Burkert FreeLINE 8645 User manual

Operating Instructions
Type 8645
FreeLINE
Modular Electrical and Pneumatic Automation System

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© 2007 Bürkert Werke GmbH & Co. KG
Operating Instructions 0709/03_EU-en_00804027


English
8645 - 


 .............................................................................................................7
The operating manual .......................................................................................................................... 8
General safety precautions ................................................................................................................ 9
Intended use .......................................................................................................................................10
Electrostatic charges .........................................................................................................................10
Scope of supply ..................................................................................................................................10
Warranty terms ....................................................................................................................................11
Declaration of conformity ..................................................................................................................11
Information in the internet .................................................................................................................11
 ........................................................................................ 1
General description ............................................................................................................................14
Technical data ....................................................................................................................................16
Dimensions ...........................................................................................................................................16
Equipment ..........................................................................................................................................17
 .............................. 19
Configuration .......................................................................................................................................20
Function ................................................................................................................................................21
 ................................................. 2
Fieldbus module PROFIBUS® .........................................................................................................29
Fieldbus module CANopen ..............................................................................................................9
FIeldbus module DeviceNet .............................................................................................................64
Multipole module ................................................................................................................................75
Intermediate module (Inside Module) ............................................................................................78

4 - 8645
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English
RIO module ..........................................................................................................................................8
Combination modules ........................................................................................................................88
Pneumatic module ..............................................................................................................................96
Valve integration ............................................................................................................................... 101
Electronic module digital Inputs ................................................................................................... 10
Electronic module digital Outputs ............................................................................................... 107
Termination module ......................................................................................................................... 111
......................................................................................................11
Packaging .......................................................................................................................................... 114
Transport ............................................................................................................................................ 114
 .............................................................................................................................115
Safety precautions ........................................................................................................................... 116
Wall mounting ................................................................................................................................... 117
Mounting on din rail ......................................................................................................................... 118
Block mounting ................................................................................................................................ 120
Expansion of the system or replacement of a module ............................................................ 121
 .......................................................................................................................12
Safety precautions ........................................................................................................................... 124
Profibus® ............................................................................................................................................ 125
CANopen ........................................................................................................................................... 141
DeviceNet .......................................................................................................................................... 147
 .......................................................................................................159
Service ............................................................................................................................................... 160
Maintenance ..................................................................................................................................... 161


English
8645 - 5
 ...............................................................................................................16
Storage .............................................................................................................................................. 164
Disposal ............................................................................................................................................. 165
 ............................................................................................................................167
System Accessories ....................................................................................................................... 168
Fieldbus module PROFIBUS® ...................................................................................................... 168
Fieldbus module CANopen ........................................................................................................... 169
Fieldbus module DeviceNet .......................................................................................................... 169
Multipole module ............................................................................................................................. 170
Intermediate module (Inside Module) ......................................................................................... 170
RIO module ....................................................................................................................................... 170
Electronic module - digital inputs ................................................................................................ 171
Electronic module - digital outputs .............................................................................................. 171
Combination module ....................................................................................................................... 171

6 - 8645
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English


English
8645 - 7
 ...........................................................................................................8
Symbols .................................................................................................................................................. 8
Safety Precautions .......................................................................................................................... 8
Recommendations and Information ............................................................................................. 8
Work Steps ....................................................................................................................................... 8
Trademarks ............................................................................................................................................. 8
 ...........................................................................................9
 ............................................................................................................................ 10
 ..................................................................................................... 10
 ..................................................................................................................... 10
 ...................................................................................................................... 11
 ........................................................................................... 11
 .......................................................................................... 11


8 - 8645

English

The operating manual describes the entire life cycle of the device. Store this manual in such a way that is
easily accessible to every user and is available to every new owner of the FreeLINE System
 Read the operating manual through carefully.
In particular, pay attention to the chapter General safety precautions.


This symbol draws attention to the various safety precautions given in this operating manual.
 signifies an immediate impending danger.
If it is not avoided, death or serious injury will result.
 signifies a potentially dangerous situation.
If it is not avoided, death or serious injury may result.
 signifies a potentially dangerous situation.
If it is not avoided,
• Minor injury or equipment damage may result.
• The product or its surroundings may be damaged.

These symbols draw attention to recommendations, tips, additional and more detailed information.
 describes important additional information, tips and recommendations that are important for
your safety and the proper functioning of the device.
 refers to information in this operating manual or in other documents.

indicates a work step which you must carry out.indicates a work step which you must carry out.

