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PLUTO Safety-PLC Operating instructions Hardware

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1. 24V e 0 0 e e lt L M O c c gt gt gt O O O g o o o o o lO 12 fe 14 5 16 E a a gd KE JE IQ Possible solutions for dual channel inputs with detection of external short circuits 24V e e e e e e e e lt lt ES A 0 0 0 0 0 0 o L lO 1 I5 4 Es 16 7 IQ static 24V A normal connection of several dual channel devices One dynamic signal combined with 29 2TLC172001M0211_A 6 2 Single channel systems Instead of using two channel systems some applications can be made failsafe by using the principle of a dynamic single channel By supplying electronic devices with dynamic signals a fault in the electronics will lead to a static on or off state at the input which will be detected immediately By inverting the signal in or at the sensor short circuits over the sensor are also detected 24V T OV 7 e e e A Adam Eva eg Transm J Rec Y GE i JSL Lightbeam system Eden sensor x m O Switch with k e e inverter 3 Gs Tina e e d d 8 L IQ IQ_ IQ Note Serial conne
2. DI Al DI Al DI Al DI Al DI Al DA DI Al DA IAO TAI IA Wa IA4 IA5 IAG IAT I30 131 132 133 134 135 136 137 140 141 142 143 144 145 146 147 B e 24V 00_ 1 ov Power of ji OV k Q1 SC m Pluto D45 Di ID Identifier IDFIX WA Safety outputs Q4 a _ e CH ADB CL Pluto bus si E CS Shield 4L IQ10 1Q11 1Q12 1013 1014 1015 1016 1017 IQ20 1Q21 1022 1023 1024 1025 1026 Q2 A al AT B Failsafe inputs Outputs not failsafe Dynamic outputs VO overview PLUTO D45 Inputs and outputs for Pluto D45 Local Global Safe Input Global Safe Analogue input 4 20mA 0 10V Counter input IA4 1A7 A LI Global Safe Analogue input 4 20mA 0 10V 130 137 20 1 Local 140 147 A0 TI Safe Input Local Global Global Global Global Local Safe Output Relay Local UNE Global Local Local is the Pluto number where 9 2TLC172001M0211_A Inputs individual failsafe AS Interface Inputs individual failsafe Inputs individual failsafe Wa am Digital Analogue gt ASi ASi IO P A d I30 181 132 133 134 135 136 137 140 141 142 143 144 145 146 147 Al Al Al 24V SR41 SR45 SR46 0 o dirs edad A ov detal oL p oY ee Open Pluto B42 AS i EES ID Identifier IDFIX ADB Safety outputs Q4 IT UL 6 e CH ur A e CL Pluto bus EC e
3. 52 2TLC172001M0211_ A Pluto 02 Indicators Pluto O2 has 6 LED indicators instead of display These have the following function On Input on Flash Two channel fault generated by function block Or power on input and program not loaded On Output on Flash Fault No answer monitor contact Not switched on On PLC run Off PLC not running Flash PLC in halt by Pluto Manager Off No error Flash Errors resettable with K button Er15 Er19 Er40 Er43 Er45 Er47 or Self programming confirm Quick flash 80 80ms System error On with short off periods 1200 80ms Er20 On All other errors On Output on Flash Fault No answer monitor contact Not switched on On Input on Flash Two channel fault generated by function block Or power on input and program not loaded Flash of all LED s Identification of Unit O JJ Cc gt 53 2TLC172001M0211_A EC declaration of conformity We ABB AB declare under our sole responsibility that the safety Jokab Safety components of ABB manufacture with type designations Kanalvagen 17 and safety functions as listed below are in conformity with SE 183 30 Taby the Directives Sweden 2006 42 EC 2004 108 EC 2006 95 EC 2011 65 EU Programmable electronic safety system Safety PLC system Pluto version A20 B20 B16 S19 S20 D20 B22 B46 S46 D45 AS i B42 AS i O2 Used harmonized EN ISO 13849 1 EN 954 1 Directive 2006 42 E
4. AE 03 Safety code missing by code teaching Teach AS i safety codes AE 04 Wrong code table Teach AS i safety codes AE 05 Internal AS i fault Reboot WAA EG AAA AC node no Channel fault in safety node Switch off both channels Ab node no AS i slave with bad or wrong safety code Routine Single slave exchange or teach safety codes PC or exchange defect slave Read AS i slaves with PC slave one slave is missing Acknowledge with K button Code Change Pluto is prepared for connection of new safety slave Code Found Code in new safety slave is available Acknowledge with K button Code Duplicate Code already stored in Plutos code table AS i LEDs The status of the AS i LEDs does not give any additional information than what is already given by the error code except in one case as illustrated by the table below but green LED off and or red LED on indicates an error Display shows Fault and possible reason Reset action Green LEDs Red LEDs error code Off ASi power missing See Error code AS i fault On On No Pluto in Slave mode not Configure master addressed by master In Output LEDs The status of the Inout and Outout LED s gives additional information for troubleshooting Indication Fault and possible reason Double flash Two channel fault at use of two channel function block in the Open and close PLC program Double flash on the channel which has opened both channels
5. 4 5 2 Solid state safety outputs Each digital failsafe output is individually safe and can therefore be used to individually control a safety function The nominal output voltage is 24V DC The negative potential is due to the charge pump principle used The charge pump is designed in such a way that the output voltage is generated by a capacitor which is charged and discharged by two transistors The transistors switch alternately One transistor switches to plus potential charges the Capacitor and then switches off The other transistor then switches on discharging the capacitor to O Volts During the discharge phase the capacitor sucks current from the output making the output a negative voltage This design principle requires that all components work and change state in the correct phase A fault in any component leads to an immediate cessation of output current generation An advantage of using a negative output potential is that it is not normally present in a control system Since the output is monitored Pluto can detect short circuit between the output and a foreign potential 22 2TLC172001M0211_A 4 5 2 1 Test pulses In order to make internal tests and to test against external short circuits the outputs Q2 and Q3 are cyclically switched off during 100 200 us so called test pulses OV 24V Uv een e A WV l E pr A 1 TI V
6. A IO Examples of two hand control 33 Safeball Left Right oe 24V Zz gt Q o o 0 I I I al IQ_ 21LC172001M0211_A 6 8 Illuminated push button function It is possible to connect both an indicator lamp and an input switch at the same time to IQ terminals e g illuminated push button A diode must be connected locally to the input device The function is mainly intended for reset devices and reduces the number of IQ terminals used OV Dyn sign r gt Input Output 1910 1017 Note that the output voltage is a square wave of 24 V amplitude and the effective voltage to the indicator is reduced to a mean value of 75 A filament bulb or LED designed for 24 VDC can be used 6 9 Monitoring of muting lamp only A20 The system can measure the current in output 1016 and 1017 The function is intended for monitoring the current in a muting lamp but other usage is not excluded As the hardware for measuring the current is not fully redundant the function must be used in a dynamic way if used for safety functions This means that the current must be read and evaluated both when the output is switched on and off DJ D dr 34 2TLC172001M0211 A 7 Connection of outputs Below are examples of output connections
7. Original instructions H E a ASi ASi Q2 99 CL IO GG ASi ASi Q3 PLUTO AS i v2 K 1Q101Q12 oL Q0 10 09 9 0 20 1Q111Q13 OV ID OV 24V PLUTO safety PLC Operating instructions Hardware English v11A 2TLC172001M0211_A Table of contents 1 SP siesta E 4 2 Belle 5 3 SIA NA te 5 4 MU AAA 6 4 1 l Digital failsafe INputS occooccocnoccnoccnocononononononononononancnnnnonnnonnnonnnnnnonanonanenanenanenanes 12 4 2 IQ Digital failsafe inputs Digital outputs non failsafe ooocccccconnncconccnccencnnnnnos 13 4 2 1 A e O OE COCO POPE A A 13 4 2 2 Current monitoring 1916 1017 Only AO 13 4 3 ANA US HEEN 14 4 3 1 Analogue inputs 0 10V 4 20mA Pluto D20 and DAD 14 4 3 1 1 Safety in application coooccccccnccconnncccnnoconncononnnnnnnononnncnnnnnnnonnonannnnnnnnnnnnnnnnnnennnnnannns 14 4 3 1 1 1 Dual channel solutions ocoocccocccocncccncocncnoncnononnnnoncnnncnnnronnnonnnonnnonnnonnnonaronnncnnrnnnrnnncnnones 14 4 3 1 1 2 Single channel UL A 14 Arola UNO laa 15 4 3 2 Possible architectures achievable safety levels and prerequisites 15 4 3 2 1 Connection of analogue voltage output Sensors 0 10 oooooncccconcccnccncnnconconcnonnononanoss 16 43 3 Analogue inputs 0 2 16 4 4 ER UA e Pe o E ii E R ia aa NRENNA 17 4 4 1 UD ee LEE 17 4 4 2 Biet Rei Beie Din dE 18 44 3 Sensor output types ccccecccssccccesecceeeeceucece
8. 4 20mA Pluto D20 and D45 Pluto D20 is equipped with 4 and Pluto D45 with 8 safe 4 20mA 0 10V analogue inputs These D20 IAO IA3 D45 IAO IA7 can be configured as either ordinary failsafe inputs as analogue inputs 0 10V or as analogue inputs 4 20mA For D45 IAO IA3 can also be configured as counter inputs see below For an application to reach SIL 3 PL e it is required that two sensors in parallel with one input each are being used See Pluto Programming Manual 4 3 1 1 Safety in application Each input is connected to both processors in order to be able to use them as standalone safety inputs There are however some faults which can give failure in the measurement such as interruption in the connector block or interruption in the cabling between sensor and Pluto which leads to that Pluto reads a value close to 0 To achieve higher degree of safety or redundancy for a complete application there are some requirements and suggested solutions 4 3 1 1 1 Dual channel solutions A complete dual channel application with two sensors using two inputs one for each sensor and DEEN the sensor values are compared with each other the AA application can achieve category 4 PL e and SIL 3 In general the physical values must be dynamic and Sensor B must not be static In case that the physical values 4 20mA 0 10V are almost static then for category 4 a test must be performed daily If not
