Lütze DIOLINE PLC User manual

Operating Instructions
DIOLINE PLC
Part-No. 746050/746051
Version 01

DIOLINE PLC - Profibus - Operating instructions
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The company Lütze Transportation GmbH reserves the right to make changes to its products in the
interest of technical development. These changes are not necessarily documented in each individual
case.
This manual and the information contained herein have been compiled with due care. However, the
company Lütze Transportation GmbH accepts no liability for printing or other errors or resulting
damage.
The brands and product names mentioned in this book are trademarks or registered trademarks of the
respective titleholders.
©Copyright 2021 by Lütze Transportation GmbH. All rights reserved.
Contact
Lütze Transportation GmbH
Bruckwiesenstraße 17-19
D-71384 Weinstadt - Großheppach
Germany
Telephone - switchboard: +49/ (0)7151 6053-545
Telefax: +49/ (0)7151 6053-6545
E-Mail: [e-mail]
Internet: www.luetze-transportation.de

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Content
1Introduction..................................................................................5
2General Information.....................................................................6
2.1 Symbol Description...........................................................................................6
2.2 Copyright...........................................................................................................6
2.3 Disclaim of Liability............................................................................................6
2.4 Related Documents...........................................................................................7
2.5 Application manual valid with these operating instructions ...............................7
3Safety............................................................................................8
3.1 Content of the manual.......................................................................................8
3.2 Intended Use.....................................................................................................8
3.3 Recipients.........................................................................................................8
3.4 Operating Employees........................................................................................8
3.5 Responsibility of the operator............................................................................9
3.6 Protective Clothing and Equipment...................................................................9
3.7 Labelling............................................................................................................9
3.8 Reconstruction and Modifications of the Product..............................................9
3.9 Safety Arrangement........................................................................................10
3.10 Special Safety Messages................................................................................10
4Product Overview.......................................................................11
4.1 Product description .........................................................................................11
4.2 Hardware options............................................................................................12
4.3 Software options .............................................................................................13
4.4 System overview.............................................................................................14
4.5 Field of application..........................................................................................15
4.5.1 All DIOLINE PLC operating instructions in overview....................................................... 16
5Technical Data............................................................................17
6Transport and storing................................................................19
6.1 Scope of delivery ............................................................................................19
7Product assembly......................................................................20
7.1 LED Display....................................................................................................21
8Mounting.....................................................................................22
8.1 Mounting Options............................................................................................22
9Initial Operation –Hardware......................................................23
9.1 Power Supply..................................................................................................23
9.1.1 PLC LED status ............................................................................................................... 24
9.2 L-Bus –interface.............................................................................................24

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9.3 Serial Interface................................................................................................26
9.4 SD Card slot....................................................................................................27
9.4.1 Changing the SD card ..................................................................................................... 27
9.5 Ethernet interfaces..........................................................................................29
9.6 Fieldbus 1 –MVB............................................................................................30
9.7 Fieldbus 2 Interface –Profibus .......................................................................32
10 Initial Operation –Software.......................................................33
11 Operation....................................................................................34
11.1 Hardware Architecture ....................................................................................34
11.2 Software Architecture......................................................................................35
11.3 Memory Architecture.......................................................................................36
12 Maintenance...............................................................................37
12.1 Maintenance –Hardware................................................................................37
12.1.1 Real Time Clock Battery .............................................................................................. 37
12.2 Maintenance –Software .................................................................................37
13 Demounting................................................................................38
14 Final Shutdown and Disposal ...................................................39
15 Service........................................................................................40
16 Appendix.....................................................................................40
17 Error treatment...........................................................................40
18 Revision of the Document.........................................................41
19 Glossary......................................................................................42

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1 Introduction
This manual is a component of the product:
DIOLONE PLC.
These instructions must be read and understood before installing,
operating, maintaining or dismantling the device.
It contains important information about the handling and safety.
Risk of injury and damage to equipment cause by non-observance of
the operating instructions.
The 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 guarantee correct use.
Always keep the document to hand.
This applies until the disposal of the product. When selling or lending, pass
the manual to the authorized person.
These operating instructions can also be found on the website of Lütze
Transportation GmbH –www.luetze-transportation.com
Search for either the article number, or the product name
“DIOLINE PLC”.

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2 General Information
2.1 Symbol Description
The manual contains several safety messages. Each safety message contains a defined signal
word and a color. The color and the word are referring to an alert level. There are 4 levels. The
safety messages point out hazardous situations and give information to avoid those.
Indicates a hazardous situation, which if not avoided will result in death
or serious injury.
Indicates a hazardous situation, which if not avoided can result in death
or serious injury.
Indicates a hazardous situation, which if not avoided can result in minor
or moderate injury.
Indicates a situation which could damage the product or the
environment. This notice does not apply to personal injury.
2.2 Copyright
This manual is intended for the operator and his staff. It is forbidden 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 liable to the industrial property
right. Contravention can be prosecuting criminally. The named brands and product names in this
document are trademarks or registered trademarks by titleholder
2.3 Disclaim of Liability
The manual 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 those discrepancies we
disclaim liability. Applicable changes and additional information will be in the next version of the
manual.
•The Lütze Transportation GmbH does not assume liability for any damages and accidents of
following reasons:
•Nonobservance of the manual
•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 controller

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2.4 Related Documents
The programming environment of the DIOLINE PLC is a product of the company PHOENIX
CONTACT Software GmbH 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-32657 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
A DIOLINE PLC 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.

