Lütze LION-BC-ETH-LUE User manual

Operating Instructions
LION
Bus Coupler Ethernet (SIL0)
LION-BC-ETH-LUE
803012
Version 01
03/19/2019

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

LION Bus Coupler ▪ Content
Content
1 Instruction Content........................................................................................... 6
2 General Information.......................................................................................... 7
2.1 Symbol Description...................................................................................................................... 7
2.2 Copyright ..................................................................................................................................... 7
2.3 Disclaim of Liability ...................................................................................................................... 8
2.4 Standards ................................................................................................................................ 8
2.5 Labeling ....................................................................................................................................... 9
3 Safety ............................................................................................................... 10
3.1 Related Documents ................................................................................................................... 10
3.2 Intended Use ............................................................................................................................. 11
3.3 Recepients................................................................................................................................. 11
3.4 Operating Employees ................................................................................................................ 11
3.5 Responsibility of the Operator ................................................................................................... 12
3.6 Protective Clothing and Equipment ........................................................................................... 12
3.7 Electrostatic Discharge (ESD) ................................................................................................... 12
3.8 Reconstruction and Modifications of the Product ...................................................................... 12
3.9 Special Safety Messages .......................................................................................................... 13
4 System Planning............................................................................................. 14
4.1 - not applicable -........................................................................................................................ 14
4.2 LION System - Overview ........................................................................................................... 15
4.3 Safety Target ............................................................................................................................. 16
4.4 System Overview....................................................................................................................... 16
4.5 System Architecture................................................................................................................... 24
5 Transport and Storing .................................................................................... 28
5.1 Scope of Delivery....................................................................................................................... 28
6 Installation....................................................................................................... 29
6.1 LION System Description – Installation Manual ........................................................................ 29
7 Product Description ....................................................................................... 30
7.1 Characteristics ........................................................................................................................... 30
7.2 Product Overview ...................................................................................................................... 31
7.3 General Technical Data ............................................................................................................. 31
7.4 LED Status................................................................................................................................. 32
7.5 Module Status............................................................................................................................ 34
7.6 Failsafe ...................................................................................................................................... 35
7.7 Ethernet – Interface X50/X60 TRDP Fieldbus and diagnosis.................................................... 36
7.8 - not applicable -........................................................................................................................ 36
7.9 - not applicable -........................................................................................................................ 36
7.10 Supply Interface – X30 L-Bus2 .................................................................................................. 37
7.11 Signal and Supply Interface – X31 L-Bus2 ................................................................................ 37
8 Function........................................................................................................... 38
8.1 Data Communication ................................................................................................................. 38
8.2 General Monitoring .................................................................................................................... 41
9 Configuration ................................................................................................. 42
9.1 TDB............................................................................................................................................ 42
9.2 Configuration Data Values......................................................................................................... 42
9.3 LION Framework ....................................................................................................................... 43
9.4 - not applicable -........................................................................................................................ 57
10 Initial Operation .............................................................................................. 59

LION Bus Coupler ▪ Content
10.1 - not applicable -........................................................................................................................ 59
10.2 LION Webserver ........................................................................................................................ 59
10.3 System Test............................................................................................................................... 62
11 Operation......................................................................................................... 63
11.1 Webserver Monitoring................................................................................................................ 63
12 Error Handling................................................................................................. 70
12.1 Error Codes ............................................................................................................................... 71
13 Maintenance and Service............................................................................... 72
13.1 Module Exchange ...................................................................................................................... 72
13.2 Proof Test Interval ..................................................................................................................... 72
13.3 Extending the LION System ...................................................................................................... 73
14 Final Shutdown and Disposal........................................................................ 74
15 Appendix ......................................................................................................... 75
15.1 Accessories ............................................................................................................................... 75
15.2 Revision of the Document.......................................................................................................... 75

LION Bus Coupler ▪ Instruction Content
6
1 Instruction Content
This manual is part of the LION Bus Coupler Ethernet (SIL0) (Part-No. 803012,
Type LION-BC-ETH-LUE). It contains important information about the handling
and safety.
▪ To avoid hazardous situations, read the manual before installing the product
and using it.This applies to every person who is getting in touch with the
product. Trained employees and experts, especially qualified persons who
have worked with similar products before, have to read and understand the
manual as well.
▪ Store the manual at a handy place. If selling, renting or in case of a divestiture
pass the manual to the authorize person.

LION Bus Coupler ▪ General Information
7
2 General Information
2.1 Symbol Description
2.1.1 Safety Messages
The manual contains safety information, which is characterized by a signal word
in combination with a certain colour to indicate the warning level. The information
highlights possible dangers and gives instructions on how to avoid them.
2.1.2 Handling Notes
You will also find icons that indicate important information and action steps:
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.
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 information foresees injuries.
Indicates technically important information to operate the device safely.
Indicates the use of tools.

