ABB HD5-B Series User manual

ABB AB JOKAB SAFETY, Varlabersvägen 11, SE-43439 Kungsbacka
www.abb.com/lowvoltage
Original instructions
HD5-B-xxx
Three position enabling device with safe AS-i slave

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Read and understand this document
Please read and understand this document before using the products.
Please consult your ABB JOKAB SAFETY representative if you have any questions or comments.
LIMITATION OF LIABILITY
ABB JOKAB SAFETY DOES NOT ACCEPT ANY LIABILITY FOR ANY SPECIAL, DIRECT, OR CONSEQUENTIAL DAMAGES, LOSS
OF PROFIT OR ECONOMIC LOSSES RELATING TO THE PRODUCTS, EVEN WHEN SUCH CLAIMS ARE BASED ON A
CONTRACT, WARRANTY, NEGLIGENCE, OR LIABILITY.
The liability of ABB JOKAB SAFETY shall, under no circumstances, exceed the relevant purchase price for the product
that is the subject of the liability claim.
ABB JOKAB SAFETY CANNOT BE MADE RESPONSIBLE FOR CLAIMS REGARDING THE PRODUCT IF THE ANALYSIS
UNDERTAKEN BY ABB JOKAB SAFETY CONFIRMS THAT THE PRODUCTS WERE NOT PROPERLY HANDLED, STORED,
INSTALLED, OR MAINTAINED OR THAT IMPROPER USE, MISUSE, UNAUTHORIZED MODIFICATIONS, OR REPAIRS WERE
CARRIED OUT.
USABILITY EVALUATION
ABB JOKAB SAFETY does not accept any liability regarding compliance with standards, provisions, or regulations that
arise when the products are used in conjunction with the applications of the customer or that apply to use of the
product. If the customer requests, ABB JOKAB SAFETY shall provide applicable third-party certifications, giving rise to
benchmarks and application restrictions on use in relation to the use of the products. This information alone is not
enough to fully determine the suitability of the product when combined with the end product, the machine, the system,
or other applications.
Several examples of applications that require special attention are listed below. These examples are not intended to be
an exhaustive list of all the possible applications of the products and they should not be understood as meaning that
products are suitable for the potential uses specified:
Use outside, use where there is the possibility of chemical exposure or electrical interference, or use under conditions
not specified in this document.
Nuclear power control systems, incineration plants, railway installations, aviation systems, medical technology, gaming
machines, vehicles, and industrial plants are subject to special industry or official regulations.
Facilities, machines, and equipment that may pose a danger to life or property.
Please observe and follow all prohibitions on the use of the products.
NEVER USE THESE PRODUCTS IN APPLICATIONS THAT CAUSE A DANGER TO LIFE OR PROPERTY UNLESS THE SYSTEM
AS A WHOLE HAS BEEN INSURED AGAINST THESE DANGERS AND THE ABB JOKAB SAFETY PRODUCT HAS BEEN
PROPERLY DIMENSIONED AND INSTALLED IN RELATION TO THE SYSTEM AS A WHOLE.
PERFORMANCE DATA
Due to the fact that efforts have been made to ensure the accuracy of the information contained in this manual,
ABB JOKAB SAFETY assumes no responsibility for errors or omissions and reserves the right to make changes and
improvements without giving notice.
The performance data contained in this document is to provide the user with guidance when assessing usability and
does not constitute a warranty-related assurance. The data may relate to test results from ABB JOKAB SAFETY. The user
must compare this with the actual situation in which the application is taking place. The current performance is covered
by the ABB JOKAB SAFETY warranty and limitations of liability.