9. Output example 4 Polarized safety relays A Y AY ES E Monitoring yr yr BK Q2 BK Q3 AO e 24 NQ_ PH ga A1 A2 X4 A1 A2 S14 S24 X1 X2 Supply Input Test S M 24VDC Supply Jo InB Test 24VDC Type BISI Type E 1T A 13 14 23 24 33 34 43 44 eoe o o o o o o When using a safety relay for output expansion of output Q2 and Q3 the connection between the Pluto output and the safety relay is failsafe against short circuit from foreign 24V This because it is operated by 24V and since the safety relay is polarized it cannot be switched on by 24V As long as a 24V potential does not exist in the cabinet which is not normally the case the connection is failsafe 37 2TLC172001M0211_A 8 Example of applications 24V e gt OV e e e e e e 2 Tina Y e 7 A D Ca Se SS j Reset E A Muting Muting y ES Transm Rec sensor sensor BB u 1 2 Tina Tina Spot e LX Lightbeam system al p pe E a AEN L e L e 0 1Q12 013 10 I1 1Q14 Al 1Q10 Q2 QS 2 e e e e A2 Ja2 K Ze Ga Gu e gt Contactor A Contactor B OV 38 2TLC172001M
10. A teaching procedure must be performed at installation and exchange of safety slaves in order to teach Pluto the correct code for each safety slave See programming manual 4 6 3 Slave types Pluto has to be configured for the type of slave s that is connected to the AS i bus This configuration is done in Pluto Manager and is explained in the Pluto_Programming_Manual Below is a short description of the different slave types that Pluto supports Safe Input This is a safe slave with a single or dual channel input For the dual channel type there is physically a dual channel input to the slave but in Pluto Pluto Manager it is configured as one input The slave can also have up to 4 non safe outputs AS i profile S x B where x depends on I O configuration Nonsafe standard slaves A non safe standard slave can have up to 4 non safe inputs and or up to 4 non safe outputs In Pluto both inputs and outputs are local AS i profile S x F where x depends on I O configuration Nonsafe A B slaves Two A B slaves one A slave one B slave share the same address number This means that up to 62 A B slaves can be used in a net instead of 31 which is the maximum number for other slave types A non safe A B slave can have up to 4 inputs and or up to 3 outputs In Pluto both inputs and outputs are local AS i profile S x A where x depends on I O configuration Combined Transaction A B slaves Pluto supports Combined Transaction slaves with 4 inp
11. MTTFa according to EN ISO 13849 1 High 1500 years Relay outputs PFDav for proof test interval 20 years 1 5 x 10 PFHb according to EN 62061 IEC 61508 2x 10 MTTFa according to EN ISO 13849 1 High 1100 years Analogue inputs Pluto D20 D45 2 sensors see 4 3 2 1 sensor see 4 3 2 SIL according to EN 62061 IEC 61508 Upto SIL 3 Up to SIL 2 PL according to EN ISO 13849 1 Up to PL e Up to PL d DCavg according to EN ISO 13849 1 Up to High Up to Medium PFDav for proof test interval 20 years 1 5x 10 1 5x 10 PFHb according to EN 62061 IEC 61508 1 6x 10 5 8 x 10 MTTFa according to EN ISO 13849 1 High 1100 years High 400 years Counter inputs Pluto D45 2 sensors see 4 4 7 1 sensor see 4 4 7 SIL according to EN 62061 IEC 61508 Upto SIL 3 Up to SIL 1 PL according to EN ISO 13849 1 Up to PL e Up to PL c DCavg according to EN ISO 13849 1 Up to High Up to High PFDav for proof test interval 20 years 1 5x 10 1 5x 10 PFHb according to EN 62061 IEC 61508 1 6x 10 1 6 x 10 MTTFa according to EN ISO 13849 1 High 1100 years High 1100 years Note PFDav Average probability of dangerous failure on demand PFHo Probability of dangerous failure per hour MTTFa Mean time to dangerous failure channel PL Performance level as defined in EN ISO 13849 1 CCF Common cause failure Input to output incl AS i and CAN bus 48 2TLC172001M0211_A 13 1 Connection of sensors Maximum number of sensors that can be conn
12. O 4in 4out O 1 chamnel Safety module S Pluto on AS i bus with some examples of AS i slave types Note For old Pluto AS i of version 1 extended non safety slaves can only be handled in Monitor only mode 4 6 1 AS i connection It is recommended to only use two of the four AS i terminals on Pluto Connect all AS i wires to the same AS i terminal and all AS i wires to the same AS i terminal If all four connections are used the AS i circuit will be broken when the terminal block is detached AA ED ED FADED 24 2TLC172001M0211_A 4 6 2 Reading safety slaves The main intention with Pluto AS i is to read and evaluate the safety slaves with its dual CPU A standard slave can have 4 input variables which are read separately by the master A safety slave has also 4 input variables but physically only one single channel or dual channel input The 4 input variables are used to send a safety code unique for each slave The safety code is transmitted in 8 cycles Pluto reads the safety code compares it with the code stored in the memory and if they match the input in the safety slave is evaluated as on 1
13. Pluto units are mounted close to each other in the same cabinet the shield can be omitted Alternative 1 Alternative 2 Both ends connected to earth One end to earth B42 AS i Connect to CS terminal B42 AS i Connect to CS terminal and other end not connected Cabinet SN Cabinet 8 Cabinet y Cabinet or CS terminal or CS terminal or CS terminal 0909050000 000900 000 UI It Wat d is 0412 1014 1074 miiy ml UI 1 UI m Du lla 990909089080 IN A on 9 012 1014 WI mola relly Re Re 09990 p98o iS Alternatives for connection of bus cable shield For B42 AS i and D45 connect shield to the CS terminal 40 2TLC172001M0211_A 9 1 3 Optional protection against conducted disturbances Conducted disturbances may cause problems with the Pluto bus communication This problem might be solved by connecting a capacitor between OV on Pluto Supply and earth Please note that this connection is optional lt shall only be tried if there is a problem with the bus communication 920000000000 2 D OK D o Oo o 00 358 eo ooo 4 15nF OV 24V KO Capacitor between OV and earth Example of terminal block with capacitor 9 2 Response time over the bus As default the system works with the Baud rat
14. Press K button for 2 seconds If one safety slave is missing the display flashes CC gt slave number Press the K button one more time to acknowledge and the display will show steady CC The new safety slave can now be connected and the display will show CF Code found If the same slave is connected again the display will show Cd Code Duplicate which means that the code is already stored in Plutos memory By pressing K a last time Pluto will automatically store the new code and reboot 4 6 5 1 Exchange of non safe slaves after commissioning For exchange of a non safe slave the requirement is that all slaves except the one that shall be replaced are working and connected to the AS i bus Remove the slave which shall be replaced Connect the new slave AL ED ED PAIDID 26 2TLC172001M0211_A 5 Connection of inputs 5 1 Dynamic signals The IO terminals can be configured as dynamic outputs and be used for voltage supply of the input devices If they are configured as dynamic each of them generates a unique pulse train as shown in the diagram below A 5 ms MU LS 125 ms The system is intended for detection of different short circuits in external cabling and dynamic monitoring of sensors It enables the connections of devices such as SPOT lig
15. modes of operation on the AS i bus Bus Master Pluto controls the AS i bus Via the PLC program Pluto can read the inputs and set the outputs of the slaves Monitor only In this case Pluto only listens to the bus traffic which is controlled by an external master Normally this external master is a non safety PLC system for control of the non safety related part of the application In monitor mode Pluto can read all I O s on the AS i bus but not set any outputs since it is the external master that controls the bus Monitor Slave This mode is the same as Monitor only mode but Pluto can also be a slave node under the external master Pluto and the external master can then communicate with each other 4 bits in each direction AS profile S 7 F 4 6 5 Exchange of Safety slaves after commissioning The system allows exchange of a safety slave without any tool for modification of the PLC program or other setup The requirement is that all slaves except the one that shall be replaced are working and connected to the AS i bus It is also necessary that the IDFIX is of type IDFIX DATA or IDFIX PROG Some AS i units contain two AS i addresses slaves For these units it is necessary to first set these two addresses to the same two addresses as in the unit it shall replace The address can be set either with a programming tool or through Pluto Manager Tools AS i Change AS i slave address The procedure is as follows