LION Bus Coupler ▪ General Information
8
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 Standards
The products are constructed and designed according following
standards:
▪ EN 50155:2007-07:
Railway applications – Rolling stock – Electronic equipment
▪ EN 50155:2017-10:
Railway applications – Rolling stock – Electronic equipment (testing
according chapter 13.3 table 12)
▪ EN 50121-3-2:2016-12:
Railway applications – Electromagnetic compatibility – Part 3-2: Rolling stock
– Apparatus
▪ EN 50124-1:2017-03:
Railway applications – Insulation coordination – Part 1: Basic requirements –
Clearances and creepage distances for all electrical and electronic
equipment
▪ EN 61373:1999-04:
Railway applications – Rolling stock equipment – Shock and vibration tests
▪ EN 45545-2:2013+A1:2015:
Railway applications – Fire protection on railway vehicles – Part 2:
Requirements for fire behaviour of materials and components
▪ EN 61375-2-3:2015:
Electronic railway equipment - Train communication network (TCN) - Part 2-
3: TCN communication profile
▪ EN 50126-1:2017:
Railway applications - The specification and demonstration of
reliability,availability, maintainability and safety (RAMS)
▪ EN 50128:2011-06:
Railway applications - Communication, signalling and processing systems -
Software for railway control and protection systems

LION Bus Coupler ▪ General Information
9
2.5 Labeling
Fig. 1: Example – Product Label
The following informations can be found on the label:
▪ Part number
▪ Hardware revision
▪ Module description
▪ Manufacturing date
▪ Software version
▪ Serial number
▪ Data matrix code, contains: serial number, part number and date
▪QR code
2.5.1 QR Code – Product Information
The code links to further product information in the online catalogue on the LÜTZE
Transportation website. To reach the page proceed as follows:
1. Scan the QR code with a smart phone or another device which can read such
codes.
2. A standard browser will open with the linked page.
Fig. 2: Screenshot Online Catalogue – Language Selection
3. Choose a language.
4. The product will be displayed. Under Downloads it is possible to download
further technical documentation.
Mind the adhesive labels.
▪ Keep them readable.
▪ In case of a malfunction the part number and the serial number might be
needed.
D-71384 Weinstadt
Made in Germnay
www.luetze.com
803101.01
Rev. A
16DI DC 24 V-36V
LION-DI16-24V-36V-LUE
0000000001
1.00 LSGP
S/N:
C/N:
SW:
Date: 31.12.12
299999
C

LION Bus Coupler ▪ Safety
10
3 Safety
3.1 Related Documents
The LION Bus Coupler is always operated together with I/O modules and
infrastructure components. It is essential to have read and understood the
relevant documents. .
3.1.1 LION System Description – Safety Manual
The system description contains safety relevant information about the LION
System. It is very important to read and understand the manual before working
with and on the products.
3.1.2 Instructions of I/O Modules
The instruction of the I/O modules contains important information about the
handling and configuration of the I/O modules.
3.1.3 Instructions of Infrastructure Components
The instruction of the infrastructure components contains important information
about the supply of the system and the structure.
Risk of injury and property damages caused by non observance of the
related documents.
▪ The manual of the components is insufficient if operating in a system with
other modules.
▪ To avoid injuries and damages also read the related documents before
planning the system.
The system description – Safety manual and the manuals for the Lütze bus
coupler and I/O modules can be found on: www.luetze-transportation.com
You should be familiar with this document, although all security issues
(SIL0) are covered in this manual, the document „System Description,
LION–Lütze Input/Output Network“ will help you get to know the overall
system better.
>This link opens the PDF document „System Description, LION–
Lütze Input/Output Network“ on the LÜTZE Transportation website.
>This link opens the PDF document „Operating Instructions LION I/O
Modules“ on the LÜTZE Transportation website.
>This link opens the PDF document „LION Infrastructure
Components“ on the LÜTZE Transportation website.

LION Bus Coupler ▪ Safety
11
3.1.4 Data sheet of the LION Bus coupler Ethernet
The data sheet contains the current technical data. Technical data are subject to
change without notice. Be sure to use the latest data.
3.2 Intended Use
The bus coupler is designed for the exclusive use in the LION system for railway
vehicles.
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 operation and for the maintenance of the products and systems.
Regarding the employees three 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 refering to the qualification level of the
operating employees.
>This link opens the product data as well as the data sheet on the
LÜTZE Transportation website.
Danger of life, serious injuries and property damages caused by an
unsafe system. Use the modules only for
▪ the listed cases and according to the system architecture.
▪ with external devices recommended and allowed by Lütze Transportation
GmbH.
Risk of injury by deploying insufficient qualified operating employees.
Inappropriate appoint of not qualified or insufficient personnel can cause
property damages and personal injuries.
▪ Tasks which apply special procedures should be done by trained and
qualified employees or experts, especially electricians.

