Burkert 8650 Operating Instructions Manual Download

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Assembly of full system and valve block AirLINE Ex

Type 8650 REV.2

assEmBly Of full sysTEm and ValVE

BlOck aiRlinE Ex

8.1

Maximum system expansion

Number of

modules

up to 32 electronic modules in the complete system Siemens SIMATIC ET 200iSP/

Bürkert AirLINE Ex
Each at least 1 interface module and 1 PowerSupply module;

these can be double (redundantly) assembled as needed.
See

SIMATIC ET 200iSP

operating instructions for details

Valve slots

Maximum width of the valve block AirLINE EX: 660 mm
When using 1 “connection segment centre” this equals

•

48 valve spots for 11 mm valves of Types 6524/6525

• 32 valve spots for 16.5 mm valves of Types 6526/6527

A mixed assembly of valve segments 44/66 mm is possible.
Multiple AirLINE Ex valve blocks can also be installed in an ET 200iSP system as long

as the permissible parameters (width of ET 200iSP, sum of current consumption of all

electronic modules) are adhered to.

For max. width of

full system

see

SIMATIC ET 200iSP operating instructions

The installation position and output restrictions may pose further limitations;

see

SIMATIC ET 200iSP operating instructions

8.2

Siemens SIMATIC ET 200iSP – system components

For information see

SIMATIC ET 200iSP operating instructions

English

Summary of Contents for 8650

Page 1: ...Operating Instructions Type 8650 REV 2 Valve block AirLINE Ex Valve block AirLINE Ex with interface to decentral peripheral system SIMATIC ET 200iSP for use in explosive applications ...

Page 2: ...riginal DE These operating instructions apply to device variant REV 2 You can find information on differentiating characteristics between device variants REV 1 and REV 2 in chapter 6 3 Information on revision status and compatibility on page 17 The operating instructions for device variant REV 1 can be found online at country burkert com ...

Page 3: ...tics of AirLINE Ex 16 6 2 Advantages of AirLINE Ex 16 6 3 Information on revision status and compatibility 17 6 4 Application range 19 6 5 Labelling 19 7 Technical data 21 7 1 Operating conditions and ambient conditions 21 7 2 General technical data 21 7 3 Pneumatic data 22 7 4 Electrical data 22 7 5 Approvals 22 7 6 Full system dimensions 23 8 Assembly of full system and valve block AirLINE Ex 24...

Page 4: ...c module 45 12 1 Structure and function 45 12 2 Labelling 45 12 3 Technical data 46 12 4 Overview 46 12 5 Displays 46 12 6 Diagnostics 46 13 Description of the valves 47 13 1 Pneumatic valve Types 6524 6525 width per valve 11 mm 48 13 2 Pneumatic valve Types 6526 6527 width per valve 16 5 mm 52 14 On off valve 54 14 1 Safety instructions 54 14 2 Structure and function 54 14 3 Technical data 55 14 ...

Page 5: ...t air lines and exhaust air lines 81 17 Initial start up and project planning 83 17 1 Safety instructions 83 17 2 Communication connection projecting 84 17 3 Configuring hardware with the DMD with SIMATIC TIA Portal as an example 85 17 4 Accessing the acyclical parameters with SIMATIC PDM as an example 87 17 5 Acyclical parameters of AirLINE Ex modules 95 17 6 Using HSP with SIMATIC STEP 7 TIA Por...

Page 6: ... Warns of an immediate danger Failure to observe will result in death or serious injuries Warning Warns of a potentially hazardous situation Failure to observe these instructions may result in serious injuries or death Caution Warns of a potential danger Failure to observe may result in moderate or minor injuries CAUTION Warns of damage Failure to observe may result in damage to the device or the ...

Page 7: ...ET 200iSP Ex area Potentially explosive atmosphere Explosion protection approval Approval s for operating the device in ex area Valve pilot valve Solenoid valve for pneumatics can be integrated in valve block Actuator process valve pneumatic cylinder pneumatic actuator pneumatic components Pneumatic consumer controlled by the valve island System Machine with pneumatic consumers actuated by valve b...

Page 8: ...peration and maintenance To use the device observe the permitted data operating conditions and application conditions These specifications can be found in the contract documents the operating instructions and on the type label Use the device only in conjunction with third party devices and components recommended or approved by Bürkert Use the device only as intended Non intended use of the device ...

Page 9: ...e media connections of the device Do not feed any liquids into the device s media connections For underpressure applications make sure that the device does not intake any flammable or explosive media Do not place the device under mechanical stress e g by placing objects on it or standing on it Do not cover the ventilation slots of the body Do not modify the device Heavy equipment must only be tran...

Page 10: ...tically sensitive components and assemblies The device contains electronic components that are susceptible to the effects of electrostatic discharging ESD Components that come into contact with electrostatically charged persons or objects are at risk In the worst case scenario these components will be destroyed immediately or fail after start up Meet the requirements specified by EN 61340 5 1 to m...

Page 11: ... in the potentially explosive atmosphere Clean the device surface by gently wiping it with a damp or anti static cloth only Risk of burns fire due to hot device surface if device operated continuously Keep the device away from highly flammable substances and media Do not touch the device with your bare hands General hazardous situations Installation operation and maintenance may only be performed ...

