Safety PLC for rolling stock Safety Controller Pluto Harsh Environment

Safety PLC for rolling stock Safety Controller Pluto Harsh Environment

Safety PLC for rolling stock More reliability and safety The requirements for rail vehicles of today and tomorrow grow constantly. Faster and faster connections must be made while maintaining a high passenger comfort. This is why, in their daily use, trains are subjected to very high stress, related to Environmentironmental, electrical and mechanical factors. This calls for higher and higher regulatory standards for rail vehicles. helps satisfy the high expectations towards the safety of the vehicles delivers reliable components, solutions and systems for rolling stock, always complying with the current standard requirements. mong others, these include: Safety Controller Pluto D20 Harsh Environment Safety Controller Pluto D45 Harsh Environment Using equipment on trains what must be taken into account Rail vehicles must be specially equipped to be reliable within their respective areas and conditions of use. Examples of such areas and conditions include, among other things, the trains being primarily used in tunnels, or used at high speeds, or used as night trains with sleeping coaches. In providing trains with equipment, particular attention must be paid so the service life of the equipment is not shorter than the service interval of the rail vehicle. Furthermore, the safety of passengers must be guaranteed, so that in the event of an emergency no additional hazard is created by defective electric equipment an important aspect especially if escape routes are limited, e.g. in tunnel systems. is a leading global independent supplier of innovative and reliable technology for rolling stock, railway operators and railway infrastructure operators. Using its all-encompassing business experience in energy and automation technology, can offer reliable and cost-effective solutions for both these fields. 2 2TLC1720150201 Safety PLC for rolling stock

General standards for railway use Fire protection and general electrotechnical requirements Continous operation in the most extreme of conditions lways on the move, despite heat, cold and humidity: the Environmentironmental conditions in which rail vehicles are used are generally far more extreme than in an industrial plant. Their electronic components must correspondingly be completely vibration-proof, resistant to cold, dry and humid heat, and the resulting condensed water. Furthermore, as well as their electromagnetic compatibility, these devices must meet particularly high fire safety requirements. In the event of a fire, danger to people comes not only from the flames, but also from the smoke and poisonous vapors. Complete reliability under extreme conditions as well as a high degree of safety must be guaranteed. Nothing can be left to chance. ll the components of a rail vehicle undergo numerous load tests before they are commissioned. Everything is tested and documented on the basis of safety standards and specifications. The standards for electronic equipment used in and on rail vehicles EN 50155 and IEC 60571 EN 50155 is the most important standard for electronic equipment used in and on rail vehicles. With the exception of local fire and smoke protection standards, this standard acts as an umbrella standard encompassing all the important electric and mechanical aspects. These include: the temperature according to EN 50125 the humidity according to EN 50125 the voltage supply according to EN 50155 the insulation coordination according to EN 50124 the electromagnetic compliance according to EN 50121 the shock and vibration resistance according to EN 61373 The fire and smoke protection standard EN 45545 EN 45545-1 provides a classification of risks according to the categories of operation and design of train. The design of trains include four very different types of trains, e.g. standard vehicles and special trains with sleeping coaches. These trains can be operated in different categories. ccording to EN 45545-1, there are four such categories that depend on how many kilometers a route may lead through a tunnel or elevated section. combination of these two criteria is decisive in classifying the hazard levels. standard vehicle that drives through a tunnel for less than a kilometer is classified as HL1. elow you will find a table that shows the hazard level that depends on the combination of the operation categories and the design categories. Operation categories Design categories N D S Standard vehicle utomated train without emergency trained crew Double decked vehicle 1 Tunnel < 1 km HL1 HL1 HL1 HL2 2 Tunnel < 5 km HL2 HL2 HL2 HL2 Sleeping coach, 2-level or 1-level 3 Tunnel > 5 km HL2 HL2 HL2 HL3 Train without HL3 HL3 HL3 HL3 4 side evacuation The Harsh Environment versions of Pluto safety PLC can be used on all trains up to hazard level HL3. The main criteria specified by EN 45545 include, among others, the oxygen index, which must be above 32%. For the Harsh Environment Plutos, this condition is met. nother critical aspect is the production of smoke, as well as the transparency and toxicity of the smoke. In the event of a fire, an opacity value of 150 guarantees that the smoke does not completely block the sight and the passengers can still orient themselves in the train. Safety PLC for rolling stock 2TLC1720150201 3

