Lütze DIOLINE 20 User manual

Operating Instructions
DIOLINE 20
Analog I/O Modules
Version 04

Lütze Transportation GmbH
Bruckwiesenstraße 17-19
D-71384 Weinstadt
Tel.: [phone]
Fax: [phone]
[e-mail]
www.luetze-transportation.de

DIOLINE Analog IO modules ▪ Table of contents
1
Table of contents
1 Introduction....................................................................................................... 5
2 General Information.......................................................................................... 6
2.1 Symbol Description...................................................................................................................... 6
2.2 Copyright ..................................................................................................................................... 6
2.3 Disclaim of Liability ...................................................................................................................... 6
2.4 Related Documents ..................................................................................................................... 6
3 Safety ................................................................................................................. 8
3.1 Content of the Manual ................................................................................................................. 8
3.2 Intended Use ............................................................................................................................... 8
3.3 Recepients................................................................................................................................... 8
3.4 Operating Employees .................................................................................................................. 8
3.5 Responsibility of the Operator ..................................................................................................... 9
3.6 Protective Clothing and Equipment ............................................................................................. 9
3.7 Reconstruction and Modifications of the Product ........................................................................ 9
3.8 Safety Appliance.......................................................................................................................... 9
3.9 Special Safety Messages .......................................................................................................... 10
4 Product overview............................................................................................ 11
4.1 Product Description ................................................................................................................... 11
4.2 System overview........................................................................................................................ 12
4.3 Field of application..................................................................................................................... 13
5 Transport and storing .................................................................................... 14
6 Scope of delivery ............................................................................................ 14
7 General technical data ................................................................................... 15
8 Mounting.......................................................................................................... 16
8.1 Mounting Options....................................................................................................................... 16
8.2 EMC Shield Clip Set .................................................................................................................. 17
9 Initial Operation – Hardware .......................................................................... 18
9.1 Power Supply............................................................................................................................. 18
9.2 L-Bus – Interface ....................................................................................................................... 19
10 Analog Inputs.................................................................................................. 21
10.1 Characteristics Voltage Inputs ................................................................................................... 21
10.2 Characteristics Current Inputs ................................................................................................... 21
10.3 Characteristics Temperature Inputs........................................................................................... 21
10.4 Analog Inputs............................................................................................................................. 22
10.4.1Product Assembly...................................................................................................................... 22
10.4.2LED Display ............................................................................................................................... 23
10.4.3Technical Data........................................................................................................................... 24
10.4.4Connecting the Analog Voltage and Current Inputs .................................................................. 28
10.4.5Operation ................................................................................................................................... 33
11 Analog Outputs............................................................................................... 36
11.1 Characteristics Voltage Outputs ................................................................................................ 36
11.2 Characteristics Current Outputs ................................................................................................ 36
11.3 Analog Outputs .......................................................................................................................... 37
11.3.1Product Assembly...................................................................................................................... 37
11.3.2LED Display ............................................................................................................................... 38
11.3.3Technical Data........................................................................................................................... 39
11.3.4Connecting the analog Outputs ................................................................................................. 42
11.3.5Operation ................................................................................................................................... 44

DIOLINE Analog IO modules ▪ Table of contents
2
12 Analog Combinations..................................................................................... 46
12.1 Characteristics ........................................................................................................................... 46
12.2 Characteristics ........................................................................................................................... 47
12.3 Product Assembly...................................................................................................................... 48
12.3.1LED Display ............................................................................................................................... 49
12.3.2Technical Data........................................................................................................................... 50
12.3.3Configuration of the analog Inputs and Outputs ........................................................................ 58
12.3.4Connecting the Analog Inputs.................................................................................................... 59
12.3.5Connecting the analog Outputs ................................................................................................. 62
12.3.6Operation ................................................................................................................................... 63
13 Demounting..................................................................................................... 68
14 Final Shutdown and Disposal........................................................................ 69
15 Service ............................................................................................................. 70
16 Appendix ......................................................................................................... 71
16.1 Overview – DIOLINE 20 Identifier.............................................................................................. 71
16.2 Error Status – Analog temperature I/O modules........................................................................ 72
16.2.1Module connected via 3-wire-technology .................................................................................. 72
16.2.2Modules connected via 2- or 4-wire-technology ........................................................................ 72
17 History of Revision ......................................................................................... 73

Analog I/O Modules ▪ Introduction
5
1 Introduction
This manual is part of the Analog I/O Modules. It contains important information
about the handling and safety. To avoid hazardous situations read the manual
before installing the product and using it.
Store the manual at a handy place. If selling, renting or in case of a divestiture
pass the manual to the authorize person.