Page 12: ...is provided with the ATEX marking 4 3 Special conditions The device may only be installed in a control cabinet with degree of protection Ex e increased safety that ensures at least IP54 ingress protection For systems in the potentially explosive atmosphere which are installed in a control cabinet degree of protection at least IP 54 ensure the following The control cabinet must be approved for use ...

Page 13: ...tics are permissible up to 96 valve functions Combination of pneumatic valves of Types 6524 6527 the maximum number of 96 valve functions must not be exceeded Structures with additional pneumatic connection segments Middle 4 5 Backwards compatibility and spare parts On a valve block of Type 8650 Revision 1 REV 1 electronic modules may be exchanged for electronic modules of Type 8650 Revision 2 REV...

Page 14: ...s used as intended and that the specified usage condi tions are taken into account 5 3 Information on the Internet Operating instructions and data sheets for Bürkert products can be found on the Internet at country burkert com Information on the distributed Siemens I O systems can be found online Operating instructions SIMATIC ET 200iSP 5 4 Conformity The device conforms to the EU directives as pe...

Page 15: ...gments valve segments connection segments future expansions or revisions of the AirLINE Ex are possible e g for an expansion of the system actuated by AirLINE Ex The integration in ET 200iSP is practically seamless including with regard to the projection in SIMATIC STEP 7 and PCS7 The pilot valves integrated in AirLINE Ex allow the actuation of pneumatic actuators in the field such as process valv...

Page 16: ...x 300 l min or 700 l min per valve with valve width per valve of 11 mm or 16 5 mm Long service life for oiled and unoiled air due to low wear valve function Centrally captured exhaust air Replacement of valves and electronic modules during operation possible due to Ex degree of protection intrinsic safety Operation with auxiliary pilot air possible for expanded pressure range see chapter 13 Descri...

Page 17: ... see below Flange image of single valves Types 6524 and 6525 made compatible with flange image of double valve Type 6524 Maximum permissible ambient temperature during operation increased to 60 C Connection segments integrated filter for compressed air supply integrated connection for pressure sensor pressure switch integrated interface for on off valve Fig 3 Overview of revision status REV 1 and ...

Page 18: ...ocks see chapter 16 9 Assembling renovating and expanding a device valve block with individual segments The pneumatic modules base modules and connection modules of REV 1 and REV 2 are not compatible with each other Differences remain in the electrical data electronic modules of REV 2 have slightly more output the Ex approvals the permissible ambient temperature range during operation expanded to ...

Page 19: ...tage before working on the terminal modules Additional information can be found in the SIMATIC ET 200iSP handbook Risk of explosion For systems in the potentially explosive atmosphere which are installed in a control cabinet ensure the following The control cabinet must be approved for use in the potentially explosive atmosphere The control cabinet must be dimensioned in such a way that the result...

Page 20: ...ing positions 4 ATEX approval number BVS 21 ATEX E 013 X 4 Identification of the Ex protection ATEX II 2G Ex eb ib IIC T4 Gb 5 Approval number IECEx IECEx BVS 21 0013X 5 Identification of the Ex protection IECEx Ex eb ib IIC T4 Gb 6 Number of the approving body auditing the production 0102 6 5 2 Type label for unit specific data Type 8650 REV 2 AirLINE Ex ID 88888888 S N 012345 W18MS Line 1 2 3 4 ...

Page 21: ...cified for SIMATIC ET 200iSP 7 2 General technical data Dimensions max 660 mm x 194 3 mm x 164 mm depending on design valve variants module variants without optional components Weight max 10 kg depending on design without optional components Body materials Pneumatic modules and valves PA PPS Terminal and electronic modules PC Seal materials Valve block AirLINE Ex REV 2 NBR valves NBR and other mat...

Page 22: ... for 11 mm single valves 171 941 max 3 2 W 8DO 11mm 8 channels for 11 mm double valves 171 942 max 3 95 W 4DO 16 5 mm 4 channels for 16 5 mm single valves 171 943 max 3 2 W The values listed refer tot he electronic modules of REV 2 The values of the power consumption for REV 1 electronic modules are somewhat lower See chapter 11 Description of the valve segments for current consumption values 7 5 ...

Page 23: ...mensions Plug connection D6 D1 4 optional Threaded bushing G3 8 G1 8 plug connection D8 5 16 On Siemens S7 standard rail 6ES7390 nx44 module quantity x width 44 mm nx66 module quantity x width 66 mm Fig 7 Dimensions mm full system Type 8650 REV 2 English ...

Page 24: ...ection segment centre this equals 48 valve spots for 11 mm valves of Types 6524 6525 or 32 valve spots for 16 5 mm valves of Types 6526 6527 A mixed assembly of valve segments 44 66 mm is possible Multiple AirLINE Ex valve blocks can also be installed in an ET 200iSP system as long as the permissible parameters width of ET 200iSP sum of current consumption of all electronic modules are adhered to ...

Page 25: ...ed in grey can optionally be installed only REV 2 but by default are not part of the valve block nor part of the approvals of AirLINE Ex The texts in parentheses are the brief descriptions of the modules These vary between REV 1 and REV 2 in the last item Valve block AirLINE Ex Type 8650 Valve segments MK0 Connection segments MK0 Pressure gauge module Pressure switch pressure sensor Pneumatic conn...

