Lütze DIOLINE PLC User manual

Operating Instructions
DIOLINE PLC
MVB(EMD)-PBM, Part-No. 746050
Version 02

Lütze Transportation GmbH
Bruckwiesenstraße 17-19
D-71384 Weinstadt
Tel.: [phone]
Fax: [phone]
[email protected]
www.luetze-transportation.com

DIOLINE PLC ▪ Table of Contents
1
Table of Contents
1 Introduction....................................................................................................... 3
2 General information.......................................................................................... 4
2.1 Symbol description ...................................................................................................................... 4
2.1.1 Handling notes............................................................................................................................. 4
2.2 Copyright ..................................................................................................................................... 4
2.3 Disclaim of liability ....................................................................................................................... 4
2.4 Related documents...................................................................................................................... 5
2.5 Application manual valid with these operating instructions.......................................................... 5
3 Safety................................................................................................................. 6
3.1 Content of this manual................................................................................................................. 6
3.2 Intended use ................................................................................................................................ 6
3.3 Recipients .................................................................................................................................... 6
3.4 Operating personnel .................................................................................................................... 6
3.5 Responsibility of the operator ...................................................................................................... 7
3.6 Protective clothing and equipment............................................................................................... 7
3.7 Labeling ....................................................................................................................................... 8
3.7.1 QR-Code – Product information .................................................................................................. 8
3.8 Reconstruction and modifications of the product......................................................................... 9
3.9 Safety arrangement ..................................................................................................................... 9
3.10 Special safety messages ............................................................................................................. 9
4 Product Overview ........................................................................................... 10
4.1 Product description .................................................................................................................... 10
4.2 Hardware options....................................................................................................................... 11
4.3 Software Options ....................................................................................................................... 12
4.4 System Overview....................................................................................................................... 13
4.5 Field of Application .................................................................................................................... 14
5 Transport and storage.................................................................................... 15
6 Scope of delivery............................................................................................ 16
7 Product assembly........................................................................................... 17
7.1 LED display................................................................................................................................ 18
8 Technical data................................................................................................. 20
9 Mounting.......................................................................................................... 23
9.1 Mounting options ....................................................................................................................... 24
10 Initial operation – hardware........................................................................... 25
10.1 Power supply ............................................................................................................................. 25
10.2 L-Bus interface........................................................................................................................... 27
10.3 Serial interface........................................................................................................................... 30
10.4 SD card slot ............................................................................................................................... 31
10.4.1Changing the SD card ............................................................................................................... 32
10.5 Ethernet interface ...................................................................................................................... 33
10.6 Fieldbus 1 Interface – MVB(EMD) ........................................................................................... 34
10.7 Fieldbus 2 Interface – Profibus Master ...................................................................................... 35
11 Initial operation – software ............................................................................ 36
12 Operation......................................................................................................... 37
12.1 Hardware architecture ............................................................................................................... 37
12.2 Memory architecture (non-volatile memory) .............................................................................. 39
12.2.1RAM architecture (volatile memory) .......................................................................................... 40

DIOLINE PLC ▪ Table of Contents
2
13 Maintenance .................................................................................................... 42
13.1 Maintenance software................................................................................................................ 42
14 Demounting..................................................................................................... 43
15 Shutdown and disposal ................................................................................. 44
16 Service............................................................................................................. 45
17 Revision of the document.............................................................................. 46

DIOLINE PLC ▪ Introduction
3
1 Introduction
This manual is a component of the product:
DIOLINE PLC.
To avoid hazardous situations, these instructions must be read and
understood before installing, operating, maintaining, or dismantling the
device
NOTICE This applies to every person who is getting in touch with the product.
Trained personnel and experts, especially qualified persons who have worked
with similar products before, have to read and understand this document as
well.
Risk of injury and damage to equipment caused by failure to read and
observe the operating instructions
These instructions contain important information on safety, commissioning,
operation, maintenance and disposal of the corresponding device.
Before installation or use, carefully read these instructions in order to rule out
possible dangers and damage and to ensure correct use.
Always keep the document ready at hand
This applies until the product is disposed of. In case of sale, rental or in case of
disposal, pass the instructions on to the authorized person.
These instructions and further information are available on the website of the
Lütze Transportation GmbH:
www.luetze-transportation.com
Search for either the article number, or the product name
„DIOLINE PLC“.

