Type 8650
AirLINE Ex
Electrical and Pneumatic Automation System
Operating Instructions
Bedienungsanleitung
Instructions de Service
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© 2006 - 2012 Bürkert Werke GmbH & Co. KG
Operating Instructions 1202/05_EU-EN_00804032
Type 8650
Contents
Electrical and Pneumatic Automation System Type 8650
GENERAL INFORMATION AND SAFETY INSTRUCTIONS ....................................................................................................5
Operating Instructions ........................................................................................................................................................6
1.
Intended Use ............................................................................................................................................................................7
2.
Basic safety instructions ....................................................................................................................................................8
3.
General Information...........................................................................................................................................................10
4.
SYSTEM DESCRIPTION ........................................................................................................................................................................... 11
General Description ...........................................................................................................................................................12
1.
Technical Data .....................................................................................................................................................................15
2.
System Accessories ..........................................................................................................................................................17
3.
CONFIGURATION AND FUNCTION ...................................................................................................................................................19
Configuration .........................................................................................................................................................................20
1.
Function ...................................................................................................................................................................................25
2.
CONFIGURATION AND FUNCTION OF THE MODULES ......................................................................................................27
Supply Segments ...............................................................................................................................................................29
1.
Valve segments ....................................................................................................................................................................34
2.
Pneumatic Connector Module .....................................................................................................................................41
3.
Basic Pneumatic Module ................................................................................................................................................43
4.
Terminal module ..................................................................................................................................................................46
5.
Electronic Module ...............................................................................................................................................................48
6.
Valve that can be integrated .........................................................................................................................................51
7.
INSTALLATION ...............................................................................................................................................................................................57
Safety Instructions .............................................................................................................................................................59
1.
Installation Instructions ...................................................................................................................................................61
2.
Installation on S7 Profile Rail
3.
(Pre-assembled System) ................................................................................................................................................63
Installation in the control cabinet ...............................................................................................................................65
4.
Configuration, Conversion and
5.
Expansion of an existing system with
individual segments ..........................................................................................................................................................66
Removal / Installation of individual Segments ...................................................................................................68
6.
english
3
Type 8650
Contents
7. Removal / Installation of the Cover flaps ..............................................................................................................70
Replacing a terminal or pneumatic module .........................................................................................................71
8.
Replacing a valve ................................................................................................................................................................72
9.
Connection of the Air Inlet and Exhaust Lines ...................................................................................................73
10.
COMMISSIONING ........................................................................................................................................................................................75
Safety Instructions .............................................................................................................................................................76
1.
Initialization ............................................................................................................................................................................77
2.
SD Card / System Serialization Data ......................................................................................................................99
3.
MAINTENANCE AND REPAIR ............................................................................................................................................................ 101
Safety Instructions ..........................................................................................................................................................102
1.
Maintenance ....................................................................................................................................................................... 103
2.
Maintenance ....................................................................................................................................................................... 104
3.
STORAGE, PACKAGING, TRANSPORT, DISPOSAL ............................................................................................................ 107
Storage .................................................................................................................................................................................. 108
1.
Packaging, Transport ..................................................................................................................................................... 110
2.
ANNEX ............................................................................................................................................................................................................. 111
EC Declaration of Conformity .................................................................................................................................... 112
1.
EC-Type Examination Certificate Terminal modules .....................................................................................118
2.
IEC-Ex Certificate of Conformity Terminal modules ..................................................................................... 120
3.
EC-Type Examination Certificate Electronic modules .................................................................................. 123
4.
IEC-Ex Certificate of Conformity Electronic modules ..................................................................................126
5.
EC-Type-Examination certificate
6.
11 mm-Valves Type 6104 ............................................................................................................................................129
IEC-Ex Certificate of Conformity
7.
11 mm-Valves Type 6104 ............................................................................................................................................133
EC-Type-Examination Certifcate
8.
16,5 mm-Valves Type 6106 ......................................................................................................................................... 136
IEC-Ex Certificate of Conformity
9.
16,5 mm-Valves Type 6106 ......................................................................................................................................... 140
EC-Type-Examintation Certificate
10.
11 mm-Valves Type 6144 ............................................................................................................................................143
IEC-Ex Certificate of Conformity
11.
11 mm-Valves Type 6144 ............................................................................................................................................149
english
4
Type 8650
Allgemeine Informationen
Sicherheitshinweise
General Information and Safety Instructions
Contents
1. OPERATING INSTRUCTIONS ........................................................................................................................................................6
Symbols ......................................................................................................................................................................................6
1.1.
INTENDED USE ....................................................................................................................................................................................7
2.
Restrictions ...............................................................................................................................................................................7
2.1.
BASIC SAFETY INSTRUCTIONS .................................................................................................................................................8
3.
GENERAL INFORMATION .............................................................................................................................................................10
4.
Contact address ..................................................................................................................................................................10
4.1.
Warranty ...................................................................................................................................................................................10
4.2.
Approvals ................................................................................................................................................................................10
4.3.
Information on the Internet ............................................................................................................................................10
4.4.
Trademarks ............................................................................................................................................................................10
4.5.
english
5
Type 8650
Allgemeine Informationen
Sicherheitshinweise
1. 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.
• The operating instructions must be read and understood.
1.1. Symbols
DANGER!
Warns of an immediate danger!
• Failure to observe the warning may result in a fatal or serious injury.
WARNING!
Warns of a potentially dangerous situation!
• Failure to observe the warning may result in serious injuries or death.
CAUTION!
Warns of a possible danger!
• Failure to observe this warning may result in a moderately severe or minor injury.
NOTE!
Warns of damage to property!
1. Failure to observe the warning may result in damage to the device or the equipment.
designates additional significant information, tips and recommendations.
refers to information in these operating instructions or in other documentation.
→ designates a procedure which you must carry out.
6
english
Type 8650
Allgemeine Informationen
Sicherheitshinweise
2. 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.
• Use according to the authorized data, operating conditions and conditions of use specified in the contract
documents and operating instructions. These are described in the chapter entitled “System Description AirLINE Ex” and “Technical Data”.
• The device may be used only in conjunction with third-party devices and components recommended and
authorised by Bürkert.
• Correct transportation, correct storage and installation and careful use and maintenance are essential for reliable and faultless operation.
• Use the Type 8650 AirLINE Ex 8793 only as intended.
The AirLINE Ex system Type 8650 was developed with due consideration given to accepted safety rules
and is state-of-the-art. Nevertheless, dangerous situations may occur.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
2.1.1. Ex-Approval
The Ex approval is only valid if the modules and components approved by Bürkert are used in the manner
described in this operating manual.
The electronic modules may only be employed in combination with the pneumatic valve types approved by
Bürkert. Use in any other way will invalidate the Ex approval!
Unauthorized modifications to the system, the modules or components will also void the Ex approval.
english
7
Type 8650
Allgemeine Informationen
Sicherheitshinweise
3. 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.
Danger – 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!
• Observe applicable accident prevention and safety regulations for electrical equipment!
(It is permitted to replace electronic modules and valves even while the power is on.)
Verbrennungsgefahr/Brandgefahr bei Dauerbetrieb durch heiße Geräteoberfläche!
• Das Gerät von leicht brennbaren Stoffen und Medien fernhalten und nicht mit bloßen Händen berühren.
General hazardous situations.
To prevent injury, ensure that:
• Do not supply aggressive or inflammable media to the media connections of the system.
• Do not supply fluids to the media connections of the system.
• In low-pressure applications ensure that no flammable or explosive media are drawn into the AirLINE-Ex system.
• Do not subject the housing to mechanical loads (e. g. by placing objects on the housing or using the
housing as a step).
• Do not cover the ventilation slots in the housing.
• The system cannot be activated unintentionally.
• Installation and repair work may be carried out by authorised technicians only and with the appropriate tools.
• After an interruption in the power supply or pneumatic supply, ensure that the process is restarted in a
defined or controlled manner.
• The device may be operated only when in perfect condition and in consideration of the operating instructions.
• The general rules of technology apply to application planning and operation of the device.
8
english
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!
• The device contains electronic components which react sensitively to electrostatic discharge (ESD). Contact
with electrostatically charged persons or objects is hazardous to these components. In the worst case scenario,
they will be destroyed immediately or will fail after start-up.
• Observe the requirements in accordance with EN 61340-5-1 and 5-2 to minimise or avoid the possibility of
damage caused by sudden electrostatic discharge!
• Also ensure that you do not touch electronic components when the power supply voltage is present!
english
9
4. 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
Type 8650
Allgemeine Informationen
Sicherheitshinweise
Contact addresses can be found on the final pages of these operating instructions.