Page 26: ...re sensor 4 Connection segment centre interim input 2 Valve segment 44 mm 4 valve functions 5 Valve segment 66 mm 4 valve functions 3 Valve segment 44 mm 8 valve functions 6 Connection segment right equipped with pressure switch 8 3 3 Valve segments and connection segments Type MK0 module combination Valve segment 44 mm Valve segment 66 mm Connection segment 44 mm Fig 10 Valve segments and connect...

Page 27: ...ule Terminal module Fig 11 Electronics assembly valve block AirLINE Ex REV 2 Type ME0 modular electronics assembly 8 3 5 Pneumatics Type MP1 modular pneumatics P shutoff optional Fig 12 Pneumatics valve block AirLINE Ex REV 2 Type MP1 modular pneumatics The detailed descriptions of the individual modules can be found in the modules chapters English ...

Page 28: ...which can be dis rupted independently of each other For pre installed systems the positions of the bulkheads on the respective pneumatic module are labelled Belated installation of bulkheads is also possible Segment 1 Segment 2 Positions of the bulkhead Segment 3 Supply 1 Supply 2 Supply 3 Position for labelling the bulkhead Segment 1 Supply with compressed air 6 bar Segment 2 Supply with nitrogen...

Page 29: ...200iSP The valves then vent and drain the connected pneumatic actuators via the work connections The connection segments of the valve block REV 2 can optionally be equipped with a pressure switch or pressure sensor This simplifies the automated monitoring of the supply pressure An on off valve can optionally be flanged onto the connection segments of the valve block REV 2 This solution provides a ...

Page 30: ...inal module Station 1 Valve block AirLINE Ex Type 8650 Power supply module Electrical power supply 1 2 3 4 5 6 Fig 14 Functional integration of the valve block in ET 200iSP example Item Item 1 Connection segment left equipped with on off valve and pressure sensor 4 Connection segment centre interim input 2 Valve segment 44 mm 4 valve functions 5 Valve segment 66 mm 4 valve functions 3 Valve segmen...

Page 31: ...sensor The pressure gauge can then be aligned in any way desired for adjusting the installation position of the valve block Connection segments are electrically passive all lines are looped through 1 1 They are not projected in the hardware configuration programs e g SIMATIC STEP 7 Terminal module Pressure gauge module Pneumatic con nection module Fig 15 Connection segment valve block AirLINE Ex R...

Page 32: ...x for fastening the valve block on the standard rail 10 Screws 4x for protective cover 4 Inclined tie rods 2x not assembled for left connection segments 11 Position indicator for item 12 5 Unlocking slider only assembled for right connection segments 12 Clamp for pressure sensor adaptor 6 Screwing point 4x for on off valve 13 Pressure sensor adaptor here sealed with dummy plugs 7 Plug for communic...

Page 33: ...n segments Type 8650 REV 2 10 4 Dimensions 54 2 190 16 30 58 44 24 35 10 5 24 35 27 2 113 2 82 45 54 2 190 16 30 58 44 24 35 10 5 24 35 27 2 113 2 82 45 Fig 17 Dimensions mm connection segment valve block AirLINE Ex REV 2 English ...

Page 34: ...ction Port size 1 R 3 S 5 Exhaust air G3 8 2 X Pre pilot exhaust air or pre auxiliary pilot air G1 8 3 P 1 Supply air G3 8 10 6 Displays Pressure gauge for displaying operating pressure Pressure gauge can be aligned in any way to match the installation position Fig 19 Pressure gauge for indicating operating pressure on the connection segment of valve block AirLINE Ex REV 2 English ...

Page 35: ...the pneumatic connection module of each connection segment a filter is integrated in the input air channel P 1 See chapter 16 10 1 Connection segments on page 73 for information on maintenance and replacement Filter Fig 20 Filter in a pneumatic connection module English ...

Page 36: ...sure in the input air channel P 1 possible This option is especially interesting when using an on off valve upstream of AirLINE Ex The pressure switch or pressure sensor is installed with a pluggable adaptor with G connection See chapter 16 12 Installing uninstalling pressure switch pressure sensor for information on installation Pluggable adaptor with G con nection internal thread Connection segm...

Page 37: ...ctuates the valves monitors their function and provides diagnostic information via ET 200iSP The pneumatic base modules can optionally be equipped with P shutoff allows valve replacement under pressure and check valves prevent accidental activation of valves through back pressure in the system For details see chapter 11 6 Pneumatic options Valve segments are electrically active They or the electro...

Page 38: ...ED green per channel valve function Pneumatic connections Push in connection D6 or D1 4 chosen by user Push in connection D8 5 16 Valve data see chapter 13 Description of the valves for more information Valve type 6524 3 2 way 6525 5 2 way 6524 2x 3 2 way 6526 3 2 way 6527 5 2 way Circuit function4 C D H 2xC C D H Width per valve mm 11 16 5 QNn5 l min 300 700 3 These values are considered in the c...

Page 39: ...module status 7 Plug for communication bus 2 LEDs green to indicate channel status 8 Plug for power bus 3 Valves 9 Lock slider below the valves 4 Label of valve spots and pneumatic options P shutoff check valves P bulkhead 10 Valve extractor only for width per valve 66 mm 5 Inclined tie rods 2x 11 Slip in label strip6 6 Pneumatic working ports 6 The slip in label strips are identical with those us...

