accept standard USB devices. Only the
proprietary token can be inserted on it. Any USB device insertion could result in damage for both
devices.
2.6.2.1.3 X3 COM1 Host
RS-422 interface connector to connect to a CN host system. The interface pins are optically coupled;
therefore it is important to connect the ground reference also.
Pin #
1
2
3
4
5
Signal Name
GNDISO-M
HcRxP
HcRxM
HcTxM
HcTxP
Signal description
Reference voltage RS-485 data signal
RS-422 positive data from MPU
RS-422 negative data from MPU
RS-422 negative data to MPU
RS-422 positive data to MPU
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2.6.2.1.4 X4 COM2 IKHC
RS-422 interface connector to connect to an auxiliary device. The interface pins are optically coupled;
therefore it is important to connect the ground reference also.
Pin #
1
2
3
4
5
Signal Name
GNDISO-S
IkRxP
IkRxM
IkTxM
IkTxP
Signal description
Reference voltage RS-485 data signal
RS-422 positive data from Cabinet IntKey
RS-422 negative data from Cabinet IntKey
RS-422 negative data to Cabinet IntKey
RS-422 positive data to Cabinet IntKey
2.6.2.1.5 X5 STOP push-button
Safe output contacts from a safety relay that replicate the Spot pushbutton contacts of the input device.
Pin # Signal Name Signal description
1
STPB2A
Side A of STPB2 relay contact (connected to STP2B when closed)
2
STPB1B
Side B of STPB1 relay contact (connected to STP1A when closed)
3
STPB2B
Side B of STPB2 relay contact (connected to STP2A when closed)
4
STPB1A
Side A of STPB1 relay contact (connected to STP1B when closed)
2.6.2.1.6 X6 Enabling Device
Safe output contacts from a safety relay that replicate the Enabling device contacts of the input device.
Pin # Signal Name Signal description
1
ENDV2A
Side A of ENDV2 relay contact (connected to ENDV2B when closed)
2
ENDV1B
Side B of ENDV1 relay contact (connected to ENDV1A when closed)
3
ENDV2B
Side B of ENDV2 relay contact (connected to ENDV2A when closed)
4
ENDV1A
Side A of ENDV1relay contact (connected to ENDV1B when closed)
2.6.2.1.7 X7 State Selector
State selector repetition. These are not clean contacts, but digital output (0- 24V# ) that replicate the
status of the state selector of the input device
Pin # Signal Name Signal description
1
GND
Reference voltage for output SSEL level
2
SSEL1
SSEL1 output 24V# level
3
SSEL2
SSEL2 output 24V# level
4
SSEL3
SSEL3 output 24V# level
5
SSEL4
SSEL4 output 24V# level
6
GND
Reference voltage for output SSEL level
2.6.2.1.8 X8 WLED
Safety LED output. At this output can be connected a LED for safety information. It can drive a LED with
6mA current.
Pin #
1
2
Signal Name
WLEDP
GND
Signal description
Positive signal to drive an external activity led (anode)
Return path for WLEDP signal (cathode)
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2.6.2.1.9 J2 BT Connection
At this RJ45 connector is inserted an Ethernet patch (not crossed) cable to connect with the NBTR
(antenna).
Cable length can be up to 20m to allow for the best antenna position in the plant.
2.6.2.1.10
Connectors and pin ordering
Top view
Figure 2.16: NSMHC connectors
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2.6.3
Recharging station specifications
Features
Electrical characteristics
24V# ± 25 % Supplied by a SELV or PELV power
Rated voltage
supply
Voltage output
5V ± 10 %
Power Consumption
21.6W (max) = 900mA (max) @ 24V
Protection type Voltage
Protection from polarity inversion, over-voltage and
input
under-voltage
Current input
Protection from overload current
Voltage output
Internally regulated
Mechanics
Recharging
Station
RAL 7016
color
Outer dimensions Length
213mm
Height
113mm
Width
89mm
Weight (without cable)
About 400g
Environment
Temperature
Operating temperature
+5◦ to +45◦C
Transport and storage
−20◦ to +70◦C
temperature
Relative humidity
Operating
Max 95%; non-condensing
Transport and storage
Max 95%; non-condensing
Altitude
Max 2000m
Protection Type
IP 64
Flame resistant
fulfils UL 94V-0: HB 1/16"
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2.6.4
Safety-related devices
2.6.4.1
Safety relays related to Stop Push-button and
Enabling Device
Characteristics
Value
Max switching voltage
24V#
Supplied by a SELV or PELV power supply
Max switching current
8A
Minimum switching power
300mW (5V, 5mA)
Danger!
An external fuse rated @ 4A shall be provided in series with the switching contact in order to avoid
an overcurrent that could weld the relais contacts
2.6.4.2
MOSFET switches related to State Selector
Even if each mosfet switch is capable of sourcing 500mA, it is recommended to limit the sourcing
current at 100mA continuously, in order to limit the power dissipation inside the HCI.
