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.
Type 8650 Contents Electrical and Pneumatic Automation System Type 8650 GENERAL INFORMATION AND SAFETY INSTRUCTIONS.....................................................................................................5 1. Operating Instructions.........................................................................................................................................................6 2. Intended Use...............................................................................................
Type 8650 Contents 7. Removal / Installation of the Cover flaps...............................................................................................................70 8. Replacing a terminal or pneumatic module..........................................................................................................71 9. Replacing a valve.............................................................................................................................................................
Type 8650 Allgemeine Informationen Sicherheitshinweise General Information and Safety Instructions Contents 1. OPERATING INSTRUCTIONS.........................................................................................................................................................6 1.1. 2. Symbols.......................................................................................................................................................................................6 INTENDED USE.......
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.
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.
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.
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).
Type 8650 Allgemeine Informationen Sicherheitshinweise 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 Contact addresses can be found on the final pages of these operating instructions. And also on the internet at: www.buerkert.com 4.2.
Type 8650 System Description System Description Contents 1. 2. 3. GENERAL DESCRIPTION..............................................................................................................................................................12 1.1. Product Description............................................................................................................................................................12 1.2. Characteristic Features and Benefits...................................
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.
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.
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).
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”.
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 Dimensions 2.2.1. The Complete System 27,7 12,5 28,5 12,5 28,5 56 31,5 17 165 2.2.
Type 8650 System Description 3. SYSTEM ACCESSORIES System accessories Ident-no. Function plates for flange pattern 6524 / 6525.
Type 8650 System Description 1) T hese 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.
Type 8650 Configuration and Function Configuration and Function Contents 1. 2. CONFIGURATION..............................................................................................................................................................................20 1.1. Maximum System Configuration.................................................................................................................................20 1.2. Configurator.......................................................
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.
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.
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 1 2 3 6 Valve segment 66 mm, 8 valve functions (not yet available) 4 5 Fig. 2: 7 Configuration of a complete AirLINE Ex system (example) 1.4.3.
Type 8650 Configuration and Function 1.4.4. Electronics - Typ ME04 (modular electronics) Electronic module Cover flap Terminal module Fig.
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.
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. Fig.
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 ... ... Electronic module I/O Electronic module I/O bus termination module Supply segment right Valve segment ... Valve segment PowerSupplyModul Supply segment left Interface module IM152 Electronic module I/O Station 1 AirLine Ex Type 8650. Station 2 Station ... Station n 1 2 3 4 5 Fig.
Type 8650 Configuration and Function of the Modules Configuration and Function of the Modules Contents 1. 2. 3. 4. 5. SUPPLY SEGMENTS........................................................................................................................................................................29 1.1. Configuration and function.............................................................................................................................................29 1.2. Technical Data.....
Type 8650 Configuration and Function of the Modules 6. 7. 5.2. Marking......................................................................................................................................................................................46 5.3. Technical Data.......................................................................................................................................................................47 ELECTRONIC MODULE............................................
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).
Type 8650 Configuration and Function of the Modules 1.2.1. Overview 1 6 1 Storage compartment for SD card 2 Hinged cover flap 3 Clamping bolt (2x) for system mounting 7 4 Pneumatic ports 8 5 Unlocking slide, only installed on right-hand supply segments; 10 6 Pressure gauge (optional) for displaying operating pressure 9 7 Shut-off slide 8 Power-Bus plug 9 Inclined tie rods (2x); not installed on left-hand supply segments 2 3 Legend 9 4 5 10 Plug for communication bus Fig.
Type 8650 Configuration and Function of the Modules Dimensions 31,5 27,2 17 56 164,5 137,3 1.2.2. 10,5 24 44 190 Connections optionally screw socket G3/8 + G1/8, NPT3/8 + NPT1/8 55,8 Fig.
Type 8650 Configuration and Function of the Modules 1.3. Pneumatic Connections Position Marking 1 Function Exhaust air 3/8“ 3/8“ 1/8“ X Control • EXT: Auxiliary control air • INT: Pilot exhaust air 1/8“ 2 3 P/1 Compressed air supply 3/8“ 3/8“ Pneumatic connections - Supply segment Displays Pressure gauge for displaying operating pressure Fig. 5: Operating pressure displayed on a pressure gauge of a supply segment 32 english NPT R/S-3/5 3 1.4. G 1 2 Fig.
Type 8650 Configuration and Function of the Modules 1.5. Spare parts Supply segment - Spare parts Ident no. Cover flap for 44 mm wide modules 667 898 Pressure gauge module 174 010 Blank module (without pressure gauge) 174 009 Terminal module, 44 mm, passive, without locking slide (for supply segment left and center) 173 368 Terminal module 44 mm, passive, with locking slide (for supply segment right) 173 369 Set with various spare parts for valve and module installation (seals, screws, etc.