Page 40: ...EV 2 11 4 Dimensions 54 2 194 3 11 32 4 44 12 14 5 28 30 5 163 5 27 2 Fig 24 Valve segment dimensions mm example width per valve 44 mm this varies for valve segments with width per valve 66 mm see chapter 7 6 Full system dimensions on page 23 English ...

Page 41: ...Possible variants of the work ports example width per valve 44 mm Assignment of work ports Item 3 2 way valves Types 6524 6526 5 2 way valves Types 6525 6527 2x3 2 way valves Type 6524 1 unused 2 2 valve 12 2 2 4 4 valve 14 11 6 Pneumatic options The following equipment options are available for the pneumatic base modules Valve segments 44 mm Valve segments 66 mm Check valves optional Check valve ...

Page 42: ...e P shutoff is not suitable for under pressure applications P bulkhead A bulkhead can be inserted into the P channel between valve segments This allows the creation of multiple pressure levels or media loops within an AirLINE Ex system see chapter 8 4 Segmenting the pressure supply on page 28 for details Labelling the options The lower edge of the base modules contains symbols indicating which opt...

Page 43: ...cted per valve segment electronic module These are occupied and assigned to the channels valves as follows Byte High byte Low byte Bit 7 0 7 6 5 4 3 2 1 0 4 channel module Channel no 3 2 1 0 LED V3 V2 V1 V0 8 channel module Channel no 7 6 5 4 3 2 1 0 LED V7 V6 V5 V4 V3 V2 V1 V0 0 2 4 6 1 3 5 7 Assignment of work ports 8 channel module Valves Valves 0 3 1 7 0 6 Valves Valves 4 channel module 8 chan...

Page 44: ...r notification Yes locally on electronic module red LED CF Diagnostics function readable via bus interface of ET 200iSP Channel status diagnostics channel open channel short circuited Switching cycle counter separate from channel with warning parameters for both pilot valve and con nected actuator English ...

Page 45: ...trol the valves It is electrically active function digital output module and must be projected accordingly in the programs for hardware configuration e g Siemens Step 7 Electronic modules can be individually alternated i e not multiple at a time see documentation for SIMATIC ET 200iSP for details Refer to chapter 17 5 3 Parameter functions for the 8 channel modules 12 2 Labelling Fig 29 General la...

Page 46: ...ction segment valve block AirLINE Ex REV 2 Item Item 1 LED red to indicate module status 4 Lock slider below the valves 2 LEDs green to indicate channel status 5 Valve extractor only for width per valve 66 mm 3 Plug for connecting the valves 6 Slip in label strip9 12 5 Displays For status indicators see chapter 11 7 Displays on page 43 12 6 Diagnostics See chapter 11 9 Diagnostics electronic modul...

Page 47: ... air Valves of the variant auxiliary pilot air make it possible to switch to 2 5 bar pressure on the work ports For reliable operation you require the auxiliary pilot air with a pressure of 2 5 bar This is fed to the con nection segments of the valve block via the connection X The pilot valve exhaust air escapes into the surrounding area when using auxiliary pilot air valves Auxiliary pilot air va...

Page 48: ...524 and Type 6525 Various flange profiles of single valves 6524 and 6525 for REV 1 and REV 2 The single valves 3 2 way valve Type 6524 and 5 2 way valve Type 6525 were optimised for REV 2 The channel cross sections and flange profile of these valves were revised among other things REV 1 and REV 2 valves thus differ from each other When replacing single valves consider The different design of the m...

Page 49: ... flange profiles of single valves Type 6524 and Type 6525 13 1 2 Technical data Body material PA PPS Seal material NBR FKM FPM Manual override yes alternatively variants without Nominal operating mode 100 duty cycle continuous operation Electrical valve connection Rectangular plug RM 2 54 mm Installation with 2 screws M2 For further information see chapter 13 1 3 Order table and the data sheet of ...

Page 50: ...x 3 2 way valve servo assisted voltage free outlet 2 4 unloaded 4 300 2 x 0 3 2 5 7 2012 25 182 086 2 x 0 3 1 810 2012 25 182 08810 D NO normally open 2 B 1 P 3 R 10 3 2 way valve servo assisted voltage free outlet 2 pressurised 4 300 0 3 2 5 7 35 45 365 624 on request11 H 14 12 4 2 5 1 3 5 2 way valve servo assisted voltage free outlet 1 with outlet 2 outlet 4 vented 4 300 0 3 2 5 7 35 45 365 625...

Page 51: ...cessory and is not part of the valve block It is actuated by 2x 3 2 way valves of the valve block unlockable double check valve Type 0498 Fig 34 Realisation of a 5 3 way function with valve Type 0498 and 2x 3 2 way valves of the valve block You can find further information and data sheets for the unlockable double check valve Type 0498 by entering the type number at country burkert com English ...

Page 52: ...rt switching times The valves are equipped with a manual override for manual operation alternatively variant without manual override Type 6526 Type 6527 Fig 35 Pneumatic valves Type 6526 and Type 6527 13 2 2 Technical data Body material PA PPS Seal material NBR FKM FPM Manual override yes alternatively variants without Nominal operating mode 100 duty cycle continuous operation Electrical valve con...

