Burkert AirLINE Ex 8650 User manual

Quickstart
Electrical and Pneumatic Automation System
Typ 8650
AirLINE Ex
www.burkert.com
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modication techniques.
© Bürkert Werke GmbH & Co. KG, 2007 - 2017
Operating Instructions 1806/02_EU-en_00805635
2
THE QUICKSTART
CAUTION!
The quickstart has to be read and understood.
•Read the quickstart through carefully. Pay attention in
particular to the chapters General Safety Precautions
and Intended Use.
The Quickstart will enable you to install the system.
You will nd more detailed information in the op-
erating instructions on the
Internet under:
www.buerkert.com → Technical Data → manuals →
type 8650
Trademarks
ET 200iSP™ Siemens AG
PROFIBUS® PROFIBUS Nutzerorganisation e. V.
3
SCOPE OF SUPPLY
Immediately upon receipt of delivery, check that the
contents have not been damaged and that the delivery
matches the delivery note or packing list in type and scope.
Please contact us immediately in the event of discrep-
ancies.
Germany
Contact Address:
Bürkert Fluid Control Systems
Sales Center
Chr.-Bürkert-Str. 13-17
D-74653 Ingelngen
Tel. : 07940 - 10 111
Fax: 07940 - 10 448
E-mail: [email protected]
International
Contact addresses are found on the nal pages of this
operating manual.
You can also nd information on the Internet under:
www.buerkert.com Bürkert Company Loca-
tions

4
SYMBOLS
Safety Precautions
DANGER!
High risk!
signies an immediate impending danger. If it is not
avoided, death or serious injury will result.
WARNING!
Medium risk!
signies a potentially dangerous situation. If it is not
avoided, death or serious injury may result
CAUTION!
Low risk!
signies a potentially dangerous situation. If it is not
avoided,
•Minor injury or equipment damage may result.
•The product or its surrounding may be damaged.
Describes important additional information, tips and
recommendations that are important for your safety
and the proper functioning of the device.
Work Steps
→indicates a work step which you must carry out.
5
INTENDED USE
WARNING!
The device may only be used for the applications
indicated in chapter System Description AirLINE Ex
of the operating manual and only in conjunction with
third-party devices or components recommended or
approved by Bürkert.
Observe the instructions in this operating manual, as
well as the conditions of use and permissible data
specied in the chapter System Description AirLINE Ex
/ Technical data.
The proper and safe function of the product depends
on porper transport, storage and installation, and on
careful operation and maintenance. Use in any other
way does not constitute an intended use.
Limitations
Pay attention to any limitations if the system is to be
exported.
The Ex approval
•Is only valid if the modules and components approved
by Bürkert are used in the manner described in the
operating manual.
•The electronic modules may only be employed in
combination with the pneumatic valves approved by
Bürkert. Use in any other way will invalidate the Ex
approval.
6
•The Ex approval will be invalidated if unauthorised
modications are made to the system, the modules or
components.
Foreseeable misuse
•Do not supply aggressive, inammable or liquid media
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 the housing
as a step).
•Do not cover the ventilation slots in the housing.
GENERAL SAFETY PRECAUTIONS
DANGER!
Hazard due to high pressure!
Interference with the system will result in an acute risk
of injury.
•Switch o the pressure and depressurise the system
before loosening pipes and modules!
Hazard due to electrical voltage!
Interference with the system will result in an acute risk
of injury.
•Always switch o the power supply before starting
work! Observe all applicable accident prevention and
safety regulations for electrical equipment.
7
Hazardous situations can arise during installation work.
This work may only be carried out by authorised spe-
cialist personnel who have been trained for working in
explosive atmospheres and using suitable tools!
WARNING!
Hazard situations!
Unintentional operation or impermissible damage can
lead to dangerous situations including physical injury.
•Take suitable measures to prevent unintentional opera-
tion or inadmissible damage!
•Ensure that the process is restarted in a dened and
controlled manner after an interruption in the electrical or
pneumatic power supply!
CAUTION!
Electrostatic charges!
The system contains electronic components that react
sensitively to electrostatic discharge (ESD). Touching by
electrostatically charged persons or objects can endan-
ger these components. In the worst case they may be
immediately destroyed or fail after commissioning.
Pay attention also not to touch electronic components
when the supply voltage is switched on.

