A MEMBER OF THE ABB GROUP

PLUTO
Safety-PLC

Manual
Absolute encoders

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Table of contents:

1 General ..................................................................................................................................3
1.1 Reaction time ........................................................................................................................ 3
2 Electrical.................................................................................................................................4
2.1 Separation with Gateway in Bridge Mode ............................................................................. 5
2.2 CAN bus data........................................................................................................................ 5
3 Singleturn encoder RSA 597..................................................................................................6
3.1 Address setting ..................................................................................................................... 6
3.2 Software settings................................................................................................................... 7
3.2.1 Baudrate.................................................................................................................................7
3.2.2 Scale ......................................................................................................................................7
3.2.3 Position adjustment................................................................................................................7
3.3 Speed limit ............................................................................................................................ 8
3.4 Technical data....................................................................................................................... 8
3.4.1 Electrical data.........................................................................................................................8
3.4.2 Mechanical data .....................................................................................................................9
4 Multiturn encoder RSA 698 ..................................................................................................10
4.1 Connectors.......................................................................................................................... 10
4.2 Indicators............................................................................................................................. 10
4.3 Address setting ................................................................................................................... 11
4.4 Baudrate.............................................................................................................................. 11
4.5 Software settings................................................................................................................. 11
4.5.1 Scaling .................................................................................................................................12
4.5.2 Position adjustment ..............................................................................................................12
4.6 Technical data..................................................................................................................... 13
4.6.1 Mechanical drawing .............................................................................................................13
5 PLC Software - Description of function blocks .....................................................................14
5.1 SafeEncoder ....................................................................................................................... 14
5.2 SafeEncoderMult................................................................................................................. 15
5.3 EncoderCam ....................................................................................................................... 15

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1 General
Pluto can handle up to 16 absolute encoders connected to the CAN bus. However, the encoders
themselves can only be addressed to one of 8 different addresses (for Multiturn encoders 9
addresses, but a safe solution requires that the encoders are mounted in pairs). This leads to that
in practice a maximum of 8 encoders can be used.

One of the Pluto units on the bus must have software option for communication with the encoders.
This special Pluto sends cyclically a sync telegram, which trigs all encoders on the bus to read the
position and send a telegram with the position value back to the bus. The special Pluto can read
the encoder telegrams and evaluate them. With block functions in the PLC code it is then possible
to make a dual channel function with two encoders. Out of this the user gets failsafe values for
position and speed including stand still monitoring and over speed detection.

The encoders are standard absolute encoders with modified software to meet the safety
requirements.

1.1 Reaction time

The encoders are read every 10 ms. The system tolerates that a single reading of an encoder fails,
but if two or more fails, it leads to failure alarm. This leads to the response times as below.

Response time:
Normal conditions: 11 ms + program execution time ≈ 14 ms
By fault: 31 ms + program execution time ≈ 34 ms

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2 Electrical

NOTE:
One (but only one!) of the
Pluto units must have software CL
PLUTO
CH

I0
I1

I2
I3

I4 I5
I6

I7
IQ10

IQ11
Q2

Q3

for communication IQ12 IQ14 IQ16 Q0 Q1

with the Encoders

IQ13 IQ15 IQ17 ID 0V +24V

120
One encoder gives busload
equivalent to two Pluto units.
CH I1 I3 I6 IQ10 Q2

CL I0 I2 I4 I5 I7 IQ11 Q3

PLUTO

PLUTO CAN bus IQ12 IQ14 IQ16

IQ13 IQ15 IQ17 ID

Q0

0V +24V
Q1

Encoder

Supply 24 VDC

Encoder

Supply 24 VDC

Encoder

Supply 24 VDC

Encoder
CH I1 I3 I6 IQ10 Q2

CL I0 I2 I4 I5 I7 IQ11 Q3

PLUTO

IQ12 IQ14 IQ16 Q0 Q1

IQ13 IQ15 IQ17 ID 0V +24V

Supply 24 VDC
120

Connection of CAN bus

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2.1 Separation with Gateway in Bridge Mode

