Lütze LION Series User manual

Operating Instructions
LION
I/O Modules
LION-DI16-24-36V
LION-DI16-72-110V
LION-RO8
LION-DO16-24V
LION-DO8-24V-110V
LION-AI4-U
LION-AI4-I
LION-AI4-PT100
LION-AI-PT1000
LION-AO4-U
LION-AO4-I
Version 00
01/24/2017

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

LION I/O Modules ▪ Content
Content
1 Instruction Content....................................................................................... 6
2 General Information...................................................................................... 7
2.1 Symbol Description ................................................................................................................. 7
2.1.1 Safety Messages .................................................................................................................... 7
2.1.2 Handling Notes ....................................................................................................................... 7
2.1.3 Special Notes.......................................................................................................................... 7
2.2 Copyright................................................................................................................................. 7
2.3 Disclaim of Liability ................................................................................................................. 8
2.4 Standards................................................................................................................................ 8
2.5 Labeling .................................................................................................................................. 8
2.5.1 QR Code – Product Information.............................................................................................. 9
3 Safety........................................................................................................... 10
3.1 Related Documents .............................................................................................................. 10
3.1.1 System Description – Safety Manual .................................................................................... 10
3.1.2 Bus coupler ........................................................................................................................... 10
3.1.3 Infrastructure Components ................................................................................................... 10
3.2 Intended Use......................................................................................................................... 10
3.3 Recepients ............................................................................................................................ 10
3.4 Operating Employees ........................................................................................................... 11
3.5 Responsibility of the Operator............................................................................................... 11
3.6 Protective Clothing and Equipment....................................................................................... 11
3.7 Electrostatic Discharge (ESD) .............................................................................................. 11
3.8 Reconstruction and Modifications of the Product.................................................................. 12
3.9 Special Safety Messages...................................................................................................... 12
4 System Planning......................................................................................... 13
4.1 Safety Integrity Level ............................................................................................................ 13
4.1.1 Standards.............................................................................................................................. 13
4.2 System Approvals ................................................................................................................. 14
4.3 Safety Target ........................................................................................................................ 14
4.3.1 Bus Coupler .......................................................................................................................... 14
4.3.2 I/O Modules........................................................................................................................... 14
4.3.3 Power Supplies ..................................................................................................................... 15
4.4 System Overview .................................................................................................................. 16
4.4.1 Bus Coupler – SIL2 .............................................................................................................. 17
4.4.2 Digital Input Modules – SIL0 ................................................................................................. 17
4.4.3 Digital Output Modules – SIL0 .............................................................................................. 18
4.4.4 Analog Input Modules – SIL0................................................................................................ 19
4.4.5 Analog Output Modules – SIL0 ............................................................................................ 20
4.4.6 Digital Input/Output Modules – SIL2 ..................................................................................... 21
4.4.7 Infrastructure Modules – SIL0/SIL2 ...................................................................................... 21
4.5 System Architecture.............................................................................................................. 23
4.5.1 Smallest System ................................................................................................................... 23
4.5.2 Maximum System ................................................................................................................. 24
4.5.3 One-Line-System .................................................................................................................. 24
4.5.4 Line Change.......................................................................................................................... 25
4.5.5 Energy Supply Range ........................................................................................................... 25
5 Transport and Storing ................................................................................ 26
5.1 Scope of Delivery.................................................................................................................. 26
6 Installation................................................................................................... 27
6.1 Mounting Options.................................................................................................................. 27
6.2 Mounting Distances .............................................................................................................. 27
6.3 DIN Rail Mounting................................................................................................................. 28

