The HD5-B-901 is a three-position enabling device with integrated AS-i technology, designed for safety-critical applications in industrial environments. It operates in standard-addressing mode, in accordance with the V3.0 specification for AS-i data. This device is part of the ABB JOKAB SAFETY product line, manufactured by ABB AB in Kungsbacka, Sweden.
Function Description
The HD5-B-901 serves as a handheld enabling device, providing a means for operators to safely interact with machinery during hazardous operations, such as maintenance or setup. It incorporates a three-position enabling button, an emergency stop button, additional buttons, signal LEDs, a home position detector, assist light (flashlight), and vibration feedback.
Three-position enabling button: This is the core safety feature, requiring the operator to maintain a specific grip. The button has three positions:
- Position 1 (OFF): Not pressed, contact is open.
- Position 2 (ON): Partially pressed, contact is closed. This is the operating position.
- Position 3 (OFF): Fully pressed (panic position), contact is open. This acts as a safety stop if the operator squeezes too hard in a panic.
The device is designed such that releasing the button from position 2 (back to position 1) or pressing it beyond position 2 (to position 3) will stop the machine. This ensures that the machine only operates when the operator is actively holding the button in the safe operating position. The enabling button is designed for two-finger operation, with the option for three fingers.
Emergency stop button: A prominent, red emergency stop button is integrated into the front area of the device. This button provides an immediate and forcible stop function for the machine. It is designed to be user-defined and can be configured for individual movements or a complete stop. The emergency stop function is monitored by the AS-i network, and its status is communicated via the AS-i bus.
Additional buttons (1 to 4): The device includes four additional user-defined buttons (No. 1, 3, and 4 are shown in the diagram, with No. 2 being the emergency stop). These buttons can be configured for various functions, such as starting a process or individual movements. They are located on the grey housing and can be customized with additional labelling.
Signal LEDs: The device features high-intensity LEDs (red and green) that provide visual feedback on the device's status and the process. These LEDs are user-defined and can be controlled via the AS-i bus.
- Red signal LED (No. 7): Indicates a specific status or warning.
- Green signal LED (No. 8): Indicates normal operation or a safe status.
Home position detector (No. 9): This sensor detects when the enabling device is placed in its specially-designed holder. This feature can be used to ensure the device is stored safely when not in use, or to trigger specific actions when the device is returned to its holder.
Assist light (flashlight) (No. 11): An integrated flashlight provides illumination for the work area. This function can be turned on in a user-defined way, and its operation is subject to duty cycle limitations to prevent overheating.
Vibration (No. 12): The device provides haptic feedback through vibration. This can be used to signal an occurrence or to provide tactile feedback to the user, enhancing safety and usability. The vibration function is controlled via the AS-i bus.
AS-i communication: The HD5-B-901 is an AS-i slave device, communicating with an AS-i master via a two-core cable. This allows for simple and cost-effective wiring, as both power and data are transmitted over the same cable. The device's status, including the state of the enabling button, emergency stop, and additional buttons, is transmitted to the AS-i master. The AS-i network also controls the signal LEDs, assist light, and vibration. The device supports AS-i Safety-at-Work, ensuring a high level of safety integrity.
Important Technical Specifications
- Supply Voltage: 30 VDC, AS-i Bus, tolerance 26 - 31.6 VDC.
- Overall Power Consumption: <150 mA.
- Protection Class: IP65, indicating protection against dust ingress and low-pressure water jets from any direction.
- Ambient Temperature for Operation: -10°C (no buildup of ice) up to +55°C (no direct sunlight).
- Ambient Temperature for Storage: -20°C (no buildup of ice) up to +70°C (no direct sunlight).
- Weight: Approx. 200 g without connection cable.
- Material: Housing: fiberglass reinforced plastic, PPH G30. Operating buttons: TPE.
- Actuating Force (Enabling Button): Approx. 20 N, 1 → 2; Approx. 45 N, 2 → 3.
- Actuating Force (Additional Buttons): Approx. 3 N (buttons 1 and 2); Approx. 7 N (buttons 3 and 4).
- Mechanical/Electrical Durability (Enabling Button): 1 x 10^6 switching cycles (position 1 → position 2); 1 x 10^6 switching cycles (position 2 → position 3).
- Mechanical Reliability B10D (Enabling Button): 2 x 10^6 (position 1 → position 2); 968,000 (position 1 → position 3).
- Mechanical/Electrical Durability (Emergency Stop Button): 5 x 10^4 switching cycles.
- Mechanical Reliability B10D (Emergency Stop Button): 250,000.
- Connection: 2x0.75mm² PUR spiral cable, up to 12m.
- Dimensions: All dimensions are given in millimeters (mm). The device is approximately 185mm long, 75mm wide, and 55mm deep.
- Safety Standards: Complies with 2006/42/EC – Machines, 2014/30/EU – EMC, 2011/65/EU – RoHS2, 2015/863-RoHS3. EN ISO 12100-1:2010, EN ISO 13849-1:2015, EN 62061:2015, EN 60204-1:2006 + A1:2009.
- SILCL: 3.
- PLe: Category 4.
- Certificates: TÜV Süd, UL.
Usage Features
- Ergonomic Design: The device is designed for comfortable handheld operation, reducing operator fatigue during prolonged use. The tactile button beneath the index finger ensures an ergonomic grip.
- Visual and Haptic Feedback: Integrated LEDs and vibration provide clear status indications and warnings to the operator, enhancing situational awareness.
- Flexible Configuration: The additional buttons, signal LEDs, and vibration function are user-defined, allowing for customization to specific application requirements.
- Easy Connection: The AS-i two-core connection cable simplifies wiring and installation. The device can be connected using a spiral cable up to 12 meters.
- Safety-at-Work: The device is designed to meet high safety standards, ensuring reliable operation in hazardous environments. The three-position enabling button and integrated emergency stop provide multiple layers of safety.
- Home Position Holder: An optional holder (HD5-M-001 or HD5-M-002) is available for storing the device when not in use. The home position detector can be used to confirm the device is securely placed in the holder.
- Assist Light: The integrated flashlight improves visibility in poorly lit work areas.
- AS-i Monitor Pluto Compatibility: The device is compatible with the ABB AS-i monitor Pluto, which can be used to monitor the device's status and manage safety functions.
Maintenance Features
- Robust Construction: The housing is made of fiberglass-reinforced plastic, and the operating buttons are made of TPE, providing durability and resistance to wear and tear in industrial environments.
- IP65 Protection: The IP65 rating ensures protection against dust and water, reducing the need for frequent cleaning and protecting internal components from environmental damage.
- Cleaning: The operating surfaces are made of soft, elastic, and very thin material designed to be hard-wearing. A soft cloth and a standard (soap-based) multi-purpose cleaner are recommended for cleaning. Abrasive cleaning agents or sharp-edged tools should not be used.
- Regular Inspections: Regular checks of the device's functionality and safety functions are crucial. This includes verifying the operation of the enabling button (all three positions), emergency stop button, and AS-i communication.
- Commissioning: The enabling device should only be commissioned by specialist personnel who have been trained to work with the machine. A functional test must be carried out after installation, based on the application case and relevant harmonized standards.
- Product Data: The device includes a QR-code, which can be scanned with a smartphone to find further data in the QR-code, such as product or ordering spare parts information.
- Disposal: The device is designed to be recyclable. At the end of its service life, it should be disposed of in an environmentally responsible manner, following applicable disposal requirements.
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