Analog I/O Modules ▪ General Information
6
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.
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
2.4 Related Documents
The digital I/O modules are always operated with different PLCs and buscoupler.
Indicates a hazardous situation which, if not avoided will result in death or
serious injury.
Indicates a hazardous situation which, if not avoided could result in death
or serious injury.
Indicates a hazardous situation which, if not avoided could result in minor
or moderate injury.
Is used to address practices not related to personal injury

Analog I/O Modules ▪ General Information
7
Read the manual of the PLC or buscoupler before using the I/O modules.

Analog I/O Modules ▪ Safety
8
3Safety
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 DIOLINE20 I/O modules are designed for the exclusive use in railway
vehicles, as:
▪ In- and output for signals which are controlled by a busnode or a PLC.
Only use the I/O modules for the listed cases and only with external devices
recommended and allowed by the Lütze Transportation GmbH.
The intended use involves also the use according to the operation instructions.
3.3 Recepients
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
Trained Employees
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.
Electrically qualified persons
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 the manual referingt to the qualification level of the
operating employees.
Risk of injury by deploying insufficient qualified operating employees.
Inappropriate appoint 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 electricians.

Analog I/O Modules ▪ Safety
9
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
3.7 Reconstruction and Modifications of the Product
3.8 Safety Appliance
▪If working with or on the I/O Modules wear special ESD clothing.
Because static electrification can destroy parts of the buscoupler which can
cause a malfunction of the whole product.
▪Follow the instructions and regulations of the employer.
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.
The I/O Modules do not garuantee the safety of the whole process and/or
the whole system.

Analog I/O Modules ▪ Safety
10
3.9 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 of the frame if
intended to do some welding. The product can be damaged by
compensating current.
▪An EMC performance according to the standards is only possible if the
EMC shield clip set is mounted.

Analog I/O Modules ▪ Product overview
11
4Product overview
4.1 Product Description
The DIOLINE20 I/O Modules are connected to a buscoupler or PLC via the
L-Bus (Lütze Bus). Following options of the I/O Modules are available:
Type
8 digital Inputs
8 digital Outputs
16 digital Inputs
16 digital Outputs
8 digital Inputs, 8 digital Outputs
4 analog Inputs
4 analog Outputs
4 analog Inputs multiplexed
4analog Outputs multiplexed
6 analog Inputs
6 analog Outputs
2 analog Inputs, 2 analog Outputs
16 digital Inputs, 8 digital Outputs
4 analog Inputs, 4 analog Outputs
4 analog Inputs, 2- analog Outputs
Spacer (alle data bits are reset)

Analog I/O Modules ▪ Product overview
12
4.2 System overview
The I/O modules can be integrated in the product line of the DIOLINE20
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 graphic shows the DIOLINE product
after their intelligence. The first module is the most intelligent one. The last one is
a module with the fewest intelligence.
DIORAIL PC 2
Vehicle Control Unit
DIOLINE PLC
Compact Control Unit
DIOLINE20
Buscoupler Ethernet IP Adapter
Remote I/O Modules
DIOLINE20
Buscoupler MVB Slave
Remote I/O Modules
DIOLINE20
Buscoupler CANopen Slave
Remote I/O Modules
DIOSWITCH
Unmanaged Ethernet Switch

Analog I/O Modules ▪ Product overview
13
4.3 Field of application
The DIOLINE20 I/O modules can be connected to buscoupler or PLCs.
The DIOLINE system 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
Example Application 2: Fire Protection Control Unit

Analog I/O Modules ▪ Transport and storing
14
5 Transport and storing
6 Scope of delivery
▪ DIOLINE20 I/O Module
▪ Plug-in Terminals
▪ Instruction Leaflet
▪Protect the product against humidity. Store the product in a dry room
between -40 and 85°C.
▪Make sure that the I/O Modules are safely packaged for transporting, to
absorbe possible crushes.
▪Dust can destroy electronic components. The circuit boards of the I/O
Modules are coated. But try to store and transport it in a dust free
environment to avoid damages of the modules.