Standards for railway use 4 2TLC1720150201 Safety PLC for rolling stock

Safety PLC Pluto D20 / D45 Harsh Environment Standards for railway use Pluto Harsh Environment. complies with the following railway standards Climate resistance a) IEC 60068-2-1, Test -25 C to -40 C b) IEC 60068-2-2, Test +55 C to +70 C Relative air humidity IEC 60068-2-30, Test Db 90-100% at +25 C to +55 C Environmentironment temperature Tests according to standard EN 50155 Shock and vibration resistance Tests according to standards EN 50155/IEC 61373 2010-05 EN 50155 temperature class T2 ICE 60068-2-1 2007 Cold ICE 60068-2-2 2007 Dry heat ICE 60068-2-30 2005 Damp heat cyclic a) IEC 60068-2-64 Random: 1.01 m/s²rms at 5 150 Hz for 10 min b) IEC 60068-2-64 Random long-life: 5.72 m/s²rms at 5 150 Hz for 5 h c) IEC 60068-2-27 Shock: 50 m/s² at 30 ms ±3 shocks Fire and smoke protection a) Hazard levels HL1 to HL3 according to EN 45545-2 b) Fire protection classes 1 4 according to DIN 5510-2 Tests according to standards EN 45545-1 and 2 / DIN 5510 Part 1 and 2 Standard references The certificate is based on the following standards: Functional safety EN 50155:2007 EN 50126-1:2006 Railway pplications Electronic equipment used on rolling stock Railway applications - The specification and demonstration of Reliability, vailability, Maintainability and Safety (RMS) - Part 1: asic requirements and generic process EN 50129:2003 EN 50128:2001 and 2011 EN 45545-1:2013 EN 45545-2:2013 EN 61373:2010 EN 60068-2-1:2007 EN 60068-2-2:2007 EN 60068-2-30 Primary safety/emc EN 50124-1:2001 EN 50121-1:2006 EN 50121-4:2006 EN 50121-3-1:2006 EN 50121-3-2:2006 EN 50125-1:1999 EN 50125-3:2003 EN 50153:2002 Railway applications - Communication, signalling and processing systems - Safety related electronic systems for signalling Railway applications - Communications, signalling and processing systems - Software for railway control and protection systems Railway applications - Fire protection on railway vehicles - Part 1: General requirements Railway applications - Fire protection on railway vehicles - Part 2: Requirements for fire behavior of materials and components Railway applications rolling stock equipment, shock and vibration tests asic Environmentironmental testing procedures - Part 2: Tests - Test : Cold Environmentironmental testing - Part 2-2: Tests - Test : Dry heat Environmentironmental testing - Part 2: Tests - Test Db and guidance: Damp heat, cyclic (12 + 12 hour cycle) Railway applications - Insulation coordination - Part 1: asic requirements - Clearances and creepage distances for all electrical and electronic equipment Railway applications - Electromagnetic compatibility - Part 1: General Railway applications - Electromagnetic compatibility - Part 4: Emission and immunity of the signalling and telecommunications apparatus Railway applications - Electromagnetic compatibility - Part 3-1: Rolling stock - Train and complete vehicle Railway applications - Electromagnetic compatibility - Part 3-2: Rolling stock - pparatus Railway applications - Environmentironmental conditions for equipment - Part 1: Rolling stock and on-board equipment Railway applications - Environmentironmental conditions for equipment - Part 3: Equipment for signalling and telecommunications Railway applications - Rolling stock - Protective provisions relating to electrical hazards Safety PLC for rolling stock 2TLC1720150201 5

pplication examples for the Pluto safety PLC 3 1 4 2 1 Locomotive Pluto D20 Harsh Environment or Pluto D45 Harsh Environment Supervising brake systems Switch-off functions for brake systems Speed monitoring and control with rotary encoders (acceleration and braking functions) Measurement and monitoring functions Monitoring of protection of high voltage area Monitoring of pantograph position Emergency power supply monitoring 2 / 3 Passenger car 4 Dining car Pluto D20 Harsh Environment or Pluto D45 Harsh Environment Door monitoring using Eden Door control, e.g. opening/closing and selection for opening doors on the right or left side of the vehicle Overheating protection Supervising brake systems Switch-off functions for brake systems Measurement and monitoring functions 6 2TLC1720150201 Safety PLC for rolling stock