2.6.4.3
STOP function
Characteristics
Performance Level (PL) as
Value
d
defined in EN ISO 13849-1:2008
Safety Integrity Level (SIL) as
2
defined in EN 62061:2005
Stop push-button:
• Mechanical life
250000 operations minimum
• Electrical life
250000 operations minimum
• Maximum operating frequency
900 operations/hour
2.6.4.4
Enabling function
Characteristics
Performance Level (PL) as
Value
d
defined in EN ISO 13849-1:2008
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Safety Integrity Level (SIL) as
2
defined in EN 62061:2005
Enabling Device:
Position 1→ 2: 1000000 operations minimum
• Mechanical life
Position 1→ 2→ 3→ 1: 100000 operations minimum
• Electrical life
100000 operations minimum
• Maximum operating frequency
1200 operations/hour
2.6.4.5
State Selecting function
Characteristics
Value
Performance Level (PL) as
c
defined in EN ISO 13849-1:2008
Safety Integrity Level (SIL) as
1
defined in EN 62061:2005
State Selector:
• Electrical life
25000 operations minimum
2.6.4.6
Details on the PL and SIL level of the safety
related functions
In the following tables we will detail PL and SIL values, the parameters useful for their calculation
and the assumptions we made.
2.6.4.6.1 Details on the PL (EN ISO 13849-1:2008)
PL
MTTFd[years]
DC
Category
Stop Push-button
d
>16837
95,09%
3
Enabling Device
d
16544
95,40%
3
State Selector
c
348
66.5%
1
2.6.4.6.2 Details on the SIL (EN 62061-1:2005)
SIL
PFHd[1/hour]
SFF
2
6.87 10-9
98.85%
1
Enabling Device
2
6.90 10
-9
98.85%
1
State Selector
1
3,28 10-7
90,03%
0
Stop Push-button
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2.6.4.6.3 Parameters useful for the PL (EN ISO 138491:2008) and SIL (EN 62061-1:2005) Calculation
Parameter Description
Dop
Hop
Tcycle
Nop
b10
MTTF
B10d
MTTFd
Average number of
annual operating days of
the safety function
Average number of daily
hours of operation of the
safety function
Average elapse time
(seconds) between two
uses of the safety
function
Stop
push-button
240
Enabling State selector
device
240
240
16
16
16
1152
288
19200
48000
720
Average number of annual 12000
operations
Number of cycles that
250000
determine a failure of
10% of the components
Mean Time To Failure
(years)
Number of cycles that
determines a dangerous
failure of 10% of the
components
1000000 25000
208
208
347
Note 2
Note 2
25000
Mean Time To Dangerous Note 2
Failure (years)
Note 2
347
Note 1
The numerical values shown in 2.6.4.6.3 consider only the highest safety performances of the
Safety Functions of the H4 Wireless system, starting from the Safety Device (Stop Push-button,
Enabling Device, State Selector) of the Terminal and ending on the HCI output connector. The
numerical values of MTTFd, PFHd, SFF and DC were obtained using the assumptions shown in
2.6.4.6.3 and are related to each safety function frequency of use. The values for the overall safety
functions of the machine depend on how the output safety signals are managed inside the machine
controller.
Note 2
The Stop Push-button and Enabling Device on board of H4 are compliant with IEC60947-5-1.
Considering that and referring to paragraph D.5.3 (table D.8) of ISO 138492, it is not possible to relate
dangerous failures to these components and, so, the values of b10d, MTTFd and PFHd for the Stop Pushbutton and Enabling Device does not have any relevance (from a mathematical point of view: b10d,
MTTFd = infinite and PFHd = 0).
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Note 3
As indicated in EN 60204-1:2006-par.9.2.7.3, in a wireless control terminal the Stop Device shall not be
marked or labeled as an Emergency Stop Device. Anyway, from an hardware point of view, the Stop
Push-button is exactly the same device used on board of H3 Wired terminal, except for the yellow
background color.
2.6.5
Timing specifications
H4 and HCI, as previously explained in detail, interface with the machine control logic. In this
section we summarize all timing characteristics relating to the communication between H4 and the
machine control logic.
All configuration and control commands selected through the keyboard or the touch screen display,
the optional handwheel and the potentiometers status are sent through a Bluetooth communication
channel to the HCI and then transmitted to the machine control logic through a RS-422 serial
communication channel. The average time that runs from the change of an input on the Wireless
terminal to when its transmission from the HCI to the machine control logic is concluded is called
tRS−422.
The safety related devices status, monitored by the H4, is sent through the Bluetooth
communication channel to the HCI. HCI provides safety relays and Mosfet switches which perfectly
replicate the safety devices status. The average time that runs from the change of the safety devices
status on the Wireless terminal to when their status is perfectly replicated on the HCI on the output
contacts of its Safety relays and Mosfet switches is called tSafety.