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3 Safety
3.1 Content of the 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
The operating manual addresses planers, project manager and programmers. It also addresses
the operating employees which are responsible for the initial operation, the operating and for the
maintenance of the products and systems. Regarding the employees different qualification levels
are differentiated.
3.4 Operating Employees
Risk of injury by deploying insufficient qualified operating employees.
Inappropriate use of not qualified or insufficient personal can cause property
damages and personal injuries. Tasks which apply special procedures should
be done by trained and qualified employees or experts, especially electrically
qualified persons.
Trained Employee
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 perform specific operations on and with the product.
Electrically qualified persons
The employee has a technical education in the required field. The employee is capable to
perform special operations on and with the product.
The different sections referring to the qualification level of the operating employees.

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3.5 Responsibility of the operator
The operator is obligate by the law of occupational safety, if the product is used in a commercial
field.
•The operator is responsible to train the employees and to inform himself about the industrial
safety regulation.
•The operator is responsible that safety-, environment protection regulations and rules for
accident prevention are observed.
•The operator has to run a risk assessment at the working environment/place of installation to
expose hazards and to alert those.
•The manual has to be stored near the product.
•The manual has to be obeyed.
•The product can just be run in a faultless technical condition.
3.6 Protective Clothing and Equipment
If working with or on the PLC special ESD clothing and equipment is mandatory. Also follow the
instructions and regulations of the employer.
3.7 Labelling
Mind the original adhesive labels. Keep them readable.
On the product following label with following data can be found:
Fig. 1: Example Label
•Part-Number
•Hardware Revision
•Assembly Term
•Software-Version
•Serial number
3.8 Reconstruction and Modifications of the Product
Reconstructions and modifications of the product can cause property
damages or personal injuries. Do not reconstruct the product if the
manufacturer does not allow it explicit in writing.

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3.9 Safety Arrangement
Do not bypass protection equipment and safety arrangements. The
product can be damaged by overvoltage and electric shocks are possible.
3.10 Special Safety Messages
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.

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4 Product Overview
4.1 Product description
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 PHOENIX CONTACT Software GmbH.
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 PLC variants are available with the following interfaces:
•MVB Slave Class 1.3 as EMD or ESD+
•CANopen Master or CANopen Slave
•SAE J939 (CAN2.0)
•RS485 / RS422
•RS232
•Ethernet TCP/IP, UDP
•TRDP
•APEX Zugbus
•Profibus (MASTER und SLAVE)
A list with an overview and links to the respective operating
instructions can be found in chapter “4.5.1. All DIOLINE PLC operating
instructions in overview”.

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4.2 Hardware options
Part. - No.
Option/Product
Type
746026
DIOLINE PLC, COM-COM
DL-PLC-COM-COM-LUE
746027
DIOLINE PLC, COM-CAN
DL-PLC-COM-CAN-LUE
746028
DIOLINE PLC, MVB-CAN
DL-PLC-MVB/EMD-CAN-LUE
746028.02
DIOLINE PLC, MCB-CAN-DI
DL-PLC-MVB-CAN-DI-4-ALS
746029
DIOLINE PLC, COM-RS485
DL-PLC-COM-NFB-RS485-LUE
746032
DIOLINE PLC, COS-COM
DL-PLC-COS-COM-LUE
746033
DIOLINE PLC, MVB-COM
DL-PLC-MVB/EMD-COM-LUE
746034
DIOLINE PLC, NFB-NFB
DL-PLC-NFB-NFB-LUE
746036
DIOLINE PLC, MVB-CAN-RS485
DL-PLC-MVB-CAN-RS485-LUE
746037
DIOLINE PLC, MVB-CAN-DI
DL-PLC-MCB-CAN-DI-4-LUE
746038
DIOLINE PLC, MVB-COM-DIO
DL-PLC-MVB-COM-DIO-LUE
746039
DIOLINE PLC, CAN-NFB
DL-PLC-CAN-NFB-LUE
746040
DIOLINE PLC, MVB(ESD)-COM
DL-PLC-MVB/ESD+-COM-LUE
746041
DIOLINE PLC, COS-CAN
DL-PLC-COS-CAN-LUE
746050
DIOLINE PLC, MVB-PBM
DL-PLC-MVB/EMD-PBM-LUE
746051
DIOLINE PLC, MVB-PBS
DL-PLC-MVB/EMD-PBS-LUE
Legend:
CAN
Controlled Area Network
MVB
Multi Vehicle Bus (Slave) (EMD)
MVB+
Multi Vehicle Bus (Slave) (ESD+)
COM
CANopen Master
COS
CANopen Slave
DI
Digital Inputs (24V)
DO
Digital Outputs (24V)
RS485
Serial interface
RS422
Serial interface
RS232
Serial interface
PBM
Profibus Master
PBS
Profibus Slave
PDnet
Apex EZB
NFB
No Field Bus

