ABB HD5-B-101 User manual

Original instructions
HD5-B
Three position enabling device with safe AS-i slave

2
Read and understand this document
Please read and understand this document before using the products. Please consult your ABB
Electrification Sweden AB representative if you have any questions or comments.
Suitability for use
ABB Electrification Sweden AB shall not be responsible for conformity with any standards, codes, or
regulations that apply to the
combination of products in the customer’s application or use of the product. At the customer’s request,
ABB Electrification Sweden AB will provide applicable third-party certification documents identifying ratings
and limitations of use that apply to the products. This information by itself is not enough for a complete
determination of the suitability of the products in combination with the end product, machine, system, or
other application or use.
The following are some examples of applications for which attention must be given. This is not intended to
be an exhaustive list of all possible uses of the products, nor is it intended to imply that the uses listed may
be suitable for the products:
• Outdoor use uses involving potential chemical contamination or electrical interference, or conditions or
uses not described in this document.
• Nuclear energy control systems, combustion systems, railroad systems, aviation systems, medical
equipment, amusement machines, vehicles, and installations subject to separate industry or government
regulations.
• Systems, machines, and equipment that could present a risk to life or property.
Please know and observe all prohibitions of use applicable to the products.
NEVER USE THE PRODUCTS FOR AN APPLICATION INVOLVING SERIOUS RISK TO LIFE OR PROPERTY
WITHOUT ENSURING THAT THE SYSTEM AS A WHOLE HAS BEEN DESIGNED TO ADDRESS THE RISKS, AND
THAT THE ABB Electrification Sweden AB IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE
WITHIN THE OVERALL EQUIPMENT OR SYSTEM.

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Table of contents
1. INTRODUCTION .............................................................................................................................................................. 4
PURPOSE ....................................................................................................................................................................................... 4
TARGET GROUP ............................................................................................................................................................................... 4
PREREQUISITES ............................................................................................................................................................................... 4
SPECIAL INSTRUCTIONS ..................................................................................................................................................................... 4
2. SAFETY ........................................................................................................................................................................... 5
INTENDED USE ................................................................................................................................................................................ 5
CORRECT USE ................................................................................................................................................................................. 5
FORESEEABLE MISUSE ................................................................................................................................................................. 5
APPROVED PERSON .......................................................................................................................................................................... 6
SAFETY PRECAUTIONS ....................................................................................................................................................................... 6
GENERAL SAFETY INFORMATION ......................................................................................................................................................... 6
DISPOSAL ....................................................................................................................................................................................... 7
3. PRODUCT DESCRIPTION ................................................................................................................................................. 8
HD5-B-XXX ................................................................................................................................................................................... 8
PRODUCT RANGE ............................................................................................................................................................................. 8
4. FUNCTION DESCRIPTIONS ............................................................................................................................................ 10
THREE-POSITION BUTTON ............................................................................................................................................................... 10
EMERGENCY STOP BUTTON .............................................................................................................................................................. 11
EMERGENCY STOP LED ................................................................................................................................................................... 12
FRONT BUTTON ............................................................................................................................................................................. 13
TOP BUTTONS ............................................................................................................................................................................... 13
SIGNAL LED ................................................................................................................................................................................. 14
HOME POSITION SENSOR ................................................................................................................................................................. 14
ASSIST LIGHT ................................................................................................................................................................................ 14
STATUS LED FOR AS-I BUS ............................................................................................................................................................. 15
5. CONNECTIONS HD5-B-XXX ........................................................................................................................................... 16
6. INSTALLATION .............................................................................................................................................................. 17
7. MAINTENANCE ............................................................................................................................................................. 19
8. MODEL OVERVIEW, ACCESSORIES ................................................................................................................................ 20
HD5-B-XXX .............................................................................................................................................................................. 20
HD5 ACCESSORIES .................................................................................................................................................................... 21
9. TECHNICAL DATA .......................................................................................................................................................... 22
AS-I DATA .................................................................................................................................................................................... 25
ABB VERSIONS HD5-B-XXX ............................................................................................................................................................ 25
10. DIMENSIONS ............................................................................................................................................................ 26
THREE POSITION DEVICE HD5-S-XXX ................................................................................................................................................. 26
HOLDER HD5-M-00X ................................................................................................................................................................... 26
11. 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 Electrification Sweden AB 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. SAFETY
Intended use
HD5-B-xxx is a three-position enabling device with integrated AS-i technology, according to the AS-i
specification V 3.0, it is operated in the standard addressing mode. (see chapter "AS-i data")
The device is intended for connection to an AS-i safety bus and connected to a suitable safety controller.
Additionally, the machinery or the equipment causing the potential danger needs to be put in jog position
or otherwise restricted in movement, speed, temperature, etc.
The operator pushes the large black button to a middle position in order to allow a movement. In case of
danger, the operator will either release the button or squeeze it to its bottom position and the machine will
stop. Some models offer additional top and front buttons to control a non-safe signal, e.g. move forward
and/or backward.
Correct use
The protective function of the safety device is only safe if the safety controller is correctly connected and
configured.
Obey the following conditions to prevent misuse and cause danger:
 Make sure that these instructions are included together with the documentation of the system to which
the protective device is attached to.
 Make sure that these instructions always are available for the operators.
 The three-position device must only be used after it has been selected refereed to related instructions,
relevant standards, rules and regulations for labor protection and safety at work, and when installation,
connection, check and start-up are done by an approved person.
 The three-position device must be connected and started according to its specifications, for example
the technical data.
 The three-position device must be connected so that its safety related capacity meets or exceed the
performance level (PL) or safety integrity level (SIL) that has been estimated in the risk analysis.
 The three-position device must not be modified. If the design or the functions are changed the
protective function can be damaged and the warranty of the three-position device is not applicable.
 Repair and exchange of parts of the three-position device is not permitted.
 The three-position device must be tested regularly by an approved person.
 The three-position device must be exchanged within a mission time 20 years, due to requirement in EN
ISO 13849-1. Depending on the use (calculation of T10D, se 6. Performance Level (PL) Calculation), the
three-position device might have to be exchanged within a shorter time than 20 years.
Foreseeable misuse
 Other use than defined as correct use and foreseeable misuse, or which is beyond that use, is
considered as incorrect use.
 The three-position device is not by itself a complete protective device.
 The three-position device is not intended for use in explosive or easily flammable adjacent air.