In case of wireless communication faults, further explained in chapter 4, or problems in the
hardware in charge of checking and transmitting the safety devices, a safety time-out (tSafetytime−out)
forces the safety relays and the Mosfet switches into a “safe" state.
Timing
Value
tRS−422
less than 150 ms
tSafety
less than 100 ms
tSafetytime−out
160 ms
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2.7 Stickers
H4 as well as the Recharging Station and HCI and TOKEN, is labeled with a sticker nameplate that
allows single component unique identification. Wireless terminal, RS and HCI provide the same kind of
sticker showing:
• Model name.
• product part number ;
• product versioning
• production serial number
• production date (mm/yy)
• producer logo ;
• CE mark.
The NSMHC module is identified by the following label:
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The label is applied on the back of the case, so it is not visible when the case is clipped on the DIN bar.
Another label is applied on the case that holds the NBTR module:
This second label holds the Token code. The Token Code is important because only the token with that
same code can allow an H4 terminal to connect with the NSMHC module.
Figure 2.17: Handheld terminal, HCI, and RS Sticker
TOKEN has a unique ID on its TOP
Figure 2.18: TOKEN Sticker
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2.8 Mounting the charging station
Recharging Station is designed to be wall mounted or desktop mounted. Each mounting type is related
to different target surfaces, hereunder summarized:
Mounting type
Target surface *
Brick made surface
Wall mount
Wooden/Plastic surface
Metal surface
Desktop mount
Wooden/Plastic surface
Metal surface
* Target surface: through hole and wall thickness more than 5mm
Figure 2.19: Recharging station holes
Warning!
Installation must be done in such a way that you cannot push the cable into the interior of the
device and even damage the cable and its entrance by accident.
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2.9 Standards and certifications
2.9.1
EC directives
Directive
2006/42/EC
2014/30/EU
1999/5/EC
2.9.2
Description
Machine Directive
Electromagnetic Compatibility Directive (EMC)
Radio equipment and telecommunications terminal equipment
and the mutual recognition of their conformity
International standards
Standard
Safety of Machinery
EN 60204-1:2006
EN ISO 13849-1:2008
EN 62061:2005
EMC
IEC 61000-(1-2-3)
EN 61000-6-2:2005
EN 61000-6-4:2007
EN 61000-4-2:2010
EN 61000-4-3:2007
EN 61000-4-5:2007
EN 61000-4-6:2007
EN 61000-4-8:1993
EN 61326-3-1:2008
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Description
Safety of machinery - Electrical equipment of machines Part 1:
General requirements
Safety of Machinery – Safety related parts of control
systemsPart 1: General principles for design
Safety of Machinery – Functional safety of safety related
electrical, electronic and programmable electronic control
systems
Electromagnetic Compatibility (EMC)
Electromagnetic Compatibility (EMC) Part 6-2: Generic
Standards – Immunity for Industrial Environments
Electromagnetic Compatibility (EMC) Part 6-4: Generic
Standards – Emission Standard for Industrial Environments
Electromagnetic compatibility (EMC) Part 4-2: Testing and
measurement techniques - Electrostatic discharge immunity
test
Electromagnetic compatibility (EMC) Part 4-3: Testing and
measurement techniques - Radiated, radio-frequency,
electromagnetic field immunity test
Electromagnetic compatibility (EMC) Part 4-5: Testing and
measurement techniques - Surge immunity test
Electromagnetic compatibility (EMC) Part 4-6: Testing and
measurement techniques - Immunity to conducted
disturbances, induced by radio-frequency fields
Electromagnetic compatibility (EMC) - Part 4-8: Testing and
measurement techniques - Power frequency magnetic field
immunity test
Immunity requirements for safety –related systems and for
equipment intended to perform safety-related functions
(functional safety)- General industrial applications
42
ETSI EN301489-1 V1.9.2
Electromagnetic compatibility and Radio spectrum Matters
(ERM) – Electromagnetic Compatibility (EMC) standard for
radio equipment and services – Part1: Common technical
requirements
ETSI EN301489-17 V2.2.1 Electromagnetic compatibility and Radio spectrum Matters
(ERM) – Electromagnetic Compatibility (EMC) standard for
radio equipment and services – Part17: Specific conditions for
broadband data transmission system
EN 55011:2007
Industrial, scientific and medical (ISM) radio-frequency
equipment - Electromagnetic disturbance characteristics Limits and methods of measurement
Degrees of protection and environmental tests
EN 60529, 1997+A1:2000 Degrees of protection provided by enclosures (IP code)
EN 60068-2-1:2007
Environmental testing Part 2-1:Tests – TestA: Cold
EN 60068-2-2:2007
Environmental testing Part 2-2:Tests – TestB: Dry heat
EN 60068-2-6:2008
Environmental testing Part 2-6:Tests – TestFc: Vibration
(sinusoidal)
EN 60068-2-30:2005
Environmental testing Part 2-30:Tests – TestDb: Damp heat,
cyclic (12h+ 12 h cycle)
EN 60068-2-31:2008
Environmental testing Part 2-31:Tests – TestEc: Rough
handling shocks, primarily for equipment-type specimens
EN 61131-2:2007 § 4.2.1, § Programmable controllers – Part2: Equipment requirements
4.2.2
and tests, § 4.2.2: Shock (according EN 60068-2-27)
Stop Push-button conforming to:
IEC 60947-5-5, 6.2
Safety Lock Mechanism
IEC 60947-5-5, 5.2
IEC60947-5-1, Annex K
Direct opening action mechanism
EN 60204-1:2006-9.2.7.3
Enabling Device conforming to:
IEC 60947-5-1
EN 60947-5-1
JIS C8201-5-1
UL508
CSA C22.2 No 14
IEC 60947-5-8:2006
Low-voltage switchgear and control gear
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2.9.3
TUV certificate
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Extract from “Report to the Certificate” (Report No.: OV87344C), chapter 5.