DIOLINE PLC ▪ General information
4
2 General information
2.1 Symbol description
This document contains safety information, which is characterized by a signal
word in combination with a specific colour to indicate the warning level. The
information highlights possible dangers and gives instructions on how to avoid
them.
2.1.1 Handling notes
You will also find icons that indicate important information and action steps:
2.2 Copyright
This document is intended for the operator and his staff. It is prohibited to give the
content to a third party, to duplicate, exploit or impart it. The Lütze Transportation
GmbH has to allow it explicit in writing.
General data, text, images, and drawings are copyrighted and are subject to
industrial property rights. Contravention will be prosecuted. The named brands
and product names in this document are trademarks or registered trademarks
owned by the respective titleholder.
2.3 Disclaim of liability
This document was written under consideration of the applied standards,
regulations and the current state of technology.
The content is verified of accuracy. Discrepancies are not excluded. For these
discrepancies we disclaim liability. Applicable changes and additional information
will be in the next version of this document.
The following causes are not covered by the Lütze Transportation GmbH's liability
policy:
Indicates a dangerous situation which leads to death or serious injuries
if not observed.
Indicates a dangerous situation which can lead to death or serious
injuries if not observed.
Indicates a dangerous situation which can lead to slight or moderate
injuries if not observed.
Indicates a situation which could damage the product or the environment.
This notice does not apply to personal injuries.
Indicates technically important information to operate the device safely.
Indicates the use of tools.

DIOLINE PLC ▪ General information
5
▪ Nonobservance of this document
▪ Untrained and unqualified employees
▪ Non-conventional use
▪ Non-approved reconstructions and functional modifications of the product
▪ Using non-original or non-admitted parts or equipment
▪ The real-time capability of the controllerRelated Documents
2.4 Related documents
The programming environment of the DIOLINE PLC is a product of the company
KW Software and Hilscher. The companies are responsible for the documentation
and the compliance of standards. This document contains short parts of the
software documentation. In particular, cases apply to:
PHOENIX CONTACT
Software GmbH
Campusallee 6
D-23657 Lemgo
Tel. [phone]
Fax. [phone]
Hilscher Gesellschaft für Systemautomation mbH
Rhein Straße. 15
65795 Hattersheim
Tel. [phone]
Fax. [phone]
2.5 Application manual valid with these operating instructions
An application manual is valid together with these operating instructions.
It summarizes the general instructions for the DIOLINE PLC. All product-specific
and supplementary information can be found in these operating instructions.

DIOLINE PLC ▪ Safety
6
3 Safety
3.1 Content of this manual
Read and follow the manual before using the product the first time.
This applies to every person which is getting in touch with the product. Trained
employees and experts especially qualified persons which had worked with
similar products before have to read and understand the manual.
3.2 Intended use
The DIOLINE PLC is designed for the exclusive use in railway vehicles.
For:
▪ automation of simple vehicles
▪ as a subsystem controller or
▪ as a high capacity gateway for the realization of different vehicle specific bus
signals
Use the DIOLINE PLC just for the listed cases and just with external devices
recommended and allowed by Lütze Transportation GmbH.
3.3 Recipients
This document addresses planners, project managers and programmers. It also
addresses the operating personnel who are responsible for the initial operation,
the operation and for the maintenance of the products and systems. Regarding
the personnel, three qualification levels can be distinguished.
3.4 Operating personnel
Trained personnel
The employee was trained by the employer on the task and possible hazardous
situations. The employee does not have any technical knowledge.
Experts
The employee has a technical education, knowledge and/or experience in the
required field. The employee is capable to do specific operations on and with the
product.
Qualified electrician
The employee has a technical education in the required field. The employee is
capable to do special operations on and with the product.The different sections of
this document refer to the different qualifiation levels of the operating personnel.
Risk of injury by deploying insufficiently qualified operating personnel
Inappropriate deployment of not-qualified or insufficiently qualified personnel
can cause property damage and personal injuries.
▪ Tasks that apply special procedures should be done by trained and qualified
personnel or experts, especially electricians.