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.
Type 8650 Configuration and Function of the Modules 2.2. Technical Data 11 mm Valves Number of valve output ports 4 Dimensions [mm] 44 x 120 x 135 Weight with valves [g] 580 Material Housing Pneumatic module PBT, PC PA Current consumption [mA] 16,5 mm Valves 8 4 8 66 x 120 x 135 690 1080 n/a 250 310 250 310 Power loss of the module [W] max. 2.9 max. 3.6 max. 2.9 max. 3.
Type 8650 Configuration and Function of the Modules 2.2.1.
Type 8650 Configuration and Function of the Modules Dimensions 27,2 28,5 12,5 164,5 137,27 2.2.2. 11 3x11 (=33) 44 Connections optionally Plug-in coupling D6 screw socket M5 + M7 190 5,5 56,6 Fig.
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.
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 X X X X X X X 3 2 1 0 Channel number with 8-channel modules X X X 7 6 5 4 3 2 1 0 The channel status LEDs on the electronic module are assigned to the channel / valve numbers.
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.
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: 3.2. Pneumatic supply module (part of the supply segment) Technical Data Pneumatic connections Dimensions G 3/8“, G 1/8“ or NPT 3/8“, NPT 1/8“ Material PA Weight 150 g ca.
Type 8650 Configuration and Function of the Modules 3.2.1. Overview Holes for clamping bolts (2x) for system mounting Pneumatic ports Inclined tie rods Fig. 13: 3.3. Overview - Pneumatic supply module Pneumatic Connections 1 2 Position Marking Function 1 R/S-3/5 Exhaust air 2 X 3 P/1 Version G NPT 3/8“ 3/8“ Control • EXT: Auxiliary control air • INT: Pilot exhaust air 1/8“ 1/8“ Compressed air supply 3/8“ 3/8“ 3 Fig.
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: 4.2.
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.
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 5 1 2 6 3 7 8 4 9 Fig. 16: 4.3.
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. Fig.
Type 8650 Configuration and Function of the Modules 5.3. Technical Data Ident no. of the module 173 368 173 369 Application Supply segment left and middle 173 370 173 371 Valve segment right 44 mm 66 mm 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 5.3.1.
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 be planned accordingly in the programs for the hardware configuration (e. g. Siemens Step7).
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] 230 270 Material (Housing) PBT, PC 250 290 Current consumption1) [mA] 250 310 250 310 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] max. 4.
Type 8650 Configuration and Function of the Modules 6.4. Displays Legend 1 1 LED for module status display (function as for Siemens modules) 2 2 LEDs showing channel status (also see the chapter Configuration and Function of the Module / Valve Segments / Channel Assignment) Fig. 28: 6.5.
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.
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.
Type 8650 Configuration and Function of the Modules 4 Closing C = NC (normally closed) Switching times Opening Orifice Description Pressure range Ordering Chart Rated power 7.1.3. [l/min] [W] [bar] [ms] [ms] 300 2.5 ... 7 35 45 QNn-. value air 0.3 184 766 186 8322) 2 12 0.3 10 1... 81) 35 45 0.3 3/2-way valve, pilot controlled, currentfree, outlet port 2 relieved 2 x C = NC (normally closed) 2 4 300 4 10 12 186 8311) 186 8331, 2) 3 1 1 Ident no.
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.
Type 8650 Configuration and Function of the Modules Opening Closing Switching times [l/min] [W] [bar] [ms] [ms] 6 700 0.3 2 ... 10 80 90 Description C = NC (normally closed) Rated power QNn-. value air Pressure range Ordering Chart Orifice 7.2.3. 175 634 175 6742) 2 12 0.3 10 -0,9 ... 8 80 90 175 6731) 175 7231,2) 3 1 Ident no. 3/2-way valve, pilot controlled, current-free, outlet port 2 relieved D = NO (normally open) 6 700 0.3 1 ... 8 80 90 175 7311) 0.3 2 ...
Type 8650 Configuration and Function of the Modules 56 english
Type 8650 Installation Installation Contents 1. SAFETY INSTRUCTIONS...............................................................................................................................................................59 2. INSTALLATION INSTRUCTIONS................................................................................................................................................61 3. 2.1. Unpacking pre-assembled systems..............................................................
Type 8650 Installation 9.2. 10. Installation...............................................................................................................................................................................72 CONNECTION OF THE AIR INLET AND EXHAUST LINES..........................................................................................73 10.1. Connection of the Pressure Supply..............................................................................................................
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.
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).
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.
Type 8650 Installation 2.3. Position of the Assemblies Clamping bolts Screws for mounting the valves Locking element Unlocking slide Fig. 2: Position of the modules to be screwed on Inclined tie rods Fig. 3: Position of the tie rods on the installed system Inclined tie rod pocket 62 Fig.