Page 53: ...loaded 6 700 0 3 2 8 80 90 263 932 175 67414 0 3 0 9 8 80 90 175 67313 175 72313 14 0 3 1 8 80 90 366 798 D NO normally open 2 B 1 P 3 R 10 3 2 way valve servo assisted voltage free outlet 2 pressurised 6 700 0 3 2 8 80 90 175 725 175 72614 H 14 12 4 2 5 1 3 5 2 way valve servo assisted voltage free outlet 1 with outlet 2 outlet 4 vented 6 700 0 3 2 8 80 90 365 024 175 72814 0 3 1 8 80 90 366 799 ...

Page 54: ...the valve block also belatedly The on off valve serves to disrupt the central compressed air supply to the valve block and to vent the valve block including all pneumatic actuators connected to it The state of the electrical outlets of the electronic modules and the position of the switch positions of the valve block valves are not relevant In combination with the option P bulkhead an individual p...

Page 55: ... epoxy PA Seal materials NBR PUR Media like valve block REV 2 see chapter 7 3 Pneumatic data on page 22 Operating pressure range 2 8 bar Manual override Yes Coil resistance R2015 310 Ohm Nominal power15 0 3 W Ex i variant of solenoid Nominal operating mode 100 duty cycle continuous operation Electrical valve connection15 Plug profile A connection e g via cable plug Type 2518 Approvals15 Type of pr...

Page 56: ...h soleniod degree of protection Ex m on request 14 5 Overview 7 8 10 9 3 8 4 5 1 6 2 Fig 36 Overview on off valve block AirLINE Ex REV 2 Item Item 1 Solenoid with Ex approval 6 Interface to connection segment REV 2 with 2 Pneumatic connections see chapter 14 7 on page 58 for details 7 Spigot 3 Armature 8 Screw 4x 4 Plug for alternative coil variants cast on cable 9 Pneumatic channels each with 1 O...

Page 57: ...57 On off valve Type 8650 REV 2 14 6 Dimensions 43 6 23 55 6 37 14 71 5 58 4 Fig 37 Dimensions on off valve mm English ...

Page 58: ...haust air or pre auxiliary pilot air G1 8 3 P 1 Supply air G3 8 4 Exhaust hole of on off valve The exhaust hole of the on off valve must not be sealed The amount of escaping air only at the moment the valve is deactivated is very low meaning no deviation is required in most cases The connection X is only made via the on off valve to the X connection of the connection segment It is not of any impor...

Page 59: ...ure switch or pressure sensor in combination with an on off valve may increase the achievable level of safety level of diagnostic coverage The pressure switch pressure sensor is installed in a connection with G internal thread The connection is part of the pressure gauge module It is equipped with a push in connection and thus allows easy instal lation of the pressure sensor pressure switch includ...

Page 60: ...ction Circular plug in connector M16 x 0 75 Outlet 4 20 mA 2 conductor supply voltage 10 30 V Types of protection Among other things ATEX IECEx II 1 2G Ex ia IIC T4 T5 T6 Ga Gb Functional safety SIL 2 Permissible temperature range during operation 20 80 C Degree of protection IP67 For further information see wika com Type IS 3 774 891 English ...

Page 61: ...w 5 1 6 2 3 4 Fig 39 Overview of connection segment valve block AirLINE Ex REV 2 with and without pressure sensor Item Item 1 Locking screw 4 Pressure gauge module 2 Insertable adaptor 5 Safety clamp 3 Interface for adaptor 6 Pressure sensor pressure switch English ...

Page 62: ...ation Only trained technicians may perform installation work Perform installation work using suitable tools only Risk of injury due to unintentional activation of the system and uncontrolled restart Secure the device or system to prevent unintentional activation Ensure a controlled restart after maintenance is completed CAUTION Medium escape and malfunction If seals are not properly positioned lea...

Page 63: ...d Restrictions The applicable restrictions must be observed for the renovation expansion of systems Learn more about this in chapter 8 1 Maximum system expansion These operating instructions describe the installation and deinstallation of Type 8650 REV 2 These differ in some aspects from Type 8650 REV 1 For installation and deinstallation of Type 8650 REV 1 see the operating instructions of this v...

Page 64: ...Nm Installation deinstallation of valves with 11 mm width per valve Cross tip screwdriver size 0 0 2 Nm Installation deinstallation of valves with 16 5 mm width per valve Cross tip screwdriver size 1 0 3 Nm Fitting valve segments connection segments to each other inclined tie rods Allen key 3 mm 0 7 Nm Fitting the protective cover for filters Key for hexalobular internal screw size T10 0 7 Nm Fitt...

Page 65: ...ping bolts 2x for fastening the AirLINE Ex on standard rail Screws 2x for fastening the pressure gauge module Fig 41 Position of fittings and operation elements Inclined tie rods Fig 42 Position of the inclined tie rods on the installed system Inclined tie rods in pockets 2x per connection valve segment Unlocking slider only for right connection segments Fig 43 Inclined tie rods of a segment and u...

Page 66: ... the device can be removed from the standard rail 16 6 1 Installing the system on a standard rail Carefully turn all clamping bolts see Fig 45 on the connection segments counterclockwise until they stop Suspend the system in the desired position from the upper edge of the standard rail and tilt it up Tighten all clamping bolts clockwise see chapter 16 4 on page 64 for required tightening torque Fi...