16. sensors pushbuttons selector switches shall be isolated for 250V SS iH 2 m GND OOH SS ae Ooo j KANGA Legd ee 10 A A 5 0000550509 AAA 8 5 v 22022070 PIDA P 1 k gt 2 ODD OOD OOO Arc suppressor T i Le gt 3 MM p Min 5 mm space between units AA ED ED PAIDID 5 2TLC172001M0211_A 4 Inputs and outputs In order to be as flexible as possible Pluto offers various combinations of different I O s There are also different families and types of PLUTO Pictured below are the IO overviews for the various Pluto types Transistor output Bit bus 1 Inputs individual failsafe individual failsafe FAA 0 0 CH CL A A A A i A g BR IO 11 12 E 14 15 16 17 Sg DS Al a NS Pluto A20 B20 S20 SR41 Q2 Q3 1Q10 1Q11 1Q12 1Q13 1Q14 IQ15 1Q1645 10175 GU Q1 d J A A y j P j Sg eeng a ID OV 24V 0 0 0 e e 0 0 0 ji 2 Identifier Current monitored Relay output input ower individual failsafe Failsafe inputs Indication outputs not failsafe Dynamic outputs 1 Not S models S20 2 Current monitored only on A20 VO overview PLUTO A20 family except B22 and D20 Inputs and
17. that give different degrees of protection against short circuits When and where they can be used depends on the kind of machine application risk and the electrical installation 7 1 Connection examples Output examples 1 Connection and monitoring of contactors A Kal Monitoring i Monitoring yA 7 Qo LIA BK Q2 LIQ OV 0 0 o 0 o o 24V 24V NQ_ NQ_ 0 0 A1 A1 A2 A2 K K 3 a K La A2 A2 At A1 OV PS e e e A fault in a contactor will not lead to the loss of the safety function and is monitored since the NC contacts are connected to an input Note Some short circuits from 24V and 24V can switch on both contactors and lead to loss of the safety function The example connections can be used where the highest safety integrity level is not required and the risk for short circuits is low or can be excluded e g inside a control cabinet Example of application is automatic machines where safety function is used by setting adjustment etc 35 21LC172001M0211_A Output examples 2 Contact expansion with expansion relays and safety relay A A AY Monitoring gt Monitoring Le A Qo e Q1 Q_ BH Q2 L 1Q_ 0V 0 4 e o 24V 24V 24V
18. that the sensors can produce A B pulses A B pulses are two square wave signals that are 90 phase shifted to each other The sensor is typically a incremental encoder 24V HTL For description of the use of Function blocks see Pluto Programming Manual Al LJ LI B ITT Illustration of A and B pulses A and B are 90 phase shifted Typical devices are rotary incremental encoders 24V HTL Example of speed monitoring with incremental encoders leaving A and B pulses to two inputs IAO IA1 or IA2 IA3 The direction is then possible to measure Two encoders with two inputs each are used in this example to achieve redundancy For overspeed monitoring safe low speed SLS category 4 and PL e is normally reached For stand still monitoring Category 3 and PL d can be reached depending on application 18 2TLC172001M0211_A 4 4 3 Sensor output types OV Push pull HTL sensor output Open collector PNP sensor output Typical for incremental encoders Typical for proximity sensors and photocells Incremental encoders with HTL output and other with push pull output can be used at frequencies up to around 14 kHz For sensors with open collector PNP output or other output not of push pull type the maximum frequency might typically be 1 4 kHz but the limit is dependent on the output resistance the cable length
19. 0211_A 9 Pluto bus communication Up to 32 Pluto units can be interconnected with CAN bus Communication is achieved by connecting a twisted pair cable to the CH and CL terminals When this connection is made the Pluto units can read each other s I O When the bus is connected each Pluto unit executes its own individual program and operates independently however it can read other units I O An interruption of the bus connection results in the I O in the unit with which communication is lost being regarded as a 0 condition by other units on the bus In this situation all units will continue program execution with the consequences of the fault being dependent upon the application program For instance if an emergency stop button connected to one unit is used by another unit as a condition for setting an output the output will switch off if communications are lost Outputs generated by l O connected directly to a unit are not affected by interruption of communications 9 1 Bus cabling The maximum length of CAN bus cabling is dependent on the transmission speed At the default setting of 400 kbit s the maximum total length is 150 meters This length can be extended by the use of Gateways as bridges See Pluto Gateway Manual chapter 1 General and chapter 8 CAN bridge mode At each end of the bus a termination resistor of 120 Q must be installed When a Pluto unit is working alone and no bus cable is connected it must still be
20. 3 Safe Input Global Safe Analogue input 4 20mA 0 10V Safe Input Global Safe Output Relay Global Safe Output Relay Global Safe Output Transistor Global Safe Output Transistor Global Safe Input Global Local where is the Pluto number 7 2TLC172001M0211_A Inputs individual failsafe Inputs individual failsafe Inputs individual failsafe Digital Analogue i lO H 2 B 14 d a d I30 131 132 133 134 135 136 137 140 141 142 143 144 145 146 147 Al Al Al AUB A 24V SR41 SR45 SR46 OO Power A OV suppl Pluto B46 S46 OL pply AQB OV QILI TI 4 iL e ID Identifier IDFIX AQB Safety outputs QJ sy CH AOB Pluto bus QS e e CL 4L IQ10 1Q11 1012 1Q13 1014 1015 1016 1017 IQ20 1021 1022 1023 1024 1025 1026 10927 Q2 aa j i i j i A B Failsafe inputs Outputs not failsafe Dynamic outputs 1 Not S46 6 I O overview PLUTO B46 and S46 Inputs and outputs for Pluto B46 and S46 ao 88 Safe Output Relay Global P Safe Output Transistor F Safe Output Relay 1Q10 1Q17 1Q20 1Q27 is the Pluto number where AA ED ED FADED 8 2TLC172001M0211_A Digital inputs individual failsafe Analogue 10V 4 20mA nalogue inputs 0 10V 4 20m Inputs individual failsafe Inputs individual failsafe Fast counter
21. 6 390 E mail aleksander qgauza at abb com Web www abb es Web www abb at Greece ABB SA Slovenia Belgium Tel 30 210 28 91 900 ABB d o o ABB N V Fax 30 210 28 91 999 Tel 386 1 2445 455 Tel 32 27186884 E mail dimitris voulgaris gr abb com Fax 386 1 2445 490 Fax 32 27186831 nikos makrakos gr abb com E mail aljosa dobersekOsi abb com E mail tech IpObe abb com Web www abb com ji Spain Brazil Ireland Asea Brown Boveri S A ABB Lida ABB Ltd Tel 34 93 4842121 Produtos de Baixa Tens o Tel 353 1 4057 381 Fax 34 93 484 21 90 ABB Atende 0800 014 9111 Fax 353 1 4057 312 Web www abb es Fax 55 11 3688 9977 Mobile 353 86 2532891 Web www abb com br E mail derek kelly ie abb com South Africa ABB Canada Israel Tel 27 10 202 5906 ABB Inc ABB Technologies Ltd Fax 27 11 579 8203 Tel 1 514 420 3100 Ext 3269 Tel 972 4 851 9204 Mobile 27 82 500 7990 Fax 1 514 420 3137 Mobile 972 52 485 6284 E mail Hendrik Spies za abb com Mobile 1 514 247 4025 E mail contact il abb com E mail alan m brown ca abb com Web www abb co il Sweden Web www abb com ABB AB Jokab Safety Italy Varlabergsvagen 11 China ABB S p A SE 434 39 Kungsbacka ABB China Limited Tel 39 02 2414 1 Tel 46 21 32 50 00 Tel 86 21 23287948 Fax 39 02 2414 2330 Fax 46 40 67 15 601 Telefax 86 21 23288558 Web www abb it E mail support jokabsafety se abb com Mobile 86 186 2182 1159 Web www abb com jokabsafety E mail harry yarong zhang cn abb com
22. AC 12 250 V 5A AC 15 250 V 3A DC 12 60V 5A DC 13 24V 3A 33 34 Relay AC 12 AC 15 DC 12 DC 13 24 V 1 5A Outputs non failsafe 1Q10 1Q11 Solid state 24V PNP open collector Also configurable as failsafe inputs Max load output 800 mA Max total load A20 B16 B20 S20 B22 D20 IQ10 17 25A B46 S46 D45 B42 AS i IQ10 17 2A 1Q20 27 2A Pluto AS i IQ10 13 2A Current monitoring 1216 1017 Only Pluto A20 Range 0 1 0A Accuracy 10 46 21LC172001M0211_A Indication Input Output LED s Controlled by processor General Enclosure A20 B16 B20 S20 B22 D20 O2 and Pluto AS i 45 x 84 x 120 mm wx hx d B46 S46 D45 and B42 AS i 90 x 84 x 120 mm wx hxd Mounting DIN Rail Response time of dynamic A or static input 24V Relay output QO Q1 Q4 Q5 lt 20 5 ms prog execution time Solid state output Q2 Q3 lt 16 5 ms prog execution time Solid state output Q10 Q17 lt 16 5 ms prog execution time Response time of dynamic B or C inputs Relay output QO Q1 Q4 Q5 lt 23 ms prog execution time Solid state output Q2 Q3 lt 19 ms prog execution time Solid state output Q10 Q17 lt 19 ms prog execution time Response time Pluto O2 From input in other Pluto to output in O2 Relay output QO Q1 lt 33 ms prog execution time Non safe output Q10 Q11 lt 29 ms prog execution time Software setting NoFilt Response times 5 ms 5 ms less Response time AS i
23. C standards EN 62061 Directive 2006 42 EC EN 61496 1 Directive 2006 42 EC EN 574 Directive 2006 42 EC EN 692 Directive 2006 42 EC EN 60204 1 Directive 2006 95 EC EN 50178 Directive 2006 95 EC EN 61000 6 2 Directive 2004 108 EC EN 61000 6 4 Directive 2004 108 EC EN 61000 4 1 6 Directive 2004 108 EC Other used standards IEC EN 61508 and documents DIN V VDE 0801 1990 with amendment A1 1994 EC Type Examination TUV Rheinland according to 2006 42 EC Am Grauen Stein D 51105 K ln Germany Notified body No 0035 Certificate no 01 205 5304 13 ep Ja Beggen Jesper Kristensson PRU Manager Kungsbacka 2013 04 16 54 2TLC172001M0211 A Contact information Australia France Poland ABB Australia Pty Limited ABB France ABB Sp Z 0 0 Low Voltage Products Division Produits Basse Tension Tel 48 728 401 403 Tel 61 0 1300 660 299 Tel 0825 38 63 55 Fax 22 220 22 23 Fax 61 0 1300 853 138 Fax 0825 87 09 26 E mail adam rasinski pl abb com Mob 61 0 401 714 392 Web www abb com safety pl abb com E mail kenneth robertsonO au abb com Web www abb pl Web www abbaustralia com au Germany ABB STOTZ KONTAKT GmbH Portugal Austria Tel 49 0 7424 95865 0 Asea Brown Boveri S A ABB AB Jokab Safety Fax 49 0 7424 95865 99 Low Voltage Products Baixa Tens o Tel 43 0 1 601 09 6204 E mail buero spaichingen de abb com Tel 35 214 256 000 Fax 43 0 1 601 09 8600 Web www jokabsafety com Fax 35 214 25
