Lütze DIOLINE PLC Operating Instructions Manual

Operating Instructions

DIOLINE PLC

COS-COM, Part-No. 746032

Version 03

Lütze Transportation GmbH

Bruckwiesenstraße 17-19

D-71384 Weinstadt

Tel.: +49 (0) 7151 6053-545

Fax: +49 (0) 7151 6053-6545

Sales.Transportation@luetze.de

www.luetze-transportation.com

3

DIOLINE PLC ▪ 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 Recipients............................................................................................................................... 8

3.4 Operating Employees............................................................................................................. 8

3.5 Responsibility of the Operator ................................................................................................ 9

3.6 Protective Clothing and Equipment ........................................................................................ 9

3.7 Labeling.................................................................................................................................. 9

3.8 Reconstruction and Modifications of the Product ................................................................. 10

3.9 Safety Arrangement ............................................................................................................. 10

3.10 Special Safety Messages ..................................................................................................... 10

4 Product Overview....................................................................................... 11

4.1 Product Description .............................................................................................................. 11

4.2 Hardware Options ................................................................................................................ 11

4.3 Software Options.................................................................................................................. 12

4.4 System Overview ................................................................................................................. 13

4.5 Field of Application ............................................................................................................... 14

5 Transport and Storing ............................................................................... 15

6 Scope of Delivery ....................................................................................... 16

7 Product Assembly...................................................................................... 17

7.1 LED Display.......................................................................................................................... 18

8 Technical Data............................................................................................ 20

9 Mounting ..................................................................................................... 23

9.1 Mounting Options ................................................................................................................. 23

10 Initial Operation – Hardware ..................................................................... 24

10.1 Power Supply ....................................................................................................................... 24

10.2 L-Bus – Interface .................................................................................................................. 25

10.3 Serial Interface ..................................................................................................................... 27

10.4 SD Card Slot ........................................................................................................................ 28

10.4.1 Changing the SD Card ......................................................................................................... 29

10.5 Ethernet Interface................................................................................................................. 30

10.6 Fieldbus 1 Interface – CANopen Master .............................................................................. 31

10.7 Fieldbus 2 Interface – CANopen Slave ................................................................................ 32

11 Initial Operation – Software....................................................................... 33

11.1 Installation ............................................................................................................................ 34

11.1.1 MULTIPROG ........................................................................................................................ 34

11.1.2 ProConOS OPC Server........................................................................................................ 35

11.1.3 Lütze Addons ....................................................................................................................... 36

11.2 IP Configuration.................................................................................................................... 37

11.2.1 PC IP Address...................................................................................................................... 37

11.2.2 Communication Check ......................................................................................................... 39

11.2.3 PLC IP Address.................................................................................................................... 40

4

DIOLINE PLC ▪ Content

11.2.4 Resetting the TCP/IP Address ............................................................................................. 41

11.3 Development Environment System – MULTIPROG............................................................. 42

11.3.1 Creating a MULTIPROG Project .......................................................................................... 42

11.3.2 Ressource Settings .............................................................................................................. 44

11.3.3 Function Blocks and Firmware Libraries .............................................................................. 46

11.3.4 ProConOS.INI ...................................................................................................................... 51

11.3.5 Variables .............................................................................................................................. 52

11.4 Configuration of the Fieldbusses and other Interfaces......................................................... 58

11.4.1 L-Bus Configuration.............................................................................................................. 58

11.4.2 SD Card Configuration ......................................................................................................... 64

11.4.3 PFD – Parallel Flash Disk .................................................................................................... 67

11.4.4 Real Time Clock Configuration............................................................................................. 73

11.4.5 CANopen Master Configuration ........................................................................................... 76

11.4.6 CANopen Slave Configuration .......................................................................................... 97

11.5 Compiling and Loading......................................................................................................... 99

11.5.1 Download of Configuration Files .......................................................................................... 99

11.5.2 Downloading a MULTIPROG Project ................................................................................. 100

11.5.3 Deleting the Flashdisk ........................................................................................................ 102

11.6 Visualization – ProVisIT ..................................................................................................... 103

12 Operation .................................................................................................. 104

12.1 Hardware Architecture........................................................................................................ 104

12.2 Software Architecture ......................................................................................................... 106

12.3 Memory Architecture (non volatile memory)....................................................................... 107