And also on the internet at:
www.buerkert.com
4.2. Warranty
The warranty is only valid if the AirLINE Ex Type 8650 is used as authorized in accordance with the specified application conditions.
4.3. Approvals
The approval rating on the Bürkert labels refers to Bürkert products.
You can find more detailed information on the approvals in the Appendix of these operating instructions.
4.4. Information on the Internet
10
The operating instructions and data sheets for Type 8650 can be found on the Internet at:
www.buerkert.com
Type 8650
4.5. Trademarks
The listed designations are trademarks of the respective companies / associations / organizations.
ET 200iSP Siemens AG
PROFIBUS PROFIBUS Nutzerorganisation e. V.
english
Type 8650
System Description
System Description
Contents
1. GENERAL DESCRIPTION .............................................................................................................................................................12
Product Description ...........................................................................................................................................................12
1.1.
Characteristic Features and Benefits ......................................................................................................................13
1.2.
Field of Application ............................................................................................................................................................14
1.3.
Marking ...................................................................................................................................................................................14
1.4.
TECHNICAL DATA ...........................................................................................................................................................................15
2.
General Technical Data ....................................................................................................................................................15
2.1.
Dimensions ............................................................................................................................................................................16
2.2.
SYSTEM ACCESSORIES ..............................................................................................................................................................17
3.
english
11
Type 8650
System Description
1. 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 pneumatic components are available. As long as simple rules are observed, it permits pneumatic, electric and electronic modules with different functions can be combined with one another. The components are connected to
each other using screws or latches. In this way both the electrical and the pneumatic connections are made.
The pilot valves integrated on the pneumatic modules allow a wide range of different pneumatic actuators to be
controlled on site (e. g. process valves or pneumatic cylinders).
Fig. 1: View of the overall system
(Siemens SIMATIC ET 200iSP and
Bürkert AirLINE Ex)
Fig. 2: View of the Bürkert AirLINE Ex system
12
english
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-optimized station configurations.
• Seamless integration into Siemens SIMATIC ET 200iSP
• Operation is possible with oiled or unoiled compressed air, as well as with neutral and non-combustible gases.
1.2.2. The benefits of AirLINE Ex
• Flow-optimized valve design.
Pressure range of vacuum up to 10 bar (depending on the valve models used).
Flow of approx. 300 l/min and 700 l/min for a valve width of 10 mm and 16 mm respectively.
• Long service life with oiled and unoiled compressed air thanks to low-wear valve function.
• Central exhaust air exhaust.
• Replacement of valves and electronic modules during operation possible thanks to „intrinsically safe“
explosion-proof construction.
• Optional operation with auxiliary control air in extended pressure ranges (also see the chapter Configuration
and Function of the Modules / Integratable Valves)
• Simple combination of various functions, configurations and add-ons thanks to high modularity
• Numerous valve functions: 3/2-, 2 x 3/2- and 5/2-way combined with various circuit functions
• Wide range of connection possibilities
• Integration of pneumatic options possible (e. g. check valves)
• Optional emergency manual override of the valves
• Different pressure levels possible in one system
• Integration of pressure gauges for operating pressure display
• Central compressed air supply
13
english
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!
The terminal modules (with upright system wiring) are designed for the Ex-protection class “Ex-e” (increased
safety).
• Before working on the terminal modules, always switch off the operating voltage to the system.
Further information can be found in the handbook for the Siemens ET200iSP.
Danger of explosion!
If a system is installed in a control cabinet in the explosion-proof area, observe the following:
• The control cabinet must be authorized for use in the explosion-protected area.
• The control cabinet must be dimensioned large enough to ensure that the generated lost heat can be dissipated to the exterior in a suitable manner.
• The internal temperature of the control cabinet must not exceed the max. permitted ambient temperature for
the device.
1.4. Marking
Type 8650
Ident no. 001xxxxxx
Serial no. 00001123
Fig. 3: Location of the type label Fig. 4: Type label
Information about the labeling of the electronic and terminal modules can be found in the chapters
Configuration and Function of the Modules / Terminal Module / Labeling and
Configuration and Function of the Modules / Electronic Module / Labeling.
14
english
Type 8650
System Description
2. TECHNICAL DATA
2.1. General Technical Data
Medium Clean, dry air (oiled or unoiled),
neutral gases (particle size max. 5 μm)
Max. power consumption see table below “Power consumption of the active
modules”.
Ambient temperature during
operation
Storage temperature -20 °C to +60 °C
Relative humidity 5 to 95 %, non-condensing
Acceleration during operation 5 m/s
Rated operating mode 100 % CDF ( continuous operation)
Operating voltage 24 V DC in EEx-e
Degree of protection IP30
Protection class 3 (VDE0580)
Housing materials Pneumatic modules and valves: PA (polyamide
0 °C to +55 °C
2
(Details: see Siemens Power Supply Module)
electronic modules: PBT (polybutylene terephthalate)
Seal materials Pneumatic modules and valves: NBR
electronic modules: PC (polycarbonate)
Approvals A prerequisite for the authorized use of the total AirLINE-Ex system is the
installation in a suitable certified housing:
- Ex-e- or Ex-d-housing for Zone 1 respectively
- Ex-d-housing for Zone 21
FA prerequisite for FM-Ex in Zone 21 or Class II, III Div. 1,2 with the substance classes E, F & G is the operation in a suitable Ex-D housing.
• Electronic modules ATEX: ATEX II 2 G Ex ib IIC T4 (Zone 1 / 21)
IEC-Ex: IECEx KEM 07.0032
FM-Ex: Class II, III, Div. 1, 2, GP E, F, G
IS Class I, Div. 1 GP A, B, C, D T4
Class I, Div. 2 GP A, B, C, D T4
Class I, Zone 1, AEx ib IIC T4
• Terminal modules ATEX: ATEX II 2 G Ex e [ia/ib] IIC T4 (Zone 1 / 21)
IEC-Ex: IECEx KEM 07.0033
FM-Ex: Class II, III, Div. 1, 2, GP E, F, G
IS Class I, Div. 1, GP A, B, C, D T4
Class I, Div 2, GP A, B, C, D T4
Class I, Zone 1 e [ia/ib] IIC T4
The AirLINE Ex satisfies the requirements of the EMC Act.
Interference resistance EN 50082-2
Emitted interference EN 50081-2
15
english
27,7
56
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. 3.6 W 171 944
2.2. Dimensions
2.2.1. The Complete System
31,5
17
10,5
165
12,5
28,5
5,5
24
11
3 x
11 (=33)
3 x
16,5
16,5
(=49,5)
8,25
12,5
28,5
Connections optinally
Screw socket G3/8 + G1/8; NPT 3/8 + NPT 1/8
Plug-in coupling D8; 5/16
Screw socket G1/8 + NPT 1/8
Plug-in coupling D6
Screw socket M5 + M7
33
190
Siemens S7
Profile rail
6ES7390
16
44
44
88 + ( n x 44 + n x 66 )
66
nx44 = Number of modules overall width 44 mm
nx66 = Number of modules overall width 66 mm
Fig. 5: Dimensions [mm] - The Complete System
english
35
44
Type 8650
System Description
3. 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
(for sealing an unused valve position)
)
Supply plate complete
(for additional medium supply for high-consumption applications or for supplying separate media
circuits or pressure stages)
)
Breather plate complete
(for additional exhaust for high-consumption applications or for exhaust of separate media circuits
or pressure stages)
Function plates for flange pattern 6524
(installation instead of a 2x 3/2-way valve / 11 mm)
Blind plate complete for 2x 3/2-way valves
(for sealing an unused valve position)
1)
Supply plate complete
(for additional medium supply for high-consumption applications or for feeding separate media
circuits or pressure stages)
1)
Breather plate complete
(for additional exhaust for high-consumption applications or for exhaust of separate media circuits
or pressure stages)
650 373
649 637
655 166
661 092
667 945
667 947
Function plates for flange pattern 6526 / 6527
(Installation instead of a 3/2-way or 5/2-way valve / 16.5 mm)
Blind plate complete for 3/2-way and 5/2-way valve 653 765
Supply plate complete
655 156
(for additional medium supply for high-consumption applications or for feeding separate media
circuits or pressure stages)
Breather plate complete
653 697
(for additional exhaust for high-consumption applications or for exhaust of separate media circuits
or pressure stages)
Further accessories
Set with various spare parts for valve and module installation (seals, screws, etc.) 186 877
Cap for plug-in valve contact 653 670
Plug for P channel shut-off (for configuration of several pressure stages or media circuits in a
655 068
system, Type 8650)
S7-Profile rail, lenght 482 mm 6ES7390-1AE80-0AA0 (Siemens) 655 982
S7-Profile rail, lenght 530 mm 6ES7390-1AF30-0AA0 (Siemens) 655 983
S7-Profile rail, lenght 585 mm 6ES7390-1AF85-0AA0 (Siemens) 671 701
S7-Profile rail, lenght 830 mm 6ES7390-1AJ30-0AA0 (Siemens) 671 702
S7-Profile rail, lenght 885 mm 6ES7390-1AJ85-0AA0 (Siemens) 671 703
S7-Profile rail, lenght 2000 mm 6ES7390-1BC00-0AA0 (Siemens) --
Suitable Ex bus connector for Siemens IM152 e. g. 6ES7-972-0DA60-0XA0 (Siemens) 655 981
17
english
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 correspondingly lower!
