ABB PLUTO Safety-PLC Operating Instructions Manual Download Page 1

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Original instructions

English v11A

2TLC172001M0211_A

PLUTO

Safety-PLC

Operating instructions

Hardware

Summary of Contents for PLUTO Safety-PLC

Page 1: ...Original instructions English v11A 2TLC172001M0211_A PLUTO Safety PLC Operating instructions Hardware ...

Page 2: ...s 19 4 4 6 Speed monitoring with one sensor 20 4 4 7 Possible architectures achievable safety levels and prerequisites 21 4 4 7 1 Application examples 21 4 5 Failsafe outputs 22 4 5 1 Relay outputs 22 4 5 2 Solid state safety outputs 22 4 5 2 1 Test pulses 23 4 5 2 1 1 Disabling of test pulses 23 4 6 AS Interface bus AS i 24 4 6 1 AS i connection 24 4 6 2 Reading safety slaves 25 4 6 3 Slave types...

Page 3: ...e length 40 9 1 2 Connection of bus cable shield 40 9 1 3 Optional protection against conducted disturbances 41 9 2 Response time over the bus 41 10 Identifier 42 11 Programming 44 11 1 Self programming by exchange of Pluto 44 12 Cleaning 45 13 Technical data 45 13 1 Connection of sensors 49 14 Appendix Message and fault code list 50 ...

Page 4: ...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 othe...

Page 5: ...l 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 0V terminal...

Page 6: ...software I O type Local Global I0 I7 I_ 0 I_ 7 Safe Input Global I20 I25 I_ 20 I_ 25 Safe Input Local IQ10 IQ17 I_ 10 I_ 17 Safe Input Global Q_ 10 Q_ 17 Nonsafe Output Local where _ is the Pluto number Failsafe inputs Indication outputs not failsafe Dynamic outputs IQ10 IQ11 Power 0V 24V Pluto bus CL IQ12 IQ13 input ID Identifier CH IQ15 IQ14 IQ16 I0 Inputs individual failsafe IQ17 I1 I2 I3 I4 I6...

Page 7: ..._ 3 Safe Output Transistor Global IQ10 IQ17 I_ 10 I_ 17 Safe Input Global Q_ 10 Q_ 17 Nonsafe Output Local where _ is the Pluto number Failsafe inputs Indication outputs not failsafe Dynamic outputs IQ10 IQ11 Power 0V 24V Pluto bus CL IQ12 IQ13 input ID Identifier CH IQ15 IQ14 IQ16 IA0 B B individual failsafe Transistor output Relay output individual failsafe B B Inputs individual failsafe Q0 IQ17...

Page 8: ...nput Global Q_ 10 Q_ 17 Nonsafe Output Local IQ20 IQ27 I_ 20 I_ 27 Safe Input Local Q_ 20 Q_ 27 Nonsafe Output Local where _ is the Pluto number Failsafe inputs Outputs not failsafe Dynamic outputs IQ10 IQ11 supply Power 24V IQ12 IQ13 Identifier IDFIX IQ15 IQ14 IQ16 I30 B Inputs individual failsafe Q0 IQ17 I31 I32 I33 I34 I35 I36 Q2 A I37 Pluto B46 S46 Pluto bus I45 I40 I41 I42 I43 I44 I46 I47 Inp...

Page 9: ...ocal IQ10 IQ17 I_ 10 I_ 17 Safe Input Global Q_ 10 Q_ 17 Nonsafe Output Local IQ20 IQ26 I_ 20 I_ 26 Safe Input Local Q_ 20 Q_ 26 Nonsafe Output Local where _ is the Pluto number Failsafe inputs Outputs not failsafe Dynamic outputs IQ10 IQ11 supply Power 24V IQ12 IQ13 Identifier IDFIX IQ15 IQ14 IQ16 I30 B Inputs individual failsafe Q0 IQ17 I31 I32 I33 I34 I35 I36 Q2 A I37 Pluto D45 Pluto bus I45 I4...

Page 10: ..._ 10 Q_ 17 Nonsafe Output Local IQ20 IQ27 I_ 20 I_ 27 Safe Input Local Q_ 20 Q_ 27 Nonsafe Output Local ASi AS i bus ASi where _ is the Pluto number IQ25 IQ24 IQ23 IQ22 IQ27 IQ26 B A A Q1 B A Q4 B Q5 A B Q3 B A 0V 0V ID CH CL AI AI AI SR46 SR45 SR41 4L 1L 0L Failsafe inputs Outputs not failsafe Dynamic outputs Power Identifier IDFIX Inputs individual failsafe Pluto bus Inputs individual failsafe S...

Page 11: ... ASi where _ is the Pluto 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 ASI IQ11 IQ12 IQ13 IQ10 Outputs not failsafe Dynamic outputs DI Failsafe inputs Analogue inputs AI AI ...