By using a Gateway GATE-C1 or GATE-D1 in bridge mode it is possible to separate the Encoders
so that different Pluto units communicate with different Encoders. The Gateway will filter out the
Encoder telegrams, but let the other telegrams pass through. (See 8.1 “Pluto filter” in the
Pluto_Gateway_Manual.)
Pluto 1

CH I1 I3 I6 IQ10 Q2

CL I0 I2 I4 I5 I7 IQ11 Q3

PLUTO

IQ12 IQ14 IQ16 Q0 Q1

IQ13 IQ15 IQ17 ID 0V +24V

120
Pluto 2

CH I1 I3 I6 IQ10 Q2

PLUTO CAN bus CL

PLUTO
I0 I2 I4 I5 I7 IQ11 Q3

IQ12 IQ14 IQ16 Q0 Q1

IQ13 IQ15 IQ17 ID 0V +24V

Encoder 1

Supply 24 VDC

Encoder 2
GATE-D1
Supply 24 VDC Bridge Mode

Encoder 3

Supply 24 VDC

Pluto 3

Encoder 4
CH I1 I3 I6 IQ10 Q2

CL I0 I2 I4 I5 I7 IQ11 Q3

PLUTO

IQ12 IQ14 IQ16 Q0 Q1

IQ13 IQ15 IQ17 ID 0V +24V

Supply 24 VDC
120

In this example Pluto 1 communicates with Encoder 1 and 2, while Pluto 3 communicates with
Encoder 3 and 4.

2.2 CAN bus data

Each encoder gives bus load equivalent to two Pluto units. This leads to that with a certain CAN
speed, the maximum amount of Pluto units will be reduced by two for each encoder. For example a
Pluto-buss running with 250 kbit/s and 4 encoders can have 14-24 Pluto units instead of 22-32.
For bus data as cable length / baudrate, amount of bus nodes, etc., see Pluto - Operating
instructions - Hardware.

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3 Singleturn encoder RSA 597

The singleturn encoder is equipped with a Encoder

1
Bit 0
12-pin connector. Besides connection of
2
power supply and CAN bus it is also used Bit 1
Adress setting
for setting the address with jumpers. Bit 2
3
Binary, odd parity
4 Connected pin = 0
Parity
5

8
CAN_H
9
CAN_L
10
0V
11
Addr. 0V
12
24V

Connector of RSA 597

3.1 Address setting

The encoder must be addressed 1-8 by connecting pin 1…4 with pin 11 in the connector. By
exchange of encoder the addressing will automatically be made by fitting the connector.

Addr. Pin 4 Pin 3 Pin 2 Pin 1

Parity Bit 2 Bit 1 Bit 0
1 0 0 0 1
2 0 0 1 0 1 = Not connected
3 1 0 1 1
0 = Connected to pin 11.
4 0 1 0 0
5 1 1 0 1
6 1 1 1 0 Example: Encoder address 3 – Pin 3 connected to Pin 11 and
7 0 1 1 1 Pin 1, 2, 4 not connected.
8 1 0 0 0

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3.2 Software settings

An encoder can be adjusted from Pluto by
using Terminal Window in Pluto Manager.

By connection the prompt Pluto_A> shall be

visible.

Type ‘encoder’ for entering the encoder menu

where it is possible to change baudrate (B),
set the current position (A) and rescale the
encoder (I).

NOTE: If an encoder with wrong baud rate is

connected to a running Pluto buss the CAN-
bus communication fails.

3.2.1 Baudrate
Baudrate: 125, 250, 500, 800 kbit/s or 1 Mbit/s. (Default Pluto setting 400kbit/s is not possible.)
At delivery the encoders are set to 500 kbps. Note that the encoder must be powered off/on before
the new setting is valid.

3.2.2 Scale
Example of setting the scale
to degrees.

3.2.3 Position adjustment

The current position is set
to 90.

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3.3 Speed limit
By use of single turn encoder for speed monitoring the maximum allowed rotating speed is limited
to 50 rev/s = 3000 rpm. If the speed is exceeded the speed value will be negative.

Note: It must be secured by limitations in application that the maximum speed is not exceeded or
that no dangerous situations can occur if it does.
Examples of such limitations are: An induction motor which speed is limited by the frequency or a
hydraulic cylinder which is limited by a maximum pump capacity.

