Burkert AirLINE Ex 8650 Operating Instructions Manual
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Burkert AirLINE Ex 8650 Operating Instructions Manual

Burkert AirLINE Ex 8650 Operating Instructions Manual

Electrical and pneumatic automation system
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Type 8650
AirLINE Ex
Electrical and Pneumatic Automation System
Operating Instructions
Bedienungsanleitung
Instructions de Service

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Summary of Contents for Burkert AirLINE Ex 8650

  • Page 1 Type 8650 AirLINE Ex Electrical and Pneumatic Automation System Operating Instructions Bedienungsanleitung Instructions de Service...
  • Page 2 We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous resérve de modification techniques. © 2006 - 2016 Bürkert Werke GmbH Operating Instructions 1601/06_EU-EN_00804032...

  • Page 3: Table Of Contents

    Type 8650 Contents Electrical and Pneumatic Automation System Type 8650 GENERAL INFORMATION AND SAFETY INSTRUCTIONS.....................5 Operating.Instructions.................................6 Intended.Use.....................................7 Basic.safety.instructions..............................8 General.Information................................10 SYSTEM DESCRIPTION....................................11 General.Description................................12 Technical.Data..................................15 System.Accessories................................17 CONFIGURATION AND FUNCTION..............................19 Configuration..................................20 Function....................................25 CONFIGURATION AND FUNCTION OF THE MODULES.......................27 Supply.Segments................................29...
  • Page 4 Type 8650 Contents Replacing.a.terminal.or.pneumatic.module......................71 Replacing.a.valve.................................72 10.. Connection.of.the.Air.Inlet.and.Exhaust.Lines....................73 COMMISSIONING......................................75 Safety.Instructions................................76 Initialization.....................................77 SD.Card./.System.Serialization.Data........................99 MAINTENANCE AND REPAIR................................101 Safety.Instructions................................102 Maintenance..................................103 Maintenance..................................104 STORAGE, PACKAGING, TRANSPORT, DISPOSAL......................107 Storage....................................108 Packaging,.Transport..............................110 ANNEX..........................................111 EC.Declaration.of.Conformity.

  • Page 5: General Information And Safety Instructions

    Type 8650 Allgemeine Informationen Sicherheitshinweise General Information and Safety Instructions ontents OPERATING.INSTRUCTIONS.................................6 1.1.. Symbols.......................................6 INTENDED.USE.....................................7 2.1.. Restrictions....................................7 BASIC.SAFETY.INSTRUCTIONS..............................8 GENERAL.INFORMATION................................10 4.1.. Contact.address...................................10 4.2.. Warranty....................................10 4.3.. Approvals....................................10 4.4.. Information.on.the.Internet.............................10 4.5.. Trademarks.....................................10 english...

  • Page 6: Operating.instructions

    Type 8650 Allgemeine Informationen Sicherheitshinweise OPERATING INSTRUCTIONS The operating instructions describe the entire life cycle of the device. Keep these instructions in a location which is easily accessible to every user and make these instructions available to every new owner of the device. WARNING! The.operating.instructions.contain.important.safety.information! Failure to observe these instructions may result in hazardous situations.

  • Page 7: Intended.use

    Type 8650 Allgemeine Informationen Sicherheitshinweise INTENDED USE Incorrect.use.of.the.Type.8650.AirLINE.Ex.can.be.dangerous.to.people,.nearby.equipment.and.the. environment.. • The device is designed for use in explosive environments (precise classification see EC-Type Examination Certificates in the Appendix). It may be used to control pneumatically operated devices. • Ensure that the device is protected before using outdoors. •...

  • Page 8: Basic.safety.instructions

    Type 8650 Allgemeine Informationen Sicherheitshinweise BASIC SAFETY INSTRUCTIONS These safety instructions do not make allowance for any • contingencies and events which may arise during the installation, operation and maintenance of the devices. • local safety regulations; the operator is responsible for observing these regulations, also with reference to the installation personnel.
  • Page 9 Type 8650 Allgemeine Informationen Sicherheitshinweise NOTE! Operate.the.system.with.direct.current.only!. To avoid damaging the system, use only direct current as the power supply for the system. Avoid.pressure.drop!. To avoid a pressure drop, the compressed air supply to the system must be as large as possible. Electrostatic.sensitive.components./.modules! •...

  • Page 10: General.information

    Type 8650 Allgemeine Informationen Sicherheitshinweise GENERAL INFORMATION 4.1. Contact address Germany Bürkert Fluid Control System Sales Centre Chr.-Bürkert-Str. 13-17 D-74653 Ingelfingen Tel. + 49 (0) 7940 - 10-91 111 Fax + 49 (0) 7940 - 10-91 448 E-mail: info@de.buerkert.com International Contact addresses can be found on the final pages of these operating instructions. And also on the internet at: www.buerkert.com 4.2.

  • Page 11: System Description

    Type 8650 System Description System Description ontents GENERAL.DESCRIPTION................................12 1.1.. Product.Description................................12 1.2.. Characteristic.Features.and.Benefits........................13 1.3.. Field.of.Application................................14 1.4.. Marking.....................................14 TECHNICAL.DATA.....................................15 2.1.. General.Technical.Data..............................15 2.2.. Dimensions.....................................16 SYSTEM.ACCESSORIES................................17 english...

  • Page 12: General.description

    Type 8650 System Description GENERAL DESCRIPTION 1.1. Product Description AirLINE Ex Type 8650 (hereafter referred to as AirLINE Ex) is an electrical and pneumatic automation system in protection class IP30 that has been developed for use in explosive environments. In combination with modules from the Siemens SIMATIC ET 200iSP System, a full range of electronic and pneu- matic components are available.

  • Page 13: Characteristic.features.and.benefits

    Type 8650 System Description 1.2. Characteristic Features and Benefits 1.2.1. Characteristic features of AirLINE Ex • Simple operation • Automatic set-up of supply and data circuits • Open, flexible and modular structure • Combination of different valve segments and different electrical I/O functions for space and application-opti- mized station configurations.

  • Page 14: Field.of.application

    Type 8650 System Description 1.3. Field of Application The AirLINE Ex System is designed for decentralized operation in industrial environments. Thanks to the modular configuration, electronics and fluidics can be combined particularly simply and efficiently. It complies with protection class IP30. DANGER! Risk.of.electric.shock!.