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Approved person
 An approved person must have ...
 A suitable technical education.
 Knowledge about rules and regulations for occupational safety, safety at work, safety technology and
how to estimate the safety of the machine.
 Received instructions from the person that is responsible for the installation and operation of the three-
position device and the device/machine which it is connected to.
 See Chapter Intended use and Chapter Correct use for further information
Safety precautions
The following safety precautions must be followed during installation, operation, maintenance and
troubleshooting.
General safety information
Attention!
 Carefully read through this entire manual before using the product.
 Always respect the documented minimum or maximum values of the product.
 For installation and prescribed use of the product, the special notes in these instructions must be
carefully observed and the technical standards relevant to this product must be considered.
 This product must be installed by a trained electrician following applicable safety regulations, standards
and the machine directive.
 Failure to comply with these instructions, operation that is not in accordance with the use prescribed in
these instructions, improper installation or handling of the device can affect the safety of people and
the plant.
 In case of failure to comply with these instructions or the applicable standards, especially when
tampering with and/or modifying the product, liability is excluded.
 The safety functions of the product must be tested before the system is put in operation.
 The safety functions of the product must be tested after installation or replacement of components or
cables.
 The safety functions and the mechanics of the product must be tested regularly to confirm that all the
safety functions are working properly.
 In case of breakdown or damage to the product, contact ABB Electrification Sweden AB. Do not try to
repair the product. It might accidentally cause permanent damage, impairing the safety of the product
and in turn lead to serious personnel injuries.

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Caution!
Please note, if you in non-compliance with the specifications and restrictions of these operating
instructions (e.g. duty cycle, temperature, etc.) can lead to the functionality of the enabling device failing
and unintended machine stop.
After a shutdown in according to this, the function of the 3-position enabling device will be restored, if the
values below the limits. But a probable damage to the electronics and a reduction of service life can´t be
ruled out.
Disposal
The three-position device shall be disposed in accordance with WEEE directive, 2012/19/EU.

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3. PRODUCT DESCRIPTION
HD5-B-xxx
HD5 is a three-position device designed for use in hazardous areas where alternative protective devices are
not possible or practical.
The “HD5-B-xxx” enabling device is designed to be connected to a Safety controller via AS-i Safety-Bus.
Additionally, the machinery or the equipment causing the potential danger needs to be put in jog position
or otherwise restricted in movement, speed, temperature, etc.
The operator pushes the larger black button to a middle position in order to allow a movement. In case of
danger, the operator will either release the button or squeeze it to its bottom position and the machine will
stop. Some models offer additional top and front buttons to control a non-safe signal, e.g. move forward
and/or backward.
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.
Product range
The HD5-B product range includes the following models.
Function HD5-B-101 HD5-B-102
1 Three-position button Yes Yes
2 Emergency stop button Yes No
3 Emergency stop button status LED Yes No
4 Front button [S4] Yes Yes
5 Top button [S5] Yes Yes
6 Top button [S6] Yes Yes
7 LEDs red and green Yes Yes
8 Assist Light Yes Yes
9 Connector M12- 5 pin M12- 5 pin
10 Home position sensor Yes Yes
11 Motion sensor No No
12 -------------------- ----------- -----------
13 AS-I Status LED Yes Yes
* position-no., regarding to the picture on next side

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9
.
Connector
5
.
TOP button [5]
6
.
TOP button [6]
7. LEDs
“
r
ed
“
and “green
“
2
.
Emergency stop
button
3.
E
mergency stop button
status LED
4.
Front button [S4]
1.
Three
-
position button
8
.
Assist Light
Integrated in housing:
10. Home position sensor
11. Motion sensor
12. ----------
1
3
.
AS
-
i Status LED

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4. FUNCTION DESCRIPTIONS
Three-position button
The three-position button provides signals, which:

When activated, allow the machine or equipment to be activated using a separate
start control signal.
 When deactivated, initiate a stop function which prevents the machine or
equipment from starting.
Two three-position switches are used and controlled simultaneously to create a two-
channel architecture.
An important feature of the three-position button is that when it is released from
position 3, the ON position is never reached, i.e. the contacts remain open. The three-position button always
go back to position 1 when released.
The three-positions functionality:
Position 1 (O): OFF mode the button is not pressed, contacts are open.
Position 2 ( I ): ON mode the button is pressed in the middle position, contacts are closed
Position 3 (O): OFF mode the button is fully pressed to bottom position, contacts are open.
Note on operation
To ensure a correct and safe operation, the three-position
button must be pressed to the middle position with two or
three fingers.
1 2 3