Pluto safety PLC for a comprehensive concept D20 / D45 Harsh Environment Pluto D45 Safety PLC, Harsh Environment Pluto D20 Safety PLC, Harsh Environment Pluto is a safety PLC concept with the ll-master key feature, which simplifies safety system design and complies with the highest safety level, PL e, according to EN ISO 13849-1 and SIL 3 according to EN 62061, IEC/EN 61508. It also complies with all the relevant parts of EN 50155. Pluto is an ll-master system for dynamic and static safety circuits, in which the inputs and other data are distributed via the same bus. One input can be used to connect several safety sensors, while maintaining the highest safety level. Pluto offers inputs for every safety product on the market. The function of the inputs is defined via the Pluto Manager software that is supplied with the equipment. part from failsafe inputs (I), Pluto offers several failsafe relay and transistor outputs (Q). On every Pluto, even more failsafe inputs, non-failsafe outputs or simultaneous input/outputs (IQ) be set up. The features are provided in a simple way in Pluto Manager. Up to 32 Plutos can be connected to the same Pluto bus, making Pluto able to manage both small and large safety systems. s Pluto is an ll-master system, each Pluto unit can control its own outputs locally and read the inputs of other Pluto units as easily as its own. Gateways on the Pluto bus allow for data exchange with other systems. Pluto D20 and D45 with analog inputs Pluto D20 is equipped with 4, and Pluto D45 with 8 safe analog inputs (4 20 m/0 10 V). These can be configured as either ordinary failsafe inputs or as analog inputs (0 10 V or 4 20 m). Counter inputs Pluto D45 In Pluto D45, four of its analog inputs can be configuredas counter inputs (pulse counting) for frequencies of up to 14,000 Hz. The counter inputs I0 I3 can be used in two ways (counting forwards or forwards/backwards). IDFIX-PROG With IDFIX-PROG 2k5 or 10k it is possible to save entire projects. IDFIX-PROG is an additional component for the Pluto safety PLC used primarily for models without safety bus. It makes sure that the program can be easily recovered, in case the Pluto should need to be replaced. This means that no laptop is required when replacing units on the rail vehicle, which can lower downtimes to a minimum. IDFIX-PROG 10k (2TL020070R2600) Safety PLC for rolling stock 2TLC1720150201 7

Safety PLC Pluto D20 / D45 Harsh Environment Technical data Ordering data Pluto D20 Safety PLC, Harsh Environment Pluto D45 Safety PLC, Harsh Environment Power supply Operating voltage 2TL020070R6401 2TL020070R6601 24 V DC Voltage tolerance -30% +25%* Max. disconnection Recommended external fuse Total power consumption Own power consumption 20 ms 10 7 500 m Electrical insulation Category II according to IEC 61010-1 Failsafe inputs (incl. counter inputs) I0, I1, I2,.. + 24 V (for PNP sensors) IQ10, IQ11,.. Logical 1 Logical 0 Current at 24 V Max. overvoltage nalogue inputs (I0-I7) Range Contacts Resolution Precision + 24 V (for PNP sensors) configurable also as non-failsafe outputs > 12 V < 8 V 5.1 m 27 V continuous 0 10 V / 4...20 m I0, I1, I2, I3, I4, I5, I6, I7 12 bit 0 10 V: ±0.4 % of the entire range 4 20 m: ±0.2 % of the entire range Counter inputs (Pluto D45) Maximum frequency Failsafe outputs 14 khz at 50% load Q2, Q3: Transistor, -24 V DC, 800 m Output voltage tolerance <10 C: 250 m Supply voltage 1.5 V at 800 m Q0, Q1, Q4, Q5: Relay C-12: 250 V / 1.5 Non-failsafe outputs IQ10, IQ11,.. Max. current/output: Max. total load: IQ10...17: IQ20..27: Indicators Input/Output LEDs C-15: 250 V / 1.5 DC-12: 50 V / 1.5 DC-13: 24 V / 1.5 Transistor +24 V (PNP open collector) configurable also as non-failsafe inputs 800 m 2 2 Processor-controlled * The increased tolerance for the Pluto D45 Harsh Environment version is intermittent and must not be used for long periods. t voltages under 18 V and over 30 V, the following warning messages are shown on the display (Er 15 and Er 16). These messages have no influence on the operation and can be suppressed. General Casing 90 x 84 x 120 mm (W x H x D) Installation DIN-rail Response times for the dynamic signal or the static (+24 V) signal: Relay outputs Q0, Q1, Q4, Q5: <20.5 ms + program execution time Transistor outputs Q2, Q3: <16.5 ms + program execution time Transistor outputs Q10...Q17: <16.5 ms + program execution time Response times for the dynamic signals and C: Relay outputs Q0, Q1, Q4, Q5: <23 ms + program execution time Transistor outputs Q2, Q3: <19 ms + program execution time Transistor outputs Q10...Q17: <19 ms + program execution time Software setting NoFilt Response times: 5 ms (5 ms less) Program execution time approx. 10 µs/command dditional response times via the bus: Normal conditions 10 ms t fault condition 10 40 ms Response time extension for Q2 and Q3 at fault condition <10 ms Recognition times Shortest recognizable impulse 10 ms mbient temperature -25 to +55 C Transportation and storage -25 to +55 C temperature Environmentironment temperature EN 50155 temperature class T2 Humidity: IEC 60068-2-30, Test Db 90 % at 40 C (e.g. 90 100 % at +25 C to +55 C) EN 60 204-1 50 % at 40 C (e.g. 90 % at 20 C) Enclosure classification, IEC 60 529: Enclosure IP 40 Connection terminals IP 20 Fire and smoke protection: EN 45545-2 Hazard levels HL1 to HL3 DIN 5510-2 Fire protection classes 1 2 Functional safety data SIL according to SIL 3 EN 62061/IEC 61508 PL according to EN ISO 13849-1 PL e Category according to 4 EN ISO 13849-1 DC avg according to EN ISO High 13849-1 CCF according to EN ISO 13849-1 Requirements are met HFT (Hardware fault tolerance) 1 SFF (Safe failure fraction) >99% for single-channel systems >90% for two-channel systems 8 2TLC1720150201 Safety PLC for rolling stock

