LUTZE DIOLINE 20 User manual

Operating Instructions
DIOLINE 20
Redundant I/O Modules
Version 1.10

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

Redundant I/O Modules ▪Content
Content
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................................................................................................................ 7
3 Safety ............................................................................................................ 8
3.1 Content of the Manual............................................................................................................ 8
3.2 Intended Use.......................................................................................................................... 8
3.3 Recepients ............................................................................................................................. 8
3.3.1 Operating Employees............................................................................................................. 8
3.4 Responsibility of the Operator................................................................................................ 8
3.5 Protective Clothing and Equipment........................................................................................ 9
3.6 Reconstruction and Modifications of the Product................................................................... 9
3.7 Safety Appliance .................................................................................................................... 9
3.8 Special Safety Messages....................................................................................................... 9
4 Product Overview ...................................................................................... 10
4.1 Product Description.............................................................................................................. 10
4.2 System Overview ................................................................................................................. 11
4.3 Field of Application............................................................................................................... 12
5 Transport and Storing ............................................................................... 13
6 Scope of Delivery....................................................................................... 14
7 General Technical Data ............................................................................. 15
8 Mounting..................................................................................................... 17
8.1 Mounting Options ................................................................................................................. 18
9 Initial Operation – Hardware ..................................................................... 19
9.1 Power Supply ....................................................................................................................... 19
9.2 L-Bus – Interface.................................................................................................................. 20
9.2.1 Connecting One Channel Modules via the L-Bus Interface ................................................. 21
10 Digital Inputs .............................................................................................. 22
10.1 Characteristics ..................................................................................................................... 22
10.2 16 Digital Inputs, DC 24 V, 2 Potentials ............................................................................... 23
10.2.1 Product Assembly ................................................................................................................ 23
10.2.2 LED Display ......................................................................................................................... 24
10.2.3 Technical Data ..................................................................................................................... 25
10.2.4 Connecting the Digital Inputs ............................................................................................... 26
10.2.5 Operation ............................................................................................................................. 28
10.3 4x4 Digital Inputs DC 24 V, DC 24 V (not inverted)
and 72 V DC 29
10.3.1 Product Assembly ................................................................................................................ 29
10.3.2 LED Display ......................................................................................................................... 30
10.3.3 Technical Data ..................................................................................................................... 31
10.3.4 Connecting Digital Inputs ..................................................................................................... 36
10.3.5 Operation ............................................................................................................................. 38
11 Digital Outputs ........................................................................................... 41
11.1 Characteristics ..................................................................................................................... 41
11.2 16 Digital Outputs, DC 24 V, 2 Potentials ............................................................................ 42
11.2.1 Product Assembly ................................................................................................................ 42

Redundant I/O Modules ▪Content
11.2.2 LED Display ......................................................................................................................... 43
11.2.3 Technical Data ..................................................................................................................... 44
11.2.4 Connecting Digital Outputs .................................................................................................. 45
11.2.5 Operation ............................................................................................................................. 47
11.3 2x3 Digital Outputs DC 24...110 V ....................................................................................... 48
11.3.1 Product Assembly ................................................................................................................ 48
11.3.2 LED Display ......................................................................................................................... 49
11.3.3 Technical Data ..................................................................................................................... 50
11.3.4 Connecting the Digital Outputs ............................................................................................ 51
11.3.5 Operation ............................................................................................................................. 52
11.4 8 Digital Outputs, DC 24 V, 4 Potentials .............................................................................. 53
11.4.1 Product Assembly ................................................................................................................ 53
11.4.2 LED Display ......................................................................................................................... 54
11.4.3 Technical Data ..................................................................................................................... 55
11.4.4 Connecting the Digital Outputs ............................................................................................ 56
11.4.5 Diagnosis ............................................................................................................................. 58
11.4.6 Operation ............................................................................................................................. 59
12 Digital Combination ................................................................................... 60
12.1 Characteristics ..................................................................................................................... 60
12.2 8 Digital Inputs, 8 Digital Outputs DC 24 V .......................................................................... 61
12.2.1 Product Assembly ................................................................................................................ 61
12.2.2 LED Display ......................................................................................................................... 62
12.2.3 Technical Data ..................................................................................................................... 63
12.2.4 Connecting of the In- and Outputs ....................................................................................... 65
12.2.5 Operation ............................................................................................................................. 67
13 Demounting ................................................................................................ 68
14 Final Shutdown and Disposal................................................................... 69
15 Service ........................................................................................................ 70
16 Appendix..................................................................................................... 71
16.1 Overview – DIOLINE 20 Identifier ........................................................................................ 71

Redundant I/O Modules ▪Introduction
5
1 Introduction
This manual is part of the Redundant 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.

Redundant 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
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.

Redundant I/O Modules ▪General Information
7
2.4 Related Documents
The redundant modules are always operated with different PLCs or buscoupler.
Read the manual of the PLC or buscoupler before using the modules.

Redundant 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 redundant 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
Use the redundant modules only for the listed cases and only with external
devices recommanded and allowed by 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.
3.3.1 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.
3.4 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
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.

Redundant I/O Modules ▪Safety
9
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.
3.5 Protective Clothing and Equipment
3.6 Reconstruction and Modifications of the Product
3.7 Safety Appliance
3.8 Special Safety Messages
▪If working with or on the redundant 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 redundant modules do not garuantee the safety of the whole process
and/or the whole system.
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.

