ABB HD5-S User manual

Original instructions
HD5-S
Three-position device

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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.
Suitability for use
ABB JOKAB SAFETY 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 JOKAB SAFETY 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 JOKAB SAFETY PRODUCT IS PROPERLY RATED AND INSTALLED FOR THE INTENDED USE
WITHIN THE OVERALL EQUIPMENT OR SYSTEM.

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Table of contents
1. INTRODUCTION .............................................................................................................................................................. 5
PURPOSE ....................................................................................................................................................................................... 5
INTENDED AUDIENCE ........................................................................................................................................................................ 5
READING PREREQUISITES ................................................................................................................................................................... 5
WARNING SYMBOLS ......................................................................................................................................................................... 5
2. SAFETY ........................................................................................................................................................................... 6
INTENDED USE ................................................................................................................................................................................ 6
CORRECT USE ................................................................................................................................................................................. 6
FORESEEABLE MISUSE ....................................................................................................................................................................... 6
APPROVED PERSON .......................................................................................................................................................................... 7
SAFETY PRECAUTIONS ....................................................................................................................................................................... 7
GENERAL SAFETY INFORMATION ......................................................................................................................................................... 8
DISPOSAL ....................................................................................................................................................................................... 8
3. PRODUCT DESCRIPTION ................................................................................................................................................. 9
HD5 ............................................................................................................................................................................................. 9
PRODUCT RANGE ............................................................................................................................................................................. 9
4. FUNCTION DESCRIPTIONS ............................................................................................................................................ 11
THREE-POSITION BUTTON ............................................................................................................................................................... 11
EMERGENCY STOP BUTTON .............................................................................................................................................................. 12
EMERGENCY STOP LED ................................................................................................................................................................... 12
FRONT BUTTON ............................................................................................................................................................................. 13
TOP BUTTONS ............................................................................................................................................................................... 13
HOME POSITION SENSOR ................................................................................................................................................................. 14
MOTION SENSOR ........................................................................................................................................................................... 14
FLASHLIGHT .................................................................................................................................................................................. 15
5. CONNECTIONS HD5 ...................................................................................................................................................... 16
HD5-S-102 ................................................................................................................................................................................ 16
HD5-S-104 ................................................................................................................................................................................ 16
HD5-S-111 ................................................................................................................................................................................ 16
6. PERFORMANCE LEVEL (PL) CALCULATION..................................................................................................................... 17
RESPONSE TIME ............................................................................................................................................................................ 17
SAFETY FUNCTION – THREE-POSITION DEVICE ...................................................................................................................................... 17
EXAMPLE ACCORDING TO EN 62061 ................................................................................................................................................ 17
SAFETY FUNCTION – EMERGENCY STOP .............................................................................................................................................. 18
CONNECTION EXAMPLE TO A SAFETY CONTROLLER ................................................................................................................................ 18
7. INSTALLATION .............................................................................................................................................................. 19
8. MAINTENANCE ............................................................................................................................................................. 20
9. MODEL OVERVIEW ....................................................................................................................................................... 21
HD5 .......................................................................................................................................................................................... 21
HD5 ACCESSORIES .................................................................................................................................................................... 21

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10. TECHNICAL DATA ...................................................................................................................................................... 22
11. DIMENSIONS ............................................................................................................................................................ 24
THREE POSITION DEVICE HD5-S-XXX ................................................................................................................................................. 24
HOLDER HD5-M-00X ................................................................................................................................................................... 24
12. EC DECLARATION OF CONFORMITY .......................................................................................................................... 25

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1. INTRODUCTION
Purpose
The purpose of this document is to describe the functions and to provide instructions for installation,
operation, maintenance and troubleshooting of the three-position device.
Intended audience
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.
Reading prerequisites
It is assumed that the reader of this document has the following knowledge:

Basic knowledge of ABB JOKAB SAFETY products

Knowledge of safety products

Knowledge of safety control devices with functions relevant to safety

Knowledge of related facilities
Warning symbols
The following warning symbols are used 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 is a three-position device designed for use in hazardous areas where alternative protective devices are
not possible or practical.
The device must be connected to a suitable safety controller with inputs for dual-channels and short circuit
protection. 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.
• 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.
• Repair and exchange of parts of the three-position device is not permitted.
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.

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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 Jokab Safety, www.abb.com/jokabsafety. 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.
Disposal
The three-position device shall be disposed in accordance with WEEE directive, 2012/19/EU.

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3. PRODUCT DESCRIPTION
HD5
HD5 is a three-position device designed for use in hazardous areas where alternative protective devices are
not possible or practical.
The device must be connected to a suitable safety controller with inputs for dual-channels and short circuit
protection. 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.
Product range
The HD5-S product range includes the following models.
Function HD5-S-102 HD5-S-104 HD5-S-111
1 Three-position button Yes Yes Yes
2 Emergency stop button No No Yes
3 Emergency stop button status LED No No Yes
4 Front button [S4] Yes Yes Yes
5 Top button 1 [S5] No Yes Yes
6 Top button 2 [S6] No Yes Yes
7 LEDs red and green Yes Yes Yes
8 Flashlight No No Yes
9 Connector M23-12 pin M23-12 pin M23-19 pin
10 Home position sensor No No Yes
11 Motion sensor No No Yes

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