8
Power supply!
The device may only be operated with direct current. Other-
wise damage may be caused to the system.
Ensure that the device is connected only to a DC
power supply!
CAUTION!
Pressure drop!
The pressure in the system may drop during switching.
•Prevent pressure drops. Design the pressure supply
system with as large a volume as possible.
Note!
Operate the AirLINE
Ex System only when it is in perfect condition and
in according with the operating manual.
Failure to observe this information and unauthorised
intervention in the AirLINE Ex System will void any
liability for us and annuls the guarantees applicable
to the devices and accessories!
The Ex approval is only valid if you the modules and
components of the AirLINE Ex System are operated
in the manner described. Unauthorised modications
will invalidate the Ex approval!
9
SYSTEM DESCRIPTION
General technical data
Media clean, dry air (oiled / unoiled)
neutral gases (particle size max. 5 μm)
Ambient temperature 0 ... +55 °C (in operation)
Storage temperature -20 ... +60 °C
Relative humidity 5 ... 95 %, non-condensing
Acceleration 5 m/s2 (in operation)
Rated operating mode 100 % CDF
(continuous operation)
Operating voltage 24 V DC in EEx-e
Degree of protection IP30
Protection class 3 (VDE0580)
Approvals
Elektronic module ATEX II 2 G Ex ib IIC T4 (Zone 1/21),
Installation in an approved
Ex-e cabinet required.
Terminalmodule ATEX II 2 G Ex e [ia/ib] IIC T4
(Zone 1/21),
Installation in an approved
Ex-e cabinet required.
10
DANGER!
Hazard due to electrical voltage!
The terminal modules (with upright system wiring) are
designed in the explosion-proof class Ex-e (increased
safety).
•When working on the terminal modules, the operating
voltage of the system must be switched o.
•Further information on this can be found in the manual
of the Siemens ET200iSP.
Interference immunity EN 50082-2
Emitted interference EN 50081-2
Power consumption of the active modules, including
the mounted valves
Modul type Power 1) ID-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
1) These values must be taken into consideration when calcu-
lating the max. total power consumption of the station.
(See also table 3-4 in the Siemens manual ET 200 iSP)
11
Installation example
123
8
7
6
5
4
8
Illustration: Installation example
1 Supply slice, left
2 Valve slice 44 mm, 4 Valve functions
3 Valve slice 44 mm, 8 Valve functions1)
4 Supply slice, middle, Intermediate power supply
5 Valve slice 66 mm, 4 Valve functions
6 Valve slice 66 mm, 8 Valve functions1)
7 Supply slice, right
8 Starting points for removal on the preassembled sys-
tem
1) not yet available

12
Supply slice
Illustration: Supply
slice
9
10
11
15
14
13
12
16
19
20
19
18
17
9 Storage compartement 15 Unlocking slide2)
for SD card 16 Pressure gauge
10 Hinged cover ap (optional)
11 Clamping bolts (2x) 17 Shut-o slide
18 Power-Bus plug
Pneumatic connections: 19 Inclined tie rods 2) (2x)
12 R/S-3/5 20 Communication bus plug
13 X 2) Not tted with left-hand
connecting slices
14 P/1
13
Technical data
Power consump-
tion
0 W (Module is electrically pas-
sive)
Pneumatic
connections
G 3/8“, G 1/8“
or NPT 3/8“, NPT 1/8“
Dimensions Appr. 50 (per station 44)
x 190 x 120 mm
Material (housing
pneumatic)
PA, PBT, PC
Weight 480 g / 520 g
(without / with manometer)
Pneumatic connections
Pos. Marking Function Version
G NPT
12 R/S-3/5 Exhaust air 3/8“ 3/8“
13 X Control
EXT: Auxiliary control
air
INT: Pilot exhaust air
1/8“
14 P/1 Compressed air supply 3/8“ 3/8“
14
Valve slice
Illustration:
Valve slice
21
27
26
25
19
23
22
10
17
18
19
20
24
21 Module status (red LED) 27 Labelling panel, slot-in
22 Channel status 24 Valve ejector1)
(green LED) 17 Shut-o slide 2)
10 Hinged cover ap 18 Power-Bus plug
23 Valves 20 Communication bus plug
19 Inclined tie rods (2x)
Pneumatic working ports: 1) only with stacking size 66 mm
2) under the valves
25 see table
26 see table
15
Technical data
Valve width 11 mm 16.5 mm
Valve outlets 4 8 4 8
Dimensions 44 x 120 x 135
mm
66 x 120 x 135
mm
Weight with valves 580 g 690 g 1080 g n/a
Material PBT, PC (Housing)
PA (Pneumatic module)
Current consumption
[mA]
250 310 250 310
Max. power loss of
the module
2.9 W 3.6 W 2.9 W 3.6 W
Status displays Module status1): LED red
Channel status: LED green
1) Function as for Siemens modules
Pneumatic connections
Possible conguration of the working ports
Pos. Valves Double valves
3/2-way
6524/6526
5/2-way
6525/6527
2x 3/2-way
6524/6526
25 not used 2 2 (valve 12)
26 2 4 4 (valve 14)