12.3.1 RAM Architecture (volatile memory)................................................................................... 108

12.3.2 Configuration of the PLC Memory Ranges......................................................................... 109

12.3.3 Monitoring the PLC tasks and CPU Capacity..................................................................... 112

12.3.4 L-Bus Performance ............................................................................................................ 115

13 Maintenance Software ............................................................................. 116

13.1 Update Firmware (ProConOs)............................................................................................ 116

13.1.1 Update via MULTIPROG.................................................................................................... 116

13.1.2 Updating the PLC via the SD Card..................................................................................... 118

14 Final Shutdown and Disposal ................................................................. 123

15 Service ...................................................................................................... 124

16 Error Treatment ........................................................................................ 125

16.1 Error Messages of the Function blocks .............................................................................. 125

16.1.1 L-BusInfo ............................................................................................................................ 125

16.1.2 MVBInfo, Sink and Source ................................................................................................. 125

16.1.3 CoRec and CoSend ........................................................................................................... 126

16.1.4 SetDateTime ...................................................................................................................... 127

16.1.5 FILE_OPEN........................................................................................................................ 127

16.1.6 FILE_READ........................................................................................................................ 127

16.1.7 FILE_WRITE ...................................................................................................................... 128

16.1.8 FILE_CLOSE...................................................................................................................... 128

17 Appendix................................................................................................... 129

17.1 Content of the Firmware Libraries ...................................................................................... 129

17.1.1 MVB-IKS Firmware Library................................................................................................. 129

17.1.2 ProConOS Firmware Library .............................................................................................. 130

17.2 DIOLINE 20 Module Types ................................................................................................ 135

17.3 Autoexec.bat Commands ................................................................................................... 136

18 Revision of the Document....................................................................... 137

DIOLINE PLC ▪ Introduction

5

1 Introduction

This manual is part of the DIOLINE PLC. 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.

DIOLINE PLC ▪ 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

▪ The real-time capability of the controller

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.

DIOLINE PLC ▪ General Information

7

2.4 Related Documents

The programming environment of the DIOLINE PLC is a product of the company

KW Software and Hilscher. The companies are responsible for the documentation

and the compliance of standards. This document contains short parts of the

software documentation. In particular cases apply to:

KW-Software GmbH

Lagesche Straße 32

32657 Lemgo

Tel. +49 52619373-0

Fax. +49 52619373-26

Hilscher Gesellschaft für Systemautomation mbH

Rhein Straße. 15

65795 Hattersheim

Tel. +49 61909907-0

Fax. +49 61909907-50

DIOLINE PLC ▪ 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 DIOLINE PLC is designed for the exclusive use in railway vehicles.

For:

▪ automation of simple vehicles

▪ as a subsystem controller or

▪ as a high capacity gateway for the realization of different vehicle specific bus

signals

Use the DIOLINE PLC just for the listed cases and just with external devices

recommended and allowed by Lütze Transportation GmbH.

3.3 Recipients

The operating manual adresses planers, project manager and programmers. It

also adresses the operating employees which are responsible for the initial

operation, the operating and for the maintenance of the products and systems.

Regarding the employees different qualification levels are differentiated.

3.4 Operating Employees

Trained Employees

The employee was trained by the employer on the task and possible hazardous

situations. The employee does not have any technical knowledge.

Experts

The employee has a technical education, knowledge and/or experience in the

required field. The employee is capable to do specific operations on and with the

product.

Electrically Qualified Persons

The employee has a technical education in the required field. The employee is

capable to do special operations on and with the product.

The different sections referringt to the qualification level of the operating

employees.

Risk of injury by deploying insufficient qualified operating employees.

Inappropriate use 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 electrically

qualified persons.

DIOLINE PLC ▪ Safety

9

3.5 Responsibility of the Operator

The operator is obligate by the law of occupational safety, if the product is used

in a commercial field.

▪ The operator is responsible to train the employees and to inform himself about

the industrial safety regulation.

▪ The operator is responsible that safety-, environment protection regulations

and rules for accident prevention are observed.

▪ The operator has to run a risk assessment at the working environment/place

of installation to expose hazards and to alert those.

▪ The manual has to be stored near the product.

▪ The manual has to be obeyed.

▪ The product can just be run in a faultless technical condition.