Page 67: ... the slider out approx 2 to 3 mm This opens up the terminal module locked to the right Only REV 2 devices If the accessibility of the unlocking slider is impeded by an on off valve the unlo cking slider can also be operated from the front side see Fig 46 Insert a thin slot screwdriver shaft with a length of at least 85 mm and a diameter of max 4 mm into the opening in the pressure gauge module I u...

Page 68: ...68 Installation Type 8650 REV 2 I II I II Unlocking for inacces sible unlocking slider Fig 46 Operating unlocking slider English ...

Page 69: ...adhered to when installing in a control cabinet can be found in the SIMATIC ET 200iSP handbook The minimum distance specified in Fig 47 is recommended for easy replacement of an electronic module Distance from the control cabinet wall 60 mm Fig 47 Distance from top control cabinet wall English ...

Page 70: ...dentification number are no longer valid upon renovation or expansion Remove the description label and label the device accordingly 16 9 1 Assembling the device The segments or pneumatic modules are each connected to each other by 2 inclined tie rods Assembly is always conducted from left to right Ensure that the O rings are correctly positioned in the segment to be attached on the right For assem...

Page 71: ...71 Installation Type 8650 REV 2 Clamping bolts Inclined tie rods II III I Fig 48 Adding segments English ...

Page 72: ...ion segment to the right Slide other segments in the same manner until the position where the system is to be altered has been reached A segment that is to be added is first suspended on the upper edge of the standard rail Tilt the segment in and slide it left against the sub system present there 16 9 3 Assembling the system Assemble the system in reverse order see chapter 16 9 1 Ensure that the O...

Page 73: ...le Loosen both screws on the pressure gauge module Tilt the pressure gauge module up out of the terminal module I and remove it II Hinge Screws O ring I II Fig 49 Installing uninstalling the pressure gauge module Installing the pressure gauge module Ensure that the O ring is correctly positioned in the pressure gauge module Suspend the pressure gauge from the hinge on the upper edge of the termina...

Page 74: ...Insert the filter into the opening in the connection module and turn it so that the crossbars lock into the opening Press the filter into the connection module until it stops lightly lubricate the O ring before inserting if necessary Ensure that the seal for the protective cover is correctly positioned Place the protective cover on top and tighten the 4 screws cross wise for tightening torque see ...

Page 75: ...lt the module out II and remove it III I Locking element III II Hinge Fig 51 Installation deinstallation of a valve segment Installing the electronic module Suspend the electronic module from the hinge on the upper edge of the terminal module Move the locking element in the direction of the arrow while fully tilting the module in Screw the valves in place Cover the plug contacts of unoccupied valv...

Page 76: ...rnal screw size T20 Ensure that the seal surfaces of the connection segment are not dirty or damaged Check that the O rings at the interface to the connection segment on the on off valve are inserted and undamaged Place the on off valve with the spigots on the connection segment such that the spigots lock into the centring holes see image then tighten the 4 screws crosswise tightening torque 0 7 N...

Page 77: ...il are equipped with a cast on cable The on off valve has no electrical connection to the valve block Note the polarity specified on the coil for variants with Ex i coil The plug cable outlet of the solenoid can be aligned in various ways to facilitate optimal laying of the connection cable Procedure Loosen nut by approx 3 turns Lift the coil somewhat turn it in the desired position and press it b...

Page 78: ...n be used to pull on the adaptor or dummy plug Removing dummy plugs from the adaptor Screw the pressure switch pressure sensor into the adaptor thread G The adaptor is equipped with an axial seal If the pressure switch pressure sensor used does not offer a suitable seal surface secure the seal by other means e g with PTFE seal band on the thread Insert assembly consisting of adaptor and pressure s...

Page 79: ...r in the pressure gauge module twisted so that the connected cable can be laid in the best position Only set up the assembly when it is not connected to power Turn it clockwise so that the fitting between the pressure switch pressure sensor and adaptor does not loosen Electrical connection Connect the pressure switch pressure sensor according to the manufacturer s specifications The pressure switc...

Page 80: ...s can be uninstalled at the same time Otherwise the pressure may drastically decrease in the other valves When the valve is being uninstalled a lot of air is emitted at first until the valve is completely loosened However an automatic block reduces the air loss so that there is only a minor residual leak when the P shutoff is closed 16 13 2 Installing DANGER Risk of injury due to pressure change W...

Page 81: ...ment if an on off valve is being used in the same pneumatic segment Ensure quick and secure venting Use all available exhaust connections of the valve block and on off valve and ensure that pressure cannot build up in the exhaust channels Exhaust air Pre pilot exhaust air auxiliary pilot air Pressure supply Fig 54 Connection to input and exhaust air lines 16 14 1 Connecting pressure supply Note Av...

Page 82: ...roblems in the event that there is high back pressure in the channels R 3 mmmm S 5 The connection should be made with the largest possible lines and a silencer if applicable with high flow rate values to prevent back pressure Valves with auxiliary pilot air For valves which are to be used in an expanded pressure range the pilot control is supplied via its own pressure port This must be connected t...

Page 83: ...ury due to system malfunction The system must be tested to ensure it functions properly before start up This prevents persons or systems from being put in danger during operation Conduct a full function test and the necessary safety tests before the initial start up Plan foreseeable errors in the tests Note Only provide the device with electricity via SIMATIC ET 200iSP In order to prevent damage t...

