Original instructions PLUTO Safety-PLC Operating instructions Hardware English v12A 2TLC172001M0212_A Table of contents: 1 General ............................................................................................................................ 4 2 Enclosure ......................................................................................................................... 5 3 Electrical installation ......................................................................................................... 5 4 Inputs and outputs ............................................................................................................ 6 4.1 I.. Digital failsafe inputs .................................................................................................. 12 4.2 IQ.. Digital failsafe inputs / Digital outputs (non failsafe) ................................................. 13 4.2.1 Dynamic signals ............................................................................................................. 13 4.2.2 Current monitoring IQ16, IQ17 (Only A20) ...................................................................... 13 4.3 Analogue inputs.............................................................................................................. 14 4.3.1 Analogue inputs 0-10V / 4-20mA (Pluto D20 and D45) ................................................... 14 4.3.1.1 Safety in application ....................................................................................................... 14 4.3.1.1.1 Dual channel solutions ................................................................................................... 14 4.3.1.1.2 Single channel solution ................................................................................................... 14 4.3.1.2 0 Volt .............................................................................................................................. 15 4.3.2 Possible architectures, achievable safety levels and prerequisites ................................. 15 4.3.2.1 Connection of analogue voltage output sensors (0-10V) ................................................ 16 4.3.3 Analogue inputs (0 – 27V) .............................................................................................. 16 4.4 Counter inputs Pluto D45 ............................................................................................... 17 4.4.1 Up count ......................................................................................................................... 17 4.4.2 Up/Down count ............................................................................................................... 18 4.4.3 Sensor output types ....................................................................................................... 19 4.4.4 “No Filt” settings for counters .......................................................................................... 19 4.4.5 Speed monitoring with two sensors ................................................................................ 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 4.5.2.1.2 Using Pluto safety outputs Q2 and Q3 for ABB AF contactors ........................................ 23 4.6 AS-Interface bus (AS-i) ................................................................................................... 25 4.6.1 AS-i connection .............................................................................................................. 25 4.6.2 Reading safety slaves .................................................................................................... 26 4.6.3 Slave types ..................................................................................................................... 26 4.6.4 Modes of operation ......................................................................................................... 27 4.6.5 Exchange of Safety slaves after commissioning ............................................................. 27 4.6.5.1 Exchange of non-safe slaves after commissioning ......................................................... 27 5 Connection of inputs ....................................................................................................... 28 5.1 Dynamic signals ............................................................................................................. 28 5.1.1 Connection of inputs, I.. .................................................................................................. 28 5.1.2 Connection of in-/outputs IQ.. ......................................................................................... 29 6 Connection of safety devices .......................................................................................... 30 6.1 Dual channel systems .................................................................................................... 30 6.2 Single channel systems .................................................................................................. 31 6.3 Emergency stop ............................................................................................................. 31 6.4 Monitoring of external short circuit .................................................................................. 32 6.5 Safety devices with transistor outputs ............................................................................. 33 6.6 Safety mats and safety edges ........................................................................................ 33 6.7 Two-hand control ............................................................................................................ 34 6.8 Illuminated push button function ..................................................................................... 35 6.9 Monitoring of muting lamp (only A20) ............................................................................. 35 2 2TLC172001M0212_A 7 Connection of outputs..................................................................................................... 36 7.1 Connection examples ..................................................................................................... 36 8 Example of applications .................................................................................................. 39 9 Pluto bus communication ............................................................................................... 40 9.1 Bus cabling ..................................................................................................................... 40 9.1.1 Cable length ................................................................................................................... 41 9.1.2 Connection of bus cable shield ....................................................................................... 41 9.1.3 Optional protection against conducted disturbances ....................................................... 42 9.2 Response time over the bus ........................................................................................... 42 10 Identifier ......................................................................................................................... 43 11 Programming .................................................................................................................. 45 11.1 Self programming by exchange of Pluto ......................................................................... 45 12 Cleaning ......................................................................................................................... 46 13 Technical data ................................................................................................................ 46 13.1 Connection of sensors .................................................................................................... 50 14 Appendix - Message and fault code list .......................................................................... 51 3 2TLC172001M0212_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