For competent advice, please contact your local Bürkert sales partner.
18
english
Type 8650
Configuration and Function
Configuration and Function
Contents
1. CONFIGURATION .............................................................................................................................................................................20
Maximum System Configuration ................................................................................................................................20
1.1.
Configurator ...........................................................................................................................................................................20
1.2.
Siemens SIMATIC ET 200iSP System Components ........................................................................................21
1.3.
Bürkert AirLINE Ex - System Components ...........................................................................................................21
1.4.
FUNCTION ............................................................................................................................................................................................25
2.
View of the Overall System ...........................................................................................................................................25
2.1.
Functional representation of the AirLINE Ex-system ......................................................................................26
2.2.
english
19
Type 8650
Configuration and Function
1. 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.
Valve positions up to 48 with 11 mm valves Types 6524/6525 (with a middle supply segment)
up to 32 with 16.5 mm valves Types 6526/6527 (with a middle supply segment)
Mixing 44 mm / 66 mm valve segments is possible.
Maximum width 1095 mm including all Siemens modules (one power supply and one interface)
1185 mm including all Siemens modules (two power supply and two interfaces)
Other limitations are possible due to the installation position and power considerations (see the Simatic ET
200iSP manual).
1.2. Configurator
With its high degree of modularity AirLINE Ex offers numerous degrees of freedom to adapt to a wide range of
application cases.
To adapt to your particular application as simply as possible, there is a PC-based configuration program available.
It is available from your Bürkert contact or you can download it directly from the Bürkert homepage (under Type
8650 software).
www.burkert.com
The configurator allows you
- to define the type and number of the required valve segments
- to define the required valve equipment
- to specify the required connections
- to use intermediate feed-ins
- to select options and accessories
- To add ET200iSP modules
At the same time the conformity is automatically checked with the applicable succession regulations.
As a result you will receive a storable parts list which you can use to inform your contact at Bürkert about the
exact configuration required.
20
Moreover, the configurator supplies technical basic data to the system which you require, e.g. weight, dimensions, power loss, etc.
english
Typ ME04
Electronic module
Typ ME04
Terminal module
Ex-i valve types
6524 - 6527
Typ ME04
Modular electronics
Typ MP13
Modular pneumatics
Type MK02
Module combination
segment
Type 8650
AirLINE Ex
Type 8650
Configuration and Function
1.3. 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.
1.4. Bürkert AirLINE Ex - System Components
1.4.1. Module Terminology
In order to simplify the overview of the system structure, designations have been defined for the modules and
assemblies. The relationships are explained in the following illustrations.
Fig. 1: Module Terminology
english
21
Type 8650
Configuration and Function
1.4.2. Configuration of a complete AirLINE Ex system (example)
Legend
1
Supply segment, left
2
Valve segment 44 mm,
4 valve functions
3
Valve segment 44 mm,
8 valve functions
4
Supply segment, middle
(Intermediate supply)
5
Valve segment 66 mm,
4 valve functions
6
Valve segment 66 mm,
1
2
3
4
5
6
7
8 valve functions
(not yet available)
7
Supply segment, right
Fig. 2: Configuration of a complete AirLINE Ex system (example)
1.4.3. Valve and Supply Segments - Type MK02
(module combination)
22
Valve segment (44 mm) Ventilscheibe (66 mm) Supply segment (44 mm)
Fig. 3: Valve and Supply Segments - Type MK02 (module combination)
english
Type 8650
Configuration and Function
1.4.4. Electronics - Typ ME04 (modular electronics)
Electronic module
Cover flap
Terminal module
Fig. 4: Electronics - Typ ME04 (modular electronics)
english
23
Type 8650
Configuration and Function
1.4.5. 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.
24
english
Type 8650
Configuration and Function
2. 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.
2.1. View of the Overall System
Fig. 6: View of the overall system (Siemens SIMATIC ET 200iSP and Bürkert AirLINE Ex Type 8650)
25
english
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
Station 2
Station ...
Station n
...
Interface module
IM152
Electronic module
I/O
1
2
3
...
Valve segment
Supply segment
left
Valve segment
Supply segment
AirLine Ex Type 8650
4
5
6
...
right
7
Electronic module
I/O
Electronic module
I/O
bus termination
module
26
Fig. 7: Functional representation of an AirLINE Ex system (example)
Legend
1
Supply segment, left
2
Valve segment 44 mm, 4 valve functions
3
Valve segment 44 mm, 8 valve functions
4
Supply segment, middle (Intermediate supply)
Bürkert components
AirLINE Ex
Siemens components
SIMATIC ET200iSP
5
6
7
english
Valve segment 66 mm, 4 valve functions
Valve segment 66 mm, 8 valve functions
(not yet available)
Supply segment, right
Type 8650
Configuration and Function of the
Modules
Configuration and Function of the Modules
Contents
1. SUPPLY SEGMENTS .......................................................................................................................................................................29
Configuration and function ............................................................................................................................................29
1.1.
Technical Data ......................................................................................................................................................................29
1.2.
Pneumatic Connections ..................................................................................................................................................32
1.3.
Displays ....................................................................................................................................................................................32
1.4.
Spare parts .............................................................................................................................................................................33
1.5.
VALVE SEGMENTS ..........................................................................................................................................................................34
2.
Configuration and Function ...........................................................................................................................................34
2.1.
Technical Data ......................................................................................................................................................................35
2.2.
Pneumatic Connections ..................................................................................................................................................38
2.3.
Displays ....................................................................................................................................................................................38
2.4.
Channel Assignment .........................................................................................................................................................39
2.5.
Diagnosis (Electronic Module) ....................................................................................................................................39
2.6.
Accessory ................................................................................................................................................................................39
2.7.
Spare parts .............................................................................................................................................................................40
2.8.
PNEUMATIC CONNECTOR MODULE .....................................................................................................................................41
3.
Configuration and Function ...........................................................................................................................................41
3.1.
Technical Data ......................................................................................................................................................................41
3.2.
Pneumatic Connections ..................................................................................................................................................42
3.3.
BASIC PNEUMATIC MODULE ....................................................................................................................................................43
4.
Configuration and Function ...........................................................................................................................................43
4.1.
Technical Data ......................................................................................................................................................................43
4.2.
Pneumatic Connections ..................................................................................................................................................45
4.3.
Accessory ................................................................................................................................................................................45
4.4.
TERMINAL MODULE .......................................................................................................................................................................46
5.
Configuration and Function ...........................................................................................................................................46
5.1.
english
27
Type 8650
Configuration and Function of the
Modules
5.2. Marking .....................................................................................................................................................................................46
Technical Data ......................................................................................................................................................................47
5.3.
ELECTRONIC MODULE .................................................................................................................................................................48
6.
Configuration and Function ...........................................................................................................................................48
6.1.
Marking .....................................................................................................................................................................................48
6.2.
Technical Data ......................................................................................................................................................................49
6.3.
Displays ....................................................................................................................................................................................50
6.4.
Diagnosis .................................................................................................................................................................................50
6.5.
Spare Parts .............................................................................................................................................................................50
6.6.
VALVE THAT CAN BE INTEGRATED .......................................................................................................................................51
7.
Pneumatic Valves Type 6524/6525
7.1.
(station width 11 mm) ......................................................................................................................................................52
Pneumatic Valves Types 6526/6527
7.2.
(station width 16.5 mm) ...................................................................................................................................................54
28
english
Type 8650
Configuration and Function of the
Modules
1. 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. They are electrically passive (all lines are looped through 1:1) and are not planned in the programs
for hardware configuration (e. g. Siemens Step7).
As an option, versions with an integrated mechanical pressure gauge to display operating pressure are available.