  • Page 15: Technical.data

    Type 8650 System Description TECHNICAL DATA 2.1. General Technical Data Medium Clean, dry air (oiled or unoiled), neutral gases (particle size max. 5 μm) see table below “Power consumption of the active Max. power consumption modules”. Ambient temperature during 0 °C to +55 °C operation Storage temperature -20 °C to +60 °C...

  • Page 16: Dimensions

    Type 8650 System Description 2.1.1. Power consumption of the active modules, including the mounted valves Modul.type max..power.consumption. Ident-no. 4 channels 11 mm max. 2.9 W 171 941 8 channels 11 mm max. 3.6 W 171 942 4 channels 16,5 mm max. 2.9 W 171 943 8 channels 16,5 mm max.

  • Page 17: System.accessories

    Type 8650 System Description SYSTEM ACCESSORIES System.accessories Ident-no. Function.plates.for.flange.pattern.6524./.6525. (Installation.instead.of.a.simple..3/2-way.or.5/2-way.valve./.11.mm) Blind plate complete for 3/2-way and 5/2-way valves 650 373 (for sealing an unused valve position) Supply plate complete 649 637 (for additional medium supply for high-consumption applications or for supplying separate media circuits or pressure stages) Breather plate complete 655 166...
  • Page 18 Type 8650 System Description 1) These plates are installed instead of a valve and use the working ports of the respective valve position. As these have smaller cross-sections than the ports on the supply segments, the possible flow rates are cor- respondingly lower! For competent advice, please contact your local Bürkert sales partner.

  • Page 19: Configuration And Function

    Type 8650 Configuration and Function Configuration and Function ontents CONFIGURATION....................................20 1.1.. Maximum.System.Configuration..........................20 1.2.. Siemens.SIMATIC.ET.200iSP.System.Components..................21 1.3.. Bürkert.AirLINE.Ex.-.System.Components......................21 FUNCTION......................................25 2.1.. View.of.the.Overall.System............................25 2.2.. Functional.representation.of.the.AirLINE.Ex-system..................26 english...

  • Page 20: Configuration

    Type 8650 Configuration and Function CONFIGURATION 1.1. Maximum System Configuration No. of modules up to 32 I/O modules / pneumatic modules in the complete system Siemens SIMATIC ET 200iSP / Bürkert AirLINE Ex At least 1 field bus interface module (IM152) and 1 power supply module each; if required, these can be installed redundantly.

  • Page 21: Siemens.simatic.et.200Isp.system.components

    Type 8650 Configuration and Function 1.2. Siemens SIMATIC ET 200iSP System Components Further information on the SIMATIC ET 200iSP system can be found in the manual ET 200iSP (Siemens order No. 6ES7152-1AA00-8AA0) or on the Internet at www.automation.siemens.com/simatic. 1.3. Bürkert AirLINE Ex - System Components 1.3.1. Module Terminology In order to simplify the overview of the system structure, designations have been defined for the modules and assemblies.
  • Page 22 Type 8650 Configuration and Function 1.3.2. Configuration of a complete AirLINE Ex system (example) Legend Supply segment, left Valve segment 44 mm, 4 valve functions Valve segment 44 mm, 8 valve functions Supply segment, middle (Intermediate supply) Valve segment 66 mm, 4 valve functions Valve segment 66 mm, 8 valve functions (not yet available) Supply segment, right...
  • Page 23 Type 8650 Configuration and Function 1.3.4. Electronics - Typ ME04 (modular electronics) Electronic module Cover flap Terminal module Fig. 4: Electronics - Typ ME04 (modular electronics) english...
  • Page 24 Type 8650 Configuration and Function 1.3.5. Pneumatics - Type MP13 (modular pneumatics) Valve type 652x EEx-i Pneumatic module Fig. 5: Bild: Pneumatics - Type MP13 (modular pneumatics) The detailed descriptions of the individual modules can be found in chapter Configuration and Function of the Modules. english...

  • Page 25: Function

    Type 8650 Configuration and Function FUNCTION AirLINE Ex is an electric and pneumatic automation system with a modular structure. It has been developed in cooperation with Siemens. Supply, communication and electrical I/O functions are available via the Siemens SIMATIC ET 200iSP system. The AirLINE Ex system can be seamlessly integrated into the Siemens system, with the modules of the AirLINE Ex system functioning as digital outputs with integrated valves.

  • Page 26: Functional.representation.of.the.airline.ex-System

    Type 8650 Configuration and Function 2.2. Functional representation of the AirLINE Ex-system Central controller (e. g.) PLC) with PROFIBUS-master DP-is -coupler Station 1 Power- Supply- Modul AirLine. Ex. Type. 8650. Station 2 Station ... Station n Fig. 7: Functional representation of an AirLINE Ex system (example) Legend Supply segment, left Valve segment 66 mm, 4 valve functions...

  • Page 27: Configuration And Function Of The Modules

    Type 8650 Configuration and Function of the Modules Configuration and Function of the Modules ontents SUPPLY.SEGMENTS..................................29 1.1.. Configuration.and.function.............................29 1.2.. Technical.Data..................................29 1.3.. Pneumatic.Connections..............................32 1.4.. Displays.....................................32 1.5.. Spare.parts....................................33 VALVE.SEGMENTS...................................34 2.1.. Configuration.and.Function............................34 2.2.. Technical.Data..................................35 2.3.. Pneumatic.Connections..............................38 2.4..
  • Page 28 Type 8650 Configuration and Function of the Modules 5.2.. Marking......................................46 5.3.. Technical.Data..................................47 ELECTRONIC.MODULE..................................48 6.1.. Configuration.and.Function............................48 6.2.. Marking......................................48 6.3.. Technical.Data..................................49 6.4.. Displays.....................................50 6.5.. Diagnosis....................................50 6.6.. Spare.Parts....................................50 VALVE.THAT.CAN.BE.INTEGRATED............................51 7.1.. Pneumatic.Valves.Type.6524/6525.. (station.width.11.mm)...............................52 7.2..

