ABB PLUTO Safety-PLC User guide

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Startup guide for Pluto Safety PLC, connected in a bus system
1. Check the bus cable
·How many meters of bus cable have been
used?
·Is the system connected with stub
cables?
·How long is each stub?
·What is the total length of stub cables?
·Resistors for end termination must only
be connected in the beginning and the
end of the system.
·When measuring the resistance between
CH and CL at one Pluto (all units shall be
dead) the resistance shall be somewhat
under 60 Ω.
The following data are necessary to select the correct communication speed in the system. A lower speed
gives the possibility to communicate over a longer distance, but it results in that somewhat fewer Pluto’s can
be connected. A more detailed description can be found in the Pluto Hardware Manual, chapter Bus
communication.
Bus speed
Cable length
Stub length
Total stub length
100 kbit/s 600 m 25 m 120 m
125 kbit/s 500 m 20 m 100 m
200 kbit/s 300 m 13 m 70 m
250 kbit/s 250 m 10 m 50 m
400 kbit/s 150 m 6 m 30 m
500 kbit/s 100 m 5 m 25 m
800 kbit/s 60 m 3 m 15 m
1 Mbit/s < 20 m 1 m 5 m
Communication speed for the project is set in the Pluto Manager. Open the window Project NoName, open
the pop-up menu under Baudrate Pluto Canbus and select the correct speed.
2. Read the IDFIX number
·Must be performed before the program is downloaded to any of the units.
·The programming cable must be connected to each Pluto when reading that particular Pluto’s IDFIX.
·Read IDFIX numbers to all Pluto’s using the command “Copy online IDFIX to clipboard” under the
menu “Tools”. Paste the number to the corresponding Pluto.

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3. Check the Operating System version
·To avoid problems with different OS versions in the Pluto
system, it is a good idea to check that the correct version
of the OS is downloaded to all Pluto units. The most
convenient way to do this is with “OnlineInfo →Pluto
connected to PC” under the “Tools” menu.
The latest version of OS can be obtained by contacting support.jokabsaf[email protected].com or your local ABB
Jokab support.
4. Check that Er20 is shown in the Pluto display window
·If another fault code is shown in the display window; the program shall be erased from the unit,
resulting in Er20 shown on the display. If another fault code is shown, the Pluto can be restarted with
voltage off/on or with the command “Reset all Pluto’s” under the “Tools” menu.
·Repeat the procedure for all units in the system.
5. Download the program
·Compile and download the project file in one of the Pluto units. Check that all units have the program
downloaded in the window that is shown. Pay attention to the units that eventually have not been
correctly loaded. Select “Start PLC program”.
·Fault code Er26 is going to be shown in the Pluto display. This is normal and is acknowledged with
the “Reset all Pluto’s” command under the “Tools” menu or with voltage off/on at all units.
·Check the system with the “Bus Status” command under the “Tools” menu. All units shall be
green/OK. If there are fault codes, check in the manual and perform necessary measures.

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Problems due to communication and downloading of programs in the network
·If the Pluto units in the “Bus Status” window is flashing red/green and showing the fault code Er18
and some other fault codes (among others Er24, Er27 and Er60) it is probable that the bus cable is
not correctly connected/installed or that a Pluto unit is causing disturbances on the bus.
·Start by disconnecting the upper left connection block at all Pluto units (put a screwdriver in the slot
on the contact block and lift the block upwards). For each and every of the units, switch off and on
the voltage and download the program again without connecting the Pluto to the bus. Check that the
correct station number is shown on all units. N.B.! Make no changes in the program and no
compilations in this stage. All units must be loaded with exactly the same project.
·Check the connections of the bus cable to the Pluto units. All CH shall be connected to each other
and all CL shall be connected to each other. The ends of the cable shall be equipped with
termination resistors of 120Ωeach.
·If the length of the bus cable is not possible to read/estimate it is possible to measure the bus cable
with a multimeter. Create a short circuit at one end of the bus cable and measure the resistance
between the two conductors for CH and CL without a termination resistor in the other end. When
performing the measurement all Pluto’s must be powered off and the terminal block for the bus
connection shall be disconnected.
Total resistance = resistivity * total cable length * 2/ cable area
For copper with the area 0,5 mm2the resistivity is 0,0172 mm2/m.
Example:
With a total resistance of 10,3Ωthe cable length will be approximately 150m.
·Now reconnect one Pluto at a time and check in the “Bus Status” window that the units are shown
and are OK. The fault code Er18 can be shown; try to reset by pressing the button “K” at the Pluto or
make a “Reset all Pluto’s” to get started again. If this doesn’t help; replace the last Pluto that was
connected with another unit, which must have the program downloaded before being connected.
·All Pluto units in a project are loaded with the same program. The IDFIX number determines which
part of the project that is being executed for the particular Pluto. This can be a help for
troubleshooting: Pluto units can be changed around to see if the fault follows a particular Pluto or
not.
10,3*0,5
0,0172*2 =149,7