DIOLINE PLC ▪ Safety
7
3.5 Responsibility of the operator
Since the device is used in a commercial area, the operator of the device is
subject to legal obligations for occupational safety:
▪ The operator of the device is obliged to instruct the operating personnel and
to inform himself about the industrial safety regulations.
▪ The operator must ensure that safety, accident prevention and environmental
protection regulations are observed.
▪ The operator must make an appropriate risk assessment on the workplace/
location to detect and warn of special hazards.
▪ The document must be kept in the immediate vicinity of the device.
▪ The information in the operating instructions must be followed.
▪ The device may only be operated in technically perfect condition.
3.6 Protective clothing and equipment
If working with or on the PLC, special ESD clothing and equipment is mandatory.
▪Destroyed parts and malfunction of the product
Inappropriate clothing can cause electrification and can damage the
product.
▪Wear appropriate ESD protective clothing
Static charging can damage individual components and lead to a defect in
the device.
▪ Always follow the employer's instructions and regulations

DIOLINE PLC ▪ Safety
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3.7 Labeling
The label contains the following information as an example:
1. Part number
2. Hardware revision
3. Type (assembly designation/module designation)
4. Software version
5. Serial number
3.7.1 QR-Code – Product information
The QR-code will lead you to additional product information of the manufacturer.
Oberve the adhesive labels.
▪ Keep them readable.
▪ In case of a malfunction the part number and the serial number might be
needed.

DIOLINE PLC ▪ Safety
9
3.8 Reconstruction and modifications of the product
3.9 Safety arrangement
3.10 Special safety messages
Reconstructions and modifications of the product can cause property
damages or personal injuries
Do not reconstruct or modify the product if the manufacturer does not allow it
explicit in writing.
Do not bypass protection equipment and safety arrangements
The product can be damaged by overvoltage and electric shocks are possible.
Use a nominal operating voltage of 24 Volts
The lower (16.8 Volts) and upper (30 Volts) threshold voltage is given in the
technical data. A higher voltage can cause electric shocks and damage the
product.
Dismount all electronic modules and their connections from the frame, if
you intend to do some welding
The product can be damaged by compensating current.

DIOLINE PLC ▪ Product Overview
10
4 Product Overview
4.1 Product description
The DIOLINE PLC is a programmable compact controller in the automation
system DIOLINE 20. The product is powered by an effective ARM
microprocessor (Advanced Risk Machine). It is possible to connect several I/O
modules via the L-Bus interface. The L-Bus is a Lütze invention.
The product can provide up to 4 bus interfaces. The interfaces can be configured
flexibly.
The DIOLINE PLC is a flexible, powerful compact control. It was developed
exclusively for use in rail vehicles. The controls are freely programmable in a
convenient IEC 61131-3 development environment, and have an L-bus interface
for the connection of local I/O modules.
The DIOLINE PLC can be programmed and configured by the application
development system MULTIPROG from KW software.
The software can handle multiuser projects over a network access. There are
several options regarding the interfaces and software.
The DIOLINE PLC can be used to automate simple vehicles, as a subsystem
controller or as a powerful gateway to implement various vehicle-specific bus
signals.
The integrated fieldbuses are available in the following designs:
▪ MVB Slave Class 1.3 as EMD or ESD+
▪ CANOpen Master or CANOpen Slave
▪ CAN2.0 (SAE J1939)
▪ RS232 or RS422/485
▪ Ethernet TCP/IP
▪ TRDP
▪ Profibus Master or Profibus Slave
Detailed and further information on technical data, standards, hardware
options, system overview, application areas can be found in the related
operating instructions.
Application examples can be found below on page 14.

DIOLINE PLC ▪ Product Overview
11
4.2 Hardware options
Option Item Number
DIOLINE PLC-COM-COM-LUE 746026
DIOLINE PLC-COM-CAN-LUE 746027
DIOLINE PLC-MVB(EMD)-CAN-LUE 746028
DIOLINE PLC-COM-NFB-RS485-LUE 746029
DIOLINE PLC-COS-COM-LUE 746032
DIOLINE PLC-MVB(EMD)-COM-LUE 746033
DIOLINE PLC-NFB-NFB-LUE 746034
DIOLINE PLC-MVB(EMD)-CAN-RS485-LUE 746036
DIOLINE PLC-MVB(EMD)-CAN-DI-LUE 746037
DIOLINE PLC-MVB(EMD)-COM-DIO-LUE 746038
DIOLINE PLC-CAN-NFB-LUE 746039
DIOLINE PLC-MVB(ESD+)-COM-LUE 746040
DIOLINE PLC-COS-CAN-LUE 746041
DIOLINE-PLC-MVB(ESD+)-COM-CIO-4/4-LUE 746042
DIOLINE-PLC-MVB(EMD)-PBM-LUE 746050
DIOLINE-PLC-MVB(EMD)-PBS-LUE 746051
Legend:
CAN Controlled Area Network
COM CANOpen Master
COS CANOpen Slave
DI Local Digital Inputs (24V)
DO Local Digital Outputs (24V)
MVB Multi Vehicle Bus (Slave) (EMD)
MVB+ Multi Vehicle Bus (Slave) (ESD+)
NFB No Fieldbus
PBM Profibus Master
PBS Profibus Slave
RS485 Two Wire Serial Bus
RSBUS One Wire Serial Bus