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3 Wireless terminal safety system
3.1 Architecture overview
H4 internal boards and HCI connection to the machine cabinet is hereunder presented:
Figure 3.1: Architecture Overview
The NMSPM system is defined as the set of components that build up the safety system part.
It is composed of:
The NSMWL module mounted into the H4 Wireless terminal.
The NSMHC module and the NBTR module on the CNC cabinet, included the cable connecting the 2
modules.
The TOKEN (single or double) that allow the virtual connection between the two parts.
The system is in charge of creating a virtual safe link between the safety related devices on board
of the H4 and the related safety relays or mosfet switches on board of HCI, directly connected to
the machine safety circuits.
From a safety point of view the H4 will behave exactly as it would have hard-wired s af e t y related
devices.
The whole system is designed to allow a point to point coupling between the Wireless terminal a n d
the related HCI in environments where more than o n e terminal HCI couple can coexist.
3.2 Operation
The aim of the NMSPM system is to establish a safe wireless connection between a control cabinet
(CNC) and a handheld terminal (H4).
The safety of the information is assured by the intrinsic safety of the message flowing thru an unsafe
communication media (black channel), while the unambiguous connection between the CNC and the
H4 is accomplished by the use of unique hardware keys called TOKEN.
Each token holds specific and unique information that are used as part of the message between the
CNC and the H4.
The NMSPM system can operate with the token in two different ways: single token operation and
double token operation. The operation mode is configured at the factory and cannot be changed on the
field.
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When the double token configuration is chosen, the NSMHC and NSMWL modules do not hold any
coupling related information. The information is hold by the couple of tokens. When the tokens are
inserted, one on the cabinet side and the other on the terminal side, the radio connection is established
between the two Bluetooth modules that hold the same information read from the token. Both token
holds the same information and they can be used equally on the cabinet or terminal side.
In the single token configuration, instead, the only token shall hold information about the NSMHC
module to which it will connect when inserted into the terminal. This information is written into the token
at the factory with a special procedure called “adoption”. So every token is registered to work with a
specific NSMHC module. In fact the information written into the token during the adoption procedure is
get from the NBTR part of the NSMHC, so these are the two parts that shall work together (Token and
NBTR module).
The handheld terminal instead is never related to a specific token, so it can work with every NC cabinet,
with single or double token configuration.
3.2.1
Operating states
At any given moment, the safety system can be in one of the following operating modes:
“off” The HCI station is powered off
“idle” The HCI station is at rest. No terminal is connected to the NSMHC module. Output contacts are
closed, allowing the NC machine to operate.
“run” The safety system is working. Communication with a handheld terminal is established by a
correct coupling procedure and the safety output contacts replay the state of the input devices on the
terminal.
“safe” Safety system is in a safe state (safety output contact are open). This state can be entered by
several conditions. The most common is when the radio link is lost after a successful coupling (possible
reasons: distance between the 2 radio devices exceed the maximum allowed, electromagnetic noise,
power off of the terminal before performing the uncoupling procedure).
“emergency” This state is reached each time an internal logic failure as POST or RTT failure
(concerning the H4 terminal or the HCI) happen. In this case, of course, the Wireless terminal
does not control the HCI and the machine to which it is connected. The Stop Push-button
contacts o n HCI are OPEN. The only way to get o E M G state is shutting OFF the system.
3.2.2
Safety s ystem details
H4 and H C I safety s ys te m , a s previously s a i d , w i l l behave as if the system would have hardwired s af e t y related devices.
In order to guarantee PL d, SIL 2 for the Stop and Enabling safety function and
PL c, SIL 1 for the State s e l e c t i n g function (according to EN ISO 13849-1:2008 and EN
62061:2005), the safety system must consider all kind of problems related to the use of a
Wireless handheld term inal:
• The safety system accounts for problems as ensuring the uniqueness of the control of a
certain machine connected to the HCI by a certain handheld terminal. The uniqueness of
the control is certified by means of executing specific coupling/uncoupling procedures using a
device called TOKEN which holds a unique identifier code (UID)
• The safety system accounts for problems as lack of wireless signal.