  • Page 29: Supply.segments

    Type 8650 Configuration and Function of the Modules SUPPLY SEGMENTS 1.1. Configuration and function An assembly consisting of a terminal module, function module and pneumatic module is referred to as a stackable segment. Supply segments are used for mounting the system on the profile rail and for connection of the fluidic supply and exhaust lines.
  • Page 30 Type 8650 Configuration and Function of the Modules 1.2.1. Overview Legend Storage compartment for SD card Hinged cover flap Clamping bolt (2x) for system mounting Pneumatic ports Unlocking slide, only installed on right-hand supply segments; Pressure gauge (optional) for displaying operating pressure Shut-off slide Power-Bus plug...
  • Page 31 Type 8650 Configuration and Function of the Modules 1.2.2. Dimensions 10,5 Connections optionally screw socket G3/8 + G1/8, NPT3/8 + NPT1/8 55,8 Fig. 3: Dimensions [mm] - Supply segments english...

  • Page 32: Pneumatic.connections

    Type 8650 Configuration and Function of the Modules 1.3. Pneumatic Connections Version Position Marking Function R/S-3/5 Exhaust air 3/8“ 3/8“ Control 1/8“ 1/8“ • EXT: Auxiliary control air • INT: Pilot exhaust air Compressed air supply 3/8“ 3/8“ Fig. 4: Pneumatic connections - Supply segment 1.4.

  • Page 33: Spare.parts

    Type 8650 Configuration and Function of the Modules 1.5. Spare parts Supply.segment.-.Spare.parts Ident.no. Cover flap for 44 mm wide modules 667 898 Pressure gauge module 174 010 Blank module (without pressure gauge) 174 009 Terminal module, 44 mm, passive, without locking slide (for supply segment left and center) 173 368 Terminal module 44 mm, passive, with locking slide (for supply segment right) 173 369 Set with various spare parts for valve and module installation (seals, screws, etc.)

  • Page 34: Valve.segments

    Type 8650 Configuration and Function of the Modules VALVE SEGMENTS 2.1. Configuration and Function An assembly consisting of a terminal module, function module and pneumatic module is referred to as a stackable segment. Valve segments function as digital output modules. They convert the electrical control signals of the interface module into pneumatic output signals that control the fluid flow.

  • Page 35: Technical.data

    Type 8650 Configuration and Function of the Modules 2.2. Technical Data 11 mm Valves 16,5 mm Valves Number of valve output ports Dimensions [mm] 44 x 120 x 135 66 x 120 x 135 Weight with valves [g] 1080 n / a Material Housing PBT, PC...
  • Page 36 Type 8650 Configuration and Function of the Modules 2.2.1. Overview Valve segments / Station width 44 mm and 66 mm Legend LED (red) for module status display LEDs (green) for channel status display Hinged cover flap Valves Inclined tie rods (2x) Pneumatic service ports Slip-in label strip Shut-off slide (under the valves) Power-Bus plug Plug for communication bus Valve ejector (only with station width 66 mm)
  • Page 37 Type 8650 Configuration and Function of the Modules 2.2.2. Dimensions 3x11 (=33) Connections optionally Plug-in coupling D6 screw socket M5 + M7 56,6 Fig. 8: Dimensions [mm] - Valve segment (example: station width 44 mm) english...

  • Page 38: Pneumatic.connections

    Type 8650 Configuration and Function of the Modules 2.3. Pneumatic Connections WARNING! Danger.–.high.pressure! A sudden escape of pressure medium may rapidly accelerate parts (hoses, small parts, …) and cause damage or injuries. If pressure changes occur, actuators may change their position and cause damage or injuries. •...

  • Page 39: Channel.assignment

    Type 8650 Configuration and Function of the Modules 2.5. Channel Assignment 2 bytes must be planned per valve segment / electronic module. These are allocated to the channels as shown here: Byte High-Byte Low-Byte Channel number with 4-channel modules Channel number with 8-channel modules The channel status LEDs on the electronic module are assigned to the channel / valve numbers.

  • Page 40: Spare.parts

    Type 8650 Configuration and Function of the Modules 2.8. Spare parts Valve.segment.-.Spare.parts Ident.no. Set with various spare parts for valve and module installation (seals, screws, etc.) 186 877 Cover flap for 44 mm wide modules 667 898 Cover flap for 66 mm wide modules 667 899 Label strip for electronic modules 667 917...

  • Page 41: Pneumatic.connector.module

    Type 8650 Configuration and Function of the Modules PNEUMATIC CONNECTOR MODULE 3.1. Configuration and Function The pneumatic supply module forms part of the supply segment. It provides for the external connections to the fluidic supply and exhaust of the system and passes this on to the valves. Fig.

  • Page 42: Pneumatic.connections

    Type 8650 Configuration and Function of the Modules 3.2.1. Overview Holes for clamping bolts (2x) for system mounting Pneumatic ports Inclined tie rods Fig. 13: Overview - Pneumatic supply module 3.3. Pneumatic Connections Version Position Marking Function R/S-3/5 Exhaust air 3/8“ 3/8“...

  • Page 43: Basic.pneumatic.module

    Type 8650 Configuration and Function of the Modules BASIC PNEUMATIC MODULE 4.1. Configuration and Function The basic pneumatic module is a part of the valve segment. It holds the valves, provides their fluidic supply and exhaust and sets up the flow outlets. Fig. 15: Basic Pneumatic Module (part of the valve segment) 4.2.
  • Page 44 Type 8650 Configuration and Function of the Modules 4.2.1. Versions The variants differ according to station width, number of valve positions, connection pattern of the valves, configu- ration of the service ports and optional use of check valves and / or P shut-offs. Types.Pneumatic MP13 Station width...

  • Page 45: Pneumatic.connections

    Type 8650 Configuration and Function of the Modules NOTE! Pressure.supply! When using the P shut-off basic modules, ensure that the pressure supply to the valve islands is configured with a sufficiently large volume. (Minimum hose diameter 8/6 mm) 4.2.4. Overview Legend check valve (optional) Labeling of valve positions and installed...

  • Page 46: Terminal.module

    Type 8650 Configuration and Function of the Modules TERMINAL MODULE 5.1. Configuration and Function All segments start out on a terminal module. It anchors all attached components to the profile rail and contains the electric backplane (energy and data bus). They can not be planned in the hardware configuration programs (e. g. Siemens Step7). Fig.

  • Page 47: Technical.data

    Type 8650 Configuration and Function of the Modules 5.3. Technical Data 173.368 173.369 173.370 173.371 Ident.no..of.the.module Application Supply segment Valve segment left and middle right 44 mm 66 mm Dimensions [mm] 55 (station width 44 mm) x 190 x 45 66 x 190 x 45 Weight [g] Housing material PBT, PC...