24. CS Shield IQ10 1Q11 1Q12 1013 1014 1015 1016 1017 IQ20 1021 1022 1023 1024 1025 1026 1027 Q2 See Al B Failsafe inputs Outputs not failsafe Dynamic outputs VO overview PLUTO B42 AS i Inputs and outputs for Pluto B42 AS i Terminal on Pluto In Output name in software I O type Local Global I0 13 0 1 3 Safe Input Global 3 10 13 03 30 1 37 Safe Input 130 ao 88 Safe Output Relay Local Q2 Q3 N ARS Q2 Safe Output Transistor QQ Safe Output Transistor Q5 Safe Output Relay 0 Q_ 17 eel ee S AS i bus OIO NMI iN IJI On A 1Q10 1Q17 10 1_ e mb N NO CO l No O call I No Y 1Q20 1Q27 where is the Pluto number 10 2TLC172001M0211_A Power supply za CAN bus AS Interface Inputs individual failsafe Identifier E e input A sep e e VE e gt 24V OV ID CH CL ASI ASI A A 11 12 Pluto AS i IQ10 lait 1012 1013 QO Q1 Q2 Q3 DI A DI Al DI Al DI Al A i A ale A all all all ll sc il ei o gt gt pa Failsafe inputs Analogue inputs Safety outputs Outputs not failsafe Dynamic outputs VO overview PLUTO AS i Inputs and outputs for Pluto AS i Hoo Safe input Global Wows TS Safe tnput Local AA oo Bate Output Reay Globa EE a Safe Output Transistor ERC Nomsafe Oulput Loca sed ASi where _ is the Plu
25. Korea ABB KOREA Switzerland i Low voltage Product ABB Schweiz AG Ge dentro Tel 82 2 528 3177 Industrie und Geb udeautomation y Tel 420 543 145 482 Fax 82 2 528 2350 Tel 41 58 586 00 00 Fax 420 543 243 489 Web www jokabsafety co kr Fax 41 58 586 06 01 E mail premysl broz cz abb com E mail industrieautomation ch abb com Web www abb cz Malaysia Web www abb ch ABB Malaysia Denmark Tel 60356284888 4282 Turkey JOKAB SAFETY DK A S E mail chang sheng saw my abb com ABB Elektrik Sanayi A S Tel 45 44 34 14 54 Tel 0216 528 22 00 Fax 45 44 99 14 54 Netherlands Fax 0216 365 29 44 E mail info jokabsafety dk ABB b v ji ji Web www jokabsafety dk Tel 31 0 10 4078 947 United Kingdom Fax 31 0 10 4078 090 ABB Ltd JOKAB SAFETY UK ABB A S E mail info lowvoltageproducts nl abb com Tel 44 0 2476 368500 Tel 45 4450 4450 Web www abb nl Fax 44 0 2476 368401 Fax 45 4359 5920 E mail orders lvo gb abb com E mail ordre komp dk abb com Web www jokabsafety com Web www abb dk SE Finland Tel 47 03500 USA Mexico inian Fax 47 32858021 ABB Jokab Safety North America ABBEY Mobile 47 40918930 Tel 1 519 735 1055 LES WW Wapo E mail Lars Erik Arvesen no abb com Fax 1 519 7351299 Web www abb no E mail jokabnaorderentryOus abb com Web www jokabsafetyna com 55 2TLC172001M0211_A
26. Minus 24 24 NQ_ NQ_ TE gt OV d 4 hd hd hd hd ke hd hd ke A2 X4 Al A2 14 S24 xi x2 A1 A2 S14 24 x1 X2 OS Ge SES Supply InA InB Test Supply INA InB Test Se 24VDC VOLT Type BT51 Type E1 Type JSR2A ry yy NANA HI 13 14 23 24 33 34 43 44 14 1 24 34 i 44 14 24 34 i 44 51 52 hd ke ke hd hd ke ke hd ke 0 hd hd ke ke hd o ke ke hd o o hd hd o ke hd The examples give the same degree of safety and have the same advantages and disadvantages as output examples 1 and can be used for the same type of applications Output examples 3 Short circuit protected Connection and monitoring of contactors with protection against short circuit for applications with very high demands on safety integrity level Category 4 In the example using output Q2 the conductor is protected with a shield connected to protective ground Examples are applications for safeguarding the operator of manual operated machines like presses and press brakes A A y Y py Monitoring ATN Monitoring AT 3 Monitoring B B B B ER QO Q1 IQ_ K QQ NQ_ K Q2 z AO OV e e e e gt e e e a 24 a A 24 24 NQ_ NQ_ NQ_ e Al A2 A2 A2 A2 A2 K a K ey Ac K K Lt ao K K Leet A2 Al Al Al A1 A1 U OV So e e e 36 2TLC172001M0211_A
27. W Ir i H B p ger Y OV OV e d 24V Principle for solid state safety outputs Diagram showing output voltage with test pulses 4 5 2 1 1 Disabling of test pulses For Pluto A20 v2 B20 v2 S20 v2 and Pluto D20 the test pulses can be disabled via Pluto Manager See Pluto Programming Manual 23 2TLC172001M0211_A 4 6 AS Interface bus AS i A Only for Pluto AS i and B42 AS i As can be seen in the I O overview Pluto AS i has only 8 digital I O but is equipped with connection for AS i bus AS i is a standardised industrial bus where both power and data is transmitted via a two wire cable There are two organisations for the standardisation of AS i AS International Association for the general specification and the consortium Safety At Work SAW for the safety protocol This manual does only explain how Pluto AS i can be used General information about the AS i bus is available at http www as interface net and in literature as AS Interface The Automation Solution Pluto Bus To other Pluto units AS i bus Pluto AS i External master Optional Bus Master Monitor only Monitor slave Safety Non safe B M light curtain extended slaves A B Non safe standard max Safety Safety slave 4in 30ut E stop switch 2 channelr O Safety O MEX a O module
28. as well Procedure Switch off power and exchange Pluto Switch power on and after a few seconds the display shall show Er20 empty Pluto O2 Error LED On with short off periods 1200 80 ms Press the K button in the Pluto front in 3 seconds until the display flashes Lo Pluto O2 Error LED Flashes 320 320 mei Release the K button and press it immediately one more time The display shall show steady Lo Pluto O2 Run LED shall be On Now the self programming has started K button can be released and when it is finished Pluto starts to run automatically If flashing Lo doesn t appear Pluto O2 Run LED shall be On Check the CAN bus connection Check that the IDFIX is connected and that it is not changed to another with other number Check that the Pluto really was member in same program project as the other on the Pluto bus 44 2TLC172001M0211_A 12 Cleaning The front plate can be cleaned by a dry dust rag The front plate can also be removed for cleaning or exchange 13 Technical data Supply Nominal Voltage Tolerance Max interruption Recommended external fuse Total current consumption Own current consumption Electrical installation 24 VDC 15 20 ms A20 B16 B20 S20 B22 D20 Pluto AS i O2 6A B46 S46 D45 B42 AS i 10A A20 B16 B20 S20 B22 D20 Pluto AS i 5A max B46 S46 D45 B42 AS i 7A max O2 1 3 A
29. bus Solid state output lt 16 5 ms prog execution time Relay output lt 20 5 ms prog execution time Response time AS i bus at fault condition Solid state output lt 29 ms with setting Short stop time lt 39 ms with setting Disturbance immunity Relay output lt 33 ms with setting Short stop time lt 43 ms with setting Disturbance immunity Program execution time approximately 10us instruction Extra response time over Pluto bus Normal condition 10 ms Fault condition 10 40 ms Q2 Q3 prolongation of response time during fault condition lt 10 ms Detection time Shortest detectable pulse on input 10 ms Ambient air temperature 10 C 50 C Temperature transportation and storage 25 55 C Operating altitude Up to 2000 m Humidity EN 60 204 1 50 at 40 C ex 90 at 20 C Degree of protection IEC 60 529 Enclosure IP 40 Terminals IP 20 AL ED ED PAIDEID 47 2TLC172001M0211 A Safety parameters SIL according to EN 62061 IEC 61508 SIL 3 PL according to EN ISO 13849 1 PLe Category according to EN ISO 13849 1 4 DCavg according to EN ISO 13849 1 High CCF according to EN ISO 13849 1 Meets the requirements HFT Hardware fault tolerance 1 SFF Safe failure fraction gt 99 for the single channel parts gt 90 for the double channel parts Charge pump outputs PFDav for proof test interval 20 years 1 1 x 107 PFHb according to EN 62061 IEC 61508 1 5x 10
30. ction is legal but a short circuit of an even number of sensors is not detected A direct connection between two terminals of IQ type is always detected Detection of a short circuit between an output of IQ and an input of is not detected See 13 1 for maximum number of sensors that can be connected in series 6 3 Emergency stop When emergency stop functions remain inactivated for long periods of time the function will not be monitored It is therefore strongly recommended that emergency stop systems are periodically manually tested and that this forms part of the maintenance instructions for the machine 30 2TLC172001M0211_A 6 4 Monitoring of external short circuit The system offers three main methods for avoiding that short circuit in input cabling leads to loss of the safety function The drawing below illustrates the different methods by which emergency stop buttons can be connected 24 V e _ Sieg 1010 e d e e _ 10_e I SI 0V AA ED ED PAIDID The first button has two NC contacts supplied by one dynamic signal and 24V The inputs are configured just to accept the expected signal and will therefore detect a short circuit between the channels as well as to other forei