DIOLINE PLC ▪ Product Overview
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4.3 Software Options
Option Description Item Number
SW-MP550-EL-
SYCON
SOFTWARE PLC Programming
environment MULTIPROG
DEVELOPMENT PRO+ V5.5
805101
SW-PG-PC-MP55-ST
SOFTWARE PLC Programming
environment MULTIPROG SUITE+
V5.5
805102

DIOLINE PLC ▪ Product Overview
13
4.4 System Overview
The DIOLINE PLC can be integrated in the product line of the DIOLINE 20
automating system as follows.
The DIOLINE product line contains modular components. A unit consists of a
controller with an integrated CPU and an extension module.
It is possible to connect max. 10 local I/O extension modules on the controller.
The extension modules are connected via the L-Bus.
DIOLINE PLC
Compact Control
Unit
DIOLINE20
Bus coupler
Ethernet IP
Adapter Remote
I/O Modules
DIOLINE20
Bus coupler
MVB Slave
Remote I/O
Modules
DIOLINE20
Bus coupler
CANOpen Slave
Remote I/O
Modules

DIOLINE PLC ▪ Product Overview
14
4.5 Field of Application
The DIOLINE PLC is designed for use in railway vehicles. It can be used for
automation of simple vehicles, as subsystems or for high-capacity gateways to
transfer vehicle specific bus signals. The graphic below shows possible
application areas in trains:
Fig. 1: Example Application 1: Powerpack Control Unit
Fig. 2: Example Application 2: Fire Protection Control Unit

DIOLINE PLC ▪ Transport and storage
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5 Transport and storage
▪Product damage caused by humidity
Store the products in a dry environment between -40° and 85°C.
▪Product damage caused by non-safely packed products
Wrap the products safely for transport to absorb possible crushes.
▪Product damage caused by dust
The circuit board of the PLC is coated. Try to store and transport them in a
dust-free environment to avoid damage to the PLC.
▪Product damage by electrostatic discharge
Store and transport electronic components only in ESD-safe and conductive
packaging.

DIOLINE PLC ▪ Scope of delivery
16
6 Scope of delivery
▪ DIOLINE PLC
▪ Dummy connector for L-Bus interface
▪ Shielding cover for SUB-D interface
▪ Instruction Leaflet
The software for the DIOLINE PLC can be requested by
[email protected]

DIOLINE PLC ▪ Product assembly
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7 Product assembly
Number Description PIN
1 LED diagnosis display
2 User and reset button
3 L-Bus Interface X8
4 RS 232 Interface X7
5 Ethernet Interface X6
6 Fieldbus 2 – Profbus Master Interface outgoing X5
7 Fieldbus 2 – Profibus Master Interface incoming X4
8 Fieldbus 1 – MVB Interface outgoing X3
9 Fieldbus 1 – MVB Interface incoming X2
10 Mounting tab X0
11 Power supply connector X1

DIOLINE PLC ▪ Product assembly
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7.1 LED display
LED Color State Description
PLC yellow 0.1s on/0.9s off
0.5s on/0.5s off
0.8s on/0.2s off
on
off
PLC is ready – no project
PLC is in STOP mode
PLC reports an error
PLC is in RUN mode
PLC is defective
APP green
red
on
on
User defined green
User defined red
FB1ST– MVB green You can configure the LED with the functional
block MVBInfo. For more information on the
configuration of the software, refer to the
“Application Manual“.
FB1ERR– MVB red You can configure the LED with the functional
block MVBInfo. For more information on the
configuration of the software, refer to the
“Application Manual“.
FB2ST – Profibus green on
flashing
flashing, acyclic
off
Communication is
established to all slaves
Profibus is configured, but
the communication is not
yet released by the
application
No configuration or faulty
configuration
Device is not switched on
or there is no network
voltage