Redundant I/O Modules ▪Product Overview
10
4 Product Overview
4.1 Product Description
The DIOLINE20 Redundant I/O Modules are connected to a buscoupler or PLC
via the L-Bus (Lütze Bus). The I/O Modules are available as:
Description Item Number.
16 DI, DC 24 V, 2 Potentials, redundant 746430
16 DI, DC 24 V, 4 Potentials, redundant 746431
16 DO, DC 24 V, 1 A, 2 Potentials, redundant 746432
8 DI, 8 DO DC 24 V, 1 A, 2 Potentials, redundant 746433
8 DO, DC 24 V, 2 A, 4 Potentials, redundant 746434
16 DI, DC 72 V, 4 Potentials, redundant 746435
6 DO, DC 24...110 V, 0.5 A, 3 Potentials, redundant 746436
16 DI, DC 24 V, 4 Potentials, redundant 746437

Redundant I/O Modules ▪Product Overview
11
4.2 System Overview
The Redundant 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 redundant modules to the controller. The extension
modules are connected via 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
Modular I/O Busnode
DIOLINE20
Buscoupler MVB Slave
Modular I/O Busnode
DIOLINE20
Buscoupler CANopen Slave
Modular I/O Busnode
DIOSWITCH
Unmanaged Ethernet Switch

Redundant I/O Modules ▪Product Overview
12
4.3 Field of Application
The DIOLINE20 Redundant I/O Modules can be connected to buscoupler or
PLCs.

Redundant I/O Modules ▪Transport and Storing
13
5 Transport and Storing
▪Protect the product against humidity. Store the product in a dry room
between -40 and 85°C.
▪Make sure that the modules are safely packaged for transporting, to
absorbe possible crushes.
▪Dust can destroy electronic components. The circuit boards of the
modules are coated. But try to store and transport it in a dust free
environment to avoid damages of the modules.

Redundant I/O Modules ▪Scope of Delivery
14
6 Scope of Delivery
▪DIOLINE20 redundant Module
▪Plug-in Connector
▪Instruction Leaflet

Redundant I/O Modules ▪General Technical Data
15
7 General Technical Data
Mechanics
Dimensions (WxHxD)) 57.0x302.0x64.0 mm
Housing aluminum
Mounting top hat rail
Electronic Module Supply
Voltage Supply DC 16.8-30 V
Ripple max. 10 %
150 mm ±0,5
302 mm
TS35
TS35
84 mm
57 mm 45 mm
64 mm
3mm
R
Technik mit System
DIOLINE 20
redundant
DO 6
LB1ALB1ERR
LB2ALB2ERR
OUTPUT 1
OUTPUT 2
34 6
5
12
X2
34 6
5
12USAPE
USBUSC
34 6
5
12
34 6
5
12
X1
USAPE
USBUSC

Redundant I/O Modules ▪General Technical Data
16
Enviromental Condition
Operating Temperature -40°C bis +70°C (+85°C for 10 min)
according 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
For additional standard information, please see the technical data sheet.

Redundant I/O Modules ▪Mounting
17
8 Mounting
Risk of injury by electric current. People can be injured by electric current and
the product can be damaged. Deenergize the system before mounting.
▪This step has to be done by trained employees.
▪For mounting a screwdriver is mandatory.
Mount the module with following
distances:
▪Top: 10 mm
▪Bottom: 30 mm
▪Right to the next redundant module:
0 mm
▪Right to the next one channel
module: 8-10 mm
Mount an end bracket (1) between
these modules.
▪Left: 0 mm
▪Front: 10 mm
1. Snap the modul on the upper top hat
rail.
2. Take the screwdriver. Stick the scr-
wedriver in the tab. Pull the tab.
3. Press the module with pulled tab on
the lower top hat rail.
4. Remove the screwdriver. The mo-
dule snaps on the top hat rail.

Redundant I/O Modules ▪Mounting
18
8.1 Mounting Options
The redundant module is going to be mounted on a top-hat rail. Following
mounting options are possible:
▪horizontal
▪vertical
▪across

Redundant I/O Modules ▪Initial Operation – Hardware
19
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 built in microcontroller of the digital Redundant I/O Modules is feeded by the
L-Bus interface. 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.

Redundant I/O Modules ▪Initial Operation – Hardware
20
9.2 L-Bus – Interface
The L-Bus interface is for coupling the local DIOLINE20 redundant modules. The
L-Bus (Lütze-Bus) is a special fieldbus invented by company Lütze.
Switch off the power when connecting or disconnecting the redundant
modules. If not observe, the whole system can be damaged. Hot Plugging is not
supported by the system.
Connect max 10 redundant modules over the L-Bus interface. Mind the
current consumption of the single modules. In the appendix on page 70 the
according values are listed. A total current of max 1 A is possible on the L-Bus.
1. Switch off the power.
A change of the pin assignment is not possible, because of the
predetermined connectors.
Pin Signal Description
124 V Supply Voltage
2 24 V Supply Voltage
3 GND 0 V Potential
4 /L_BUS_
RESET
Module Reset
5BUS_END Identifier Bus End
6 OUT_OK Data Confirmation
7MDIN Serial Receiving Data
Master
8 SCK Clock
9SDOUT Sending Serial Data
10 GND 0 V Potential