LION I/O Modules ▪ Content
6.4 Demounting........................................................................................................................... 29
6.5 Grounding the Modules......................................................................................................... 30
6.6 Wiring the Modules ............................................................................................................... 31
6.7 Terminal coding .................................................................................................................... 32
6.7.1 Locking the Push-In Terminals ............................................................................................. 32
6.7.2 Releasing the Push-In Terminals.......................................................................................... 32
6.8 EMC Shield Clip Set ............................................................................................................. 33
6.8.1 Measurements ...................................................................................................................... 33
6.8.2 Mounting ............................................................................................................................... 33
6.8.3 Wiring.................................................................................................................................... 34
6.9 Connecting the Modules ....................................................................................................... 34
6.10 Disconnecting the Modules................................................................................................... 35
6.11 System Termination.............................................................................................................. 36
6.11.1 Bus Termination Connector ................................................................................................. 36
6.11.2 Bus Dummy Connector......................................................................................................... 36
7 Product Description ................................................................................... 37
7.1 General Technical Data ........................................................................................................ 37
7.2 LED Status............................................................................................................................ 38
7.3 Module Status....................................................................................................................... 38
7.3.1 Fail Safe................................................................................................................................ 40
7.3.2 Limited Run........................................................................................................................... 40
8 Digital Inputs, SIL0 ..................................................................................... 41
8.1 Module Types ....................................................................................................................... 41
8.1.1 Characteristics ...................................................................................................................... 41
8.1.2 LED Status............................................................................................................................ 41
8.1.3 Pin Assignment ..................................................................................................................... 42
8.1.4 Process Data Image ............................................................................................................. 43
8.1.5 Input Data ............................................................................................................................. 43
9 Digital Outputs, SIL0 .................................................................................. 44
9.1 Module Types ....................................................................................................................... 44
9.1.1 Characteristics ...................................................................................................................... 44
9.2 803202 SIL0 DO16, 24 V...................................................................................................... 45
9.2.1 LED Status............................................................................................................................ 45
9.2.2 Pin Assignment ..................................................................................................................... 46
9.2.3 Module Function ................................................................................................................... 47
9.2.4 Process Data Image ............................................................................................................. 48
9.3 803203 SIL0 DO 8, 24-110 V................................................................................................ 51
9.3.1 LED Status............................................................................................................................ 51
9.3.2 Pin Assignment ..................................................................................................................... 52
9.3.3 Module Function ................................................................................................................... 53
9.3.4 Process Data Image ............................................................................................................. 54
9.4 803201, SIL0 RO8 ................................................................................................................ 56
9.4.1 Switching Cycle Counter....................................................................................................... 56
9.4.2 LED Status............................................................................................................................ 56
9.4.3 Pin Assignment ..................................................................................................................... 57
9.4.4 Process Data Image ............................................................................................................. 58
10 Analog Inputs, SIL0 .................................................................................... 60
10.1 Module Types ....................................................................................................................... 60
10.1.1 Characteristics ...................................................................................................................... 60
10.2 LED Status............................................................................................................................ 61
10.3 803301 AI 4, Voltage ............................................................................................................ 62
10.3.1 Pin Assignment..................................................................................................................... 62
10.3.2 Module Function ................................................................................................................... 63
10.3.3 Process Data Image ............................................................................................................. 63
10.4 803302 AI 4, Current............................................................................................................. 66

LION I/O Modules ▪ Content
10.4.1 Pin Assignment..................................................................................................................... 66
10.4.2 Module Function ................................................................................................................... 67
10.4.3 Process Data Image ............................................................................................................. 67
10.5 803303 AI 4, PT100.............................................................................................................. 69
10.5.1 Pin Assignment..................................................................................................................... 70
10.5.2 Module Function ................................................................................................................... 71
10.5.3 Process Data Image ............................................................................................................. 71
10.6 803304 AI4, PT1000............................................................................................................. 73
10.6.1 Pin Assignment..................................................................................................................... 74
10.6.2 Module Function ................................................................................................................... 75
10.6.3 Process Data Image ............................................................................................................. 76
11 Analog Outputs, SIL0 ................................................................................. 78
11.1 Module Type ......................................................................................................................... 78
11.2 Characteristics ...................................................................................................................... 78
11.3 LED Status............................................................................................................................ 78
11.4 803401 AO, 0-10 V ............................................................................................................... 79
11.4.1 Pin Assignment..................................................................................................................... 79
11.4.2 Module Function ................................................................................................................... 80
11.4.3 Process Data Image ............................................................................................................. 80
11.5 803402 AO, 0...20 mA .......................................................................................................... 83
11.5.1 Pin Assignment..................................................................................................................... 83
11.5.2 Module Function ................................................................................................................... 84
11.5.3 Process Data Image ............................................................................................................. 84
12 Maintenance and Service........................................................................... 87
12.1 Module Exchange ................................................................................................................. 87
12.1.1 MTTR (Mean Time To Restore)............................................................................................ 87
12.2 Proof Test Interval................................................................................................................. 87
12.3 Extending the LION System.................................................................................................. 88
13 Final Shutdown and Disposal.................................................................... 89
14 Appendix ..................................................................................................... 90
14.1 Accessories........................................................................................................................... 90
14.2 Revision of the Document..................................................................................................... 90