Safety PLC Pluto D20 / D45 Harsh Environment Technical data Transistor outputs* PFD V (for mission time = 20 years) 1.1x10-4 PFH D according to EN 62061/IEC 61508 1.5x10-9 MTTF d according to EN ISO 13849-1 Relay outputs* PFD V (for mission time = 20 years) 1.5x10-4 PFH D according to EN 62061/IEC 61508 2x10-9 MTTF d according to EN ISO 13849-1 High/1500 years High/1100 years nalog inputs* Pluto D45 2 sensors 1 sensor SIL according to EN 62061/IEC 61508 up to SIL 3 up to SIL 2 PL according to EN ISO 13849-1 up to PL e up to PL d DC avg according to EN ISO 13849-1 up to High up to Medium PFD V (for mission time = 20 years) 1.5x10-4 1.5x10-3 PFH D according to EN 62061/IEC 61508 1.6x10-9 5.8x10-9 MTTF d according to EN ISO 13849-1 High/1100 years High/400 years Counter inputs* Pluto D45 2 sensors 1 sensor SIL according to EN 62061/IEC 61508 up to SIL 3 up to SIL 1 PL according to EN ISO 13849-1 up to PL e up to PL c DC avg according to EN ISO 13849-1 up to High up to High PFD V (for mission time = 20 years) 1.5x10-4 1.5x10-4 PFH D according to EN 62061/IEC 61508 1.6x10-9 1.6x10-9 MTTF d according to EN ISO 13849-1 High/1100 years High/1100 years Note: PFD V = average probability of failure on demand of the safety function PFH D = average probability of a dangerous failure per hour MTTF d = average time until a dangerous failure/channel PL = Performance Level (according to the definition specified in EN ISO 13849-1) SIL = Safety Integrity Level (according to the definition specified in EN 62061/IEC 61508) * from the input to the output (incl. the S-i and CN us) Outline drawings Safety PLC for rolling stock 2TLC1720150201 9