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Table of contents
LIMITATION OF LIABILITY............................................................................................................................................................2
USABILITY EVALUATION .............................................................................................................................................................2
PERFORMANCE DATA.................................................................................................................................................................2
1. INTRODUCTION ..............................................................................................................................................................5
PURPOSE .......................................................................................................................................................................................5
TARGET GROUP...............................................................................................................................................................................5
PREREQUISITES ...............................................................................................................................................................................5
SPECIAL INSTRUCTIONS .....................................................................................................................................................................5
2. OVERVIEW ...................................................................................................................................................................6
PRODUCT DESCRIPTION...............................................................................................................................................................6
APPLICATION AREA ..........................................................................................................................................................................6
SAFETY REGULATIONS.......................................................................................................................................................................7
3. FUNCTIONAL DESCRIPTION ............................................................................................................................................8
ENABLING BUTTON ..........................................................................................................................................................................8
EMERGENCY STOP BUTTON (OPTIONAL) ...............................................................................................................................................9
ADDITIONAL BUTTON NO.1 ............................................................................................................................................................11
ADDITIONAL BUTTONS NO.3AND NO.4(OPTIONAL)..........................................................................................................................11
SIGNAL LED .................................................................................................................................................................................12
HOME POSITION DETECTOR .............................................................................................................................................................12
ASSIST LIGHT (FLASHLIGHT)(OPTIONAL).............................................................................................................................................12
STATUS LED FOR AS-I BUS .............................................................................................................................................................13
CONNECTION WITH AS-I-NETWORK..................................................................................................................................................13
Pluggable..............................................................................................................................................................................13
4. INSTALLATION .............................................................................................................................................................. 14
GENERAL .....................................................................................................................................................................................14
INSTALLING THE HOLDER .................................................................................................................................................................14
5. COMMISSIONING ......................................................................................................................................................... 15
FUNCTIONAL TEST .........................................................................................................................................................................15
6. REVIEW, MAINTENANCE AND CLEANING ..................................................................................................................... 16
PRODUCT DATA.............................................................................................................................................................................16
7. DISPOSAL ..................................................................................................................................................................... 16
8. OPERATION .................................................................................................................................................................. 17
THREE-POSITION ENABLING SWITCH ..................................................................................................................................................17
EMERGENCY STOP BUTTON..............................................................................................................................................................17
ADDITIONAL BUTTONS 1TO 4..........................................................................................................................................................18
SIGNAL LEDS................................................................................................................................................................................18
HOME POSITION DETECTOR .............................................................................................................................................................18
ASSIST LIGHT (FLASHLIGHT) .............................................................................................................................................................18
9. MODEL OVERVIEW ....................................................................................................................................................... 19
STANDARD ABB VERSIONS ..............................................................................................................................................................19

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INFORMATION ON POSITIONS...........................................................................................................................................................20
10. ACCESSORIES ............................................................................................................................................................ 21
ACTIVE HOLDER,“HD5-M-001”.....................................................................................................................................................21
PASSIVE HOLDER,“HD5-M-002“....................................................................................................................................................21
11. TECHNICAL DATA...................................................................................................................................................... 22
AS-I DATA....................................................................................................................................................................................25
ABB VERSIONS HD5-B-XXX ............................................................................................................................................................25
12. DIMENSIONS ............................................................................................................................................................ 26
3-POSITION ENABLING DEVICE..........................................................................................................................................................26
DEVICE SPECIFIED HOLDER ..............................................................................................................................................................26
13. EC DECLARATION OF CONFORMITY .......................................................................................................................... 27

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1. INTRODUCTION
Purpose
The purpose of this operating manual is to describe the HD5-B-xxx three position enabling device
and to provide the information necessary for planning, assembly, maintenance, and operation.
Target group
This document is aimed at planners, as well as specialist staff working in assembly and maintenance.
In addition, this operating manual is aimed at users who have received training and authorization, from the
operator of the facility, in relation to these devices, how to handle them, and the hazards they pose.
Prerequisites
It is assumed that the reader of this document has the following knowledge:
•Basic knowledge of ABB JOKAB SAFETY products
•Knowledge of the AS-i Bus system
•Knowledge of safety products
•Knowledge of safety control devices with functions relevant to safety
•Knowledge of related facilities
Special instructions
Please pay attention to the following special instructions in this document:
Attention!
Danger of personal injury!
Failure to follow instructions or work sequences properly may result in personal
injury.
Caution
Risk of damage to the equipment!
Failure to follow instructions or work sequences properly may result in damage to
the equipment.
Note
Notes are used to provide important or explanatory information.