Page 12: ...three contacts each Pluto O2 is also equipped with two safe inputs for monitoring and two combined safe in non safe outputs IQ 4 1 I Digital failsafe inputs Each input is separately connected to both processors which facilitating both single channel and dual channel safety devices The inputs can be supplied by 24V or by the dynamic signal outputs A B or C CL I0 CH ID Pluto O2 IQ10 Q1 B IQ11 33 A 1...

Page 13: ...or functions that do not require redundancy E g indicators and status signals 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 ci...

Page 14: ...e physical values must be dynamic and must not be static In case that the physical values are almost static then for category 4 a test must be performed daily If not the solution can only be regarded as category 3 PL d 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...

Page 15: ...he application Structure Achievable SIL PL Prerequisites necessary diagnostic to be realized in the application program 1 standard sensor SIL 1 PL c Measurement values 3 0mA resp 1 5V have to be handled as failure conditions DC 60 1 FS certified sensor SIL 2 PL d SIL 2 PL d Measurement values 3 0mA resp 1 5V have to be handled as failure conditions Eventual additional diagnostic measures mentioned...

Page 16: ...ce 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 I5 B46 I5 I6 I7 These analogue inputs are read by both processors and can therefore be used for safety applications In the PLC program the value can be read i...

Page 17: ... 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 IA0 µA µB 24V Pluto IA4 µB µB µA IA1 IA3 µA µA µB 0V 24V 0V T R Example of sensor solution for speed monitoring The sensors can for exa...

Page 18: ...ypically a incremental encoder 24V HTL For description of the use of Function blocks see Pluto Programming Manual Typical devices are rotary incremental encoders 24V HTL A B Illustration of A and B pulses A and B are 90 phase shifted 0V 24V IA0 µB µA IA1 µA µB A B A B µB IA3 IA2 24V 0V µA µB µA Pluto Example of speed monitoring with incremental encoders leaving A and B pulses to two inputs IA0 IA1...

Page 19: ...ed 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 monitori...

Page 20: ... 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 example 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...

Page 21: ...ncoder Overspeed Cat 2 PL c SIL 1 Monitoring of dynamic behavior E g Stand still is off at expected movement Stand still monitoring Cat 2 PL c SIL 1 Monitoring of dynamic behavior Stand still should not last in more than approx 1 hour 2 sensors encoders homogeneous redundant Overspeed Cat 3 PL d SIL 3 Monitoring of dynamic behavior E g Stand still is off at expected movement Stand still monitoring...

Page 22: ...age 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 ca...

Page 23: ...ts Q2 and Q3 are cyclically switched off during 100 200 µs so called 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 Principle for solid state safety outputs Diagram showing output voltage with test pulses ...

Page 24: ... 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 Pluto Bus To other Pluto units Pluto Safety E stop Bus Master Monitor only Monitor slave Q2 I6 IQ10 Q3 IQ11 I7 I5 I3 I1 CH I2 CL I0 I4 24V ID 0V IQ17 IQ15 IQ13 ...

Page 25: ...ave 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 ca...

Page 26: ...ssioning 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 ...

Page 27: ...with the configured signal are regarded as 0 5 1 1 Connection of inputs I Input type I_ 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 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 Dyn A B or ...

Page 28: ... WARNING OK I IQ_ Reset IQ_ OK IQ_ IQ_ WARNING IQ_ OK OK OK IQ15 IQ16 IQ_ Dyn A B or C IQ_ IQ_ IQ terminals only connected to 24V fulfils category 4 by combination with another dynamic input IQ terminals connected to 24V does not fulfil category 4 IQ terminal connected to 24V fulfils the safety requirements used for reset start etc Example of declaration I0 17 static with diode current from input ...

Page 29: ...n 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 Possible solutions for dual channel inputs with detection of external short circuits A normal connection of several dual channel devices One dynamic signal combined with stat...

Page 30: ... 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 I 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 f...

Page 31: ...r foreign 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 d...

Page 32: ...e short interruptions of the output signals are taken care of by the Pluto input filtering system 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 dua...

Page 33: ... 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 Dyn 24V Dyn 24V Classic two hand Safeball Examples of two hand control ...

Page 34: ...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 IQ16 and IQ17 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 ful...

Page 35: ... 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 cabine...

Page 36: ...tection 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 B Q1 A 0V Q2 B A Monitoring 0V IQ_ 24 I_ IQ_ I_ IQ_ Monitoring IQ_ 24 24V 24...

Page 37: ...nsion 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 ...

Page 38: ...38 2TLC172001M0211_A 8 Example of applications ...

Page 39: ...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 W must be installed When a Pluto unit is working alone and no bus cable is connected it must still be equipped with a termination resistor The bus connection shou...