• The safety system accounts for problems as insertion of TOKENs w i t h different ID in the H4
terminal a n d HCI.
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• The safety system accounts for problems as internal logic malfunctions executing a POST
(Power On Self- Test) at Power ON and RTT (Real Time Test) during the whole system
working life.
• The safety system communicates its status b y means of LEDs on board of the terminal and
HCI.
The safety system manages all possible events that can occur while operating the H4 wireless
handheld terminal and HCI, appositely controlling the safety relays and mosfet switches.
We can summarize a l l of the safety system work ing conditions i n statuses, each one related to
a specific configuration of the safety relays and mosfet switches on the HCI.
The safety output contacts s t a t u s i n all possible working system statuses i s hereunder
summarized:
Status
Condition
OFF
IDLE
HCI OFF
HCI ON,
TOKENs
not inserted
HCI and
Terminal
coupled
Lack of
WLS signal,
coupling/
uncoupling
time-out
expired
POST or
RTT failed
RUN
SAFE(i)
SAFE(r)
EMG
WL
S
Connectio
n
DROPPED
DROPPED
HCI Output Contacts
Stop
Enabling
State
Push-button
Device
Selector
OPEN
OPEN
(0) OPEN
CLOSED
OPEN
LAST
VALID
ACTIVE
AS ON
TERMINAL
AS ON
TERMINAL
AS ON
TERMINAL
DROPPED
OPEN
OPEN
LAST
VALID
DROPPED
OPEN
OPEN
LAST
VALID
Resuming we can say that:
• OFF: this state is reached each time HCI is powered OFF (or, rather, power supply into the
machine cabinet, to whom HCI is connected, is OFF). Obviously, i n this case, Stop Pushbutton contacts o n HCI are OPEN.
• IDLE: in this state the Wireless terminal d o e s not control the HCI and the machine to which it
is connected. Stop Push-button contacts o n HCI are CLOSED in order to let the machine work
in automatic mode. This state c a n be mainly reached in two situations:
-
each time, starting from OFF st at e , H C I is powered ON with no TOKEN i n s e r t e d (double
token configuration) or with TOKEN inserted (single token configuration);
each time, starting from RUN state, a correct uncoupling procedure has been executed.
• RUN: this state can be mainly reached if a correct coupling procedure has been executed.
In this case the Wireless terminal controls the safety outputs on HCI and user data are
transferred through the wireless channel. The Wireless terminal controls the HCI and the
machine to which it is connected.
• SAFE(i)/SAFE(r): these states can be mainly reached in case of lack of wireless signal or
coupling/uncoupling procedures failed and the related time-out expired. SAFE(i) state is
reached if these problems occurred when state of origin was IDLE state. SAFE(r) state is reached
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if these problems occurred when state of origin was RUN state. In this case, of course, the
Wireless terminal does not control the HCI and the machine to whom it is connected. The Stop
Push-button contacts on HCI are OPEN.
• EMG: this state is reached each time an internal logic failure as POST or RTT failure (concerning
the Wireless terminal or the HCI) happen. In this case, of course, the Wireless terminal does not
control the HCI and the machine to which it is connected. The Stop Push-button contacts on HCI
are OPEN. The only way to get t o EMG state is shutting OFF the system.
3.2.3
LED functionality
Safety LED output signals are present both on the NSMHC and the NSMWL.
At any given moment, each LED can be in one of the following state.
The meaning of each state is described inside each procedure.
LED status
OFF
BlinkF
BlinkS
Blink22
ON
Description
Led is off
Fast blinking (100ms on / 100ms off)
Slow blinking (500ms on / 500ms off)
Irregular blinking (200ms on / 200ms off /
200ms on / 400ms off)
Led is steady on
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3.2.4
Complete safety system status diagram
We hereunder show a diagram that resumes all possible transitions between system statuses. Dashed
lines are related to transition statuses. Each status is represented together with the related LED status.
Figure 3.2: Safety system status diagram
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In figure 3.2 we evidenced with colored arrows situations that m u s t be satisfied sequentially:
• blue arrows: if we are in SAFE(r) state because of a lack of Bluetooth signal,we can
automatically re-enter RUN state once the Bluetooth signal is sufficiently powerful
• green arrows: if we are in SAFE(r) state as a consequence of a shutdown of the Terminal,
we can go to coupling phase and then to RUN state simply shutting on the terminal, inserting
the TOKEN and executing the Stop Push-button test;
• red arrows: if we are in RUN state and the HCI is switched OFF, as soon as it is switched
ON again (there is no tC ouplingtime−out ), if TOKENs are left inserted into the terminal and
HCI, after a correct POST the system can go directly to the coupling phase and to RUN state.