LION Bus Coupler ▪ Safety
12
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 Electrostatic Discharge (ESD)
Electrostatic discharge can destroy electronical components by voltage and
energy, which are not noticeable by humans. Damages can occur if an
electronical component is touched by an electrostatic discharged person.
Modules will not immediately recognized as malfunctioned, the maloperation will
occur after a longer operating time.
▪ Switch off the voltage before working with or on the module and work
according the ESD guidelines.
▪ Electronic components should not be contact electronic insulated material like
plastic foil, plastic parts, insulated table pads or clothing.
▪ Place the modules only on conductive surfaces.
3.8 Reconstruction and Modifications of the Product
▪Destroyed parts and malfunction of the product.
Inappropriate clothes can cause electrification and can damage the product.
If working with or on the components, wear special ESD clothing.
▪Also follow the instructions and regulations of the employer.
Personal injuries and property damages caused by reconstructions and
modifications of the product.
▪ Do not reconstruct or modify the product if the manufacturer does not allow
it explicit in writing.

LION Bus Coupler ▪ Safety
13
3.9 Special Safety Messages
Electric shocks and product damages caused by wrong voltage
application.
▪ Use the nominal operating voltage (see technical data).
▪ The lower and upper thresholds are given in the technical data.
Product damages caused by compensating current.
▪ Dismount all electronic modules and their connections of the frame if
intended to do some welding.

LION Bus Coupler ▪ System Planning
14
4 System Planning
4.1 - not applicable -
4.1.1 Standards
Danger of life, serious injuries and property damages if planning a
system with an incorrect system architecture.
▪ Check the technical data of each module.
▪ Read the operating instruction, especially the system and product
description.
▪ Check the surrounding conditions of the operating place.
▪ Check, wether the modules are designed for the operating case and the
application.
▪ Qualified employees, especially experts like engineers, should plan the
system.
The safety life cycle, as well as the safety management process, is
implemented according to
▪EN 50126:2000-03
Railway applications - The specification and demonstration of reliability,
availability, maintainability and safety (RAMS)
▪EN 50128:2011-06
Railway applications - Communication, signalling and processing systems -
Software for railway control and protection systems and
▪EN 50129:2003-12
Railway applications - Communications, signalling and processing systems -
Safety related electronic systems for signalling (SIL2 relevant)
The modules are devided into two classes:
▪Class 1 – SIL0
The software on the modules is programmed according EN 50128
SIL0 regarding error prevention and organized procedures.
▪Class 2 – SIL2
The hardware was developed according to EN 50129 SIL2.
The software on the modules is programmed according EN 50128 SIL2
regarding error prevention and organized procedures.
This LION Bus Coupler Ethernet (SIL0) is Class 1 – SIL0.

LION Bus Coupler ▪ System Planning
15
4.2 LION System - Overview
Fig. 3: LION System overview (SIL0/SIL2)
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Using the SIL0 bus coupler only SIL0 can be reached.

LION Bus Coupler ▪ System Planning
16
4.3 Safety Target
4.3.1 Bus Coupler
▪ Transmitting of process information from the PLC to the connected I/O
modules on the local system bus and vice versa in an environment up to SIL0.
4.3.2 I/O Modules
▪ Recording, processing of the data and the providing of process information of
the I/O system on the fieldbus in an environment up to SIL0.
▪ Receiving, processing and puting out the received process information via
fieldbus in an environment up to SIL0.
4.3.3 Power Supplies
Voltage supplying of the internal system regarding the specified thresholds for the
upper voltage limit of the modules on the local bus in an environment up to SIL0.
4.4 System Overview
LION (Lütze Input Output Network) is a decentral input and output system for
railway vehicles.
Fig.4: Overview – Bus coupler with connected
I/O Modules
The LION product line contains modular components and modules for capturing
and releasing digital and analog signals.
The modules can be differentiated by two colors:
▪ SIL2 modules are yellow
▪ Non SIL (SIL0) modules are grey
Also the modules are differentiate between Lütze and Brandlabel modules. All
part numbers ending with .XX are Brandlabel products, as listed in the following
tables.
Using the SIL0 bus coupler only SIL0 can be reached.