31. e B B inverse C or C inverse For some two channel devices also 24V can be used Dyn A Bor C S Configured as dynamic output The system does not accept a direct connection between a dynamic output and another IQ terminal A component or device blocking current from input must be applied Example of declaration 10 15 a_pulse 10 16 a_pulse non_inv with diode Y WARNING WARNING Q terminals only connected to 24V does not fulfil category 4 Q terminal connected to 24V fulfils the safety requirements used for reset start etc Example of declaration 10 17 static lQ terminals connected to 24V fulfils category 4 by combination with another dynamic input NOTE The connections above are only to show how devices can be electrically connected and are not to be taken as connections for any specific applications 28 2TLC172001M0211_A 6 Connection of safety devices 6 1 Dual channel systems The classic way of making a failsafe system is to use two channel devices The system offers various possibilities for connection of such devices The figures below show solutions for connection of two channel devices The first figure gives example of possible connections and the second shows the common connection of several dual channel safety devices
32. e Le LI 10 0 10 1 10 2 100 10 1Q0 12 100 13 Declaration in software Pluto no 0 10 0 static 10 2 static 10 1 static 10 10 static NOTE Only one of the inputs may be of the lO type IQ 6 6 Safety mats and safety edges Safety mats and safety edges must be supplied by two different dynamic signals and be connected to two inputs By activation the two inputs will both get wrong input signal and give 0 in the software as result The programming can be made in the same way as for other dual channel functions 24V o e 0 e Y WV 5 nO lt o 3 o lt O O 3 y O o lt m O S c c gt gt gt O O O nana E E ET gt J a A e A mr ANZA ES BN BR ER A IQ IQ IQ IQ IQ om IO IQ IQ Connection of safety mats The diodes shall be placed before the mat as shown AA ED ED PAIDID 32 2TLC172001M0211_A 6 7 Two hand control Two hand control devices can be realized in many ways depending on the contact configuration in the two hand device and which Pluto inputs are used Below are some examples of solutions All of the examples shown fulfil the requirements for type IIIC according to EN 574 Classic two hand Two hand control device Left 7 WA Right l 8 24V E gt a ke 0 9 I I
33. e set to 400 kbit s and CAN cycle to 20 ms CAN cycle 20 ms gives 10 ms extra response time for data over the bus 10 40 ms under fault condition The records under Technical data for response time over bus etc are related to this To enable the use of longer cable lengths it is possible to change the baud rate to a lower value but care must be taken as the bus can be overloaded To avoid this overload there are two solutions either to limit the amount of Pluto units connected on the bus or to increase the Bus cycle time which also increases the response time Note that Bus cycle time is individually set for each Pluto unit which means that it is possible to give variables of some Pluto units better response times than others It is also important to note that if an input in one unit controls an output in another it is regarding the response time only relevant where the input is located If the Bus cycle time in the unit with the output is changed it has no influence on the response time The table below is a guideline for selection of bus parameters ser SCHER 100 kb s 125 kb s 200 kb s 250 kb s 400 kb s 500 kb s 800 kb s Bus cycle time Joms poms BBP Bolte E fae 25 32 20 32 A 32 20 32__ 25 32 12 23 20 30 28 32 30 32 Possible number of units connected to the bus NOTE 1 The exact value for number of units can not be established since it depends on the application If I Os in a Pluto unit changes state of
34. ected in series with 100m cable Eden 10 Spot 35 3 Spot 10 1 Tina 10 Maximum cable length without sensors for inputs using dynamic signals depending on capacitance Example 10x0 75 mm approx 1000 meter 49 2TLC172001M0211_A 14 Appendix Message and fault code list Note Reboot can either be made from PC computer or by power off on Status messages No Description O RR SS Run mode nn station number Lo Program load mode state Flashing Lo ready for self programming program found in other unit HA Program execution stopped from PC computer or not started after program download SR11 7 Can be started either from PC or by power off on Application specific user error controlled by SR_PlutoDisplay in the PLC program User faults No _ Fault and possible reason Dynamic output short circuited to foreign voltage Automatically reset IQ_ for illuminated push button function Missing diode Automatically reset Static output Q10 17 Q20 27 short circuited to OV or Automatically reset overloaded K button Static output Q10 17 Q20 27 short circuited to 24V Autom 3 min or K button Autom 3 min or K button Autom 3 min or K button Autom 3 min or K button Ert9 Other unit with same station number on Can bus lt o o Y Er23 Unmatched ID IDFIX doesn t match declaration in Exchange of identifiers or re prog
35. equipped with a termination resistor The bus connection should be made with a twisted pair cable to the CH and CL terminals Connection of CAN bus CH to CH and CL to CL A terminating resistor in each end of the bus Stubs are restricted to certain max length and shall not have terminating resistor AA ED ED FADED 39 2TLC172001M0211_A 9 1 1 Cable length The maximum cable length is depending on the bus speed Data Trunk Distance Stub length Rate Units connected on a Stub must not have termination resistors fitted 1 400 kbit s m 6m_ 20m AA 9 1 2 Connection of bus cable shield It is not clear which is the right solution for connection of the bus cable shield because there are different disturbances that can make influence on the system In some cases with high disturbances it can be necessary to test different solutions The figure below shows two alternatives Alternative 1 is the common solution giving a god protection against disturbances along the cable but have the disadvantage in that current in the shield can appear and by noisy supply voltage to Pluto it can also give problems Alternative 2 solves the problems with alternative 1 but does not give good protection against high frequency disturbances If the
36. etc The reason for this is that the signal will not have time to return to zero at higher frequencies This will be interpreted by Pluto and the function block as Speed 0 MK 1 Output p 10V 0 ov gt Sensor output Signal at low freguency Signal at too high freguency Pluto reads 0 speed Signal behaviour for sensor outputs with no active pull to OV 4 4 4 No Filt settings for counters For incremental encoders with HTL output and frequencies over 4 kHz the setting No Filt shall be selected For lower frequencies and use of for example standard proximity switches the option No Filt shall not be selected since the filter will give protection against disturbances 4 4 5 Speed monitoring with two sensors Overspeed Safe low speed etc With a two channel solution where 2 sensors monitor that the speed are within certain limits the application can reach Category 3 PL d or 4 PL e if diverse types of sensors are used As long as there is a speed the two sensors can be compared with each other and if one fails it is detected since they need to be equal Stand still monitoring dual channel For stand still monitoring with two sensors Category 3 PL d can be achieved This requires however that motion is detected regularly so that the application is tested A typical solution is every time a motion in a machine is started the PLC prog
37. geneous failure conditions redundant Monitoring if the measured values of both channels match together DC 2 60 2 standard sensors SIL3 PLe Measurement values lt 3 0mA resp lt 1 5V have to be handled as diverse redundant failure conditions Monitoring if the measured values of both channels match together DC 2 90 15 2TLC172001M0211_A 4 3 2 1 Connection of analogue voltage output sensors 0 10V It is important that the OV wire from the analogue sensor is connected directly to the terminal 0V on Pluto and not to OV somewhere else Otherwise current in the OV conductor may affect the measured analogue value e IAO IA1 IA2 O O lt Pluto D20 D45 24 V 0 10V OV o NO Avet euBis AO Sensor with 0 10V output OV supply to the sensor should be directly connected to Pluto OV When using long cables from the analogue sensor a current output sensor is to be preferred over a voltage output sensor since long cables may cause a voltage drop A current loop 4 20 mA is not affected by this 4 3 3 Analogue inputs 0 27V Depending on type there are one or more analogue inputs These inputs are connected to terminals for digital inputs example A20 15 B46 15 16 17 These analogue inputs are read by both processors and can therefore be used for safety applications In the PLC program the
38. gn voltage The button in the middle has one NC and one NO contact supplied by 24V The software requires that the inputs operate in opposition to each other A short circuit in the connecting cable will have the effect that both inputs will at sometime during the cycle be ON which the system does not accept The last emergency stop button uses a short circuit proof single channel technique A dynamic signal is converted by an inverter mounted close to the contact The input is configured just to accept the inverted result of the supplied dynamic signal A short circuit in the connecting cable will result in an incorrect signal being presented to the input which will not be accepted by the system 31 2TLC172001M0211_A 6 5 Safety devices with transistor outputs Certain safety devices on the market i e light curtains light beams scanners etc are designed with dual monitored safety 24V DC transistor outputs These devices monitor the output circuits by making short interruptions in the output signals Both channels can be connected to the system as static inputs Faults are detected by the safety device instead of by the Pluto system But note that at least one of the inputs must be of lO type I The short interruptions of the output signals are taken care of by the Pluto input filtering system O O SG VS g g a y e y ER y y 0 0 0 0 Cc E Le Le e