Fig. 1: Supply segment, left / middle / right (with / without pressure gauge)
1.2. Technical Data
Power consumption
Pneumatic connections
Dimensions
Material (Housing pneumatic)
Weight (without / with pressure gauge)
0 W (Module is electrically passive)
G 3/8“, G 1/8“ oder NPT 3/8“, NPT 1/8“
ca. 50 (station width 44) x 190 x 120 mm
PA, PBT, PC
480 g / 520 g
29
english
1.2.1. Overview
Type 8650
Configuration and Function of the
Modules
1
2
3
4
5
Fig. 2: Overview - Supply segments
6
7
8
9
10
9
Legend
Storage compartment for SD card
1
Hinged cover flap
2
Clamping bolt (2x) for system mounting
3
Pneumatic ports
4
Unlocking slide, only installed on right-hand
5
supply segments;
Pressure gauge (optional) for displaying
6
operating pressure
Shut-off slide
7
Power-Bus plug
8
Inclined tie rods (2x);
9
not installed on left-hand supply segments
Plug for communication bus
10
30
english
Type 8650
Configuration and Function of the
Modules
1.2.2. Dimensions
137,3
164,5
56
31,5
17
27,2
10,5
24
44
Connections optionally
screw socket G3/8 + G1/8,
NPT3/8 + NPT1/8
190
55,8
Fig. 3: Dimensions [mm] - Supply segments
31
english
1.3. Pneumatic Connections
Type 8650
Configuration and Function of the
Modules
1
2
3
Fig. 4: Pneumatic connections - Supply segment
1.4. Displays
Pressure gauge for displaying operating pressure
Position Marking Function
1 R/S-3/5 Exhaust air 3/8“ 3/8“
Control
2 X
3 P/1 Compressed air supply 3/8“ 3/8“
• EXT: Auxiliary control air
• INT: Pilot exhaust air
Version
G NPT
1/8“ 1/8“
32
Fig. 5: Operating pressure displayed on a pressure gauge of a supply segment
english
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)
Terminal module 44 mm, passive, with locking slide (for supply segment right)
Set with various spare parts for valve and module installation (seals, screws, etc.) 186 877
Pneumatic module Preassembled groups of pneumatic module and corresponding terminal
module
Ask your Bürkert representative which versions or which options are suitable for your requirements.
173 368
173 369
english
33
Type 8650
Configuration and Function of the
Modules
2. 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.
Two different versions (44/66 mm wide) for valves of different air capacity are available. The different valve functions can be freely combined.
Additional pneumatic functions can be integrated as options.
Valve segments are planned with the hardware configuration programs (e. g. Siemens Step7).
34
Fig. 6: Valve segment
Further information can be found in the chapter Configuration and Function of the Modules / Electronic
Module and Configuration and Function of the Modules / Basic Pneumatic Module.
english
Type 8650
Configuration and Function of the
Modules
2.2. Technical Data
11 mm Valves 16,5 mm Valves
Number of valve output ports 4 8 4 8
Dimensions [mm] 44 x 120 x 135 66 x 120 x 135
Weight with valves [g] 580 690 1080 n / a
Material
Housing
Pneumatic module
Current consumption [mA] 250 310 250 310
Power loss of the module [W] max. 2.9 max. 3.6 max. 2.9 max. 3.6
Status display 1 LED (red) for the module status
PBT, PC
PA
1 LED (green) per channel (valve function)
Pneumatic power data
Valve type 6524
3/2-way
Circuit functions
1)
C/D H 2x C C/D H
6525
5/2-way
6524
2x 3/2-way
6526
3/2-way
6527
5/2-way
Stacking sizes [mm] 11 16.5
Pneumatic connections
Plug-and-socket connections D45), D6, D1/4“
5)
D8 = (5/16“)
Threaded connections M5, M7 G 1/8“, NPT 1/8“
Orifice [mm] 4 6
2)
[l/min] 300 700
QNn
3)
Opening time
Closing time
Pressure range
with auxiliary control air
10 % [ms] 35 80
3)
10 % [ms] 45 90
4)
[bar] 2.5 ... 7 2 ... 8
6)
1 ... 7 1 ... 8
Power [W] 0.3
1)
C=NC (normally closed), D=NO (normally open)
2)
Flow rate QNn value air [l/min]: Measured at +20 °C, pressure 6 bar at the valve inlet and 1 bar pressure
difference
3)
Switching times [ms]: measured in accordance with ISO 12238
These values may differ, depending on the valve type and function (see operating manual, chapter
Configuration and Function of the Modules / Integrable Valves).
4)
Pressure data [bar]: Overpressure with respect to atmospheric pressure
5)
Connections variants on request
6)
Versions for vacuum on request
english
35
2.2.1. Overview Valve segments /
Station width 44 mm and 66 mm
1
2
7
Legend
Type 8650
Configuration and Function of the
Modules
3
1
2
11
3
4
5
8
4
12
5
6
9
5
10
6
7
8
9
10
11
12
Fig. 7: Overview - Valve segments (example: station width 66 mm)
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)
Valve number identification
36
english
Type 8650
Configuration and Function of the
Modules
2.2.2. Dimensions
137,27
164,5
28,5
12,5
27,2
5,5
11
3x11 (=33)
44
Connections optionally
Plug-in coupling D6
screw socket M5 + M7
190
56,6
Fig. 8: Dimensions [mm] - Valve segment (example: station width 44 mm)
english
37
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.
• Before working on pressure-operated devices, always depressurize and vent them.
• Mechanically secure actuators beforehand to prevent them from shifting.
Possible configuration of the service ports
Position Valves Double valves
3/2-way 5/2-way 2x 3/2-way
6524/6526 6525/6527 6524/6526
1 not used 2 2 (valve 12)
2 2 4 4 (valve 14)
1
2
Fig. 9: Possible configurations of the service ports (example: station width 44 mm)
2.4. Displays
LED for module status display
(function like Siemens modules)
LEDs to display the channel status
(also see the chapter Configuration and Function of the Module / Valve Segments /
Channel Assignment)
38
Fig. 10: Display elements of the valve segment
english
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
Bit 7 ... 0 7 6 5 4 3 2 1 0
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.
Valves
Valves
0 . . . 3
1 . . . 7
0 . . . 6
X X X X X X X 3 2 1 0
X X X 7 6 5 4 3 2 1 0
Service port assignment
(8-channel module)
(4-channel module)
(8-channel module)
Valves
Valves
1 3 5 7
0 2 4 6
Fig. 11: Valve assignment
2.6. Diagnosis (Electronic Module)
Group fault display: Yes, locally at the electronic module (red LED)
Diagnostic functions (can be read out using Profibus):
• Channel status diagnosis (channel open, channel short circuited)
• Individual switching cycle counter for each channel with warning limits for pilot valve and connected actuator
2.7. Accessory
Valve segment - Accessory Ident no.
Plug to block P-channel
(to build up several pressure levels or medium groups in an AirLINE Ex system type 8650)
655 068
39
english
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
Electronic module 4 channels 11mm (for valve segments 44 mm station width )
Electronic module 8 channels 11mm (for valve segments 44 mm station width)
Electronic module 4 channels 16.5 mm (for valve segments 66 mm station width)
Electronic module 8 channels 16.5 mm (for valve segments 66 mm station width)
Terminal module 44 mm, active (for valve segments 44 mm station width)
Terminal module 66 mm, active (for valve segments 66 mm station width)
Pneumatic modules
Ask your Bürkert representative which versions or which options are suitable for your requirements.
Preassembled groups of pneumatic module and corresponding terminal module
171 941
171 942
171 943
171 944
173 370
173 371
40
english
Type 8650
Configuration and Function of the
Modules
3. 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. 12: Pneumatic supply module (part of the supply segment)
3.2. Technical Data
Pneumatic connections G 3/8“, G 1/8“ or NPT 3/8“, NPT 1/8“
Dimensions
Material
Weight
ca. 50 (station width 44) x 70 x 75 mm
PA
150 g
english
41
3.2.1. Overview
Holes for clamping bolts (2x) for
system mounting
Pneumatic ports
Type 8650
Configuration and Function of the
Modules
Inclined tie rods
Fig. 13: Overview - Pneumatic supply module
3.3. Pneumatic Connections
Position Marking Function
1 R/S-3/5 Exhaust air 3/8“ 3/8“
1
2
3
Fig. 14: Pneumatic Connections - Pneumatic supply modules
2 X
3 P/1 Compressed air supply
Control
• EXT: Auxiliary control air
• INT: Pilot exhaust air
Version
G NPT
1/8“ 1/8“
3/8“ 3/8“
42
Supplementary information can be found in chapter Configuration and Function of the Modules / Supply
segments“.
english
Type 8650
Configuration and Function of the
Modules
4. 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. Technical Data
Pneumatic connections
of the valve segment for
Valves with station width 11 mm
Valves with station width 16.5 mm
Dimensions
Material
Weight
Plug-and-socket connection Ø 6 mm (4 mm, ¼“ on request);
Thread M5, M7
Plug-and-socket connection Ø 8 mm; Thread G 1/8“, NPT 1/8“
ca. 50 (station width 44 mm) x 70 x 55 mm
ca. 72 (station width 66 mm) x 70 x 55 mm
PA, PBT, PC
140 g (station width 44 mm)
180 g (station width 66 mm)
english
43
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, configuration of the service ports and optional use of check valves and / or P shut-offs.