LION Bus Coupler ▪ System Planning
17
4.4.1 Bus Coupler Ethernet TRDP (SIL0)
Fig.5: Bus coupler
The Bus Coupler Ethernet (SIL0) can be a gateway to a superior network, like the
vehicle control, or it can be connected via fieldbus to a PLC.
The fieldbus protocol is TRDP. Via the fieldbus data can be transmitted or
received to or from LION I/O modules.
4.4.2 Digital Input Modules (SIL0)
Fig.6: Digital Input Modules
The modules capture digital input signals in the defined voltage range via galvanic
insulated input ranges. The information are transmitted via L-Bus² to the bus
coupler. The modules are supplied via internal bus.
Product Description Type Part-No.
Bus coupler
Ethernet, SIL0
Connects the LION
System to a TRDP
Fieldbus system.
LION-BC-ETH-
LUE
803012
803012.XX
CH1
X50
C2H
X60
LIONBCETH
MSLBACT1ACT2
NSLNK1LNK2
CH1
X50
C2H
X60
LION BC ETH MS LB ACT1 ACT2
NS LNK1 LNK2
Product Description Type Part-No.
16 Digital Inputs
DC 24...36 V,
SIL0
Reads 16 inputs in
the nominal voltage
wide range for
battery supplies.
LION-DI16-24V-36V 803101
803101.XX
16 Digital Inputs
DC 72 ...110 V,
SIL0
Reads 16 inputs in
the nominal voltage
wide range for
battery supplies.
LION-DI16-72V-110V 803102
803102.XX

LION Bus Coupler ▪ System Planning
18
4.4.3 Digital Output Modules (SIL0)
Fig.7: Digital Output Modules
The modules release digital information on the galvanic insulated output ranges
via L-Bus2. The outputs can have relays or semiconductors for a defined nominal
voltage.
Product Description Type Part-No.
16 Digital
Outputs DC 24 V,
SIL0
Writes the
information on 16
semiconductor
outputs in the
nominal voltage
value for battery
supply.
LION-DO16-24V 803202
803202.XX
8 Digital Outputs
DC 24...110 V,
SIL0
Writes the
information on 8
semiconductor
outputs in the
nominal voltage
value for battery
supply.
LION-DO8-24V-110V 803203
803203.XX
8 Relay Outputs,
SIL0
Writes the
information on 8
relay outputs.
LION-RO8 803201
803201.XX

LION Bus Coupler ▪ System Planning
19
4.4.4 Analog Input Modules (SIL0)
Fig.8: Analog Input Modules
The modules capture analog input signals in the definied voltage range via
galvanic insulated input ranges. The information are transmitted via L-Bus² to the
bus coupler.
Product Description Type Part-No.
4 Analog
Inputs 0...10 V,
SIL0
Reads 4 voltage inputs in
a range of 0 to 10 V.
LION-AI4-U 803301
803301.XX
4 Analog
Inputs
0...20 mA,
SIL0
Reads 4 current inputs in
a range of 0 to 20 mA.
LION-AI4-I 803302
803302.XX
4 Analog
Inputs PT 100,
SIL0
Reads 4 PT100
temperature sensors.
LION-AI4-PT100 803303
803303.XX
4 Analog
Inputs PT
1000,
SIL0
Reads 4 PT1000
temperature sensors.
LION-AI4-PT1000 803304
803304.XX

LION Bus Coupler ▪ System Planning
20
4.4.5 Analog Output Modules (SIL0)
Fig.9: Analog Output Modules
The modules release analog information on the galvanic insulated output ranges
via L-Bus². The outputs can base on relays or semiconductors for a defined
nominal voltage.
Product Description Type Part-No.
4 Analog
Outputs 0...10 V,
SIL0
Writes information on 4
voltage outputs in a range of
0 to 10 V.
LION-AO4-U 803401
803401.XX
4 Analog
Outputs
0...20 mA, SIL0
Writes information on 4
current outputs in a range of
0 to 20 mA.
LION-AO4-I 803402
803402.XX

LION Bus Coupler ▪ System Planning
21
4.4.6 Digital Input/Output Modules (SIL2)
Fig. 10: SIL2 Digital Input and Output Module
The modules capture digital input signals in the defined voltage range via galvanic
insulated input ranges. The information are transmitted via L-Bus² to the bus
coupler.
Product Description Type Part-No.
16 Digital Inputs,
DC 24...36 V
8 Digital Outputs
DC 24...110 V
SIL2
Reads 16 inputs in the
nominal voltage wide
range for battery supplies
with DC 24 V ...36 V.
Writes the information on
8 outputs.
LION-SAFE-
DI16-DO8-LV
803501
803501.XX
16 Digital Inputs,
DC 72...110 V
8 Digital Outputs
DC 24...110 V
SIL2
Reads 16 inputs in the
nominal voltage wide
range for battery supplies
with DC 24 V ...36 V.
Writes the information on
8 ouputs.
LION-SAFE-
DI16-DO8-HV
803502
803502.XX
LB
MS
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I10
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I14I13 Q7
I16I15 Q8
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LION SAFE DI/DO
X10 X11
X20
X30 X13
GNDA
GNDC
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8
This module (digital input/output modules - SIL2) cannot perform a safe
function in conjunction with the SIL0 bus coupler. This means a
maximum of SIL0, but this module provides considerably more
diagnostic information than a SIL0 module.