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3.2.5
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.
The operator shall be aware which machinery or group of machinery is controlling.
The operator shall be aware if the handheld terminal is enabled and connected to the machinery that is
supposed to control.
Information!
The SMWL module can safely drive an LED that can inform the operator about the status of the safety
system. The safety LED is off when the handheld terminal is not powered or when in idle mode (i.e.
powered but with the radio communication off). The LED will blink when establishing a connection and
finally be steady on when connection is established and the telegram packets are flowing.
Caution!
It is important that the LED shall be clearly visible and the operator instructed that he can rely on the
stop pushbutton only when the LED is steady ON
Information!
The handheld terminal is not linked to any specific machinery by default. The link between the handheld
terminal and the machinery is accomplished by the token and by the coupling procedure. The token,
therefore shall help to clearly identify the machinery under control, for example by putting a well visible
label on the token and a similar label on the cabinet of the machinery under control
Warning!
Furthermore, the coupling procedure shall be driven by the application software in such a way that will
force the operator to be aware of the machinery is going to take control.
The following condition shall always be analyzed:
The handheld terminal is off.
In such case the stop pushbutton will not be able to perform its duty.
When the safety led is off, the operator shall be aware that the stop pushbutton won’t be able to perform
its duty. It is under the system integrator to decide if machinery is allowed to operate by other meaning
than the handheld terminal, instruct the operator of such possibility and the safety behavior to comply
with
The handheld terminal is powered but not connected to any control cabinet. (No token inserted).
Also in this case the stop pushbutton will not be able to perform its duty. The absence of the token, the
safety LED off and possibly an evident message by the local software shall inform the operator of such
condition.
The handheld terminal is powered and connected but the connection drops due to
electromagnetic interference or out of range.
The token is present but the safety LED will be blinking. In such cases the control cabinet shall behave
as if it received a stop command and consequentially should be in safe state.
All over this discussion is always mentioned the Stop Pushbutton and never the Enabling device. In
fact, both devices work together, i.e. when the Stop Pushbutton is able to perform its duty, the same is
for the enabling device. It is up to the application environment to allow the machinery to work or not to
work when the enabling device is not held by the operator
Caution!
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 Stop Pushbutton will halt all the machinery
that could be involved
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3.2.6
Coupling procedure details
Depending on the system configuration (single or double token) and on the operator behavior, there are
four different approaches to achieve the coupling between a CNC and a H4.
The different operating modes only differ for the initial condition. The final coupling procedure is the
same for all the operating modes and is performed as follow:
1) The handheld terminal is powered on and token is inserted into it.
2) The coupling led on the terminal blinks fast
3) Operator performs the stop-button test by pressing and releasing the stop pushbutton (during
this operation the enabling device handle shall be released).
4) The coupling led on the terminal blinks slow.
5) Coupling succeeded. Both LEDs on the terminal and HCI are stable ON. System is in RUN
state.
3.2.6.1
Single token configuration with token always
inserted in the handheld terminal
This could be the default configuration when there is one terminal for every machine and the terminal is
the only interface to control the machine.
When the controller cabinet is powered on the safety system enters the safe state and waits indefinitely
for a terminal to link to.
The coupling operation shall take place when the handheld terminal is powered on.
Following the indication from the safety LED and/or messages from the local software, the operator
shall exercise the stop pushbutton while leaving the enabling device in the rest position.
The handheld terminal starts looking for the assigned cabinet to connect to. While the radio connection
is not established, the local software on the handheld terminal shall display a well visible warning
message informing the operator its stop pushbutton is not operative. When connection is established,
the safety led will be steady on, informing the operator the stop pushbutton is able to perform its task.
The application software should help the operator to identify the machinery under control. The safety
system changes from “safe” to “run” state. It could reenter “safe” state if any of the general condition
occurs.
3.2.6.2
Single token configuration with token
dynamically inserted in the handheld terminal
This could be the default configuration when there is one terminal to control several machines (however
one at the time). This implies that the machines not connected to the terminal can operate by their own
(i.e. by meaning of a fixed console in the NC cabinet.
Tokens (one for every HCI) are usually inserted into the HCI to allow the safe system enters the “idle”
state.
When the operator wants to take control of one machine, he has to remove the token from the HCI
controlling that machine, insert it into the handheld terminal and follow the coupling procedure. If the
coupling is accomplished before the timeout elapses, the safe system switch from “idle” to “run” state”,
without entering the “safe” state. Otherwise, after time out elapses the safe system enters “safe” state
and holds it until a successful coupling is accomplished or the token is inserted back into the HCI.
Once in “safe” state, however, coupling can be retried any time later without having to return the token
to the HCI.
The coupling operation could take place at any moment after power on.