39. ht beams EDEN sensors etc that inverts the input signal In the software a configuration of the inputs must be made to decide which kind of input signal each input shall accept as logic 1 Other signals that do not match with the configured signal are regarded as 0 5 1 1 Connection of inputs I Input type _ can be connected to A B C A inverse B inverse C inverse or 24V The diagram below shows possible connections and how they are configured in the software Configured as dynamic output Example of software declaration 00 10 a_pulse Dyn A Bor C Direct connection to dynamic output Configured as dynamic input not inverted Example of software declaration 10 0 a_pulse non_inv Connection to dynamic input with inversion by either inverter or inverting safety device Example of software declaration 10 0 a_pulse Direct connection to 24V or safety device with transistor outputs Example of software declaration 10 0 static NOTE The connections are only to show how devices can be electrically connected and are not to be taken as connections for any specific applications AA ED ED PAIDID 27 2TLC172001M0211_A 5 1 2 Connection of in outputs IQ The lO type IQ_ have some restrictions If they are to be used as failsafe single channel inputs they must be configured as dynamic A A invers
40. ith each other to ensure integrity of data Each safety output is connected to both processors and cannot be set unless both have checked that the logic conditions in the application program are fulfilled Each Pluto unit has connections for CAN bus and can be interconnected with other Pluto units The degree of safety is the same over the bus as it is within each unit Pluto is designed for fulfilling the demands of the EU Machinery Directive 2006 42 EC regarding safety of control systems however the system can be used in other applications such as processing industry furnaces railways etc which have similar requirements Pluto is designed according to the following functional safety standards for control systems EN 954 1 Category 4 EN 62061 SIL3 EN 13849 1 Category 4 and Performance level e IEC 61508 SIL 3 IEC EN 61511 SIL 3 EN 50156 1 For an application to fulfil any of the standards above it is necessary that the design and installation of the complete safety related system not only Pluto including sensors and actuators fulfils the requirements 4 2TLC172001M0211_A 2 Enclosure Pluto is constructed in an enclosure for snap mounting on a DIN rail in control cabinets or other suitable enclosures External wiring is connected via screw terminals To make it easy and to avoid incorrect connection when a unit is exchanged the connector blocks are detachable so that individual wires do not have to be disc
41. le to evaluate the correctness There are two reasons for this O can be a consequence of an internal fault in Pluto Variables in the PLC code are then often set to O An analogue value close to 0 0 0 5V 0 0 5mA can be caused by wire break or other interruption of the connected sensor The use of 4 20mA or 2 10V range is therefore recommended Note If O signals are used the evaluation of the correctness must be performed by the application program 4 3 2 Possible architectures achievable safety levels and prerequisites This table is an overview of safety levels for different applications The achievable SIL PL depend on the sensor which is used in the application Achievable Prerequisites TT a necessary diagnostic to be realized in the application program 1 standard sensor SIL 1 PLe Measurement values lt 3 0mA resp lt 1 5V have to be handled as failure conditions DC 2 60 1 FS certified sensor SIL 2 PL d reno values lt 3 0mA resp lt 1 5V have to be handled as SIL 2 PL d failure conditions Eventual additional diagnostic measures mentioned in the safety manual of the sensor 1 FS certified sensor SIL 2 PL d Measurement values lt 3 0mA resp lt 1 5V have to be handled as SIL 3 PL e failure conditions Eventual additional diagnostic measures mentioned in the safety manual of the sensor 2 standard sensors SIL 2 3 PL d Measurement values lt 3 0mA resp lt 1 5V have to be handled as homo
42. max A20 B16 B20 S20 B22 D20 Pluto AS i 100 300 mA B46 S46 D45 B42 AS i 100 500 mA O2 100 mA Category Il according to IEC 61010 1 Failsafe inputs including counter inputs lO 11 12 IQ10 IQ11 Logic 1 Logic 0 Input current at 24V Max over voltage Analogue inputs 0 27V Range A20 family Double family Pluto B42 AS i Pluto AS i 24V for PNP sensors 24V for PNP sensors also configurable as non failsafe outputs gt 12V lt 8V 5 1 mA 27 V continuously 0 27 V Terminal 15 Terminal 15 16 and I7 Terminal 11 12 and 13 Terminal 110 111 112 and 113 Analogue inputs IAO 1A3 1A0 1A7 Range D20 D45 Resolution D20 Resolution D45 Accuracy D20 Accuracy D45 0 10V 4 20mA Impedance D20 0 10V 4 20mA Impedance D45 0 10V 4 20mA Counter inputs Pluto D45 Max frequency A ED ED AIDED 0 10 V 4 20mMA Terminal IAO lA1 IA2 lA3 Terminal IAO IA1 IA2 IA3 1A4 IA5 IA6 IA7 10 bits 12 bits 0 75 of full scale value 0 4 of full scale value 0 2 of full scale value gt 10 kQ 420 0 gt 10kQ 300 Q 14 kHz at 50 duty cycle 45 2TLC172001M0211_A Safety output Q2 Q3 Solid state 24V DC 800mA Output voltage tolerance Supply voltage 1 5V at 800mA Q0 Q1 Q4 Q5 Relay AC 12 250 V 1 5A AC 15 250 V 1 5A DC 12 50V 1 5A DC 13 24V 1 5A Pluto O2 QO Q1 13 14 23 24 Relay
43. nd dual channel safety DA L devices e O e ee ie The inputs can be supplied by 24V or by the dynamic signal outputs A B or C 12 2TLC172001M0211_A 4 2 1Q Digital failsafe inputs Digital outputs non failsafe This type of lO terminals provides 4 different functions Each terminal is connected to both processors and may therefore be used as a failsafe input Each terminal is also equipped with an output transistor giving the user the possibility to configure it as either a failsafe input or non failsafe output The outputs are intended for functions that do not require redundancy E g indicators and status signals CPU mt gp sl aU Al Current monitored only A20 Failsafe inputs Outputs non failsafe Dynamic outputs 4 2 1 Dynamic signals The IQ terminals can be configured as dynamic outputs A B or C for supplying inputs When an output is configured as dynamic a unique pulse train is generated A safety input can then be configured just to accept this specific pulse train as input condition and the system will detect external short circuit conditions See separate description 4 2 2 Current monitoring 1016 1017 Only A20 See 6 9 13 2TLC172001M0211_A 4 3 Analogue inputs 4 3 1 Analogue inputs 0 10V
44. on program SIL 1 E g Stand still is off at expected movement monitoring SIL 1 should not last in more than approx 1 hour homogeneous SIL 3 E g Stand still is off at expected movement monitoring SIL2 should not last in more than approx 1 hour diverse redundant SIL 3 E g Stand still is off at expected movement monitoring SIL2 should not last in more than approx 1 hour 4 4 7 1 Application examples ELA ER a VV Vid Y aa aa d avo Gat Fe ee TAS d oS Example with two incremental encoders Example of two channel solution with one encoder and a second channel from a frequency converter Cat 3 PL d SIL 2 AA ED ED FADED 21 2TLC172001M0211_A 4 5 Failsafe outputs 4 5 1 Relay outputs Each potential free relay output is made individually redundant by the use of two series connected relay contacts controlled by each processor A single output can be used to individually control a safety function however the outputs cannot detect short circuits in e g connection cables In addition to the output relays being controlled by separate processors the power to the relay coils are generated by charge pumps For description of function of charge pump see section on failsafe solid state outputs uP A d uP i ae S ch up N uP B e A O Principle for relay outputs
45. onnected TE TY z s4004 ni Wi GK Note that the power shall be off during connection and disconnection Electrical installation The system is powered by 24V DC The system has internal overcurrent protection but should be protected by an external fuse See technical data In installations with several Pluto units connected together via bus they must be installed in the same earthing system Proper potential equalization is necessary The Pluto is designed for applications which fulfil IEC EN 60204 1 and with special attention to Transformers shall be used for supplying the control circuits Where several transformers are used it is recommended that the windings of those transformers be connected in such a manner that the secondary voltages are in phase see EN 60204 1 9 1 1 These requirements are relevant for connection of the relay outputs For electrical safety reasons and in order to be able to detect safety critical earth faults in single channel circuits the OV terminal must be connected to protective bonding circuit see EN 60 204 1 9 4 3 1 Method a For installation in lifts according to EN 81 1 A3 and or EN 81 2 A3 it is required that Pluto is installed in enclosure at least IP54 The system is designed and tested for installation category ll according to IEC 61010 1 all connected circuits are supplied via control voltage transformers Cables and connected devices such as