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2. OVERVIEW
Product description
The “HD5-B-xxx” is a three position enabling device with integrated AS-i technology. It operates in standard-
addressing mode, in accordance with the V.3.0 specification. (See “AS-i data” section)
The “HD5-B-xxx” enabling device is designed to be connected to the AS-i Safety-Bus and is available in a
range of configurations, which can be equipped with a maximum of two safe and one unsafe slaves.
There are two three-position enabling switches, which are both operated using one button providing a high
level of safety. The contacts are only closed in the middle position and are opened both when the button is
released and when it is pressed down further into the third and final position. Closing the contacts always
requires the contacts to be released. (See Functional description)
The signals from the three-position enabling switches and the emergency stop button (if the device is
equipped with this) are detected by the integrated electronics and transmitted to the AS-i safety monitor
via the safe slave.
Signals used to provide haptic or visual feedback are transmitted from additional integrated command
buttons and sensors to the AS-i logic and from the AS-i logic to the enabling device via a third, unsafe slave.
The enabling device is connected to the AS-i Bus in the usual way using a fixed spiral-cable or via a M12
connector built into the device.
If you have any questions regarding the existing configurations or the possibilities for a configuration
adapted to your needs, please contact ABB JOKAB SAFETY.
Application area
The enabling device is used in machines and facilities to provide protection to people, who, because of their
work (e.g. maintenance or installation work), move through danger zones in which other forms of
protection for users is neither possible nor practical.
Performing a risk assessment is essential for choosing protective devices. This should be done by the
manufacturer of the machine.
Caution!
Please note that failure to comply with the provisions and restrictions contained in this operating manual,
(e.g. in relation to the duty cycle, temperature etc.), may lead to loss of functionality of the enabling device
and to unintended machine stoppage.
If a shutdown has occurred, the enabling device will become functional again once the values drop below
the limits. However, there may still be damage to the electronics and a reduction in service life.

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Safety regulations
Attention!
Read the manual carefully and in full before using the device.
The enabling device may only be installed by specialist personnel, in compliance with regulations for AS-i
networks, the applicable regulations and standards, and the enclosed data sheet.
Failure to comply with the instructions, or a use that is not in accordance with the specified instructions, as
well as the improper installation or operation of the device, may adversely affect the safety of the user and
the facility.
A safety logic unit, configured in accordance with the specified use of the product, is required to monitor
(evaluate the signals) of the enabling device, allowing the product to be used the specified way.
All liability is excluded if the instructions are not complied with, especially in cases of interference with or
modifications to the product.

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3. Functional description
Enabling button
The enabling button works in accordance with the three-position principle. This allows for
operators to be protected if the button is released or fully pressed down (e.g. if cramping).
An enabling button with three positions transmits signals, which:
•When activated, allow the machine or equipment to be initiated using a separate start
control and
•When deactivated, initiate a stop function which prevents the machine or equipment
from starting
Two three-position enabling switches are operated and analyzed redundantly to create a two-channel
architecture.
•The symbol for a three-position enabling switch identifies the three positions
(OFF, ON, OFF) using O and I, the movement direction from left to right, as well as the
possible ways to move the switch.
•An important feature of the three-position enabling switch is that when shifting back
from position 3, the ON position is not actuated, i.e. the contacts remain open.
The three positions function as follows:
•Position 1 (O): OFF mode (enabling button has not been pressed, contact is open)
•Position 2 ( I ): ON mode
(Enabling button has been pressed as far as the release position, contact is closed)
•Position 3 (O): OFF mode (enabling button has been fully pressed down, contact is open).
When released, the three-position enabling switches always go back to position 1, regardless of whether
they were in position 2 or 3.
Notice on operation
To ensure a correct and safe operation, the enabling button must be pressed in the middle
with two fingers or three fingers