  • Page 48: Electronic.module

    Type 8650 Configuration and Function of the Modules ELECTRONIC MODULE 6.1. Configuration and Function The electronic module forms part of the valve segment. It contains the plug-and-socket connections for the valves and the electronics necessary to control the valves. It is electrically active (function: Digital output module) and must be.planned accordingly in the programs for the hardware configuration (e.

  • Page 49: Technical.data

    Type 8650 Configuration and Function of the Modules 6.3. Technical Data Ident.no..of.the.module 171.941 171.942 171.943 171.944 Number of valve output ports Dimensions [mm] 44 x 120 x 135 (for 11 mm valve) 66 x 120 x 135 (for 16.5 mm valve) Weight [g] Material (Housing) PBT, PC...

  • Page 50: Displays

    Type 8650 Configuration and Function of the Modules 6.4. Displays Legend LED for module status display (function as for Siemens modules) LEDs showing channel status (also see the chapter Configuration and Function of the Module / Valve Segments / Channel Assignment) Fig.

  • Page 51: Valve.that.can.be.integrated

    Valves with auxiliary control air cannot be combined with standard valves (internal auxiliary control air) on the valve island, as the X port then has a different function. Further information on the valves can also be found on the Internet under the respective type number. www.burkert.com english...

  • Page 52: Pneumatic.valves.type.6524/6525

    Type 8650 Configuration and Function of the Modules 7.1. Pneumatic Valves Type 6524/6525 (station width 11 mm) 7.1.1. Configuration and function The pneumatic valves of Type 6524 and 6525 consist of an Ex-i pilot solenoid valve (Type 6104 or Type 6144) and a pneumatic seat valve as an amplifier. This operating principle enables high pressures to be controlled with low power consumption and short switching times.
  • Page 53 Type 8650 Configuration and Function of the Modules 7.1.3. Ordering Chart Switching. times Description Ident.no. QNn-. value. [l/min] [W] [bar] [ms] [ms] C.=.NC (normally closed) 2.5 ... 7 184 766 186 832 1... 8 186 831 186 833 1, 2) 1 ... 7 186 835 3/2-way valve, pilot controlled, current- free, outlet port 2 relieved...

  • Page 54: Pneumatic.valves.types.6526/6527

    Type 8650 Configuration and Function of the Modules 7.2. Pneumatic Valves Types 6526/6527 (station width 16.5 mm) 7.2.1. Configuration and Function The valves of Type 6526 and 6527 consist of an Ex-i pilot solenoid valve (Type 6106) and a pneumatic seat valve as an amplifier. The operating principle enables high pressures to be controlled with low power consumption and short switching times.
  • Page 55 Type 8650 Configuration and Function of the Modules 7.2.3. Ordering Chart Switching. times QNn-. value. Description Ident.no. [l/min] [bar] [ms] [ms] C.=.NC (normally closed) 175 634 2 ... 10 175 674 175 673 -0,9 ... 8 175 723 1,2) 175 731 1 ...
  • Page 56 Type 8650 Configuration and Function of the Modules english...

  • Page 57: Installation

    Type 8650 Installation Installation ontents SAFETY.INSTRUCTIONS................................59 INSTALLATION.INSTRUCTIONS..............................61 2.1.. Unpacking.pre-assembled.systems..........................61 2.2.. Installation.Tools.and.Torques............................61 2.3.. Position.of.the.Assemblies.............................62 INSTALLATION.ON.S7.PROFILE.RAIL.. (PRE-ASSEMBLED.SYSTEM)..............................63 3.1.. Removing.a.System.from.a.Profile.Rail........................63 3.2.. Installation/Removal.of.the.ET.200iSP-Modules....................64 INSTALLATION.IN.THE.CONTROL.CABINET........................65 CONFIGURATION,.CONVERSION.AND.. EXPANSION.OF.AN.EXISTING.SYSTEM.WITH.. INDIVIDUAL.SEGMENTS................................66 5.1.. System.Configuration...............................66 5.2.. Conversion.and.Expansion.............................67 5.3..
  • Page 58 Type 8650 Installation 9.2.. Installation....................................72 10.. CONNECTION.OF.THE.AIR.INLET.AND.EXHAUST.LINES..................73 10.1.. Connection.of.the.Pressure.Supply...........................73 10.2.. Connection.of.the.Exhaust.Air............................73 10.3.. Pilot.Exhaust.Air./.Auxiliary.Control.Air........................73 10.4.. Plug.to.Block.P-channel..............................74 english...

  • Page 59: Safety.instructions

    Type 8650 Installation SAFETY INSTRUCTIONS DANGER! Risk.of.injury.from.high.pressure!. • Before loosening the lines and valves, turn off the pressure and vent the lines. Risk.of.electric.shock! • Before reaching into the device or the equipment, switch off the power supply and secure to prevent reactivation! •...
  • Page 60 Type 8650 Installation NOTE! Operate.the.system.with.direct.current.only!. To avoid damaging the system, use only direct current as the power supply for the system. Avoid.pressure.drop!. To avoid a pressure drop, the compressed air supply to the system must be as large as possible. Electrostatic.sensitive.components./.modules! The device contains electronic components which react sensitively to electrostatic discharge (ESD).

  • Page 61: Installation.instructions

    Type 8650 Installation INSTALLATION INSTRUCTIONS NOTE! Incorrectly installed systems (e.g. inclined tie rods not tightened properly) may leak. • Prior to start-up, always firmly seal all open attachments and locking devices. • The blue cover flaps of the individual segments can be removed if required. •...

  • Page 62: Position.of.the.assemblies

    Type 8650 Installation 2.3. Position of the Assemblies Clamping bolts Screws for mounting the valves Locking element Unlocking slide Fig. 2: Position of the modules to be screwed on Inclined tie rods Fig. 3: Position of the tie rods on the installed system Inclined tie rod pocket Fig.

  • Page 63: Installation.on.s7.Profile.rail.(Pre-Assembled.system)

    Type 8650 Installation INSTALLATION ON S7 PROFILE RAIL (PRE-ASSEMBLED SYSTEM) 3.1. Removing a System from a Profile Rail → Loosen all clamping bolts (1) on the connection modules (turn counter-clockwise) → Swivel system out of the profile rail. → Bring all clamping bolts (1) on the connection modules to the home position (by turning them counter- clockwise all the way).