Analog I/O Modules ▪ General technical data
15
7 General technical data
For detailed description of the standards, please see the technical data
sheets.
Mechanics
Dimensions (WxHxD)) 57.0x141.5x48.0 mm
Weight ca. 200 g without cage clamps
Housing aluminum
Mounting top hat rail
Electronic Module Supply
Voltage Supply DC 16.8-30 V
Ripple max. 10 %
Nominal Voltage nom. 10 mA
Enviromental Condition
Operating Temperature -40°C bis +70°C (+85°C for 10 min) accor-
ding to EN 50155 class TX
Storage Temperature range min./max. -40°C bis +85°C
Standards
EN 50155 Electronic equipment on railway vehicles
EN 50121 Electromagnetic compability
EN 50124 Insulation coordination
EN 61373 Vibration and shocks

Analog I/O Modules ▪ Mounting
16
8 Mounting
8.1 Mounting Options
The I/O Modules can be mounted on a top-hat rail. Following mounting options
are possible:
Risk of injury by electric current. People can be injured by electric current and
the product can be damaged. Deenergize the system before mounting.
Mount the product with a distance of 5 mm minimum to other products to
provide good air conditions.
1. Hook the module into the lower part
of the top-hat rail.
2. Push the module a little bit up.
3. Push the module back that it
catches the top-hat rail.
▪horizontal
▪vertical
▪across

Analog I/O Modules ▪ Mounting
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8.2 EMC Shield Clip Set
To get an EMC performance according to the standardsit is mandatory to mount
an EMC shield clip set to the analog module.
The shield clip set is not scope of the delivery.
To mount the shield clip set proceed as follows:
1. Losen the screws on the analog mo-
dule.
2. Mount the shield sheet and the
shield clip as shown in the drawing.
3. Connect the module.
4. Remove the jacket of the cable, till
you can see the shielding.
5. Fix the cable with the shield clip.
The shield of the cable must have
contact to the shield clip.
The shield clip can be adjust in 3 levels.
6. For strain relieve fix the cable with a
wire strap to the module as shown in
the picture.
7. Insulate the cable.

Analog I/O Modules ▪ Initial Operation – Hardware
18
9 Initial Operation – Hardware
To connect the modules correctly read the chapter of the required module. In the
chapters you will also find information about the pin assignments.
9.1 Power Supply
The power supply has to be connected over the cage clamps of the modules.
Read the required chapter. To ground the module connect the mounting tab X0.
Fig. 1: Mounting Tab X0
The initial operation has to be done by electricians.

Analog I/O Modules ▪ Initial Operation – Hardware
19
9.2 L-Bus – Interface
The L-Bus interface is for coupling the local DIOLINE20 I/O Modules. The L-Bus,
Lütze-Bus is a special fieldbus invented by company Lütze.
Switch off the power when connecting or disconnecting the I/O Modules.
If not observe, the whole system can be damaged. Hot Plugging is not supported
by the system.
▪Connect max 10 I/O Modules over the L-Bus interface. Mind the current
consumption of the single modules. In the appendix Seite 71 the according
values are listed. A total current of max 1 A is possible on the L-Bus.
▪A change of the pin assignment is not possible, because of the
predetermined connectors.
1. Switch off the power.
Pin Signal Description
124 V Supply Voltage
2 24 V Supply Voltage
3GND 0 V Potential
4 /L_BUS_
RESET
Module Reset
5BUS_END Identifier Bus End
6 OUT_OK Data Confirmation
7SDIN Receiving Serial Data
8 SCK Clock
9SDOUT Sending Serial Data
10 GND 0 V Potential

Analog I/O Modules ▪ Initial Operation – Hardware
20
2. Connect the DIOLINE20 I/O mo-
dules via the L-Bus Interface.
3. Switch on the power.
4. The „LB“ LED is green.
The devices are ready for operation.
Abb. 2: L-Bus Master
Abb. 3: MVB Buscoupler with I/O Modules