While the handheld terminal is powered but not connected (because token is not inserted and coupling
procedure has not taken place), the safety led is off. Furthermore, the local application software should
inform the operator that the Stop Pushbutton is not active.
When connection is established, the safety led will be steady on informing the operator the stop
pushbutton is able to perform its task. The application software should help the operator to identify the
machinery under control.
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3.2.6.3
Double token configuration with tokens always
inserted in the handheld terminal
As for the analog single token, this configuration is used when there is one terminal for every machine
and the terminal is the only interface to control the machine.
When the controller cabinet is powered on the safety system enters “idle” state and waits for a coupling
procedure to occur before timeout elapses (approx. 60 seconds). After that the cabinet enters safe state
and will be necessary to extract and re-insert the token to try for a next coupling procedure.
3.2.6.4
Double token configuration with tokens
dynamically inserted both in the cabinet and in the
handheld terminal
This configuration assumes that there is more than one machinery in a plant which can work without the
need of the handheld terminal. When the operator decides to take control of one of the machinery thru
the handheld terminal, he performs the coupling procedure with the specific cabinet controlling the
machinery. Coupling can be performed without entering the safe state (i.e. the machinery can continue
to work while coupling is in progress), the function of the Stop Pushbutton will be active only when the
coupling procedure is completed successfully and the safety LED is steady on. Before coupling and
while coupling procedure is in progress, the local software on the handheld terminal shall display a well
visible warning message informing the operator its stop pushbutton is not yet operative.
When connection is established, the safety led will be steady on informing the operator the stop
pushbutton is able to perform its task. The application software should help the operator to identify the
machinery under control.
3.2.6.5
Operation without handheld terminal
In case the operation without the handheld terminal is required, the token shall be removed from the
terminal and inserted into the NSMHC slot in the CN cabinet. The safety system will then enter the “idle”
state.
We assume the token is inserted into the handheld terminal and the terminal has just been powered on.
The steps are:
As soon as the initial self-test procedure has finished or the token is sensed (whichever comes last), the
safety led start blinking fast.
At this time the operator shall push and release the Stop pushbutton while leaving the Enabling device
in its rest position. If the safe system was in the “idle” state (double token configuration only) the
pushing of the Stop pushbutton will not affect that state.
When the test on the Stop pushbutton is accomplished, the safety LED will start flashing slowly while
the radio system tries to connect.
If the 2 radio’s antennas are in the allowed distance range, after a few seconds (usually from 5 to 25) a
valid link is established and the safety LED is lit steady on. From now on the system enters “run” state.
If, for any reason, the radio link is not established after timeout elapses (about 30 seconds), the safety
LED start flashing fast again.
To start a new coupling procedure, the token shall be removed from the terminal, the safety led turns
off, token is reinserted into the terminal slot and the test over the stop pushbutton can start again.
Alternatively, instead of removing and reinserting the token, the handheld terminal can be powered off
and then on again.
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In case of double token configuration, also NSMHC module has a timeout that can elapse if coupling is
not accomplished. To restart the coupling procedure then, also the token from the NSMHC module shall
be removed and then reinserted.
3.2.7
Run state
When the handheld terminal and a HCI are coupled, the safety system is up and active. Wireless
connection is also active and user data are transferred from the handheld terminal to the CNC.
The output contacts o n HCI follow the status o f the safety devices on the handheld term inal.
Three timings are related to RUN state:
• tSafety: typical average elapsed time measured from the changing of state of an input safety
device on terminal t o the changing of the related output contact o n HCI;
• tSafetytime­out: maximum t i m e -out allowed before setting the output contacts in SAFE state in
case of lack of information from the handheld term inal.
• tC ouplingtime­out: maximum time-out f o r correctly concluding coupling procedure. Hereunder we
summarize these timing v alues :
Timing
tSafety
tSafetytime­out
tC ouplingtime­out
Value
less than 100 ms
160 ms
50 s
In conclusion it is important to say that i n case tSafetytime­out elapses due to a lack of
wireless signal, the safety system goes from RUN state t o SAFE(r) state, a s it is well described
in figure 3.2. As soon as the wireless connection w i l l be restored t h e safety system will
automatically enter RUN state.
3.2.8
Uncoupling procedure
When the handheld terminal is no longer needed to control a HCI and the related machine,
the uncoupling procedure shall be performed.
Uncoupling procedure can be executed each time the system is in RUN state
Uncoupling procedure is slightly different depending on system configuration.
In both cases uncoupling procedure starts with step 1.
1) TOKEN is removed from the handheld term inal. Its LED starts b l i n k i n g fast.
A time-out c o u n t e r (tUncouplingtime­out) is started.
2s) In Single token configuration, TOKEN is inserted into HCI station
2d) In double token configuration, the second TOKEN is removed from the HCI station
Two different cases may occur:
a) Uncoupling succeeded. Both LEDs on the terminal a n d HCI are OFF. System is in IDLE
state.
b) The 5s tUncouplingtime­out elapsed. HCI goes into SAFE(r) state. Both LEDs blink fast.
