Lütze LION-DI16-DO8-S-LV User manual

Operating Instructions
LION
SIL2 I/O Modules
LION-DI16-DO8-S-LV
LION-DI16-DO8-HV
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 Charcateristics ...................................................................................................................... 37
7.1.1 Digital Inputs ......................................................................................................................... 37
7.1.2 Digital Outputs....................................................................................................................... 37
7.2 Product Overview.................................................................................................................. 38
7.3 General Technical Data ........................................................................................................ 38
7.4 Interfaces – Pin Assignment ................................................................................................. 39
7.5 LED Status ............................................................................................................................ 41
7.6 Module Status ....................................................................................................................... 42
7.6.1 Fail Safe ................................................................................................................................ 43
7.6.2 Limited Run ........................................................................................................................... 44
8 Safe Data Communication ......................................................................... 45
8.1 General ................................................................................................................................. 45
8.2 Outputs.................................................................................................................................. 47
8.3 Inputs .................................................................................................................................... 47
9 Digital Inputs ............................................................................................... 48
9.1 Error Detection ...................................................................................................................... 48
9.1.1 Fail safe................................................................................................................................. 48
9.1.2 Testpulse............................................................................................................................... 48
9.2 Safety Integrity ...................................................................................................................... 48
9.2.1 SIL1....................................................................................................................................... 49
9.2.2 SIL2....................................................................................................................................... 50
9.3 Process Data Image.............................................................................................................. 51
9.3.1 Input Data.............................................................................................................................. 51
10 Digital Outputs ............................................................................................ 53
10.1 Error Detection ...................................................................................................................... 53
10.1.1 Fail safe................................................................................................................................. 53
10.1.2 Testpulse............................................................................................................................... 53
10.2 Safety Integrity ...................................................................................................................... 54
10.2.1 SIL1....................................................................................................................................... 55
10.2.2 SIL2....................................................................................................................................... 56
10.3 Process Data Image.............................................................................................................. 56
10.3.1 Input Data.............................................................................................................................. 56
10.3.2 Configuration Data – Filter Constant..................................................................................... 59
10.3.3 Output Data........................................................................................................................... 60
11 Maintenance and Service ........................................................................... 61
11.1 Module Exchange ................................................................................................................. 61
11.1.1 MTTR (Mean Time To Restore) ............................................................................................ 61
11.2 Proof Test Interval................................................................................................................. 61

LION I/O Modules ▪ Content
11.3 Extending the LION System.................................................................................................. 62
12 Final Shutdown and Disposal.................................................................... 63
13 Appendix...................................................................................................... 64
13.1 Accessories........................................................................................................................... 64
13.2 Revision of the Document ..................................................................................................... 64

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.