LION I/O Modules ▪ Instruction Content
6
1 Instruction Content
This manual is part of the LION 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.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 I/O Modules ▪ General Information
7
2 General Information
2.1 Symbol Description
2.1.1 Safety Messages
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.
2.1.2 Handling Notes
2.1.3 Special Notes
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 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.
Points out technical information.
Points out the use of tools.
SIL
relevant
LION-XXX
Points out a safety-related application condition.
These notes are marked with an ID for example: LION-001.
The IDs refer to the handling checklists in the system manual.

LION I/O Modules ▪ 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
2.5 Labeling
SIL
relevant
LION-070
The products are constructed and designed according following standards:
▪ EN 50155:2007-07, Railway applications – Electronic equipment used on
rolling Stock
▪ EN 50121-3-2:2006-07, Railway applications – Electromagnetic
compatibility,
Part 3-2: Rolling stock apparatus 2006
▪ EN 61373:2010-09, Railway applications – Rolling stock equipment.
Shock and vibration tests
▪ EN 50124-1:2005-06, Railway applications – Insulation coordination, Part 1
▪ EN 50126:2000-03 Railway applications - The specification and
demonstration of Reliability, Availability, Maintainability and Safety (RAMS)
▪ EN 50128:2011-06 Railway applications - Software for railway control and
protection systems
▪ EN 50129:2003-12 Railway applications - Safety related electronic systems
for signaling
▪ N FF 16-101:1988-10-01 Railway rolling stock, Fire behavior, Material
choosing – application for electrical system I0 to I2 and F0 to F2
▪ House standard 2008-04, grounded conductor test (30 A for 2 min)
SIL
relevant
LION-029
The following label can be found on the product:

LION I/O Modules ▪ General Information
9
Abb. 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.
Abb. 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 I/O Modules ▪ Safety
10
3 Safety
3.1 Related Documents
The modules are always operated with other LION modules.
3.1.1 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 Bus coupler
The bus coupler instruction contains important information about the handling and
configuration of the bus coupler and the communication with the I/O modules.
3.1.3 Infrastructure Components
The instruction of the infrastructure components contains important information
about the supply of the system and the structure..
3.2 Intended Use
The infrastructure components are designed for the exclusive use in railway
vehicles, as a power supply and line coupler of the LION system.
The intended use also involves the use according to the operation instructions.
3.3 Recepients
The operating manual addresses planers, project managers and programmers. It
also addresses the operating employees who 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.
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 infrastructure components can be found on: www.luetze-
transportation.de
Danger of life, serious injuries and property damages caused by a 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.

LION I/O Modules ▪ Safety
11
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.
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.
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.
▪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.

LION I/O Modules ▪ Safety
12
▪ 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
3.9 Special Safety Messages
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.
Electric shocks and product damages caused by wrong voltage
application.
▪ Use the nominal operating voltage (see technical data of the individual
devices).
▪ The lower and upper thresholds are given in the technical data of the
individual devices.
Product damages caused by compensating current.
▪ Dismount all electronic modules and their connections of the frame if
intended to do some welding.

LION I/O Modules ▪ System Planning
13
4 System Planning
4.1 Safety Integrity Level
Depending on the application, the infrastructure modules can be used in a safety
application (up to SIL2). If the components are used in an environment which is
not SIL certified, the components cannot work as safety components.
The technical data for all modules can be found in the regarding operating
instruction.
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.
SIL
relevant
LION-008
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 50128:2012-03
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
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 SIL0
regarding error prevention and organized procedures.