  • Page 64: Installation/Removal.of.the.et.200Isp-Modules

    Type 8650 Installation 3.2. Installation/Removal of the ET 200iSP-Modules Installation → The ET 200iSP™ modules (terminal modules and bus termination modules) can be placed onto the profile rail and latched to the AirLINE Ex System. → Modules, which are attached to the right supply segment, interlock with the supply segment. Removal →...

  • Page 65: Installation.in.the.control.cabinet

    Type 8650 Installation INSTALLATION IN THE CONTROL CABINET The distances to be observed for installation in the control cabinet can be found in the handbook for the SIMATIC ET200iSP. To facilitate replacement of an electronic module, the minimum distance indicated in the picture below is recommended.

  • Page 66: Configuration,.Conversion.and.expansion.of.an.existing.system.with

    Type 8650 Installation CONFIGURATION, CONVERSION AND EXPANSION OF AN EXISTING SYSTEM WITH INDIVIDUAL SEGMENTS 5.1. System Configuration Two inclined tie rods (3) connect the modules to each other. → To assemble modules, place two modules on the profile rail and push together. → Now screw the right module to the left one with two inclined tie rods. (Hexagon-socket wrench 3 mm, torque 0.6 Nm) →...

  • Page 67: Conversion.and.expansion

    Type 8650 Installation 5.2. Conversion and Expansion → Loosen the clamping bolts (1) on the right supply segment. → Loosen the two inclined tie rods (3) → Push the supply segment to the right. → In the same way more segments can be moved until the position is reached in which the system is to be changed.

  • Page 68: Removal./.Installation.of.individual.segments

    Type 8650 Installation REMOVAL / INSTALLATION OF INDIVIDUAL SEGMENTS 6.1. Removal Supply.segments → Release required module by actuating the locking element and swivel out. → In the case of the pressure gauge module ensure that the hose is disconnected from the pneumatic module (see figure: Hose connection of the pressure gauge module). Fig.

  • Page 69: Installation

    Type 8650 Installation 6.2. Installation Supply.segment Pressure gauge module: → In the case of the pressure gauge module connect the hose to the pneumatic module before hooking in the module (see figure: Hose connection of the pressure gauge module). → Hook module into the terminal module and swivel in until it engages.

  • Page 70: Removal./.Installation.of.the.cover.flaps

    Type 8650 Installation REMOVAL / INSTALLATION OF THE COVER FLAPS 7.1. Installation To install the cover flap, attach it in the half swiveled open position and then push it into the hinge contour until it engages. Fig. 13: Attaching the cover flap 7.2. Removal Swivel open the cover flap and carefully lift the hinge plate over the hinge contour (e.g. using a small cross- head screwdriver).

  • Page 71: Replacing.a.terminal.or.pneumatic.module

    Type 8650 Installation REPLACING A TERMINAL OR PNEUMATIC MODULE For installation of the terminal-pneumatic module subassembly, the modules are aligned to each other during pro- duction. The alignment ensures compliance with all tolerances on the interfaces (profile holder - plug – fluidic ducts). Mount the pneumatic module itself on a terminal module and, when integrating it into the system, ensure that all interfaces (profile holder - plug –...

  • Page 72: Replacing.a.valve

    Type 8650 Installation REPLACING A VALVE DANGER! Risk.of.injury.due.to.pressure.change! When the valve is removed, only the P-channel is shut off. As a result, the pressure at the service outputs A or B is reduced. A connected actuator is therefore also depressurized and may move as a result. •...

  • Page 73: Connection.of.the.air.inlet.and.exhaust.lines

    Type 8650 Installation 10. CONNECTION OF THE AIR INLET AND EXHAUST LINES Exhaust air Pilot exhaust air / auxiliary control air Compressed air supply Fig. 15: Connections of the air inlet and exhaust lines 10.1. Connection of the Pressure Supply → Connect the compressed air supply to the P/1 connections on the connection modules. DThe supply should be fed via the largest possible lines to prevent pressure drops.
  • Page 74 Type 8650 Installation 10.3.2. Valves with Auxiliary Control Air In the case of valves that are to be employed for a wider range of pressures, the pilot control valve is supplied with air via a separate pressure port. This should be connected to port X. 10.4. Plug to Block P-channel Optionally, the pressure supply of the system can be segmented using a partition in the central P-channel between two pneumatic modules.

  • Page 75: Commissioning

    Type 8650 Commissioning Commissioning ontents SAFETY.INSTRUCTIONS................................76 INITIALIZATION....................................77 2.1.. Communication.Connection............................77 2.2.. Configuration.of.the.Hardware.Using.Siemens.Step7...................77 2.3.. Access.to.the.Acyclic.Parameters.with.the.Siemens.PDM................81 2.4.. Example.with.Two.Different.Function.Modules....................86 2.5.. Acyclic.Parameters.of.the.AirLINE.Ex.Modules....................89 2.6.. Use.of.“HSP”.and.“SUP”.under.Siemens.Step7./.PCS7................93 2.7.. Software.Update.Package.(SUP).for.PCS7......................97 SD.CARD./.SYSTEM.SERIALIZATION.DATA........................99 3.1.. Serialization.Data.Record..............................99 english...

  • Page 76: Safety.instructions

    Type 8650 Commissioning SAFETY INSTRUCTIONS DANGER! Risk.of.injury.from.high.pressure!. • Before loosening the lines and valves, turn off the pressure and vent the lines. Risk.of.electric.shock! • Before reaching into the device or the equipment, switch off the power supply and secure to prevent reactivation! •...

  • Page 77: Initialization

    Type 8650 Commissioning INITIALIZATION 2.1. Communication Connection The valve segment communicate with the interface module IM152 via the backplane bus system of the ET 200iSP. This exchanges not only input / output data but also parameter, configuration and diagnostic data with a central master (controller) via PROFIBUS-DP-is.
  • Page 78 Type 8650 Commissioning Configuration: → Before the AirLINE Ex system can be accessed, the corresponding GSD (file package) must be imported into the hardware catalog of the tool. Fig. 1: Select ET 200iSP → Select ET 200iSP in the hardware catalogue and drag it onto the Profibus. english...
  • Page 79 Type 8650 Commissioning Fig. 2: ET 200iSP on the Profibus → Select the desired modules from the catalogue listings of the ET200iSP and drag the selection onto the respective slot of the ET 200iSP station. Fig. 3: Determine module and slot english...
  • Page 80 Type 8650 Commissioning The active AirLINE Ex pneumatic modules can.be.found.in.the.same.part of the hardware catalogue. They are handled in the same way as a digital electric output module Supply segments are passive and are not planned (see also chapter Configuration and Function of the Modules / Supply segments! english...