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4.3 Software options
Part-No.
Type/Option
Description
746090
DR-PC2-SW-KWS
DIORAILPC SOFTWARE 4.6
MULTIPROG Suite+
- MULTIPROG Pro+ for IEC61131 programming (also
contains the MAS machine sequence language)
- SYCON.net for the bus configuration
- ProVisIT for visualization and
- SYCON.net for interconnecting PROFInet components
Additional functions:
Multi-user function
SDC
1-1046-1005-101-X0C
incl. Multiuser
746090.99
MultiProg Upgrade 4.8
to 5.50
Upgrade from Mutliprog 4.8 to 5.50
746091
DR-PC2-SW-KWPD
ProVisIT Development License
746092
DR-PC2-SW-KWM
MULTIPROG Suite 4.8 Monitoring Pro+ (E)
Version Lütze
programming languages:
IL/LD/FBD/ST/SFC/MSFC
Half Version, Multiuser incl. download possibility and
Sycon. Special version for Lütze.
746095
DR-PC2-SW-KWPR
ProVisIT Runtime License
Desktop (Windows 2000/XP)
805101
SW-MP550-EL-
SYCON
SOFTWARE
PLC Programming environment
MULTIPROG DEVELOPMENT PRO+ V5.5
805102
SW-PG-PC-MP55-ST
SOFTWARE
PLC Programming environment
MULTIPROG SUITE+ V5.5

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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 over the L-Bus. The following
graphic shows the DIOLINE products sorted by intelligence. The first module is the most
intelligent one. The last one is a module with the fewest intelligence.
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

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DIOSWITCH
Unmanaged Ethernet Switch
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. 2: Example Application 1: Powerpack Control Unit

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Fig. 3: Example Application 2: Fire Protection Control Unit
4.5.1 All DIOLINE PLC operating instructions in overview
A list with an overview and links to the respective operating instructions can be found here.
In the corresponding operating instructions, you will find further
information about safety, scope of delivery, product assembly,
technical data, assembly, commissioning, operation, disassembly and
disposal of the hardware.
See chapter "4.2. Hardware options".

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5 Technical Data
Mechanics
Dimensions
123x141.5x64.1 mm (wxhxd)
Weight
0.550kg/piece
Housing
Aluminium, anodized surface
Mounting
Top Hat Rail TS 35 7.5 mm
Electrical Characteristics
Power Supply
DC 24 V (voltage range 16.8-30 V)
Ripple
Max. 10 %
Power Consumption
5 W + L-Bus Module Consumption
Protective Device
Inverse-polarity protection, overvoltage protection
Potential Separation
AC 500 V Profibus interface and electronic
AC 500 V Ethernet interface and electronic
AC 500 V MVB Interface and electronic
Interfaces
•RS232
•Ethernet 100Base TX
•SD Card Slot
Fieldbus Interfaces
•L-BUS
•Profibus
•MVB
Software
Operating System
Real-Time Operating System rcX
Controller Software
IECX 61131 Soft-PLC ProConOS PHOENIX CONTACT Software
GmbH
CPU
Processor
ARM9-CPU NetX 500, 32 Bit
Monitoring
External Watchdog voltage monitor of the control software

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Boot time
Run up time state: “ready” after switching on the power supply <15s
Memory
Internal Serial Flash
Memory
4 MB Serial Flash Memory
Internal Working
Memory
32 MB SDRAM
Internal FRAM
4 kB
Internal parallel Flash
Memory
2 MB
Diagnosis
Diagnosis Interface
Ethernet 100BaseTX
Diagnosis LED
10 LED for visual device diagnosis
Switches/Key-Buttons
1 reset key button, 1 key button, evaluated in the control software
Clock
Real Time Clock RTC
Environmental Condition
Operating Temperature
-40°C to +70°C
Storage Temperature
-40°C to +85°C
Relative Humidity
100% short time condensation allowed
Internal Protection Class
(IP)
IP20
Standards
EN 50155
Electronic Equipment on Railway Vehicles
EN 5021-3-2
Electromagnetic Compatibility
EN 50124-1
Insulation Coordination
EN 61373
Vibration and Shock

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6 Transport and storing
•Protect the product from humidity. Store the product in a dry room
between -40 and 85°C.
•Make sure that the PLC is safely packaged for transporting, that
possible crushes can be absorbed.
•Dust can destroy electronic components. The circuit board of the PLC
is coated. But try to store and transport it in a dust free environment to
avoid damages of the PLC.
6.1 Scope of delivery
The software for the DIOLINE PLC can be downloaded in the internet.
The Link and the password will be sent by e-mail.
•DIOLINE PLC
•Dummy connector for L-Bus interface
•Shielding Cover for SUB-D interface
•Instruction Leaflet

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7 Product assembly
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 –Profibus
X5
7
Fieldbus 2 –Profibus
X4
8
Fieldbus 1 –MVB Interface outgoing
X3
9
Fieldbus 1 –MVB Interface incoming
X2
10
Mounting Tab
X0
11
Power Supply Connector
X1