Page 40: ...sy 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 Pluto units are mounted close to each other in the same cabinet the shield can be omitted Both ends connected to earth Cabinet Cabinet Inside cabinet B42 AS i Connect to CS terminal or CS terminal or CS terminal K K K...

Page 41: ...me 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 re...

Page 42: ...e several types of identifier circuits available IDFIX R pre programmed The number is programmed by the circuit manufacturer who guarantees that two circuits with the same number do not exist IDFIX RW programmable The number can be programmed by the user IDFIX DATA programmable 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 ca...

Page 43: ...ing 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 example be used where it is required to deliver units with the same PLC program e g for a special machine or safety application ...

Page 44: ...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 as well Procedure Switch off power and exchange Pluto Switch power on and after a few s...

Page 45: ...inputs including counter inputs I0 I1 I2 24V for PNP sensors IQ10 IQ11 24V for PNP sensors also configurable as non failsafe outputs Logic 1 12V Logic 0 8V Input current at 24V 5 1 mA Max over voltage 27 V continuously Analogue inputs 0 27V Range 0 27 V A20 family Terminal I5 Double family Terminal I5 I6 and I7 Pluto B42 AS i Terminal I1 I2 and I3 Pluto AS i Terminal I10 I11 I12 and I13 Analogue i...

Page 46: ...24 Relay AC 12 250 V 5 A AC 15 250 V 3 A DC 12 60 V 5 A DC 13 24 V 3 A 33 34 Relay AC 12 AC 15 DC 12 DC 13 24 V 1 5 A Outputs non failsafe IQ10 IQ11 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 2 5 A B46 S46 D45 B42 AS i IQ10 17 2 A IQ20 27 2A Pluto AS i IQ10 13 2 A Current monitoring IQ16 IQ17 Only Pl...

Page 47: ...ecution time Non safe output Q10 Q11 29 ms prog execution time Software setting NoFilt Response times 5 ms 5 ms less Response time AS i bus Solid state output 16 5 ms prog execution time Relay output 20 5 ms prog execution time Response time AS i bus at fault condition Solid state output 29 ms with setting Short stop time 39 ms with setting Disturbance immunity Relay output 33 ms with setting Shor...

Page 48: ...Up to 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 5 x 10 4 1 5 x 10 3 PFHD according to EN 62061 IEC 61508 1 6 x 10 9 5 8 x 10 9 MTTFd 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...

Page 49: ...ors Maximum number of sensors that can be connected 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 ...

Page 50: ...resistor etc Autom 3 min or K button Er19 Other unit with same station number on Can bus Er20 PLC program not loaded Load of PLC program Er21 PLC program CRC error Reload with valid PLC program Er22 IDFIX problem External IDFIX can not be read Reboot Replace IDFIX Er23 Unmatched ID IDFIX doesn t match declaration in program Exchange of identifiers or re declaration of identifier in program Er24 Er...

Page 51: ...sed by a bad sensor Reboot Er51 Output data difference between processor A and B Processor A and B sets a global variable differently Q0 Q3 GM0 11 See below Reboot Check PLC program Er52 No answer from any internal relay when output is off Both relays stuck Reboot Er58 AS i safety code table CRC error Reboot Teach AS i safety codes Er59 Calibration analogue functions CRC fault Reboot Er60 System e...

Page 52: ...ion of new safety slave CF Code Found Code in new safety slave is available Acknowledge with K button Cd 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 Indicat...

Page 53: ...t switched on Run On PLC run Off PLC not running Flash PLC in halt by Pluto Manager Error 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 Q1 On Output on Flash Fault No answer monitor contact Not switched on I1 On Input on Flash Two channel faul...

Page 54: ...AS i O2 Used harmonized standards EN ISO 13849 1 EN 954 1 EN 62061 EN 61496 1 EN 574 EN 692 EN 60204 1 EN 50178 EN 61000 6 2 EN 61000 6 4 EN 61000 4 1 6 Directive 2006 42 EC Directive 2006 42 EC Directive 2006 42 EC Directive 2006 42 EC Directive 2006 42 EC Directive 2006 95 EC Directive 2006 95 EC Directive 2004 108 EC Directive 2004 108 EC Directive 2004 108 EC Other used standards and documents...

Page 55: ...derek kelly ie abb com Israel ABB Technologies Ltd Tel 972 4 851 9204 Mobile 972 52 485 6284 E mail contact il abb com Web www abb co il Italy ABB S p A Tel 39 02 2414 1 Fax 39 02 2414 2330 Web www abb it Korea ABB KOREA Low voltage Product Tel 82 2 528 3177 Fax 82 2 528 2350 Web www jokabsafety co kr Malaysia ABB Malaysia Tel 60356284888 4282 E mail chang sheng saw my abb com Netherlands ABB b v ...

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