  • Page 81: Access.to.the.acyclic.parameters.with.the.siemens.pdm

    Type 8650 Commissioning 2.3. Access to the Acyclic Parameters with the Siemens PDM A software program such as e. g. Siemens Process Device Manager (PDM) is required for accessing the acyclic parameters of the modules. Use the PDM program from Siemens (version 6.0 or higher) to ensure compatibility with the hardware. The corresponding EDDL (file package) must be imported into the device catalogue of the tool before the AirLINE Ex modules can be accessed.
  • Page 82 Type 8650 Commissioning → Insert the new object. Fig. 5: Inserting a new object → To insert a new device, first select the device type. Fig. 6: Selection of a new device english...
  • Page 83 Type 8650 Commissioning → Define the station designation and address. Fig. 7: Defining the station designation and address. → Add the function modules. Fig. 8: Addition of the function modules english...
  • Page 84 Type 8650 Commissioning → Define the desired number of identical modules. Fig. 9: Defining the number of identical modules → Select the module type via the menu “Allocate”. Fig. 10: Selecting the module type english...
  • Page 85 Type 8650 Commissioning → Terminate the module selection with OK. Fig. 11: Terminating the module selection english...

  • Page 86: Example.with.two.different.function.modules

    Type 8650 Commissioning 2.4. Example with Two Different Function Modules → Select the head station. Fig. 12: Selection of the head station → Open the station for access to the acyclic functions. Fig. 13: Opening the station english...
  • Page 87 Type 8650 Commissioning → Select the access mode (specialist: full access; maintenance staff: limited access). Fig. 14: Selection of the access mode → Select the head station to obtain the interface module parameters and to get an overview of the station configuration Fig.
  • Page 88 Type 8650 Commissioning Fig. 16: Parameters of an AirLINE Ex pneumatic module english...

  • Page 89: Acyclic.parameters.of.the.airline.ex.modules

    Type 8650 Commissioning 2.5. Acyclic Parameters of the AirLINE Ex Modules 2.5.1. Parameters that can be displayed or modified by modules Name Value Unit Status 4.DO.Bürkert.11.mm PDM_ConfigurationTool 1: PDM Initial value #.Identification #.#.Operating.unit 4 DO Bürkert 11 mm Description Initial value #.#.Device Manufacturer BUERKERT Device designation BUERKERT-ID00171941 Device serial number 00001234 Hardware revision Software revision A 0.0.4 Static revisions no.
  • Page 90 Type 8650 Commissioning 2.5.2. Access rights maintenance staff / specialist Some of the parameters described below can only be modified when access is made in the PDM as a SPECIALIST. Further information on read and write rights can be found in the online Help for the Siemens PDM program.
  • Page 91 Type 8650 Commissioning 2.5.4. Parameters that can be displayed or modified by channels Name Value Unit Status #.#.Channel.0 Channel enable enable Behavior at CPU/Master-STOP switching alternative value Initial value Alternative value #.#.#.Pilot.valve Switching cycle counter reset inactive Initial value ID number of the pilot valve Initial value Current number of the switching cycles 74766 #.#.#.Actuator Enable switching cycle counter diagnosis...
  • Page 92 Type 8650 Commissioning 2.5.7. Functions of the actuator (connected to the pilot valve of this channel) Enable.switching.cycle.counter.diagnosis.(read./.write). • Defines whether a diagnosis message is generated when the warning limit for the switching cycle counter is exceeded. • Switching.cycle.counter.warning.limit.(read./.write). Defines the value of the switching cycle counter at which a diagnosis message is generated as a warning. •...

  • Page 93: Use.of."Hsp".And."Sup".Under.siemens.step7./.Pcs7

    Type 8650 Commissioning 2.6. Use of “HSP” and “SUP” under Siemens Step7 / PCS7 2.6.1. Hardware Support Package (HSP) for STEP7 From STEP7 V5.3 SP2 the HSP2033 can be re-installed for the hardware catalog. The HSP2033 supplements the Decentralized Peripheral ET 200iSP with the 4 and 8-channel valve modules from AirLINE Ex. 2.6.2. Installation of the HSP2033: →...
  • Page 94 Type 8650 Commissioning Fig. 18: Installing HW updates, step 2 → When the copying process is complete, close the dialog field. → Now select the HSP with the number 2033 and acknowledge with install. Fig. 19: Installing HW updates, step 3 english...
  • Page 95 Type 8650 Commissioning When the installation is complete, the AirLINE Ex 8650 valve modules are included in the hardware catalog. Fig. 20: HW updates, completely installed english...
  • Page 96 Type 8650 Commissioning Changing.the.parameters → The parameters of a module can be changed via its “Object properties”. Fig. 21: Changing the parameters of a module Currently the settings of the switching cycle counters can be changed via SIMATIC PDM only. english...

  • Page 97: Software.update.package.(Sup).For.pcs7

    The installation program checks whether the required STEP 7 programs or whether PCS 7 V6.1 + SP1 are available. When the installation is complete, the AirLINE Ex 8650 valve modules are included in the hardware catalog of HW config. Fig. 22: Software Update Package Currently the settings of the switching cycle counters can be changed via SIMATIC PDM only.
  • Page 98 Type 8650 Commissioning The installation of the Software Update Package is recorded and can be checked under Start > SIMATIC > Infor- mation >“- Installed software”. Fig. 23: SIMATIC Software english...

  • Page 99: Sd.card./.System.serialization.data

    Type 8650 Commissioning SD CARD / SYSTEM SERIALIZATION DATA The serialization data of completely installed systems of type 8650 can be provided as a data record. The record includes the serial numbers of the valves, the electronic modules and the terminal module. The order always refers to the system configuration from left to right (serial number of the valve island – serial number of all electronic modules –...
  • Page 100 Type 8650 Commissioning Valve island ID number Valve island serial number ID number of the first electronic module Serial number of the first electronic module ID number of the second electronic module Serial number of the second electronic module ID number of the first valve Serial number of the first valve Data of the valves 2 - 7 hidden ID number of the last valve...