Page 84: ...hese files are managed to communicate with Siemens the Bürkert homepage does not contain the files but rather a link through which the respectively current versions are available The EDD file is currently only offered in conjunction with the PCS7 SIMATIC TIA Portal STEP 7 and PCS7 When using Siemens STEP 7 there is also the option to integrate AirLINE Ex via a hardware support package HSP or in Si...

Page 85: ... higher or SIMATIC TIA Portal version 11 or higher Configuration Before accessing the AirLINE Ex system the corresponding DMD file package must be imported in the program s hardware catalogue Select the desired interface module in the hardware catalogue of the TIA Portal and drag it into the work area via drag and drop The active AirLINE Ex modules are in the same branch of the hardware catalogue ...

Page 86: ...e branch and drag them to the respective slot of the ET 200iSP station via drag and drop While doing so display the real station assembly from left to right The respective identification number is specified on the front of the electronic module e g 00171941 and the module function as well for electronic modules REV 2 e g 8 DO Fig 56 Select the modules and assign the ET 200iSP station slots English...

Page 87: ...rdware The EDD is currently only offered in conjunction with SIMATIC PCS7 New versions of SIMATIC PCS7 offer an integrated version of PDM The advantage of these versions is that they prevent uncoordinated access to parameters After starting the S7 manager select Extras SIMATIC PDM Manage device catalogue via the menu list Via Search enter the source index in which the EDD file is saved Then select...

Page 88: ...88 Initial start up and project planning Type 8650 REV 2 Add the new object Fig 58 Adding the new object Select the device type to ad a new device Fig 59 Selecting the device type English ...

Page 89: ...tial start up and project planning Type 8650 REV 2 Define the station name and bus address Fig 60 Defining the station name and bus address Add the function modules Fig 61 Adding the function modules English ...

Page 90: ... up and project planning Type 8650 REV 2 Set the desired number of equivalent modules Fig 62 Setting the number of equivalent modules Select the module type via the menu Assign Fig 63 Selecting the module type English ...

Page 91: ...91 Initial start up and project planning Type 8650 REV 2 Confirm the module selection with OK Fig 64 Confirming the module selection English ...

Page 92: ...and project planning Type 8650 REV 2 17 4 1 Example with 2 different function modules Select the head station Fig 65 Selecting the head station Open station to access acyclical functions Fig 66 Opening the station English ...

Page 93: ...ccess type specialist full access maintenance limited access Fig 67 Selecting the access type Select head station to obtain parameters of interface module and overview of station assembly Fig 68 Parameters of interface module and overview of station assembly English ...

Page 94: ...94 Initial start up and project planning Type 8650 REV 2 Fig 69 Parameters of an AirLINE Ex pneumatic module English ...

Page 95: ... Manufacturer BUERKERT Device designation BUERKERT ID00171941 Device serial number 00001234 Hardware revision 0 Software revision A 0 0 4 Static revision no 3 Installation date Initial value Module Slot number 14 Module type 4 DO Bürkert 11 mm 4 DO Bürkert 11 mm Data format S7 Initial value Module type 4 DO Bürkert 11 mm BUERKERT ID00171941 Switching cycle counter diagnostics approval enabled Init...

Page 96: ...ide In the 8 channel modules the valves 0 3 or 4 7 each form one group In the event that more than 4 valves are to be switched on simultaneously including the valves already switched on the following may occur Case 1 In group 0 3 no more valves are switched on Then the valves of group 4 7 yet to be activated are immediately switched on Case 2 In group 0 3 additional valves are switched on Then the...

Page 97: ...nostics blocked Wire break Short circuit 17 5 5 Functions of the channel parameter general Channel enable read write Defines whether the channel is cleared for use or not Behaviour for CPU Master STOP read write Defines which value the channel takes on when the master is set to STOP Substitute value read write Defines the substitute value in the case Switch substitute value for Master STOP 17 5 6 ...

Page 98: ...ycles the actuator has performed since the last counter reset 17 5 8 Functions of the diagnostics parameter Compound diagnostics read write States whether compound diagnostics will be generated Wire break read write States whether a diagnostics alert is generated when the outlet is open Short circuit read write States whether a diagnostics alert is generated when there is a short circuit in the ou...

Page 99: ... are required The HSP2033 for SIMATIC Step 7 V 5 x is suitable for SIMATIC Step 7 V 5 3 or higher The HSP0020 is required for SIMATIC Step 7 TIA Portal 17 6 2 Installation of the HSP The hardware support package can be downloaded from the Bürkert homepage country burkert com 8650 Downloads Software Save and unzip the file hspXXXX zip in an index of your choosing In the menu Extras in SIMATIC STEP ...

Page 100: ...100 Initial start up and project planning Type 8650 REV 2 17 6 3 Using the HSP Select ET 200iSP from the branch Decentral periphery Fig 71 Selecting the interface module English ...

Page 101: ...101 Initial start up and project planning Type 8650 REV 2 Select AirLINE Ex modules from the branch Pneumatic modules and assign the plugs of the ET 200iSP station Fig 72 Assignment of modules English ...

Page 102: ...Changing the parameters in HSP Mark the module This displays its parameters some of which can also be changed Fig 73 Changing the parameters of a module Changes to the settings of the switching cycle counters can currently only be made via SIMATIC PDM English ...