16
Pneumatic power data
Valve type
6524
3/2-way
6525
5/2-way
6524
2x 3/2-way
6526
3/2-way
6527
5/2-way
Circuit functions1) C/D H2x C C/D H
stacking size [mm] 11 16.5
Pneumatic connections:
Plug-and-socket
connections
D45), D6, D1/4“ 5) D8
Threaded connections M5, M7 G 1/8“,
NPT 1/8“
Orice [mm] 4 6
QNn2) [l/min] 300 700
Opening time3) 10 % [ms] 35 80
Closing time3) 10 % [ms] 45 90
Pressure range4) [bar] 2.5 ... 7 2 ... 8
with auxiliary control air6) 1 ... 7 1 ... 8
Output [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 dierence
17
3) Switching times [ms]: measured in accordance with ISO 12238
These values may dier, depending on the valve type and
function (see operating manual, chapter Conguration and
Function of the Modules / Integratable Valves)
4) Pressure data [bar]: Overpressure with respect to atmospheric
pressure
5) Connection variants on request
6) Versions for vacuum on request
WARNING!
Hazard due to high pressure!
Interference with the system will result in an acute risk
of injury.
•Change the tted valves only when AirLINE Ex is
depressurised.
•When using a P shut-p at the corresponding valve
position, the valves can also be exchanged under
pressure.
Diagnosis (Elektronic module)
Group fault display: Yes, locally at the electronic mod-
ule (red LED)
Diagnostic function (can be read out via Probus):
•Channel status diagnosis (channel open, channel short
circuit).
•Individual switching cycle counter for each channel with
warning limits for pilot valve and connected actuator.
18
Pneumatic supply module
Illustration:
Pneumatic supply
module
11
12
19
13
14
11 Clamping bolts (2x) for system connection
Pneumatic connections:
12 R/S-3/5
13 X
14 P/1
19 Inclined tie rod
19
Technical data
Pneumatic
connections
G 3/8“, G 1/8“ or
NPT 3/8“, NPT 1/8“
Dimensions [mm] Appr. 50 (per station 44) x 70 x 75
Material PA
Weight [g] 150
Pneumatic Connections
Pos. Marking Function Version
G NPT
12 R/S-3/5 Exhaust air 3/8“ 3/8“
13 X Control
EXT: Auxiliary control
air
INT: Pilot exhaust air
1/8“ 1/8“
14 P/1 Compressed air supply 3/8“ 3/8“
Supplementary information can be found in the
operating manual also in chapter Conguration and
Function of the Modules / Supply Slices.