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Emergency stop button (optional)
The optional built-in emergency stop button is providing an emergency stop function for
stopping hazardous functions and removing power to them.
The emergency stop button has two forcibly-guided normally closed contacts.
Note on safe actuation!
To allow for the emergency stop button to operate safely, we recommend to use and assembly our holders,
designed especially for this enabling device.
Detailed description of this is to be found in the accessories section.
Attention!
Particular caution should be exercised in relation to enabling devices that are connected, as standard, using
a connector. Be aware of the following items:
•The correct function of the emergency stop must be check monthly!
•The emergency stop function must always be available and functional, and should have priority over all
other functions and operations in all operating modes of the machine without affecting any facilities
which are designed to release trapped persons.
•No start command (whether intentional, unintentional or unexpected) should be able to affect working
processes that were stopped by initiating the emergency stop function until the emergency stop
function has been reset manually.
•If it is possible to remove emergency stop buttons (e.g. portable programming devices) or shut down
sections of a machine, it must be ensured that operational and non-operational emergency stop
buttons are not mixed up.

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Feedback on the functioning of the emergency stop button
•Feedback LED integrated into the housing of the enabling device below the emergency
stop button
oRed LED row, can be controlled in a user-defined way via the AS-i Bus.
oGreen LED row, can be activated via the AS-i Bus. The function of the green LED
depending of activation, see in the table below
LED row red
controlled via AS-I Bus
function LED green
controlled via AS-I Bus
LED row green
Off
not activated
Off
On
not activated
Off
Off
activated
On
On
activated
Off
Attention!
The controls for the feedback LED are independent from the emergency stop button function.
The programmer is solely responsible for their signaling function.
ABB JOKAB Safety does not accept any liability for damages of any kind caused by signaling that is not
logical, and the resulting misjudgments and errors by users.

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Additional button No. 1
This button is built-in as standard and is located above the enabling button in the front area.
Its optimized ergonomic shape, as well as the tactile button beneath it, ensures it can be
operated easily and safely. This is usually done using the index finger.
Note on actuation!
The button must be actuated by pressing it down vertically, to an angle of between 0° and 15°. If the angle is
exceeded when actuating the switch, there is a possibility that the switch contact may be damaged, and the
switching cycles specified in the technical data will not be achieved.
Additional buttons No. 3 and No. 4 (optional)
These buttons are installed on the grey housing. They can be controlled in a user-defined
way via the AS-i Bus.
Additional labelling of the buttons is an option for custom configurations.

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Signal LED
The high-intensity LEDs are installed in the housing in such a way that they can easily be
perceived even in the normal ambient light in the workplace.
The controls are user-defined and can be controlled in a user-defined way via the AS-i
Bus.
Home position detector
A sensor, which can be implemented in the housing of the enabling device can recognize when the enabling
device has been hung-up in the specially-designed holder. (This holder is available as an accessory).
The signal from the sensor is transmitted via the AS-i Bus.
Attention!
This signal is not failsafe and shall never be used for safety purposes.
Assist light (flashlight) (optional)
This function is an optional function and acts as an assist light to illuminate work spaces for
short periods in which the ambient light is not sufficient.
The controls are user-defined and can be controlled in a user-defined way via the AS-i Bus.
When using these, you must comply with the following:
Notice on duty cycle
•On time = 60%, max. 15 min., ambient temperature ≤35°C
•On time = 40%, max. 10 min., ambient temperature > 35°C
•Calculation
oOn-time percentage = (on time/on time + off time) x 100
oOn time = (D%/100- D%) x off time
oOff time = (100-D%/D%) x duty cycle
Caution! Increased heat build-up
Compliance with the requirements is absolutely vital, due to the additional heat generated by the assist
light!
If the specified limits are exceeded, the possibility that the AS-i electronics may be damaged cannot be
ruled out.
Attention! Hazards arising from glare
Avoid looking directly into the lens of the assist light. Looking directly into the lens, and the glare effect
which may result from this, can sometimes impair vision, which may cause irritation, adverse effects, or
even accidents.