Page 103: ...ecentralised peripheral system Siemens SIMATIC ET 200iSP with the AirLINE Ex modules 17 7 2 Installing the HUP The hardware update package can be downloaded from the Bürkert homepage country burkert com 8650 Downloads Software There are various HUP versions available for different versions of PCS7 HUPs were formerly referred to as SUPs The version compatibilities are documented in the ZIP containe...

Page 104: ...g 75 Projecting PCS7 HW Konfig The filter in the hardware catalogue must be set to Standard so that the AirLINE Ex modules are displayed Changes to the switching cycle counter settings can currently only be made via SIMATIC PDM can be integrated in PCS7 English ...

Page 105: ...umber of valve block serial numbers of all electronic modules serial numbers of all valves serial numbers of all terminal modules A suitable mobile device can be used to pull up the device specific information via the Internet with the 2D code on the device type label including the aforementioned data set Alternatively the data set can be accessed via the website country burkert com After entering...

Page 106: ...l number of 2nd electronic module Identification number of 1st valve Serial number of 1st valve Date of valves 2 7 minimised Identification number of last valve Serial number of last valve Identification number of 1st terminal module Serial number of 1st terminal module Data of terminal modules 2 and 3 minimised Identification number of last terminal module Serial number of last terminal module Fi...

Page 107: ...entially explosive area In addition to the activities listed in the documentation for SIMATIC ET 200iSP the following also apply to AirLINE Ex Type 8650 Pulling plugging valves and electronic modules during operation in Zone 1 and Zone 2 see chapter 19 3 Upkeep WARNING Risk of injury due to improper maintenance work Only trained technicians may perform maintenance work Perform maintenance work usi...

Page 108: ...trostatically sensitive components and assemblies The device contains electronic components that are susceptible to the effects of electrostatic discharging ESD Components that come into contact with electrostatically charged persons or objects are at risk In the worst case scenario these components will be destroyed immediately or fail after start up Meet the requirements specified by EN 61340 5 ...

Page 109: ... devices or persons there is a risk of explosion in the potentially explosive atmosphere Clean the device surface by gently wiping it with a damp cloth only Only use a damp lint free cloth to clean the system Detergents or alcohol are not suitable for cleaning They can damage plastic parts 19 2 3 Diagnostics function Switching cycle counter The current counter values are saved in the electronic mo...

Page 110: ... respective valve position is not equipped with a P shutoff depressurise the system first Base module with P shutoff If valves are switched under pressure only a maximum of 4 valves can be uninstalled at the same time Otherwise the pressure may drastically decrease in the other valves When the valve is being uninstalled a lot of air is emitted at first until the valve is completely loosened Howeve...

Page 111: ...If mul tiple electronic modules are being removed simultaneously the station reports the disruption First remove all connected valves as described in the previous chapter 19 3 1 Remove the protective caps of the electrical contacts of unused valve positions Remove the electronic module The procedure is described in chapter 16 10 2 Valve segments on page 75 The substitute module is installed in rev...

Page 112: ...an only occur in an extreme malfunction Replace the electronic module Check whether the respective valves might be damaged Valves switch with a delay or blow off at the exhaust ports Pressure supply insufficient or not available Set up the largest possible volume of pressure supply also for upstream devices such as pressure regulators maintenance units on off valves etc Minimum operating pressure ...

Page 113: ...set of the module or system If the ET 200iSP station interface module IM 152 has started up with a profibus address X the address can be changed as follows for details see SIMATIC ET 200iSP operating instructions Switch off the station Set the address 0 all DIP switches in OFF position Switch on the station and wait approx 10 seconds Switch off the station and then wait approx 10 seconds Set the n...

Page 114: ...trained technicians may perform installation work Perform installation work using suitable tools only Risk of injury due to unintentional activation of the system and uncontrolled restart Secure the device or system to prevent unintentional activation Following interruption of the process ensure that the process is restarted in a controlled manner 20 2 Deactivate the system Vent the system Switch ...

Page 115: ...r valve 16 5 mm valves Type 6526 and 6527 653 765 Cover plate for valve plug contact 653 670 21 2 Spare parts Description Ident No Seals set 12 pc for valves Type 6524 and 6525 width per valve 11 mm 2001 6305 Seals set 12 pc for valves Type 6526 and 6527 width per valve 16 5 mm 2001 6307 Seals set for 4 module interfaces for pneumatic base and connection modules 2001 6310 Contact our sales partner...

Page 116: ...he following information applies to assemblies stored in the original packaging Requirement Permissible range Free fall 1 m Temperature 40 70 C change in temperature max 20 K h Air pressure 1 080 660 hPa equates to a height of 1 000 m 3 500 m Relative humidity 5 95 without condensation AirLINE Ex exceeds the storage condition requirements of IEC 61131 2 English ...

Page 117: ...following information applies to assemblies transported in the original packaging Requirement Permissible range Free fall 1 m Temperature 40 70 C change in temperature max 20 K h Air pressure 1 080 660 hPa equates to a height of 1 000 m 3 500 m Relative humidity 5 95 without condensation AirLINE Ex exceeds the transportation requirements of IEC 61131 2 24 Disposal Dispose of the device and packagi...

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Burkert 8650, Operating Instructions Manual

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