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 counterclockwise all the way). →→Hook the system in the required position on the upper edge of the profile rail and swivel open.
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.
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.
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.
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. 3. Inclined tie rods Fig. 9: 5.3.
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.
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.
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: 7.2. Attaching the cover flap Removal Swivel open the cover flap and carefully lift the hinge plate over the hinge contour (e.g. using a small crosshead screwdriver). Fig.
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.
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.
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: 10.1. Connections of the air inlet and exhaust lines 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.
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.
Type 8650 Commissioning Commissioning Contents 1. SAFETY INSTRUCTIONS...............................................................................................................................................................76 2. INITIALIZATION...................................................................................................................................................................................77 3. 2.1. Communication Connection...........................................
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.
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).
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.
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. 79 Fig.
Type 8650 Commissioning The active AirLINE Ex pneumatic modules can be found in the same part of the hardware catalogue.
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.
Type 8650 Commissioning →→Insert the new object. Fig. 5: Inserting a new object →→To insert a new device, first select the device type. 82 Fig.
Type 8650 Commissioning →→Define the station designation and address. Fig. 7: Defining the station designation and address. →→Add the function modules. Fig.
Type 8650 Commissioning →→Define the desired number of identical modules. Fig. 9: Defining the number of identical modules →→Select the module type via the menu “Allocate”. 84 Fig.
Type 8650 Commissioning →→Terminate the module selection with OK. Fig.
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.
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.
Type 8650 Commissioning Fig.
Type 8650 Commissioning 2.5. Acyclic Parameters of the AirLINE Ex Modules 2.5.1. Parameters that can be displayed or modified by modules Name Value Unit Status 1: PDM - Initial value 4 DO Bürkert 11 mm PDM_ConfigurationTool # 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.
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).
Type 8650 Commissioning 2.5.4.
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.
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.
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.
Type 8650 Commissioning When the installation is complete, the AirLINE Ex 8650 valve modules are included in the hardware catalog. Fig.
Type 8650 Commissioning Changing the parameters →→The parameters of a module can be changed via its “Object properties”. Fig. 21: Changing the parameters of a module Currently the settings of the switching cycle counters can be changed via SIMATIC PDM only.
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.
Type 8650 Commissioning The installation of the Software Update Package is recorded and can be checked under Start > SIMATIC > Information >“- Installed software”. Fig.
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.
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
Type 8650 Maintenance and Repair Maintenance and Repair Contents 1. SAFETY INSTRUCTIONS............................................................................................................................................................ 102 2. MAINTENANCE................................................................................................................................................................................ 103 3. 2.1. Module Maintenance....................................
Type 8650 Maintenance and Repair 1. SAFETY INSTRUCTIONS DANGER! Risk of injury from high pressure in the equipment! • Before loosening the lines and valves, turn off the pressure and vent the lines.
Type 8650 Maintenance and Repair 2. MAINTENANCE 2.1. Module Maintenance The modules of the AirLINE Ex system are maintenance-free when operated in accordance with the instructions in this operating manual. 2.2. Cleaning DANGER! Danger of explosion caused by electrostatic charge! If there is a sudden discharge from electrostatically charged devices or persons, there is a danger of explosion in the EX area. • Clean the device surface of the solenoid valve by gently wiping it with a damp cloth only.
Type 8650 Maintenance and Repair 3. MAINTENANCE DANGER! Risk of injury from high pressure in the equipment! • Before loosening the lines and valves, turn off the pressure and vent the lines. 3.1. Changing Valves During Operation 3.1.1. Installation instructions Before replacing the valve, ensure that the relevant equipment is in an electrically safe state. If the respective valve position does not feature a P-shutoff, first depressurize the system.
Type 8650 Maintenance and Repair 3.3. Troubleshooting Fault Possible cause Remedy Valves do not switch No or insufficient operating voltage. →→Check the electrical connection. Manual override not in neutral position. No or insufficient pressure supply. →→Ensure the correct operating voltage. →→Move the manual override to the neutral position.
Type 8650 Maintenance and Repair Fault Possible cause Remedy SF LED lights up. Wrong configuration. →→Use the corresponding module from the hardware catalogue. Valve diagnosis trips (short circuit, open outlet port). →→Check the proper installation of the valve. →→Replace defective valves. →→Deactivate the diagnosis for valve positions not in use. Module does not start due to internal current limit (short circuits at the outlet ports).
Type 8650 Storage, Packaging, Transport, Disposal Storage, Packaging, Transport, Disposal Contents 1. 2. STORAGE............................................................................................................................................................................................ 108 1.1. Storage Conditions for Modules in Original Packaging.............................................................................. 108 1.2. Shutdown................................................