The listed designations are trademarks of the respective companies / associations / organisations.
PROFIBUS® PROFIBUS Nutzerorganisation e. V.
Korrvu® Sealed Air© Verpackungen GmbH, D-604 Alsfeld
Retenchen™ Brangs & Heinrich GmbH
RESY™ Organisation für Wertstoffentsorgung GmbH


English
8645 - 9

 • Hazard due to high pressure!
Working on the unit involves acute risk of injury.
Switch off the pressure and depressurise the system before loosening pipes and
modules!
 • The general rules of technology apply to the planning and operation of the device!
Failure to observe these rules may result in injury and/or damage to the equipment or its
surroundings.
Observe the general rules of technology.
• Unintentional operations or unauthorized tampering can lead to generally dangerous
situations including personal injury.
Take suitable measures to prevent unintentional operation or inadmissible damage!
• Dangerous situations may occur during installation and maintenance work.
This work may only be carried out by authorized service personnel using appropriate
tools!
• Observe the applicable accident prevention and safety regulations for electrical
appliances when operating and servicing the device!
 • The device may only be operated with direct current.
Otherwise the system could be damaged.
Ensure that the device is only connected to a DC power supply.
• The system is live.
Working on the unit involves acute risk of injury.
Always switch off the power supply before starting work!
Observe all applicable accident prevention and safety regulations for electrical
equipment.
• The pressure in the system may drop during switching. Prevent pressure drops.
Design the pressure supply system with as large a volume as possible.
• Ensure that the process is restarted in a defined and controlled manner after an
interruption in the electrical or pneumatic power supply!
 Failure to observe this information or doing unauthorized work the device releases us from
all liability and voids the warantees for the devices and accessories!

10 - 8645

English

The FreeLINE Type 8645 modular, electrical and pneumatic automation system may only be used for the appli-
cations described in chapter FreeLINE System Description and only in conjunction with equipment and com-
ponents from other companies recommended or approved by Bürkert.
Observe the instructions in this operating manual, as well as the conditions of use and permissible data speci-
fied in the chapter Technical Data.
The proper and safe functioning of the system depends on proper transport, storage and installation, and on
careful operations and maintenance.
Use in any other way does not constitute an intended use.

Pay attention to any limitations if the system is to be exported.

• Do not supply aggressive or inflammable media to the media connections of the system.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.Do not supply fluids to the media connections of the system.
• Do not subject the housing to mechanical loads (e.g. by placing objects on the housing or using theDo not subject the housing to mechanical loads (e.g. by placing objects on the housing or using the
housing as a step).

 The system contains electronic components that react sensitively to electrostatic dischar-
ge (ESD).
Contact with electrostatically charged persons or objects can endanger these compo-
nents. In the worst case, they will immediately be destroyed or fail after commissioning.
Observe the requirements of EN 100 015-1 in order to avoid or minimise the risk of dam-
age caused by sudden electrostatic discharges. Also ensure that you do not touch elec-
tronic components when the supply voltage is switched on.

Immediately after receiving the shipment, ensure that the contents are not damaged and that the contents are
as listed on the shipping documents.
If there are discrepencies, please immediately contact us.

Contact information:
Bürkert Fluid Control Systems
Sales Center
Chr.-Bürkert-Str. 1-17
D-7465 Ingelfingen
Tel. : 07940 - 10 111
Fax: 07940 - 10 448
E-mail: [email protected]


English
8645 - 11

The contact addresses are found on the last page of this instruction manual as well as on the internet at:
www.buerkert.com Bürkert Company Locations

This document does not offer any form of warranty. Please refer to our general terms and conditions of busi-
ness. The warranty is only valid if the device has been used correctly and in accordance with the specified
operating conditions.
 The warranty covers only the freedom from errors of the FreeLINE Type 8645 modular
electrical and pneumatic automation system.
No liability is accepted for consequential damage of any kind that results from device failu-
re or malfunctioning.

 The Declaration of Conformity does not form part of this operating manual.
It will be provided to you on request.

The operating manual and the corresponding data sheets on Type 8645 can be found on the Internet under:
www.buerkert.com Technical Data Manuals/Approvals TYPE 8645
Furthermore, the complete documentation is available on CD.
The operating manual can be ordered under the following identification number: 00804027

12 - 8645
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English


English
8645 - 1

 ........................................................................................................... 14
Characteristic Features and Benefits ............................................................................................14
Field of Application .............................................................................................................................15
Marking ................................................................................................................................................15
........................................................................................................................ 16
 ................................................................................................................................. 16
Complete System with Fieldbus Module ......................................................................................16
Complete System with Multipole Module .....................................................................................17
 ................................................................................................................................. 17