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Status LED for AS-i Bus
One green and one red LED will inform you, about the status of the slave on the
AS-i Bus.
The LEDs are positioned in a way that means they are not directly visible when the
enabling device is placed in the holder intended for this purpose.
They are positioned in this way so that these signals are not confused with those
from the signal LEDs.
AS-i (green)
Fault (red)
Description
Off
Off
No power supply to AS-i
ON
Off
Normal operation
Off
ON
AS-i communication disrupted
Flashing
ON
No data exchange because address = 0
alternating flashing
alternating flashing
Peripheral error
Off
flashing
Recognizes double addresses (ABB version only)
Connection with AS-i-Network
Connecting the enabling device with integrated AS-i technology, as described in the data sheet enclosed
with the product (and available from ABB under the following link).
Pluggable
In this connector version, an M12 connector with A-coding is built into the base of the enabling device. The
benefit of this version is that it is easy to switch the enabling device, e.g. during maintenance work, without
any intervention in the electrical installation.
Attention!
Please note, if an emergency stop button is implemented in the enabling device and the connection
becomes disconnected, additional measures can be required, as described in
Section 3 “Functional description, emergency stop button”.
Note on the connection cable!
When connecting the version with a connector, always use cables without additional shielding in order to
prevent interference.
The accessories section outlines how to obtain cables that can be used safely. These are also available on
request.
If the enabling device is connected using a spiral cable and more than three HD5-B-xxx are used on an AS-i
cable, you must reduce the AS-i cable by 12m per device.

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4. Installation
General
The connection of the enabling device to the machine must only be carried out by specialist personnel who
are qualified in this field, in accordance with the regulations for AS-i networks, the applicable guidelines and
standards, as well as the data sheet enclosed with the product.
Attention should be paid to existing or preset addressing (delivery state) of the enabling device. If
necessary, it should be adjusted before integrating it into the AS-i network!
The connection to the AS-i network uses a two-core connection cable.
A suitable contact according to the connection methods to the AS-i network should be
established
It is recommended to follow the procedure shown in the picture on the right, using an
M12 connector.
Normally, the M12 connector should be attached to Pin1 (AS-i +) and Pin 3 (AS-i -).
Please ensure
in accordance to the national electrical codes, the separate laying of cable that serve the
power supply (control and main circuits) and the cable that serve to transmit control
signals!
The connection cable of this device must be laid in the area for control signals!
All functions, especially those relevant to safety, shall be checked and tested to ensure
they are working properly before commissioning takes place.
If this is not done, the possible property damage or personal injury can occur!
Installing the holder
At mounting the specific holder “HD5-M-xxx” please ensure that the enabling device is hang up completely
in the holder.
The position should be selected in view of ergonomic and safety relevant aspects.
More Information in Section 10 “Accessories”

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5. Commissioning
The enabling device should only be commissioned by specialist personnel who have been trained to work
with the machine.
It is always important to make sure that the operation of the device is not tampered with and ensure the
intended use (see scope of application) is complied with.
Attention!
Other protective measures must be taken in order to protect other people in the same or adjacent
hazardous area.
Functional Test
At first commissioning after installation, a functional test based on the application case must be carried out
in accordance with current guidelines for the case of application and the relevant harmonized standards.

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6. Review, maintenance and cleaning
The enabling device itself does not require any maintenance in addition to regular functional testing and
cleaning.
The emergency stop safety functions must to check monthly. All other safety functions and mechanisms
must be tested regularly, at least once a year, to confirm that all of the safety functions are working as they
should.
Depending on the application, machine manufacturers may stipulate requirements for shorter maintenance
intervals. If this is the case, such requirements should be given priority.
As a general rule, it is recommended to document all maintenance work.
To ensure that command buttons continue to function in the long term, it is advisable to regularly wash
them with a soft cloth and a standard (soap-based) multi-purpose cleaner.
Caution!
The degree of protection for the enabling device specified in the data sheet should be complied with during
cleaning.
The operating surfaces are made out of soft, elastic and very thin material designed to be hard wearing.
Using abrasive cleaning agents or sharp-edged tools can weaken or penetrate the surface, which results in
the protection class being lost in a relatively short space of time. (Dirt and moisture may penetrate the
housing)
The use of cleaning agents containing solvents should be avoided. This is not only to protect the surfaces,
but also to protect the health of employees.
Attention!
If the device doesn´t have functionality or has become damaged, the device must immediately be put out of
service. Please get in touch with your regular contact for maintenance work or your nearest
ABB JOKAB SAFETY customer service or dealer. Do not attempt to repair the product yourself. Any attempt
to interfere with the device will result in a loss of warranty. There is also a possibility of the product
becoming damaged, affecting its safety and how it functions, which may lead to serious injury.
Product data
If you have any queries regarding the product or ordering spare parts, you can find the
item number right on the base of the enabling device. You can also find further data in
the QR-code, which can be read using a smartphone with a QR-code scanner app.
7. Disposal
We kindly ask you to think about the environment to recycle the device as
electrical waste once it reaches the end of its service life.
Please comply with currently applicable disposal requirements.