3.6 Protective Clothing and Equipment

If working with or on the PLC special ESD clothing and equipment is mandatory.

Also follow the instructions and regulations of the employer.

3.7 Labeling

On the product following label with following data can be found:

Fig. 1: Example Label

▪ Part-Number

▪ Hardware Revision

▪ Assembly Term

▪ Software-Version

▪ Serialnumber

Mind the original adhesive labels. Keep them readable.

DIOLINE PLC ▪ Safety

10

3.8 Reconstruction and Modifications of the Product

3.9 Safety Arrangement

3.10 Special Safety Messages

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.

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 from the frame if

you intend to do some welding. The product can be damaged by

compensating current.

DIOLINE PLC ▪ Product Overview

11

4Product Overview

4.1 Product Description

The DIOLINE PLC is a programmable compact controller in the automation

system DIOLINE20. The product is based on a high-performance

ARM = Microprocessor (Advanced Risk Machine). It is possible to connect

several I/O modules over the L-Bus interface. The L-Bus is a Lütze invention. The

product can provide up to 4 bus interfaces. The interfaces can be flexible

configured.

The DIOLINE PLC can be programmed and configured by the application

development system MULTIPROG from KW software. The programming can be

done in the established languages which are based on the IEC 61131 standard.

The software can handle multiuser projects over a network access.

There are several options regarding the interfaces and software.

4.2 Hardware Options

Option Item Number

DIOLINE PLC-COM-COM-LUE 746026

DIOLINE PLC-COM-CAN-LUE 746027

DIOLINE PLC-MVB-CAN-LUE 746028

DIOLINE PLC-COM-NFB-RS485-LUE 746029

DIOLINE PLC-COS-COM-LUE 746032

DIOLINE PLC-MVB-COM-LUE 746033

DIOLINE PLC-NFB-NFB-LUE 746034

DIOLINE PLC-MVB-CAN-RS485-LUE 746036

DIOLINE PLC-MVB-CAN-DI-LUE 746037

DIOLINE PLC-MVB-COM-DIO-LUE 746038

DIOLINE PLC-CAN-NFB-LUE 746039

DIOLINE PLC-MVB+-COM-LUE 746040

DIOLINE PLC-COS-CAN-LUE 746041

Legend:

CAN Controlled Area Network

MVB Multi Vehicle Bus (Slave) (EMD)

MVB+ Multi Vehicle Bus (Slave) (ESD+)

COM CANopen Master

COS CANopen Slave

DI Local Digital Inputs (24V)

DO Local Digital Outputs (24V)

DIOLINE PLC ▪ Product Overview

12

4.3 Software Options

RS485 Two Wire Serial Bus

RSBUS One Wire Serial Bus

NFB No Field Bus

Option Description Item Number

DR-PC-SW-KWS KW MULTIPROG Development

Suite+ V 4.8

▪ Multiprog development

environment

▪ IEC61131 Editor

▪ SYCON.NET CANopen fieldbus

configurator

▪ ProVisIT visualizing editor

▪ ProVisIT runtime license

746090

DR-PC2-SW-KWPD KW ProVisIT Development

enviroment

746091

DR-PC2-SW-KWM KW MULTIPROG Monitoring

Pro+ V 4.8

▪ MULTIPROG download and

debugging environment

746092

DR-PC2-SW-KWOPC ProConOS OPC Server 2.1 Desktop 746093

DR-PC2-SW-KWPR ProVisIT Runtime 746095

DR-PC2-SW-KWP KW MULTIPROG Development

Pro+ V 4.8

▪ Multiprog development

environment

▪ IEC61131 Editor

746096

DIOLINE PLC ▪ Product Overview

13

4.4 System Overview

The DIOLINE PLC can be integrated in the product line of the DIOLINE 20

automating system as follows.

The DIOLINE product line contains modular components. A unit consists of a

controller with an integrated CPU and an extension module. It is possible to

connect max. 10 local I/O extension modules on the controller. The extension

modules are connected over the L-Bus. The graphic shows the DIOLINE product

after their intelligence. The first module is the most intelligent one. The last one is

a module with the fewest intelligence.