3.4 Technical data

Type designation: RSA 597
Interface: CAN04
Article number, Leine&Linde: 535503-01
Article number, Jokab: 20-070-36
Encoder data
Type RSA 597
Operating temperature -40°C .. +70°C
Storage temperature -30°C .. +70°C
Ingress protection class IP-67 according to IEC 60529
At shaft inlet IP-66 according to IEC 60529
Vibration (55 to 2000Hz) < 300 m/s2 according to IEC 60068-2-6
Shock (6ms) < 2000 m/s2 according to IEC 60068-2-27
Cover material Aluminium
Cover surface treatment Coated and cromated or anodized
Weight Approx. 300g
Accuracy and resolution
Resolution 13 Bit, 8192 positions per revolution
Accuracy ± ½ LSB

3.4.1 Electrical data Power supply 9-36 Vdc

Polarity protected Yes
1
Default baud rate is 500kbit/s
Output interface CAN Open
Note: Baud rate and CAN identifier
Short circuit protected Yes
could be ordered with pre-selected
Interface CAN specifications 2.0 part A and B
values from Leine & Linde or
Application layer Safe Encoder
programmed via the CAN Open
interface. Baud rate1 5 kbit/s - 1 Mbit/s
CAN identifier 3 bit hardware adjustable
Address input2 Active low
Code type Binary
Programmable functions Resolution, Preset
Direction, Baud rate
Node ID
Current consumption 50mA @ 24Vdc
Max current consumption 100mA

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3.4.2 Mechanical data

Shaft option

Shaft type Ø 10 with face Flange option

Axial shaft load 50 N
Radial shaft load 60 N Flange type 63, Synchro
Mech. permissible 6000 rpm (12 000) Outer diameter ø58 mm
speed Mounting holes 3 x M4
Shaft material Stainless steel Flange material Aluminium
Moment of inertia 2,0 x 10-6 kgm2 Surface treatment Anodized

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4 Multiturn encoder RSA 698

Switches under the cover.

Address switches must be set to same value.
Connectors and indicators

4.1 Connectors
Power supply Pin CAN Bus Pin
24 VDC
+24 Volt 1 CAN Shield 1
- 2 CAN V+ 2
0 Volt 3 CAN GND 3
- 4 CAN High 4
CAN Low 5

4.2 Indicators
STATUS: Follows the CANopen standard.
Green OK
Flashing red/green Fault
Example:
Wrong baudrate
Baudrate conflict
Flashing green/short red No contact with bus

MODULE: Indicates sensor status.

Green OK
Flashing red Fault
Example:
Address switches set to different values
Baudrate switch set to 9.
Sensor fault

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4.3 Address setting
The address is set by the two rotary Address Switch 1, 2
switches under the cover. The two address 1 1, 1
switches shall be set to the same value. 2 2, 2
3 3, 3
4 4, 4
Note: The encoder must be powered off/on 5 5, 5
before the new setting is valid. 6 6, 6
7 7, 7
8 8, 8
9 9, 9

4.4 Baudrate
The baudrate is set by the switch under the Baud rate Baudrate switch
cover. 10 Kbit 0
20 Kbit 1
50 Kbit 2
Note: The encoder must be powered 125 Kbit 3
off/on before the new setting is valid. 250 Kbit 4
500 Kbit 5
800 Kbit 6
1000 Kbit 7
400 Kbit 8
Error 9

4.5 Software settings

Via Terminal window in Pluto Manager it is possible to scale, set actual position and get
information.
- Connect the computer to Pluto and start Pluto Manager. Start the terminal window.
- Start by typing encoder and v and s to see if the encoders are present on the bus:

In this case encoder 5 and 6 are present on the bus.

The “v” command (version) shows serial number, version of hardware and software and operating
time.
The status command “s” gives scaled and hardware resolution, position. Here the encoders are
configured to emulate singleturn encoders (scaled res turns=1) with 4000 increments/rev.
The encoders must be scaled so that the total range is with 0 to 31999.