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4 Software wireless features
4.1 Installation Notes
Correct positioning of wireless
It is necessary to make sure that the antenna is located far from metal walls, in the central part of the
work area, possibly with the crow flies free between the antenna and the docking station and in general
with the work area.
4.1.1
Check Performance Wireless Antenna
Given that the wireless antenna is correctly placed as indicated in the manual and that the work area is
defined by the device it is possible to check the status of your wireless connection.
You have to use the system variables indicating the signal strength to have information of the full
coverage of the work area.
The procedure must be completed for both the Bluetooth Signal Strength and WIFI Signal Strength.
To verify that the wireless signal coverage is satisfactory in the work area set is necessary to move the
device H4 in all positions of use.
During this procedure, verify that the minimum signal recorded never drops below the threshold
value of 50.
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4.2 Wi-Fi connection using JMobile software
When the Wi-Fi connection is use the following holds:
the BT channel only transfers safety-related data
data exchange between the JMobile runtime in the HMI and the control system use the Wi-Fi
connection.
The Wi-Fi connection require a Wi-Fi access point installed in the control system.
This chapter describes how to set-up the Wi-Fi connection.
4.3 Setting-up Wi-Fi connection
The user must select a proper Wi-Fi access point to estabilish communication with H4 handheld.
The access point must be compatible with wireless communication according to IEEE 802.11g.
When installing the access point you will to assign a proper SSID name to the equipment. This name
will be used by the H4 handheld to uniquely select the access point for wireless connection.
The access point must be connected to the network where the control systems is included.
Please note that JMobile Studio will use the same network connection to configure the H4 handheld for
the application.
4.4 Setting-up Wi-Fi connection in H4
4.4.1
Connecting H4 to the Wi-Fi network
The H4 handheld includes a tool dedicated to setting-up the Wi-Fi connection. Use connection tool to
choose the Wi-Fi network for the connection.
Please note the following:
‒
association in the Wi-Fi network between H4 handheld and the available access point is manual
‒
association must be performed using the System Settings menu in the H4 handheld
‒
association to multiple Wi-Fi access points is possible
‒
H4 handheld will connect to only one access point at the time
‒
if more than one access point has been configured in the list, the H4 handheld may connect to any of
the points in the configuration
‒
diagnostic information on wireless connection is available to JMobile runtime. Presentation to user can
be designed at application level
‒
connection to configured access point, when available, is automatic
‒
Wi-Fi connection may be active also in the case the BT Safety Channel is not connected
Use System Settings to access the Wi-Fi configuration tool as shown in figure.
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Note: In the System Settings menu, the "Network" item will appear as "Not available" when operating
an H4 handheld device because no wired network interface exists.
Use the Wi-Fi configuration tool to Activate/Deactivate and Configure the wireless network in the H4
handheld.
Use WLAN Configurations page to enter Wi-Fi communication properties.
Use Settings page to enter network properties.
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Use Wireless Information page to view connection status and to select the access point for connection.
Use Advanced Wireless Settings page to select the Preferred Networks. In case more networks are
available, the H4 handheld will attempt connection based on the priority specificed by the list Preferred
Networks.
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Use Wireless Networking Log to review information on status of Wi-Fi connection.
4.5 Operation status information
H4 handheld devices running the JMobile HMI runtime include a set of System Variables dedicated to
information on BT and Wi-Fi networks.
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These system variables are added automatically to the HMI project when it is created for H4 handheld
devices.
Note: All system variables for wireless operation are read-only.
The value of a system variable can be copied to other protocols/devices using Data Transfer or using
Javascript.
Note: It is strongly suggested to use relaxed polling periods (Tag Refresh Rate >= 1s) in order not to
waste CPU resources.
Battery Level
Integer value in the range [0..100] indicating the battery charge percentage
(0=battery low, 100=battery fully charged).
Wi-Fi Signal Strength
An integer value in the range [0,100] indicating the level of the current Wi-Fi
network (0=no signal, 100=max signal level).
Selector Position
Position of the selector switch (0..15) in the device.
Emergency
Status of the Emergency Stop button (1 = button pressed).
Bluetooth Coupled
Coupling status between the wireless handheld and remote safety module
(TRUE = coupled).
Token Present
Presence of the Token (TRUE = token inserted).
Token Valid
Status of the Token (TRUE = token inserted and VALID).
Bluetooth Signal
Strength
Bluetooth RSSI level in range [0, 100 = Max quality]
Token ID
TOKEN ID value if token is present/connected, otherwise 0.
0 is returned also in case of error.
The content of these system variables is available to the JMobile programmer. The presentation of
information to the user is under the programmer’s responsibility.
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5 Accessory ordering information
Type:
Part Number:
Description:
Spare battery H4
R-BATT3V74A401
Rechargeable battery replacement for H4
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