Type 8650 Storage, Packaging, Transport, Disposal 1. STORAGE NOTE! Incorrect storage may damage the device. • Store the device in a dry and dust-free location! • Storage temperature: -40 … 70 °C 1.1. Storage Conditions for Modules in Original Packaging The following information applies to modules transported in their original packaging.
Type 8650 Storage, Packaging, Transport, Disposal 1.2. Shutdown 1.2.1. Safety Instructions DANGER! Risk of injury from high pressure in the equipment! • Before loosening the lines and valves, turn off the pressure and vent the lines.
Type 8650 Storage, Packaging, Transport, Disposal 2. PACKAGING, TRANSPORT NOTE! Transport damages! Inadequately protected equipment may be damaged during transport. • During transportation protect the device against wet and dirt in shock-resistant packaging. • Avoid the action of heat and cold which can lead to temperatures above or below the admissible storage temperature. • Protect the electrical interfaces and pneumatic connections from damage by placing protective caps on them. 2.1.
Type 8650 Annex Annex Contents 1. EC DECLARATION OF CONFORMITY.................................................................................................................................. 112 1.1. Standards used for CSA-, FM-Ex and IEC-Ex-certification........................................................................ 115 1.2. Set-Up of the Type 8650 System for Certification Conformity................................................................ 116 1.3. Certificates.....................
Type 8650 Annex 1.
Type 8650 Annex One or several of the following standards have been used to assess the products with respect to Pressure Equipment Directive (97/23/EG): EN 60730-1 Automatic electrical controls for household and similar use - Part 1: General requirements EN 60730-2-8 Automatic electrical controls for household and similar use - Part 2-8: Particular requirements for electrically operated water valves, including mechanical requirements The products have been subjected to the following conformity assessme
Type 8650 Annex The following standards were also used to assess non-electrical equipment and equipment in the filling station area: EN 13463-1 Non-electrical equipment for potentially explosive atmospheres Part 1: Basic method and requirements EN 13617-1 Petrol filling stations - Part 1: Safety requirements for construction and performance of metering pumps, dispensers and remote pumping units The production of electrical equipment, for which an EC-type examination certificate is available, is monitor
Type 8650 Annex 1.1. Standards used for CSA-, FM-Ex and IEC-Ex-certification For the CSA-certification, the following standards have been applied: CAN/CSA 22.2 No. 157-92 CAN/CSA 22.2 No. 213-M1987 CAN/CSA 22.2 E-60079-0 -07 CAN/CSA 22.2 E-60079-7 -03 CAN/CSA 22.2 E-60079-11 -02 ANSI/ISA-60079-0 (12.00.01)-2005 ANSI/ISA-60079-7 (12.16.01)-2002 ANSI/ISA-60079-11 (12.02.
Type 8650 Annex 1.2. Set-Up of the Type 8650 System for Certification Conformity Observe the following regulations to ensure that the configuration of the system is authorized: When converting or expanding a system, check whether the satisfied approvals are affected. A type 8650 system can be placed at any chosen location between IM152 and the bus termination module of a SIMATIC ET200iSP station. Set-up conformity for the type 8650 system is based on a left to right assembly order: 1.
Type 8650 Annex 1.3. Certificates • Terminal module (permit designation: KEMA 06ATEX0092) • Electronic module (permit designation: KEMA 06ATEX0093) • Valve type 6144 Ex-i (permit designation: PTB 07ATEX2048) • Valve type 6104 Ex-i with solenoid”G1 642 735“ (permit designation: PTB 01 ATEX2173) • Valve type 6106 Ex-i with solenoid ”AC21“ (permit designation: PTB 01 ATEX2175). 1.3.1.
Type 8650 Annex 2.
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Type 8650 Annex 3. IEC-EX CERTIFICATE OF CONFORMITY TERMINAL MODULES (Certificate Number: KEMA IECExKEM07.
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Type 8650 Annex 4.
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Type 8650 Annex 5. IEC-EX CERTIFICATE OF CONFORMITY ELECTRONIC MODULES (Certification Number: KEMA IECExKEM07.
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Type 8650 Annex 6.
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Type 8650 Annex 7. IEC-EX CERTIFICATE OF CONFORMITY 11 MM-VALVES TYPE 6104 Certification Number: PTB06.
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Type 8650 Annex 8.
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Type 8650 Annex 9. IEC-EX CERTIFICATE OF CONFORMITY 16,5 MM-VALVES TYPE 6106 (Certification Number: PTB06.
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Type 8650 Annex 10.
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Type 8650 Annex 11. IEC-EX CERTIFICATE OF CONFORMITY 11 MM-VALVES TYPE 6144 (Certification Number: IECEx PTB07.
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