46. outputs for the A20 family except B22 and D20 oa 108 Safe Output Relay Global Safe Output Transistor 1Q10 1Q17 where is the Pluto number Pluto bus Inputs individual failsafe A nd ke CH CL ae ea FD a fo tf oF IO 1 2 D 14 15 16 17 I20 I21 122 123 124 125 Al Pluto B22 SR41 IQ10 1Q11 lQ12 1013 lQ14 1015 lQ16 1Q17 i i l 4 l 4 a a ID OV 24V 0 hd hd Identifier v Failsafe inputs Indication outputs not failsafe Dynamic outputs input Power VO overview PLUTO B22 Inputs and outputs for Pluto B22 Terminal on Pluto In Output name in software l O type Local Global 10 17 lOd Safe Input Global 120 125 120 125 Safe Input Local 1Q10 1Q17 Can Um Safe Input Global Q_ 10 Q_ 17 Nonsafe Output where is the Pluto number 6 2TLC172001M0211_ A Inputs individual failsafe Transistor output Pluto bus individual failsafe 0 10V 4 20mA e e 2 2 zi 2 D M Si mA a ay DI DI DI DI DI DI DI DI J a A Al Al Al Al Al AR Pluto D20 0 24V Q2 Q3 IQ10 1Q11 lQ12 1Q13 lQ14 lQ15 1016 lQ17 QO Q1 A A i i i l 4 R ii ID OV 24V 0 Ke nd K 0 eo Ka Identifier Failsafe inputs Indication outputs not failsafe Dynamic outputs Relay output input Power individual failsafe VO overview PLUTO D20 Inputs and outputs for Pluto D20 In Output name in software I O type Local Global OI
47. ple a feed back from another system such as frequency converter The independent source of the speed information must be proven Stand still monitoring single channel For stand still monitoring with one sensor Category 2 PL c can be achieved under the requirement that the sensor application is automatically cyclically tested The interval is typically several times a day One solution for testing is to read the speed value at every cycle start and stop of the machine cycle Every time a motion in a machine is started the PLC program requires a corresponding reaction from the sensor At start the program can check that the sensor value changes from stand still to an expected speed within a certain time At stop command the program can check that the speed value decreases down to stand still NOTE Interruption in the cabling to a sensor will lead to that Pluto reads speed At stand still monitoring this is loss of safety function if it happens during a stop This is however according to the definition of category 2 20 2TLC172001M0211_A 4 4 7 Possible architectures achievable safety levels and prereguisites This table is an overview of safety levels for different applications The achievable Cat SIL PL depends on the sensor which is used in the application and the detection capability of faults listed in IEC 61800 5 2 table D 16 beer Le Achievable Prerequisites necessary diagnostic to be Cat PL SIL realized in the applicati
48. ram declaration of identifier in program Erroneous PLC code Invalid PLC instructions Reload with valid PLC program Er25 For versions as B16 or B22 Non existing output used in E program Er26 Baud rate conflict Unit programmed for other baud rate Reprogramming or reboot than current bus baud rate Note that Pluto must be rebooted after change of baudrate in the PLC program Er28 PLC program does not match the Pluto family Change to other type of Pluto Families A B S D 20 16 22 B S D 45 46 Pluto AS or change the program B42 AS i Er29 Unsupported program version The program contains Update of operating system aaa WA operating systems See below Er30 Unsupported function block used See below Update of operating system Er31 IDFIX PROG program mismatch Load program to flash memory with K button Combined with LED flashing for the affected I O Additional information can be retrieved via Pluto Manager 50 2TLC172001M0211_A I O faults No _ Fault and possible reason Er40 Error safety output Q2 or Q3 K button Q2 Q3 connected together or to other negative voltage Q2 Q3 has too high capacitive load positive voltage monitoring when output is off Error relay output Self test of transistors Error relay output Internal relay does not switch on K button Er45 Analogue functions not calibrated System must be calibrated Can be reset wi
49. ram requires a corresponding reaction from the sensors speed sources Note that in machines vibrations can cause indication of small speed values AA ED ED PAIDID 19 2TLC172001M0211_A Interruption in the cabling to a sensor will lead to that Pluto read 0 speed from that sensor Such fault must therefore be detected in the application by using two independent sensors that are automatically cyclically checked with regard to that there is motion in the machine at least a couple of times per day Note By use of two encoders which are compared with each other faults in one sensor are monitored The encoder can normally be of same type since the same fault in the two sensors in the same time is unlikely But to get even higher degree of safety two of different type can be used in order to achieve diversity This diversity minimises the risk of common cause failures 4 4 6 Speed monitoring with one sensor Overspeed Safe low speed etc With a single sensor normally Category 2 PL c is reached However by monitoring of dynamic behaviour in the application it is possible to reach Category 3 PL d Such monitoring for safe low speed monitoring SLS can be 1 When the motion in the machine is stopped Pluto checks that the sensor also indicates a stop Then when the motion is started the program checks that the sensor value changes from indicating stop to the expected speed 2 Another solution is to compare the sensor value with for exam
50. seeceeecsueeecausecsueeecseeecsueessueeesaeeesseeessaeeees 19 4 4 4 No Filt settings for COUNTENS cccecceecceeeceeeceeeceeeceueeseeeneeeneeneeeeeeseeeteeseeeseeeteeeseeenaes 19 445 Speed monitoring with wo Sensors cccoccccoccnccccnnconcncnonononnnnnnnncnnonnnonnnnonnnnnnnnnnnonnnnnnanoss 19 4 4 6 Speed monitoring with onesensor 20 4 4 7 Possible architectures achievable safety levels and prereguisites 21 44l Application example EE 21 4 5 Failsafe e ET 22 4 5 1 AA AAA 22 4 5 2 Solid state safety outputs occcconcccooccncccnnnonnnnnnncnnnnononnnnonnnnnnnnnnnnnnnnnnrnnnnnnnnnnnnnnnnnnnnnaness 22 EE Eet 23 Are Da Mee liebe ge 23 4 6 Tee IA AAA EE 24 4 6 1 o A AA 24 4 6 2 Reading safety slaves cnt aia 25 4 6 3 VE IA E 25 4 6 4 WIOGESS lt Ol OD Sl ATOM yaad EE 26 4 6 5 Exchange of Safety slaves after Commssioninmg 26 4 6 5 1 Exchange of non safe slaves after commissioning coocccccconncnococoninonenaninnnnnnnonononanenanos 26 5 Connection Of le D 27 5 1 Ref det Signals APO jo e E OO EE RR Eei 27 5 1 1 Sora IA 27 5 12 Connection OF IN OUTDUTS 1G NAI 28 6 Connection of salety Le 29 6 1 Dual eil EE ET 29 6 2 Single channel ovstems kununu nu kuniuwa kani nani makin kanuna 30 6 3 Emergency SI N IAA 30 6 4 Monitoring of external short ei Lei TI 31 6 5 Safety devices with transistor oufpoute 32 6 6 Safety mats and salety Canes esencias 32 6 7 Two and A PA 33 6 8 Illuminated push bu
51. ten it produces more CAN telegrams NOTE 2 The prolongation of response time for I O over the bus is equal with the Bus cycle time 41 2TLC172001M0211_A 10 Identifier The identifier is an external component that can be connected to the ID and OV terminals The circuit contains a unique ID number that can be read by the system In the PLC program the identifier number can be declared which connects the program so that it will only work together with the correct identifier The use of identifier is voluntary as long as a unit works alone but if an identifier is connected to the unit and the PLC program is declared to work without the program will not run The function gives a protection against a unit being exchanged by mistake The identifier circuit should be securely fastened to the physical location of the unit by e g tie it together with other connection conductors ID OV gt Black ac N Blue Connection of identifier When a number of Pluto units are interconnected with the bus identifiers are necessary The units are numbered 0 31 In the application program it is necessary to declare which identifier number has to be connected to which Pluto unit 0 31 Example id_pluto 01 023474526654 There are several types of identifier circuits available IDFIX R pre programmed The number is programmed by the circuit manufacturer who guarantees that two circ
52. th K button but analogue value will be 0 Analogue input error See below Automatically reset Positive voltage on Q2 and or Q3 Automatically reset Combined with LED flashing for the affected I O Additional information can be retrieved via Pluto Manager CPU faults No Faultand possible reason ________ Resetaction Input data difference between processor A and B Reboot Processor and B reads an input differently The fault is often caused by a bad sensor Er51 Output data difference between processor A and B Reboot Processor A and B sets a global variable differently Check PLC program Q0 Q3 GMO0 11 See below Er52 No answer from any internal relay when output is off Reboot Both relays stuck Er58 AS i safety code table CRC error Reboot Teach AS i safety codes Reboot Er59 Reboot Er64 OS flash CRC Reboot Reload operating system OS 5 volt under over voltage monitoring See below System error No communication AUX processor System error Wrong program version CRC error Reload operating system OS Reboot Reboot Combined with LED flashing for the affected 1 0 Additional information can be retrieved via Pluto Manager AA ED ED PAIDID 51 2TLC172001M0211_A Fault and possible reason Reset action AS i No i AE 01 ASi power missing Automatically reset AE 02 No connection with ASi master in Monitor mode Automatically reset