Types Pneumatic MP13
Station width 11 mm 16 mm
Valve types 6524 - Ex-i
6525 - Ex-i
Port configuration
(basic pneumatic module)
Plug-and-socket connection Ø 4 mm
Plug-and-socket connection Ø 6 mm
Plug-and-socket connection Ø ¼“
Thread M5
Thread M7
check valves (optional) without check valve
check valve in R channel
check valve in R+S channel
1)
P shut-off (optional) with P shut-off
not available
6526 - Ex-i
6527 - Ex-i
Plug-and-socket connection Ø 8mm
( = 5/16“)
Thread G1/8“
Thread NPT 1/8“
1)
Only available for certain valve types and with functional limitations (see chapter Basic pneumatic modules with
integrated P shut-off)
4.2.2. Check Valve for Venting Ports
Because some applications require the use of a check valve, different versions are available:
• without a check valve
• check valve in R channel
• check valve in R+S channekl
4.2.3. Basic Pneumatic Modules with Integrated P Shut-off
General description
For the basic pneumatic modules MP 13 in the version for valve types 6524 and 6525, a P shut-off integrated into
the module is available as an option. With this option, a valve to be replaced can be exchanged under pressure
without having to depressurize the complete valve island or system. During valve exchange the open cross-section
is reduced mechanically so much, that there is only slight residual leakage.
Features and limitations
The use of the P shut-off results in certain limitations with respect to the operating data of the complete system:
• The flow rate of the valves, Type 6524/6525, is reduced to approx. 60 %.
44
• For proper operation avoid back-pressures in the exhaust lines R and S (see chapter Installation / 10.2. Connection of the Exhaust Air).
• The possible operating pressure range is between 5 and 7 bar.
• Since the pressure supply for the pilot valves is not shut off when using valves with external auxiliary control air,
the use of the P shut-off is possible only in conjunction with the valves internal control air in the limited pressure
range.
• The P shut-off can be combined with the integrated check valves.
english
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
1
2
3
4
5
1
check valve (optional)
2
6
7
8
9
Labeling of valve positions and installed
options
3
Inclined tie rods
4
Service ports
(assignment dependant on valve type)
5
Flange for valve
6
P shut-off (optional, only for certain versions)
7
X channel
8
R- & S channel
9
P channel
Fig. 16: Overview - Basic pneumatic module (Station width: 44 mm, with the options check valves and P shut-off)
4.3. Pneumatic Connections
Possible configuration of the service ports
Valves
Position
1
2
1 not used 2 2 (valve 12)
2 2 4 4 (valve 14)
3/2-way 5/2-way 2x 3/2-way
6524/6526 6525/6527 6524/6526
Double
valves
Fig. 17: Possible configuration of the service ports - basic pneumatic module
4.4. Accessory
Basic pneumatic module - Accessory Ident nr.
Plug to block P-channel
(to build up several pressure levels or medium groups in a AirLINE Ex system type 8650)
english
655 068
45
Type 8650
Configuration and Function of the
Modules
5. 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. 18: Terminal module
The EC type-examination certificate can be found in the Annex to this operating manual.
5.2. Marking
46
Fig. 19: General labelling Fig. 20: Identification and serial number Fig. 21: Location of
the marking
english
Type 8650
Configuration and Function of the
Modules
5.3. Technical Data
Ident no. of the module
Application Supply segment Valve segment
Dimensions [mm] 55 (station width 44 mm) x 190 x 45 66 x 190 x 45
Weight [g] 150 210
Housing material PBT, PC
Power loss of the module [W] 0 (The module contains no electrically active components)
Type of protection II 2 G Ex e [ia/ib] IIC T4
173 368 173 369 173 370 173 371
left and middle right 44 mm 66 mm
5.3.1. Overview
1
2
2
5
3
4
Legend
1
Hinge contour for the electronic module
2
Plug connector for the power bus
3
Plug for the electronic module
(not with Identification No. 173 678 and
173 369)
4
Plug connector for the data bus
5
Abutment for the electronic module
6
Fig. 22: Overview - Terminal module (Version: station width 44 / 66 mm)
6
Unlocking slide
(only with Identification No. 173 369)
english
47
Type 8650
Configuration and Function of the
Modules
6. 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
hardware configuration (e. g. Siemens Step7).
During operations, the electronic modules can be exchanged individually (not more than one at a time).
Fig. 23: Electronic module
• For 8-channel modules, have a look at the chapter, Commissioning / Non-cyclical Parameters of AirLINE
Ex-Module / The Number of Simultaneously Switchable Pilot Valves.
be planned accordingly in the programs for the
48
• The type examination certificate can be found in the Annex to this operating manual.
6.2. Marking
Fig. 24: General labelling Fig. 25: Identification and serial
number
Fig. 26: Location of the
marking
english
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 4 8 4 8
Dimensions [mm] 44 x 120 x 135 (for 11 mm valve) 66 x 120 x 135 (for 16.5 mm
valve)
Weight [g] 230 250 270 290
Material (Housing) PBT, PC
1)
Current consumption
Power loss of the module [W] max. 2.9 max. 3.6 max. 2.9 max. 3.6
Power loss in the event of a system
error [W]
Status displays LED (red) for the module status
Type of protection II 2 G Ex ib IIC T4
[mA] 250 310 250 310
max. 4.2
LED (green) per channel (valve function)
1)
These values must be taken into account when calculating the max. total power consumption of the station
(see also Table 3-4 in the Siemens handbook ET 200 iSP).
6.3.1. Overview
Electronic module / station width 44 mm
1
2
3
4
Fig. 27: Overview - Electronic module (Version station width 44 mm)
5
Legend
1
LED (red) for module status display
2
LEDs (green) for channel status display
3
Hinged cover flap
4
Plug for connection of the valves
5
Slip-in label strip
english
49
6.4. Displays
Type 8650
Configuration and Function of the
Modules
Legend
1
2
Fig. 28: Operating / display elements of the electronic module
1 2LED for module status display
(function as for Siemens modules)
LEDs showing channel status
(also see the chapter Configuration and
Function of the Module / V
Assignment)
alve Segments / Channel
6.5. Diagnosis
Group fault display: Yes, locally at the electronic module (red LED)
Diagnostic functions (can be read out using Profibus):
• Channel status diagnosis (channel open, channel short circuited)
• Individual switching cycle counter for each channel with warning limits for pilot valve and connected actuator
50
6.6. Spare Parts
Electronic module - Spare parts Ident no.
Cover flap for 44 mm wide modules
Cover flap for 66 mm wide modules
Label strip for electronic modules
667 898
667 899
667 917
english
Type 8650
Configuration and Function of the
Modules
7. VALVE THAT CAN BE INTEGRATED
Pilot Control
The pilot valves employed in the AirLINE Ex system essentially consist of two components:
• Component 1: the pilot control in protection class Ex-i.
The pilot control converts the supplied electrical energy into a pneumatic switching signal.
The EC-Type Examination Certificates for the pilot controls can be found in the Appendix of these operating instructions.
• Component 2: the amplifier.
The amplifier is a purely pneumatic element that increases the relatively low flow rate of the pilot control system
to the level necessary for the application.
Because, from an electrical point of view, only the pilot control is important, much information is based upon this,
e. g. boost time or approval-related facts.
The pilot control system is an independent module (e. g. Type 6104). In complete valves (e. g. Type 6525), it may
already be integrated.
Valves with auxiliary control air
When using valves in the auxiliary control air version, the exhaust air of the pilot control valve escapes into the
environment.
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
51
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. Normally, the valves are equipped with an emergency manual override (versions without this feature are
available).