  • Page 101: Maintenance And Repair

    Type 8650 Maintenance and Repair Maintenance and Repair ontents SAFETY.INSTRUCTIONS................................102 MAINTENANCE....................................103 2.1.. Module.Maintenance............................... 103 2.2.. Cleaning....................................103 2.3.. Diagnosis.Function................................103 MAINTENANCE....................................104 3.1.. Changing.Valves.During.Operation......................... 104 3.2.. Changing.Electronic.Modules.During.Operation..................... 104 3.3.. Troubleshooting................................. 105 3.4..

  • Page 102: Safety.instructions

    Type 8650 Maintenance and Repair SAFETY INSTRUCTIONS DANGER! Risk.of.injury.from.high.pressure.in.the.equipment! • Before loosening the lines and valves, turn off the pressure and vent the lines. Risk.of.injury.due.to.electrical.shock! • Before reaching into the system, switch off the power supply and secure to prevent reactivation! •...

  • Page 103: Maintenance

    Type 8650 Maintenance and Repair MAINTENANCE 2.1. Module Maintenance The modules of the AirLINE Ex system are maintenance-free when operated in accordance with the instructions in this operating manual. 2.2. Cleaning DANGER! Danger.of.explosion.caused.by.electrostatic.charge! If there is a sudden discharge from electrostatically charged devices or persons, there is a danger of explosion in the EX area.

  • Page 104: Maintenance

    Type 8650 Maintenance and Repair MAINTENANCE DANGER! Risk.of.injury.from.high.pressure.in.the.equipment! • Before loosening the lines and valves, turn off the pressure and vent the lines. 3.1. Changing Valves During Operation 3.1.1. Installation instructions Before replacing the valve, ensure that the relevant equipment is in an electrically safe state. If the respective valve position does not feature a P-shutoff, first depressurize the system.

  • Page 105: Troubleshooting

    Type 8650 Maintenance and Repair 3.3. Troubleshooting Fault Possible.cause Remedy → Valves do not switch No or insufficient operating voltage. Check the electrical connection. → Ensure the correct operating voltage. → Manual override not in neutral Move the manual override to the neutral position.

  • Page 106: Repair

    Type 8650 Maintenance and Repair Fault Possible.cause Remedy → SF LED lights up. Wrong configuration. Use the corresponding module from the hardware catalogue. → Valve diagnosis trips (short circuit, Check the proper installation of the valve. open outlet port). → Replace defective valves.

  • Page 107: Storage, Packaging, Transport, Disposal

    Type 8650 Storage, Packaging, Transport, Disposal Storage, Packaging, Transport, Disposal ontents STORAGE......................................108 1.1.. Storage.Conditions.for.Modules.in.Original.Packaging................108 1.2.. Shutdown....................................109 PACKAGING,.TRANSPORT................................ 110 2.1.. Transport.Conditions.for.Modules.in.Original.Packaging................110 english...

  • Page 108: Storage

    Type 8650 Storage, Packaging, Transport, Disposal STORAGE NOTE! Incorrect.storage.may.damage.the.device. • Store the device in a dry and dust-free location! • Storage temperature: -40 … 70 °C 1.1. Storage Conditions for Modules in Original Packaging The following information applies to modules transported in their original packaging. Requirement Admissible.range ≤1 m...

  • Page 109: Shutdown

    Type 8650 Storage, Packaging, Transport, Disposal 1.2. Shutdown 1.2.1. Safety Instructions DANGER! Risk.of.injury.from.high.pressure.in.the.equipment! • Before loosening the lines and valves, turn off the pressure and vent the lines. Risk.of.injury.due.to.electrical.shock! • Before reaching into the system, switch off the power supply and secure to prevent reactivation! •...

  • Page 110: Packaging,.Transport

    Type 8650 Storage, Packaging, Transport, Disposal PACKAGING, TRANSPORT NOTE! Transport.damages! Inadequately protected equipment may be damaged during transport. • During transportation protect the device against wet and dirt in shock-resistant packaging. • Avoid the action of heat and cold which can lead to temperatures above or below the admissible storage temperature.

  • Page 111: Annex

    Type 8650 Annex Annex ontents EC.DECLARATION.OF.CONFORMITY..........................112 1.1.. Standards.used.for.CSA-,.FM-Ex.and.IEC-Ex-certification................ 115 1.2.. Set-Up.of.the.Type.8650.System.for.Certification.Conformity..............116 1.3.. Certificates................................... 117 EC-TYPE.EXAMINATION.CERTIFICATE.TERMINAL.MODULES................118 IEC-EX.CERTIFICATE.OF.CONFORMITY.TERMINAL.MODULES................120 EC-TYPE.EXAMINATION.CERTIFICATE.ELECTRONIC.MODULES............... 123 IEC-EX.CERTIFICATE.OF.CONFORMITY.ELECTRONIC.MODULES..............126 EC-TYPE-EXAMINATION.CERTIFICATE.. 11.MM-VALVES.TYPE.6104............................... 129 IEC-EX.CERTIFICATE.OF.CONFORMITY.. 11.MM-VALVES.TYPE.6104............................... 133 EC-TYPE-EXAMINATION.CERTIFCATE..

  • Page 112: Ec.declaration.of.conformity

    Type 8650 Annex EC DECLARATION OF CONFORMITY We hereby declare that the products with the designation: Electrical.and.Pneumatic.Automation.System.AirLINE.Ex.Type.8650 satisfy the requirements which are specified in the Council Directives to approximate the laws of the member states: •. Low.Voltage.Directive.(LVD).(2006/95/EC) •. Electromagnetic.compatibility.Directive.(2004/108/EC) •. Pressure.Equipment.Directive.(97/23/EC) •. ATEX-Directive.(94/9/EC). One or several of the following standards were used to assess the products concerning compliance with the Low.
  • Page 113 Type 8650 Annex One or several of the following standards have been used to assess the products with respect to Pressure. Equipment.Directive.(97/23/EG): EN 60730-1 Automatic electrical controls for household and similar use - Part 1: General requirements Automatic electrical controls for household and similar use - Part 2-8: Particular requirements 60730-2-8 for electrically operated water valves, including mechanical requirements The.products.have.been.subjected.to.the.following.conformity.assessment.procedure:...
  • Page 114 Type 8650 Annex The following standards were also used to assess non-electrical equipment and equipment in the filling station area: EN 13463-1 Non-electrical equipment for potentially explosive atmospheres - Part 1: Basic method and requirements EN 13617-1 Petrol filling stations - Part 1: Safety requirements for construction and performance of metering pumps, dispensers and remote pumping units The production of electrical equipment, for which an EC-type examination certificate is available, is monitored by;...