LION I/O Modules ▪ System Planning
14
4.2 System Approvals
The following components are in scope of approval:
Fig. 3: Scope of approval
4.3 Safety Target
4.3.1 Bus Coupler
▪ Safe 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 SIl2.
4.3.2 I/O Modules
▪ Safe recording, processing of the data and the providing of process
information of the I/O system on the fieldbus in an environment up to SIL2.
SIL
relevant
LION-005
The system is certified. The system integrator or vehicle manufacturer can use
the certificate for vehicle registration.
SIL
relevant
LION-006
The Approval is only valid for the whole LION SIL2 system.
▪ The single infrastructure modules do not have an approval.
The approval is not valid if a non certified component or a non reactive
component is build in an I/O module.
PLC
line coupler
fieldbus
I/O module
bus coupler
power
supply
field power
System ScopeLION
interface
power
supply
fieldbus
configuration
I/O module
SIL2
SIL0
config.
power
supply I/O moduleI/O module
I/O moduleI/O modulepower
supply I/O moduleI/O moduleline coupler
line coupler
field power
I/O peripherals I/O peripherals I/O peripherals I/O peripherals
I/O peripherals I/O peripherals field power I/O peripherals I/O peripherals
field power
power
supply I/O moduleI/O modulepower
supply I/O moduleI/O module
line coupler
I/O peripherals I/O peripherals
field power
I/O peripherals I/O peripherals
field power
SIL
relevant
LION-030
The system is approved by
TÜV Süd
The approval cerificate is available on request at the Lütze Transportation
GmbH.
SIL
relevant
LION-010

LION I/O Modules ▪ System Planning
15
▪ Safe receiving, processing and puting out the received process information via
fieldbus in an environment up to SIL2.
4.3.3 Power Supplies
▪ Safe 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 SIL2.

LION I/O Modules ▪ System Planning
16
4.4 System Overview
LION (Lütze Input Output Network) is a decentral safety 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.

LION I/O Modules ▪ System Planning
17
4.4.1 Bus Coupler – SIL2
Fig.5: Bus coupler
The SIL2 bus coupler can be a gateway to a superior network, like the vehicle
control, or it can be connected via fieldbus to a PLC.
The bus coupler uses a safe fieldbus protocol. Via the safe fieldbus protocol, non
safe data can be transmitted or received to or from non safe I/O modules.
A safe operation of the I/O Modules is possible, because of an error detection and
evaluation done by the SIL2 bus coupler.
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 SIL2 bus
coupler. The modules are supplied via internal bus.
Product Description Type Part-No.
MVB Bus
coupler, SIL2
Operates with a safe MVB
fieldbus protocol.
LION-BC-
MVB-LUE
803001
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-LUE
803101
16 Digital Inputs
DC 72 ...110 V,
SIL0
Reads 16 inputs in the
nominal voltage wide
range for battery supplies
.
LION-DI16-72V-
110V-LUE
803102

LION I/O Modules ▪ 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-LUE
803202
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-LUE
803203
8 Relay Outputs, SIL0 Writes the information
on 8 relay outputs. The
outputs are designed
for the nominal voltage
values of the battery
supply.
LION-RO8-LUE 803201

LION I/O Modules ▪ 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
SIL2 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-LUE 803301
4 Analog Inputs
0...20 mA, SIL0
Reads 4 current inputs in
a range of 0 to 20 mA.
LION-AI4-I-LUE 803302
4 Analog Inputs
PT 100, SIL0
Reads 4 PT100
temperature sensors.
LION-AI4-PT100-
LUE
803303
4 Analog Inputs
PT 1000, SIL0
Reads 4 PT1000
temperature sensors.
LION-AI4-PT1000-
LUE
803304

LION I/O Modules ▪ 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-
LUE
803401
4 Analog Outputs
0...20 mA, SIL0
Writes information on 4
current outputs in a range of
0 to 20 mA.
LION-AO4-I-
LUE
803402