Fig. 29: Pneumatic valves type 6524 and type 6525
7.1.2. Technical Data
Housing material PA (polyamide)
Gasket material NBR
Media
Line connection
Pneumatic module
Manual override
Rated power
Rated operating mode
Electrical connection at the
valve
Installation
dry compressed air, oiled or oil-free
neutral gases (5 μm filter recommended)
Flange for MP13
Type MP13 with thread M5, M7 or
Type MP13 with plug connector Ø 6 mm, (Ø 4 mm, Ø ¼“ on request)
yes (alternative versions without)
0.3 W
100 % continuous operation
rectangular plug RM 5.08 mm
with 2 screws M2 x 20
52
english
2
2
4
Type 8650
Configuration and Function of the
Modules
7.1.3. Ordering Chart
Switching
times
Description
C = NC (normally closed)
12
1
10
3
3/2-way valve, pilot controlled, currentfree, outlet port 2 relieved
2 x C = NC (normally closed)
12
2
10
1
3
14
4
10
1
3
3/2-way valve, pilot controlled,
current-free, outlet port 2 relieved
D = NO (normally open)
10
1
12
3
QNn-
Ident no.
value
air
Orifice
[l/min] [W] [bar] [ms] [ms]
Rated power
Pressure range
Opening
Closing
4 300 0.3 2.5 ... 7 35 45 184 766
186 832
0.3 1... 8
1)
35 45 186 831
186 833
0.3 1 ... 7 35 45 186 835
3)
4 300 2 x 0.3 2.5 ... 7 20
1)
2 x 0.3 1 ... 8
20
25 182 086
3)
25 182 088
4 300 0.3 2.5 ... 7 35 45 184 767
184 768
2)
1)
1, 2)
1)
1)
2)
2 x 3/2-way valve, pilot controlled,
current-free,
outlet port 2 and 4 relieved
H
2
14
5
12
3
1
4 300 0.3 2.5 ... 7 35 45 184 769
184 773
0.3 1 ... 7 35 45 186 834
2)
1)
5/2-way valve, pilot controlled,
current-free,
outlet port 1 with outlet port 2,
outlet port 4 vented
1)
Version with auxiliary control air
2)
Without manual override
3
) Please observe the information for the characteristics of the 8-channel modules in the chapter “Start-up”,
section “Acyclic parameters of the AirLINE Ex modules”!
5/3-way function with locked mid-position:
This function can be implemented with the delockable double check valve, Type 0498 (control is by 2x 3/2-way
function).
53
english
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.
Normally, the pilot control valves are equipped with an emergency manual override (versions without this feature
are available)
54
Fig. 30: Pneumatic valves type 6526 and type 6527
7.2.2. Technical Data
Housing material PA (polyamide)
Gasket material NBR
Media
Line connection
Pneumatic module
Manual override
Rated power
Rated operating mode
Electrical connection at the valve
Installation
dry compressed air, oiled or oil-free
neutral gases (10 μm filter recommended)
Flange for MP13
Type MP13 with G 1/8“, NPT 1/8“ or
Type MP13 with plug-and-socket connection Ø 8 mm
yes (alternative versions without)
0.3 W
100 % continuous operation
rectangular plug RM 5.08 mm
with 2 screws M3 x 30
english
4
Type 8650
Configuration and Function of the
Modules
7.2.3. Ordering Chart
Description
QNnvalue
air
Switching
times
Ident no.
C = NC (normally closed)
12
2
10
3
1
3/2-way valve, pilot controlled, current-free,
outlet port 2 relieved
D = NO (normally open)
2
10
1
12
3
3/2-way valve, pilot controlled, current-free,
outlet port 2 pressurized
H
2
14
5
12
3
1
5/2-way valve, pilot controlled, current-free,
outlet port 1 with outlet port 2,
outlet port 4 vented
1)
Version with auxiliary control air
2)
Without manual override
Rated power
Orifice
[l/min] [W] [bar] [ms] [ms]
6 700 0.3
0.3
0.3
6 700 0.3
6 700 0.3
0.3
Pressure range
2 ... 10
-0,9 ... 8
1 ... 8
2 ... 8
2 ... 8
1 ... 8
Opening
Closing
80 90 175 634
175 674
80 90 175 673
175 723
80 90 175 731
80 90 175 725
175 726
80 90 175 727
175 728
80 90 175 729
2)
1)
1,2)
1)
2)
2)
1)
55
english
Type 8650
Configuration and Function of the
Modules
56
english
Type 8650
Installation
Installation
Contents
1. SAFETY INSTRUCTIONS ..............................................................................................................................................................59
INSTALLATION INSTRUCTIONS ...............................................................................................................................................61
2.
Unpacking pre-assembled systems .........................................................................................................................61
2.1.
Installation Tools and Torques .....................................................................................................................................61
2.2.
Position of the Assemblies ............................................................................................................................................62
2.3.
INSTALLATION ON S7 PROFILE RAIL
3.
(PRE-ASSEMBLED SYSTEM) .....................................................................................................................................................63
Removing a System from a Profile Rail .................................................................................................................63
3.1.
Installation/Removal of the ET 200iSP-Modules .............................................................................................64
3.2.
INSTALLATION IN THE CONTROL CABINET .....................................................................................................................65
4.
CONFIGURATION, CONVERSION AND
5.
EXPANSION OF AN EXISTING SYSTEM WITH
INDIVIDUAL SEGMENTS ..............................................................................................................................................................66
System Configuration .....................................................................................................................................................66
5.1.
Conversion and Expansion ............................................................................................................................................67
5.2.
Assembly .................................................................................................................................................................................67
5.3.
REMOVAL / INSTALLATION OF INDIVIDUAL SEGMENTS .........................................................................................68
6.
Removal ...................................................................................................................................................................................68
6.1.
Installation ..............................................................................................................................................................................69
6.2.
REMOVAL / INSTALLATION OF THE COVER FLAPS ....................................................................................................70
7.
Installation ..............................................................................................................................................................................70
7.1.
Removal ...................................................................................................................................................................................70
7.2.
REPLACING A TERMINAL OR PNEUMATIC MODULE ..................................................................................................71
8.
REPLACING A VALVE .....................................................................................................................................................................72
9.
Installation instructions ...................................................................................................................................................72
9.1.
english
57
Type 8650
Installation
9.2. Installation ..............................................................................................................................................................................72
CONNECTION OF THE AIR INLET AND EXHAUST LINES .........................................................................................73
10.
Connection of the Pressure Supply ..........................................................................................................................73
10.1.
Connection of the Exhaust Air .....................................................................................................................................73
10.2.
Pilot Exhaust Air / Auxiliary Control Air ..................................................................................................................73
10.3.
Plug to Block P-channel ..................................................................................................................................................74
10.4.
58
english
Type 8650
Installation
1. 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!
• Observe applicable accident prevention and safety regulations for electrical equipment!
WARNING!
Risk of injury from improper installation!
• Installation may be carried out by authorised technicians only and with the appropriate tools!
Risk of injury from unintentional activation of the system and an uncontrolled restart!
• Secure system from unintentional activation.
• Following assembly, ensure a controlled restart.
CAUTION!
Escape of medium and malfunction!
If the seals are seated incorrectly, leaks and malfunctions may occur due to pressure losses.
• Ensure that the seals are seated correctly in the area of the electronics and pneumatics.
Short circuit, malfunction
The electrical connection requires exact contacting.
• Do not bend contacts.
• If connections are damaged or bent, replace the affected components.
• Do not switch on the system unless the components are in perfect working order.
english
59
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). Contact
with electrostatically charged persons or objects is hazardous to these components. In the worst case scenario,
they will be destroyed immediately or will fail after start-up.
• Observe the requirements in accordance with EN 61340-5-1 and 5-2 to minimise or avoid the possibility of
damage caused by sudden electrostatic discharge!
• Also ensure that you do not touch electronic components when the power supply voltage is present!
Restrictions!
Observe the applicable restrictions for the conversion / expansion of systems.
• Read about this in the chapter “Structure and function of the AirLINE Ex system”, section “Maximum
system expansion”).
60
english
Type 8650
Installation
2. 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.
• If moving from a cold to a warm environment, do not install the system until it has adjusted itself to the
ambient temperature in order to prevent condensation!
2.1. Unpacking pre-assembled systems
NOTE!
Important – take module correctly out of the packaging!
To prevent damage to the pre-assembled system when taking it out of the packaging, observe the following:
→ Take hold of the system by the pneumatic connection modules and take it out of the packaging (see figure
“Holding points”).
Holding points
Fig. 1: Holding points for removal of pre-assembled systems
2.2. Installation Tools and Torques
Application Type and size of the tool Torque
Actuation of the locking elements Plain screwdriver, size 5 Screw the clamping bolts onto the supply modules,
screw fitting of terminal module - pneumatic module
Installation / removal
of the valves with 11 mm station width
Installation / removal
of the valves with 16.5 mm station width
Tightening of the inclined tie rods Allen key (3 mm) 0.6 Nm
Plain screwdriver, size 7 1.3 ... 1.5 Nm
Cross-head screwdriver
Size 0
Cross-head screwdriver
Size 1
english
0.2 Nm
0.3 Nm
61
2.3. Position of the Assemblies
Clamping bolts
Screws for mounting the valves
Type 8650
Installation
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
62
Inclined tie rod pocket
Fig. 4: Two inclined tie rod pockets of one segment
english
Type 8650
Installation
3. 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).