14 - 8645

English

Type 8645 FreeLine (hereafter referred to as FreeLINE) is a modular, electrical and pneumatic automation system
with elevated protection class IP 65/67 that has been developed for use in open areas. In a homogeneous
system, all the electronic and pneumatic components are standardised so that just by observing a few simple
rules, pneumatic, electrical and electronic modules with different functions can be very easily combined with
one another. All the modules are linked by a locking system. This system also makes the necessary electrical
connections.
1
2

4
5
6
Illustration: General view of the system (example)
Legend
1
2
3
Fieldbus module
Combination module KM1)
2 * 2x 3/2-Wege-way valve / 4 * DI2)
Combination module KM1) 2 * 5/2-way valve / 4 * DI2)
4
5
6
Pneumatic module PM) 2 * 2x 3/2-way valve
Combination module KM1)
2 * 5/2-way valve / 4 * DI2)
Termination module
1) KM: Combination module
2) DI: Digital input
3) PM: Pneumatic module


• Simple operationSimple operation
• Automatic configuration of potential groups, current, data and safety circuitsAutomatic configuration of potential groups, current, data and safety circuits
• Open, flexible and modular structureOpen, flexible and modular structure
• Combination of pneumatic and DI/DO functions to modules of different granularityCombination of pneumatic and DI/DO functions to modules of different granularity
(double, quadruple, etc.) for space and price-optimised station configuration


English
8645 - 15

• Flow-optimized valve configuration
• Pressure range from vacuum up to 10 bar (depending on the valve variant employed)
• Flow rate of approx. 00 l/min with a valve width of 10 mm
• Long service life thanks to rocker technology with oiled and unoiled airLong service life thanks to rocker technology with oiled and unoiled air
• Simple combination of different functions, configuration and expansion thanks to high modularitySimple combination of different functions, configuration and expansion thanks to high modularity
• Numerous valve functionsNumerous valve functions
/2, 2 x /2, 5/2 (monostable, bistable) and 5/-way functions
• Mechanical emergency manual operationMechanical emergency manual operation
• Different pressure levels possible in one systemDifferent pressure levels possible in one system
• Central compressed air supplyCentral compressed air supply

FreeLINE is designed for decentralized use in tough industrial environments.
Electronics and fluidics can be combined extremely easily thanks to the modular design as the fluidics also
pass through the electronic modules.
The system satisfies the elevated protection classes IP65 / IP 67.

Legend
1 Type plate
Illustration: Type plate with designation, serial number and identification number
1

16 - 8645

English

System structure per segment 16 DI (digital inputs)
16 DO / PO (digital / pneumatic outputs)
Max. power consumption see chapter Technical Data of the respective module
Ambient temperature 0 °C to +55 °C
Storage temperature -20 °C to +60 °C
Rated operating mode 100% CDF (continuous operation)
Operating voltage 24 V DC -15 % / +20 %
Current consumption
• Inputs / logic (UL)
• Outputs (UO)
max. 1 A
max. 4 A (M12)
Residual ripple 2 Vss
Degree of protection IP65 / IP67
Protection class  (VDE0580)
Interference suppression
• Interference immunity
• Emitted interference
IEC 61000-6-2
IEC 61000-6-4


Ø 3.2
34.75 59.75 37 37 37
223.5
148.45
Ø 3.2
36 37 37 37 37 39.5
5.75 126.25
109.43
Illustration: Complete system with fieldbus module


English
8645 - 17

Ø 3.2
34.75 59.75 37 37 37
223.5
148.45
Ø 3.2
36 37 37 37 37 39.5
5.75 126.2
105.55
Illustration: Complete system with multipole module

Modular electrical and pneumatic automation system ready for operation,
without connecting cables.

18 - 8645

English


English
8645 - 19


 ......................................................................................................................... 20
 ....................................................................................................................................... 21



20 - 8645

English

The illustration shows schematically the structure of the FreeLINE system.
Illustration: Schematic representation of a FreeLINE system (example)
The following illustration shows the configuration of the FreeLINE system using an example.
5
4

2
1
6
7
Illustration: Structural configuration of a FreeLINE system (example)
Legend
1
2
3
4
Fieldbus module
Combination module KM 2 * 2x 3/2-way valve / 4 * DI
Combination module KM 2 * 5/2-way valve / 4 * DI
Pneumatic module PM 2 * 2x 3/2-way valve
5
6
7
Pneumatic module PM 2 * 5/2-way valve
Termination module
Connection bracket
Central controller
(e.g. PLC)
Fieldbus module 1
(e.g. Profibus)
Combination module 2 PO / 4 DI
Termination module
Pneumatic module 4 PO
Pneumatic module 2 PO
Fieldbus module 2
Fieldbus module ...
Fieldbus module n
Combination module 4 PO / 4 DI