  • Page 115: Standards.used.for.csa-,.Fm-Ex.and.iec-Ex-Certification

    Type 8650 Annex 1.1. Standards used for CSA-, FM-Ex and IEC-Ex-certification For the CSA-certification, the following standards have been applied: CAN/CSA 22.2 No. 157-92 CAN/CSA 22.2 No. 213-M1987 CAN/CSA 22.2 E-60079-0 -07 CAN/CSA 22.2 E-60079-7 -03 CAN/CSA 22.2 E-60079-11 -02 ANSI/ISA-60079-0 (12.00.01)-2005 ANSI/ISA-60079-7 (12.16.01)-2002 ANSI/ISA-60079-11 (12.02.01)-2002 For the FM-Ex-certification, the following standards have been applied: FM Class 3600-1998 FM Class 3610-2007...

  • Page 116: Set-Up.of.the.type.8650.System.for.certification.conformity

    Type 8650 Annex 1.2. Set-Up of the Type 8650 System for Certification Conformity Observe the following regulations to ensure that the configuration of the system is authorized: When converting or expanding a system, check whether the satisfied approvals are affected. A type 8650 system can be placed at any chosen location between IM152 and the bus termination module of a SIMATIC ET200iSP station.

  • Page 117: Certificates

    Type 8650 Annex 1.3. Certificates • Terminal module (permit designation: KEMA 06ATEX0092) • Electronic module (permit designation: KEMA 06ATEX0093) • Valve type 6144 Ex-i (permit designation: PTB 07ATEX2048) • Valve type 6104 Ex-i with solenoid”G1 642 735“ (permit designation: PTB 01 ATEX2173) •...

  • Page 118: Ec-Type.examination.certificate.terminal.modules

    Type 8650 Annex EC-TYPE EXAMINATION CERTIFICATE TERMINAL MODULES (Certificate number: KEMA 06ATEX0092, Issue Number: 2) english...
  • Page 119 Type 8650 Annex english...

  • Page 120: Iec-Ex.certificate.of.conformity.terminal.modules

    Type 8650 Annex IEC-EX CERTIFICATE OF CONFORMITY TERMINAL MODULES (Certificate Number: KEMA IECExKEM07.0033 , Issue Number: 0) english...
  • Page 121 Type 8650 Annex english...
  • Page 122 Type 8650 Annex english...

  • Page 123: Ec-Type.examination.certificate.electronic.modules

    Type 8650 Annex EC-TYPE EXAMINATION CERTIFICATE ELECTRONIC MODULES (Bescheinigungs-Nummer: KEMA 06ATEX0093, Ausgabe Nummer: 3) english...
  • Page 124 Type 8650 Annex english...
  • Page 125 Type 8650 Annex english...

  • Page 126: Iec-Ex.certificate.of.conformity.electronic.modules

    Type 8650 Annex IEC-EX CERTIFICATE OF CONFORMITY ELECTRONIC MODULES (Certification Number: KEMA IECExKEM07.0032 , Issue Number: 0) english...
  • Page 127 Type 8650 Annex english...
  • Page 128 Type 8650 Annex english...

  • Page 129: Ec-Type-Examination.certificate.11.Mm-Valves.type.6104

    Type 8650 Annex EC-TYPE-EXAMINATION CERTIFICATE 11 MM-VALVES TYPE 6104 (Certification Number: PTB 01ATEX2173) english...
  • Page 130 Type 8650 Annex english...
  • Page 131 Type 8650 Annex english...
  • Page 132 Type 8650 Annex english...

  • Page 133: Iec-Ex.certificate.of.conformity.11.Mm-Valves.type.6104

    Type 8650 Annex IEC-EX CERTIFICATE OF CONFORMITY 11 MM-VALVES TYPE 6104 Certification Number: PTB06.0101) english...
  • Page 134 Type 8650 Annex english...
  • Page 135 Type 8650 Annex english...

  • Page 136: Ec-Type-Examination.certifcate.16,5.Mm-Valves.type.6106

    Type 8650 Annex EC-TYPE-EXAMINATION CERTIFCATE 16,5 MM-VALVES TYPE 6106 Certification Number: PTB 01ATEX2175) english...
  • Page 137 Type 8650 Annex english...
  • Page 138 Type 8650 Annex english...
  • Page 139 Type 8650 Annex english...

  • Page 140: Iec-Ex.certificate.of.conformity.16,5.Mm-Valves.type.6106

    Type 8650 Annex IEC-EX CERTIFICATE OF CONFORMITY 16,5 MM-VALVES TYPE 6106 (Certification Number: PTB06.0102) english...
  • Page 141 Type 8650 Annex english...
  • Page 142 Type 8650 Annex english...

  • Page 143: Ec-Type-Examintation.certificate.11.Mm-Valves.type.6144

    Type 8650 Annex 10. EC-TYPE-EXAMINTATION CERTIFICATE 11 MM-VALVES TYPE 6144 (Certification Number: PTB 07ATEX2048) english...
  • Page 144 Type 8650 Annex english...
  • Page 145 Type 8650 Annex english...
  • Page 146 Type 8650 Annex english...
  • Page 147 Type 8650 Annex english...
  • Page 148 Type 8650 Annex english...

  • Page 149: Iec-Ex.certificate.of.conformity.11.Mm-Valves.type.6144

    Type 8650 Annex 11. IEC-EX CERTIFICATE OF CONFORMITY 11 MM-VALVES TYPE 6144 (Certification Number: IECEx PTB07.0063) english...
  • Page 150 Type 8650 Annex english...
  • Page 151 Type 8650 Annex english...
  • Page 152 Type 8650 Annex english...
  • Page 153 Type 8650 Annex english...
  • Page 154 Type 8650 Annex english...
  • Page 156 www.burkert.com...

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