→ Hook the system in the required position on the upper edge of the profile rail and swivel open.
→ Tighten all clamping bolts (1) by turning them clockwise (stipulated torque 1.5 Nm).
Fig. 5: Mounting on to the profile rail
63
english
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
→ Using a cross-head screwdriver, remove the unlocking slide (2) from the supply segment. This will release the
engaged module.
→ Push module to the right.
1
1
Clamping bolts 1
Unlocking slide 2
Fig. 6: Clamping bolts / Unlocking slide
64
english
Type 8650
Installation
4. 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.
Distance to the control cabinet wall
60 mm
Fig. 7: Distance to top of the control cabinet wall
english
65
Type 8650
Installation
5. 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)
→ Other modules can be installed on the right in the same way.
→ Finally, tighten all clamping bolts (1) by turning them clockwise (stipulated torque 1.5 Nm).
66
1
Clamping bolts
Fig. 8: Adding segments
english
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.
→ When a segment is added, first hook it into the upper edge of the profile rail.
→ Swivel in the segment and push it to the left up to the existing subsystem.
Fig. 9: Dock the segment to the system
5.3. Assembly
→ Reassemble the system in reverse order.
3
Inclined tie rods
english
67
Type 8650
Installation
6. 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. 10: Removal / installation of a supply segment
Valve segments
→ Remove valves and any protective caps from the plug-in contacts (either depressurized or all affected loca-
tions with P-shutoff).
→ Release the electronic module by actuating the locking element in the direction of the arrow and swivel out the
module (see figure: Removal / installation of the valve segment).
entriegeln
68
Fig. 11: Removal / installation of a valve segment
english
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.
→ Valve segment
→ Hook electronic module into the terminal module.
→ Actuate locking element in the direction of the arrow and swivel in the module all the way.
→ Screw on valves (either depressurized or all affected locations with P-shutoff).
Fig. 12: Hose connection of the pressure gauge module
Hose connection
english
69
Type 8650
Installation
7. 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).
Fig. 14: Engaging the cover flap
70
The cover flaps have no effect on the function of the system and can be omitted or removed if required.
english
Type 8650
Installation
8. REPLACING A TERMINAL OR PNEUMATIC MODULE
For installation of the terminal-pneumatic module subassembly, the modules are aligned to each other during production. 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 – fluidic ducts) interlock without difficulty. Otherwise, proceed as follows:
→ Take the subassembly out of the system again.
→ Slacken the three screws on the back of the terminal module.
→ Re-align the pneumatic module on the terminal module.
→ Tighten the three screws again.
Instructions for conversion or expansion of the system.
Grease sealing rings!
To facilitate installation and to prevent damage, the sealing rings of the pneumatic modules should be
greased during the installation work (e.g. with Centoplex 2 from Klüber Lubrication).
S
erial numbers and identification number of the system lose their validity!
During conversion or expansion work the serial and identification numbers of the pre-assembled systems
lose their validity.
In this case we recommend removing the identification plate and affixing a suitable note to the device.
english
71
Type 8650
Installation
9. 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.
• If there is a fairly large volume on the actuator side, provide a shut-off option for the service ports to prevent
the actuator from moving.
9.1. 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.
If the valves mounted on modules with P-shutoff are changed under pressure, only a maximum of four valves may
be removed at the same time.
When the valve is being removed, a relatively large amount of air is initially released, as the P-shutoff cannot close
until the required pressure difference is reached. However, as the automatic shut-off considerably reduces the
exhaust air, only a low residual leakage remains when the P-shutoff is closed.
9.2. Installation
→ When installing the valve, ensure that the seal has been inserted correctly.
→ Tighten the valve to the tightening torques indicated in the operating instructions.
→ When installing the valve, ensure that the service ports are also pressurized in the corresponding rest position
of the valve until it switches over. As a result, a connected actuator can perform a movement according to the
pressurization.
→ Ensure that these actuator movements cannot cause any damage or unwanted operations in the equipment.
72
english
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.
In larger AirLINE Ex systems and high-consumption applications the supply should be connected for the right
and left supply segment, optionally also via additional supply segments in the middle
→ Seal the unused P/1 connections with a plug.
10.2. Connection of the Exhaust Air
→ Connect the exhaust air to the R/S 3/5 connections on the connection modules.
The exhaust air should be conveyed along the largest possible lines and, if required, via silencers at high flow
rates in order to prevent back pressures.
The exhaust air should be connected for the right and left supply segment, optionally also via additional supply
segments in the middle.
10.3. Pilot Exhaust Air / Auxiliary Control Air
Depending on which valves you operate on the AirLINE Ex system, port X is used as follows:
10.3.1. Standard Valves
In this case the exhaust air from the pilot control valves is exhaust separately from the R/S 3/5 port to port X. This
avoids problems in the event that higher back-pressures occur in the R/S 3/5 channel.
This should be done using the largest possible lines if necessary with mufflers for high flow rates in order to avoid
back-pressure.
english
73
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. This allows different pressure levels or different media to be used in the same
system.
With pre-assembled systems, the position for the partition is indicated on the appropriate pneumatic module.
74
english
Type 8650
Commissioning
Commissioning
Contents
1. SAFETY INSTRUCTIONS ..............................................................................................................................................................76
INITIALIZATION ..................................................................................................................................................................................77
2.
Communication Connection .........................................................................................................................................77
2.1.
Configuration of the Hardware Using Siemens Step7 ..................................................................................77
2.2.
Access to the Acyclic Parameters with the Siemens PDM ..........................................................................81
2.3.
Example with Two Different Function Modules ..................................................................................................86
2.4.
Acyclic Parameters of the AirLINE Ex Modules ..................................................................................................89
2.5.
Use of “HSP” and “SUP” under Siemens Step7 / PCS7 ...............................................................................93
2.6.
Software Update Package (SUP) for PCS7 ..........................................................................................................97
2.7.
SD CARD / SYSTEM SERIALIZATION DATA ......................................................................................................................99
3.
Serialization Data Record ...............................................................................................................................................99
3.1.
english
75
Type 8650
Commissioning
1. 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!
• Observe applicable accident prevention and safety regulations for electrical equipment!
WARNING!
Risk of injury from improper operation!
Improper operation may result in injuries as well as damage to the device and the area around it.
• Before start-up, ensure that the operating personnel are familiar with and completely understand the contents
of the operating instructions.
• Observe the safety instructions and intended use.
• Only adequately trained personnel may operate the equipment/the device.
Risk of injury from unintentional activation of the system and an uncontrolled restart!
• Secure system from unintentional activation.
• Following assembly, ensure a controlled restart.
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). Contact
with electrostatically charged persons or objects is hazardous to these components. In the worst case scenario,
they will be destroyed immediately or will fail after start-up.
76
• Observe the requirements in accordance with EN 61340-5-1 and 5-2 to minimise or avoid the possibility of
damage caused by sudden electrostatic discharge!
• Also ensure that you do not touch electronic components when the power supply voltage is present!
english
Type 8650
Commissioning
2. 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.
Many PROFIBUS masters (controllers) require a program that describes the hardware configuration (e. g.
Siemens Step7 for the S7 controllers). These programs require the equipment master data file (GSD file) that
contains the equipment-specific information.
For the use of acyclic services, an EDD file is also required. Programs such as the Siemens PDM permit access
to extensive additional information (I&M data, switching cycle counters, etc.).
A current version of both of these files is available on CD or on the internet.
Because these files for communicability are taken care of by Siemens, when you look on the Bürkert homepage
you will not find the information directly. Instead, you will find a link leading you to the appropriate current
versions.
Siemens Step7 & Siemens PCS7:
If Siemens Step7 is used, an alternative to the method stated above is the option of linking AirLINE Ex by means
of a Hardware Support Package (“HSP”) or, analogously, by means of a Software Update Package (“SUP”) in
Siemens PCS7.
This method has the following advantages:
The acyclic functions of AirLINE Ex can be parameterized directly in HW config.
Extended functions of the ET200iSP can be used (e.g. redundancy).
Hardware-specific diagnoses can be displayed in PCS7.
You can download “HSP” and “SUP” from the Bürkert homepage (under Type 8650 software) or receive them
directly from Bürkert.
Supply segments are electrically passive (logically transparent) and are not taken into consideration in the
configuration tools.
2.2. Configuration of the Hardware Using Siemens Step7
A software program such as Step 7 from Siemens is necessary for the configuration of the bus master.
Use the program Step7 from Siemens in version 5.3 or higher to ensure hardware compatibility.
english
77
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.
78
english
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
79
english
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!
80
english
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.