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4.5.1 Scaling
The encoder is rescaled by the command “i”.
In below example the encoder is set to 100 increments/rev in multiturn mode. This means we can
have up to 320 turns within the total range. Rotation direction is clockwise:

By typing “s” after the rescaling we can see that the total range is 409600, but since Pluto only has
16-bit arithmetic only the part between 0 and 31999 is usable.

4.5.2 Position adjustment

In below example the actual encoder position is adjusted to 5000.

By typing “s” after the rescaling we can see that the position is changed to 5000.
If the encoder is turned and “s” is typed again we can see that the position is changed.

It is also possible to type “p” (position) to get the actual position. If position is displayed by the
status command but not for the “p” command, probably the position is outside range 0-31999.

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4.6 Technical data

Type designation: RSA 698
Article number, Jokab: 20-070-37

4.6.1 Mechanical drawing

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5 PLC Software - Description of function blocks

The safety blocks for reading encoders are located in file “encoder01.fps”.

5.1 SafeEncoder
Function block for singleturn encoders generating safe position and speed value out of two
absolute encoders.

------------ Function ------------------------------

The function block reads and evaluates two absolute encoders. The
average
of the two encoders is calculated and set to the output 'Position'.
The output 'Speed' is also an average value given in increments/10ms.
It is also monitored that the two encoder values do not deviate more than
the value set by the input 'MaxDiff'.
If something is wrong the output 'OK' is set '0'. In some application
the values 'Position' and 'Speed' must be used together with the 'OK'
output.

---------- Description of in- and outputs ------------------

- AdrEncoderA: Encoder A node address
- AdrEncoderB: Encoder B node address
- MaxDiff: Max allowed deviation between the encoders (max 2% of
Range)
- Range: Number of increments per revolution
- OK: Set when encoders are working OK and
the position values are within the margin set by 'MaxDiff'
- Position: Position value
- Speed: Speed value as increments/10ms
- A: Encoder A position. Must not be used in PLC program!
- B: Encoder B position. Must not be used in PLC program!

NOTE! Position values from single encoders are only available

for adjustment purposes and must NOT be used for safety.

NOTE! When error occurs 'Position' = -1, 'Speed' = -32768 and the OK output will be reset.

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5.2 SafeEncoderMult
Function block for multiturn encoders generating safe position and speed value out of two absolute
encoders.
Operating system must be of version 2.4.4 or higher.

------------ Function ------------------------------

The function block reads and evaluates two absolute multiturn
encoders. The average of the two encoders is calculated and set to the
output 'Position'.
The output 'Speed' is also an avrage value given in increments/10ms.
It is also monitored so the two encoder values do not deviate more
than
the value set by the input 'MaxDiff'.
If something is wrong the output 'OK' is set '0'. In some application
the values 'Position' and 'Speed' must be used together with the 'OK'
output.

---------- Description of in- and outputs ------------------

- AdrEncoderA: Encoder A node address
- AdrEncoderB: Encoder B node address
- MaxDiff: Max allowed deviation between the encoders
(max 2% of IncrPerRev)
- IncrPerRev: Number of increments per revolution
- OK: Set when encoders are working OK and
the position values are within the margin set by 'MaxDiff'
- Position: Position value
- Speed: Speed value as increments/10ms
- A: Encoder A position. Must not be used in PLC program!
- B: Encoder B position. Must not be used in PLC program!

NOTE! Position values from single encoders are only available

for adjustment purposes and must NOT be used for safety.

NOTE! When error occurs 'Position' = -1, 'Speed' = -32768 and

the OK output will be reset.

5.3 EncoderCam
Function block for electronic cam limit switch.

------------ Function ------------------------------

The output Q is set when the value in the input register PosReg
is within the limits MinPos and MaxPos. The input value is normally
Generated by the function block SafeEncoder.
NOTE! It is possible to specify a cam which passes through
the zero position of an encoder. Position<0 is forbidden.
Example: If MinPos=3000 and MaxPos=200, Q is set
when the position is greater than 2999 or less than 201.

---------- Description of in- and outputs ------------------

- PosReg: Register where the position is stored
- MinPos: Min allowed value
- MaxPos: Max allowed value

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