Safety PLC Pluto D20 Harsh Environment Technical data Pluto bus 0-10V/4-20m Inputs, individual failsafe Transistor output, individual failsafe CH IQ10 CL IQ11 I0 I1 Pluto D20 Harsh Env DI I IQ12 DI I I2 DI I IQ13 I3 DI I I4 IQ14 I5 IQ15 I6 I7 DI DI DI DI I 0-24V IQ16 IQ17 Q0 Q1 Q2 Q3 ID 0V +24V Failsafe inputs / Indication outputs (not failsafe) / Dynamic outputs Relay output, individual failsafe Identifier input Power Overview for inputs/outputs in Pluto D20 Harsh Environment Terminals at Pluto Input/Output name in the software I/O type I4 I7 I_.4 I_.7 Safe digital input/safe analog input 4 20 m/0 10 V Global Q0 Q_.0 Safe output (relay) Global Q1 Q_.1 Safe output (relay) Global Q2 Q_.2 Safe output (transistor) Global Q3 Q_.3 Safe output (transistor) Global IQ10 IQ17 I_.10 I_.17 Safe digital input Global Where _ is the Pluto module number. Q_.10 Q_.17 Non-safe output Local Local/global Safety PLC Pluto D20 Harsh Environment The Pluto safety PLC D20 has 16 failsafe inputs and 4 independent failsafe outputs (2x relay and 2x transistor). Out of the 16 failsafe inputs, any 4 can be configured as analog inputs with a high 10 bit resolution, and 8 can be configured as non-safe outputs. The analog inputs are analyzed with safe function blocks with scalable outputs. 10 2TLC1720150201 Safety PLC for rolling stock

Safety PLC Pluto D45 Harsh Environment Technical data Digital inputs, individual failsafe nalogue inputs 0-10V/4-20m Fast counter Inputs, individual failsafe Inputs, individual failsafe +24V 0V 0V Power supply ID Identifier IDFIX CH CL I0 CS (Shield) I1 I2 Pluto bus I3 I4 I5 I6 I7 I30 Pluto D45 Harsh Env I31 I32 I33 I34 I35 I36 I37 I40 I41 I42 I43 I44 I45 I46 Safety outputs Q0 Q1 Q4 Q5 I47 0L 1L 4L IQ10 IQ11 IQ12 IQ13 IQ14 IQ15 IQ16 IQ17 IQ20 IQ21 IQ22 IQ23 IQ24 IQ25 IQ26 Q2 Q3 Failsafe inputs / Outputs (not failsafe) / Dynamic outputs Overview for inputs/outputs in Pluto D45 Harsh Environment Terminals at Pluto Input/Output name in the software I/O type I0 I3 I_.0 I_.3 Safe digital input/safe analog input 4 20 m/0 10 V/counter input Global I4 I7 I_.4 I_.7 Safe digital input/safe analog input 4 20 m/0 10 V Global I30...I37 I_.30 I_.37 Safe digital input Local I40...I47 I_.40 I_.47 Safe digital input Local Q0 Q_.0 Safe output (relay) Global Q1 Q_.1 Safe output (relay) Global Q2 Q_.2 Safe output (transistor) Global Q3 Q_.3 Safe output (transistor) Global Q4 Q_.4 Safe output (relay) Local Q5 Q_.5 Safe output (relay) Local IQ10 IQ17 I_.10 I_.17 Safe digital input Global Q_.10 Q_.17 Non-safe output Local IQ20 IQ26 I_.20 I_.26 Safe digital input Local Where _ is the Pluto module number. Q_.20 Q_.26 Non-safe output Local Local/global Pluto D45: the all-in-one solution that makes rolling stock safe The new Pluto safety PLC D45 has 39 failsafe inputs and 6 independent failsafe outputs (4x relay and 2x transistor). Out of the 39 inputs, any 8 can be configured as analog inputs with a high 12 bit resolution, and 15 can be configured as non-safe outputs. Furthermore, the 4 inputs can be configured as fast and failsafe counter inputs for monitoring frequencies of up to 14 khz. Using the fast counter inputs, demanding applications via incremental encoders, inductive sensors and photo cells can be implemented. Safety PLC for rolling stock 2TLC1720150201 11

Contacts Jokab Safety Varlabergsvägen 11 SE-434 39 Kungsbacka Tel. +46 (0) 21-32 50 00 www.abb.com/jokabsafety Note We reserve the right to make technical changes or modify the contents of this document without prior notice. With regard to purchase orders, the agreed particulars shall prevail. does not accept any responsibility whatsoever for potential errors or possible lack of information in this document. We reserve all rights in this document and in the subject matter and illustrations contained therein. ny reproduction, disclosure to third parties or utilization of its contents - in whole or in parts is forbidden without prior written consent of. 2TLC1720150201 Copyright 2016 ll rights reserved