→ When the S7 Manager has started, select “Extras / SIMATIC PDM / Manage device catalog” via the menu
bar.
→ Using “Search”, indicate the source directory in which the EDDL file is stored. Then select the device type ET
200iSP and acknowledge with OK.
The data of the ET 200iSP system is now included in the device catalog.
The following screenshots indicate how a new station is structured in the PDM.
→ To insert a new object, select the object type
Fig. 4: Selecting a new object
81
english
→ Insert the new object.
Type 8650
Commissioning
Fig. 5: Inserting a new object
→ To insert a new device, first select the device type.
82
Fig. 6: Selection of a new device
english
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
83
english
→ Define the desired number of identical modules.
Type 8650
Commissioning
Fig. 9: Defining the number of identical modules
→ Select the module type via the menu “Allocate”.
84
Fig. 10: Selecting the module type
english
Type 8650
Commissioning
→ Terminate the module selection with OK.
Fig. 11: Terminating the module selection
english
85
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.
86
Fig. 13: Opening the station
english
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. 15: Parameters of the interface module and overview of the station configuration
87
english
Type 8650
Commissioning
Fig. 16: Parameters of an AirLINE Ex pneumatic module
88
english
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
4 DO Bürkert 11 mm
PDM_ConfigurationTool 1: PDM - Initial value
# Identification
# # Operating unit
TAG 4 DO Bürkert 11 mm
Description Initial value
# # Device
Manufacturer BUERKERT
Device designation BUERKERT-ID00171941
Device serial number 00001234
Hardware revision 0
Software revision A 0.0.4
Static revisions no. 3
Installation date - Initial value
Unit Status
-
-
-
-
# Module
Slot number 14
Module type 4 DO Bürkert 11 mm
# 4 DO Bürkert 11 mm
Data format S7
Module type 4 DO Bürkert 11 mm
(BUERKERT-ID00171941)
Enable switching cycle counter diagnosis enable Initial value
Switching cycle counter warning limit 1000000
Number of simultaneously switchable pilot
valves
Boost time for the pilot valves 300
4
- -
Initial value
-
-
-
89
english
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.
2.5.3. Functions of the parameters
• Enable switching cycle counter diagnosis (read / write)
Defines whether a diagnosis message is to be generated when the warning limit for a pilot valve switching
cycle counter is exceeded.
• Switching cycle counter warning limit(read / write)
Defines the value of the pilot valve switching cycle counter at which a diagnosis message is to be generated as
a warning.
• Number of simultaneously switchable pilot valves – only relevant for the 8-channel module – (read). Indi-
cates how many pilot valves can be simultaneously activated (also see boost time) (depending on the type and
amount of pilot valves, the total amount of current at actuation might be higher than the maximum the electronic
module can provide).
With the 8-channel module, valves 0 to 3 and/or 4 to 7 each make up a group.
If more than 4 valves are activated at once (including the previously activated valve), the following
might occur:
• Situation 1: No valves are activated in group 0 to 3. Then, the co-activated valves of group 4 to 7 are
immediately activated.
• Situation 2: Additional valves of group 0 to 3 are activated. Then the co-activated valves of group 4
to 7 are only activated after the boost time has elapsed.
• Boost time for the pilot valves (read / write)
When switching on, the pilot valves receive a higher current. At the end of the boost time, the current is
reduced in order to minimize the power loss and to optimize the current balance in the electronic module.
Modul e Value „Boost time“
00171941 (4 channels 11mm) 500
00171942 (8 channels 11mm) 300
00171943 (4 channels 16.5mm) 800
00171944 (8 channels 16.5mm) 300
• Date of the last switching cycle counter reset (read only)
Indicates the last reset of the actuator switching cycle counter.
• Enable switching cycle counter diagnosis (read / write)
Defines whether a diagnosis message is to be generated when the warning limit for the switching cycle counter
is exceeded.
90
english
Type 8650
Commissioning
2.5.4. Parameters that can be displayed or modified by channels
Name Value
# # Channel 0
Channel enable enable
Alternative value 0
# # # Pilot valve
Switching cycle counter reset inactive
ID number of the pilot valve 0 Initial value
Current number of the switching cycles 74766 -
# # # Actuator
Enable switching cycle counter diagnosis enable
Switching cycle counter warning limit 0
Switching cycle counter reset inactive
Date of the last switching cycle counter reset Current number of switching cycles 74766 -
# # # Diagnosis
Group diagnosis
Broken wire
Short circuit
barred
Unit Status
- Initial valueBehavior at CPU/Master-STOP switching alternative value
Initial value
-
-
- -
Initial value
2.5.5. Functions of the channel parameter (general)
• Enable channel (read / write)
Defines whether or not the channel is enabled for use.
• Behavior at CPU/Master STOP (read / write)
Defines which value the channel assumes when the master is set to STOP.
• Alternative values (read / write)
Defines the alternative value for the case „Switch alternative value at master STOP“.
2.5.6. Functions of the parameter actuator (that are connected to
the pilot valve (of this channel)
• Switching cycle counter reset
Initiates a reset of the actuator switching cycle counter.
• ID number of the pilot valve (read / write)
You can enter the ID number of the pilot valve used here. This makes it quickly available if replacement or preventive maintenance are forthcoming.
• Current number of switching cycles (read only)
Indicates how many switching cycles the pilot valve has performed since the last counter reset.
91
english
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.
• Switching cycle counter reset
Triggers a reset of the corresponding switching cycle counter.
• Date of the last switching cycle counter reset (read only)
Indicates when the switching cycle counter of the actuator was reset the last time.
• Current number of switching cycles (read only)
Indicates how many switching cycles the actuator has performed since the last reset of the counter.
2.5.8. Functions of the diagnosis parameter
• Group diagnosis (read / write)
Indicates whether group diagnostic messages should be generated.
• Broken wire (read / write)
Indicates whether a diagnosis message is generated when an output port is open.
• Short circuit (read / write)
Indicates whether a diagnosis message is generated in the event of a short circuit of the output port.
2.5.9. Why separate switching cycle counters for pilot valve and
actuator?
Each electronic module provides two independent switching cycle counters (1x for pilot valve, 1x for actuator) for
each channel, as the two devices (pilot valve on the island, actuator in the field) can also be serviced or replaced
independently of each other.
Example:
On a process valve in the field the diaphragm and stuffing box packing are replaced in line with preventive
maintenance.
• Actuator switching cycle counter can be reset;
• However, the pilot valve and its current number of switching cycles remain unaffected.
92
english
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:
→ The “hsp2033.zip” file is saved and extracted in a directory of your choice.
→ Open “HW config” in STEP 7.
→ Select the “Install extras / HW updates” menu command
→ In the subsequent dialog select and execute “Copy data carrier” (see screenshots “Installing HW updates”
step 1-2).
Fig. 17: Installing HW updates, step 1
93
english
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.
94
Fig. 19: Installing HW updates, step 3
english
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
95
english
Changing the parameters
→ The parameters of a module can be changed via its “Object properties”.
Type 8650
Commissioning
Fig. 21: Changing the parameters of a module
Currently the settings of the switching cycle counters can be changed via SIMATIC PDM only.
96
english
Type 8650
Commissioning
2.7. Software Update Package (SUP) for PCS7
By installing the Software Update Package for AirLINE EX 8560, the full functional range of the Decentralized
Peripheral ET 200iSP can also be used in PCS7 (from V6.1 SP1).
2.7.1. Installation of the HSP2033:
→ The “Buerkert_Pack.zip” file is saved and extracted in a directory of your choice.
→ Prior to setup, end all SIMATIC applications.
→ Start the “Buerkert_ET200iSP_SM.exe” file by double clicking and follow the instructions for setup.
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.
english
97
Type 8650
Commissioning
The installation of the Software Update Package is recorded and can be checked under Start > SIMATIC > Information >“- Installed software”.
Fig. 23: SIMATIC Software
98
english
Type 8650
Commissioning
3. 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 – serial number of all valves – serial number of all terminal modules)
The structure of a serialization data record is provided as an example in the chapter; Commissioning /
SD-card / System Serialization Data / Serialization Data Record
The data record is on an sd-card, which is located in the storage compartment of the pressure gauge module.
The data is in common .xml format and can be easily worked on (i.e. for your facilities records) using a variety of
tools (e.g. a simple text editor, browsers or a spreadsheet program).
3.1. Serialization Data Record
The following is an example of the structure of a serialization data record.
english
99
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
Serial number of the last valve
ID number of the first terminal module
Serial number of the first terminal module
Data of the valves 2 and 3 hidden
100
ID number of the last terminal module
Serial number of the last terminal module
Example of a serialization data record
english
Loading...