53. the solution can only be regarded as category 3 PL d Dual channel application In the application there is normally some trip out function when a limit value is passed such as over temp overpressure etc Since there in process industry are applications which do not trip out under normal operation a test procedure should be implemented especially for test of the sensors Such test can be a manual test once a year 4 3 1 1 2 Single channel solution A safety function with a single sensor using a single input gives category 2 PL b c SIL 2 Factors which have influence on the safety level are lf there is a dynamic behaviour in the application that is predictable If wire break or other interruptions of the signal is detected Input values close to OV and OmA can be used as fault condition by using for example 4 20mA as correct values lf the sensor value can be compared with another value from another source This can however be seen as a dual channel solution f automatic test procedure can be implemented Protected cables The cables can be protected against mechanical damage and separated from other cabling F type approved sensor A maximum of Category 2 PL d SIL2 is achievable with approved sensors A ED ED AIDED 14 2TLC172001M0211_A 4 3 1 2 0 Volt In general 0 or close to O volt mA cannot be trusted as a true signal except when there is a dynamic behaviour in the application which makes it possib
54. to number Pluto AS i can also read inputs and set outputs in AS i slaves connected to the AS i bus The different slave types are explained further in chapter 4 5 2 Slave types and the corresponding Pluto configurations for these are explained in the Pluto Programming Manual 11 2TLC172001M0211_A Safe inputs Dynamic outp 24V 1 5A 250VAC 5A Non safe outp O oO OO OO CL CH CSh A 33 34 13 14 23 24 B IO IQ10 dl i Pluto O2 SR Safety Output Module Q1 Q11 A 1 B 24V OV ID U PA z e e34 GH eit Sch on Non safe outp Power supply Dynamic outp 24V 1 5A 250VAC 5A Safe inputs VO overview PLUTO O2 Inputs and outputs for Pluto O2 Terminal on Pluto In Output name in software I O type Local Global IO 11 Safe Input for monitoring Global Q0 13 Q0 34 Safe Output Relay Global Q0 Q1 13 Q0 34 Safe Output Relay Global IQ10 IQ11 10 11 Safe Input Global Q_ 10 Q_ 11 Nonsafe Output Local is the Pluto number where _ Pluto O2 is a safety output module with two relay output groups with three contacts each Pluto O2 is also equipped with two safe inputs for monitoring and two combined safe in non safe outputs IQ 41 l Digital failsafe inputs Each input is separately connected to both processors which facilitating both single channel a
55. tton FUNCTION oocccocccocnconcnnncnonnconononcnnconnnncnnnnoncnnnnnonnnnnonnnnnnrncnaninons 34 6 9 Monitoring of muting lamp only A2 34 7 Solace HOM OF ue 35 2 2TLC172001M0211_A 7 1 Sora EE gie eo 35 8 Example Of appliCalONS siicinoinanas idea 38 9 PIUS DUS COMUNICA HON EE 39 9 1 BUS Cab ING D 39 9 1 1 A een ee o EE eee 40 9 1 2 Connection of bus Cable held 40 9 1 3 Optional protection against conducted dsturbances 41 9 2 Response time Over febus cece ceeccceeeeceeeceeeeeseeeseeeceeeceueeseeeceueeseuseseueeseeessneeseeesanes 41 10 A eiii ceci 42 11 mio o Ie PP 44 11 1 Self programming by exchange Of Pluto 44 12 E ue EE 45 13 Keller Be AAA 45 13 1 Connection Of sensors kuna kunanu nan naaunuwa 49 14 Appendix Message and fault code liSt oocococcccccnccccnconnonanononnccncnconcncnncnnnanonanonos 50 3 2TLC172001M0211_A 1 General Pluto is a programmable safety system intended for safety applications where it is not accepted that faults in the control system lead to loss of a safety function To achieve this requirement the system is designed with integral redundancy and monitoring Unlike ordinary PLC systems Pluto utilizes two microprocessors which both control and monitor each safety function for correct operation Each input to the system is separately connected to each processor each having their own memory and executing their own program The processors continuously compare the results w
56. uits with the same number do not exist IDFIX RW programmable The number can be programmed by the user IDFIX DATA programmable amp data storage For Pluto AS i and B42 AS i The number can be programmed by the user and safety codes of AS i safe slaves can be stored IDFIX PROG 2k5 IDFIX PROG 10k programmable data amp PLC program storage For Pluto with OS version 2 50 or higher PROG 2k5 2 52 3 2 or higher PROG 10k This IDFIX has enough memory to also store the PLC program maximum size IDFIX PROG 2k5 2 3 kbyte IDFIX PROG 10k 10 kbyte Only one Pluto is allowed in the project and the IDFIX code is always EEEEEEEEEEEO PROG 2k5 or EEEEEEEEEEE2 PROG 10k Can be used to store AS i safety codes in the same way as IDFIX DATA When a program is downloaded to Pluto the IDFIX PROG will automatically be updated lf there is a difference between the program in the IDFIX PROG and the flash memory then Er31 willbe displayed and PLC program execution is prohibited This is checked at program download and at boot time AA ED ED PAIDID 42 2TLC172001M0211_A The PLC program in IDFIX PROG can be loaded into flash memory by pressing the K button in the same way as self programming over the CAN bus This can be done when Pluto displays error message Er20 No program loaded Er24 Erroneous PLC program or Er31 IDFIX PROG program mismatch Programmable identifiers IDFIX RW and IDFIX DATA can for e
57. uts and 4 outputs AS i profile S 7 A 7 Analogue input slaves This is a non safe analogue input slave which can have up to 4 input channels Pluto supports Analogue slaves with AS i profile S 7 3 x where x can be C F depending on number of channels C 1 channel D 2 channels E 4 channels F 4 channels Analogue output slaves This is a non safe analogue output slave which can have up to 4 output channels Pluto supports Analogue slaves with AS i profile S 7 3 x where x can be 4 6 depending on number of channels 4 1 channel 5 2 channels 6 4 channels Safe Output A safe slave has at this moment one safe output and a special function block is needed for the PLC program This slave is usually combined with a non safe slave for feedback status Even if this non safe slave is included in the same housing as the safe output slave they have different addresses and they are treated as two separate slaves by Pluto Pluto can handle up to 16 PlutoAsSafelnput SafeOutput slaves A ED ED AIDED 25 2TLC172001M0211_A Pluto as Safe Input This is the setting for a Pluto that is used as a safe input slave A special function block PlutoAsSafelnput is needed for the PLC program Configuration of the safe input and non safe outputs are the same as for the ordinary Safe input slave Pluto can handle up to 16 PlutoAsSafelnput SafeOutput slaves 4 6 4 Modes of operation Pluto has three
58. value can be read in system registers See Pluto Programming Manual AA ED ED PAIDID 16 2TLC172001M0211_A 44 Counter inputs Pluto D45 For Pluto D45 the inputs IAO IA3 can be configured as counter inputs pulse counting which work for frequencies up to 14000 Hz As counter inputs IAO IA3 can be used in two ways Up counting or Up Down counting Type of signal Counter input el JU No_Filt Undefined Ml Undefined E 4 4 1 Up count When the input is configured for Up count Pluto counts the pulses on the input Via a function block the user gets the pulse rate which for example can represent a speed The sensor is typically a proximity switch or photocell For description of the use of Function blocks see Pluto Programming Manual ERR Example of sensor solution for speed monitoring The sensors can for example be proximity switches or photocells Any of the inputs lAO0 A3 can be used 17 2TLC172001M0211_A 4 4 2 Up Down count m No Pit a E Counter input e 1A0 1 Counter input In order to determine the direction of a movement input IAO and IA2 can be configured as Up Down counters When this is done the next input IA1 or IA3 is automatically reserved for Up Down counting This means that for Up Down counting IAO IA1 are a pair and IA2 1A3 are another pair In order to make up down counting it requires
59. xample be used where it is required to deliver units with the same PLC program e g for a special machine or safety application AA ED ED PAIDID 43 2TLC172001M0211_A 11 Programming The development of application programs Pluto PLC program is made with a standard Personal Computer using a specially developed software Pluto Manager Communication between the PC and the Pluto is made via the PC Com Portor USB port The link facilitates program down loading and monitoring of inputs outputs memory timers etc with the PC on line See separate programming manual for further information 11 1 Self programming by exchange of Pluto In applications with several Pluto units connected together with the Pluto CAN bus it is possible to exchange a unit and let it self load PLC program from another Pluto on the bus This is possible since in a program project with at least two Pluto units all of them are loaded with the same program file and this file has program for all units The following conditions are required The new Pluto must be empty of PLC program showing Er20 Pluto O2 Error LED On with short off periods 1200 80 ms The new Pluto must be member in a Pluto program project The IDFIX must NOT be exchanged Note that the connector blocks are detachable For Pluto AS i the IDFIX must be of type IDFIX DATA or IDFIX PROG Otherwise the Teach safety codes procedure has to be performed

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