DIORAIL PC 2

Vehicle Control Unit

DIOLINE PLC

Compact Control Unit

DIOLINE20

Buscoupler Ethernet IP Adapter

Remote I/O Modules

DIOLINE20

Buscoupler MVB Slave

Remote I/O Modules

DIOLINE20

Buscoupler CANopen Slave

Remote I/O Modules

DIOSWITCH

Unmanaged Ethernet Switch

DIOLINE PLC ▪ Product Overview

14

4.5 Field of Application

The DIOLINE PLC is designed for use in railway vehicles. It can be used for

automation of simple vehicles, as subsystems or for high-capacity gateways to

transfer vehicle specific bus signals. The graphic below shows possible

application areas in trains:

Fig. 2: Example Application 1: Powerpack Control Unit

Fig. 3: Example Application 2: Fire Protection Control Unit

DIOLINE PLC ▪ Transport and Storing

15

5 Transport and Storing

▪ Protect the product from humidity. Store the product in a dry room

between -40 and 85°C.

▪ Make sure that the PLC is safely packaged for transporting, that

possible crushes can be absorbed.

▪Dust can destroy electronic components. The circuit board of the PLC is

coated. But try to store and transport it in a dust free environment to avoid

damages of the PLC.

DIOLINE PLC ▪ Scope of Delivery

16

6 Scope of Delivery

▪DIOLINE PLC

▪ Dummy connector for L-Bus interface

▪ Shielding Cover for SUB-D interface

▪ Instruction Leaflet

The software for the DIOLINE PLC can be downloaded in the internet. The

Link and the password will be send by e-mail.

DIOLINE PLC ▪ Product Assembly

17

7 Product Assembly

1 LED-Diagnosis Display

2User and Reset Button

3 L-Bus Interface X8

4RS 232 Interface X7

5 Ethernet Interface X6

6Fieldbus 2 – CANopen Master Interface outgoing X5

7 Fieldbus 2 – CANopen Master Interface incoming X4

8Fieldbus 1 – CANopen Slave outgoing X3

9 Fieldbus 1 – CANopen Slave incoming X2

10 Mounting Tab X0

11 Power Supply

DIOLINE PLC ▪ Product Assembly

18

7.1 LED Display

LED Color State Description

PLC yellow 0.1s on/0.9s off

0.5s on/0.5s off

0.8s on/0.2s off

on

off

PLC is ready – no project

PLC is in STOP mode

PLC alert an error

PLC is in RUN mode

PLC is defect

APP green

red

on

User defined green

User defined red

FB1ST– CANopen green flashes one time

flashing

on

Stop mode.

Preoperational mode.

Operational mode.

FB1ERR– CANopen red off

flashes one time

flashes two

times

on

At least one error counter

of the CAN-Controller has

reached the warning limit.

An error control event or a

heartbeat event occured.

CAN-Controller is in the

mode: bus off

FB2ST– CANopen green flashes one time

flashing

on

Stop mode.

Preoperational mode.

Operational mode.

FB2ERR– CANopen red off

flashes one time

flashes two

times

on

At least one error counter

of the CAN-Controller has

reached the warning limit.

An error control event or a

heartbeat event occured.

CAN-Controller is in the

mode: bus off

L-Bus green

red

flashing

on

Initialization of L-Bus is

OK, waiting on PLC.

L-Bus in RUN mode-

configuration is OK

L-Bus error

UL green on

off

Power supply of the logic

is OK.

Power supply is defect.

DIOLINE PLC ▪ Product Assembly

19

LNK green on

off

Ethernet connection is OK.

No Ethernet connection.

ACT yellow flashing

off

Ethernet data transfer is

OK.

No Ethernet data transfer.

DIOLINE PLC ▪ Technical Data

20

8 Technical Data

Mechanics

Dimensions 123x141.5x64.1 mm (wxhxd)

Weight 0.550kg/piece

Housing Aluminum, anodized surface

Mounting Top Hat Rail TS 35 7.5 mm

Electrical Characteristics

Power Supply DC 24 V (voltage range 16.8-30 V)

Ripple Max. 10 %

Power Consumption 5 W + L-Bus Module Consumption

Protective Device Inverse-polarity protection, overvoltage protection

Potential Separation AC 500 V CAN and electronic

AC 500 V Ethernet and electronic

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Lütze DIOLINE PLC Operating Instructions Manual

Lütze DIOLINE PLC Operating Instructions Manual

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