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8. Operation
The following points should provide you with examples of applications as well as the behavior of control
and signaling devices.
User-defined statuses that are provided from machine/equipment manufacturer, must be documented.
These are a part of this “original operating manual for HD5-B-xxx”.
Attention!
You can find further explanations and warnings relating to the below functions in
Section 3. “Functional description”
Three-position enabling switch
Position 1 - “idle status” or “stop status”:
oSwitch in off position, i.e. not pressed down
oProcess initiation not permitted
oUntil the button is put into the
middle position (position 2 “operating status”)
Position 2 - “operating status”:
oButton pressed down, moved into middle position
oSignal sent to the controls, start process
oThe process stops when the button is put into its end position
(position 3, “stop status”)
Position 3 - “Stop status”:
oButton has been moved into the third and final position
oSignal sent to the controls, stop process
oThe button must be put into “idle mode” (position 1) before it can be
put back into “operating mode” (position 2).
Emergency stop button
The emergency stop button shall initiate an emergency stop function, thereby removing energy to the
hazardous functions in the event of emergency.
The holders specifically developed for this enabling device allow for the emergency stop button to be
pressed when the enabling device is placed there.
The feedback LED integrated into the actuator cap of the emergency stop button or the enabling button
housing also offers a range of different possibilities for signaling as part of its functions.
Attention!
You can find further explanations and warnings relating to the below functions in
Section 3. “Functional description”
1 2 3

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Additional buttons 1 to 4
The functionality of the additional buttons is user-defined and can be used, for example, for a start/stop
function for individual movements etc.
Signal LEDs
The controls for the LEDs can be controlled in a user-defined way via the AS-i Bus.
They usually signal when the process is approved and whether the enabling button is ready.
Home position detector
This function, in conjunction with the HD5-M-001 holder, provides information as to whether the enabling
device is in its holder.
Assist light (flashlight)
This can be turned on in a way that is defined by the user, so that the work areas can light up for a short,
selected length of time.
Caution!
Please pay attention to the instructions in section 3. “Functional description”

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9. Model overview
HD5-B-xxx enabling device with integrated AS-i technology are described below.
It may be possible to produce additional custom solutions after checking feasibility and gaining approval
from ABB JOKAB SAFETY. If interested please get in touch with ABB JOKAB SAFETY.
Standard ABB versions
•Type name: HD5-B-xxx
•Item number: 2TLA920502Rxxxx
Position
number
Function
Additional information
1
Enabling button
2
Emergency stop button (optional)
Feedback LED, integrated in the housing, placed
beneath the emergency stop button
3
Additional button 1
4
---------------------------------------------
5
Additional button 3 (optional)
6
Additional button 4 (optional)
7
Red signal LED
8
Green signal LED
9
Home position detector
detection only possible with the HD5-M-001 holder
10
---------------------------------------------
11
Assist light (flashlight) (optional)
12
---------------------------------------------
13
Pluggable connection
M12 connector

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No. 1,
enabling button
No. 2,
emergency stop button
Feedback LED
implemented in case,
translucent
Information on positions
No. 7, red signal LED
No.3,
additional button 1
No. 5,
additional button 3
No. 11, Assist light
(flashlight)
No.6,
additional button 4
No. 13, connection
No. 8, green signal LED
integrated into housing
No. 9, home position sensor
No. 10, ------------------------
No. 12, ------------------------