20
Basic pneumatic module
Illustration:
Basic pneumatic
module
28
26
19
29
30
31
13
12
14
25
28 Check valve (opt.) 30 Flange for valve
29 Labelling of the valve 31 P shut-o (optional)
positions / options Pneumatic connections:
19 Inclined tie rod 12 R/S-3/5
Pneumatic working ports: 13 x
25 see table 14 P/1
26 see table
Technical data
Dimensions
[mm]
Appr. 50 (per station 44 mm) x 70 x 55
Appr. 72 (per station 66 mm) x 70 x 55
Material PA, PBT, PC
Weight [g] 140 (per station 44 mm)
180 (per station 66 mm)
21
Pneumatic connections
Possible conguration of the working ports
Position Valves Double valve
3/2-way
6524/6526
5/2-way
6525/6527
2x 3/2-way
6524/6526
25 not used 2 2 (valve 12)
26 2 4 4 (valve 14)
Pneumatic connections on the valve slice
for valves with stacking size
11 mm 16.5 mm
Plug-and-socket
connection Ø 6 mm
(4 mm, ¼“ on request);
Thread M5, M7
Plug-and-socket connec-
tion Ø 8 mm;
Thread G 1/8“, NPT 1/8“
Versions
The variants dier according to stacking size, number of
valve positions, ange type of the valves, conguration of
the working ports and optional use of check valves and
/ or P shut-os.
22
Pneumatic types MP13
stacking size 11 mm 16,5 mm
Valve types 6524-Ex-i
6525-Ex-i
6526-Ex-i
6527-Ex-i
Port conguration (basic pneumatic module)
Plug-and-socket
connection
Ø 4 mm
Ø 6 mm
Ø ¼“
Ø 8 mm
Thread M5 1/8“
M7 NPT 1/8“
Check valves
(optional)
without check valves
Check valve in R channel
Check valve in R+S channel
P shutt-o
(optional)
with P shut-o1) without
P shut-o
1) Available only for certain valve types and with functional limita-
tions (see chapter Basic pneumatic modules with integrated P
shut-o).
Supplementary information can be found in the
operating manual also in chapter Conguration and
Function of the Modules / Valve Slices.
23
Features and limitations with
integrated P shut-o
•Flow rate reduced to approx. 60 % with valves Type
6524/6525.
•The possible working pressure range lies between 5
and 7 bar.
•P shut-o only possible in conjunction with valves with
internal
control air in a limited pressure range.
•P shut-o can by combined with integrated check
valves.
Pay attention when using the basic modules with P
shut-o that the pessure supply to the valve islands
is dimensioned suciently large.
(Minimum hose diameter 8/6 mm)

24
Terminal
module
Illustration:
Terminal module
33
32
20
18
18
34
15
32 Hinge contour for the electronic module
18 Power-Bus
20 Communication bus
33 Abutment for the electronic module
34 Plug for the electronic module 1)
15 Unlocking slide (only with ID no. 173 369)
1) not with ID no. 173 368, 173 369
Technical data
ID no. 173 368 173 369 173 370 173 371
Application Supply slice Supply slice
left, mid-
dle
right 44 mm 66 mm
Dimensions
[mm]
55 (Stacking size 44 mm)
x 190 x 45
66 x 190 x 45
Weight [g] 150 210
Material PBT, PC (Gehäuse)
PV
(Power loss) [W] 02)
Type of protection II 2 G Ex e [ia/ib] IIC T4
2) The module contains no electrically active components.
25
Elektronic module
Illustration:
Electronic module
21
22
10
27
35
21 Module status red LED
22 Channel status green LED
10 Hinged cover ap
35 Valve connector
27 Labelling panel, slot-in
The electronic module is electrically active (function:
Digital output module) and must be planned accord-
ingly in the programs for the hardware conguration
(e. g. Siemens Step7™).
26
Technical data
ID no. 171 941 171 942 171 943 171 944
Valve outlets 4 8 4 8
Dimension
[mm]
44 x 120 x 135
(for 11 mm valves)
66 x 120 x 135
(for 16.5 mm valves)
Weight [g] 230 250 270 290
Material PBT, PC (Housing)
Power con-
sumption [mA]
250 310 250 310
Power loss [W] max. 2.9 max. 3.6 max. 2.9 max. 3.6
Status displays LED (red) for the module status
LED (green) per channel (valve function)
Type of
protection
II 2 G Ex ib IIC T4
Diagnosis
Group fault display: Yes, locally at the electronic module
(red LED)
Diagnostic functions (can be read out via Probus):
•Channel status diagnosis (channel open, channel short
circuit.)
•Individual switching cycle counter for each channel
with warning limits for pilot valve and connected actu-
ator.
27
Pneumatic valves type 6524/6525
Technical data
Stacking size 11 mm
Material PA (Housing)
Gasket material NBR
Media dry compressed air, oiled or oil-free
neutral gases (5μm lter recommended)
Line connection Flange MP13
Pneumatic
module
Type MP13 with thread M5, M7 or
Type MP13 with plug connector Ø 6
mm, (Ø 4 mm, Ø ¼“ on request)
Manual actu-
ation Yes (alternative versions without)
Rated power 0.3 W
Rated operat-
ing mode 100 % continuous operation
Elec. connec-
tion at the valve rectangular plug RM 5.08 mm
Installation with 2 screws M2 x 20
Orice 4
QNn value air 300 l/min
Pressure range 0,3 W
Pressure range 2.5 ... 7 bar
1 ... 7 bar (with auxiliary control air)
Switching
times
Opening: 35 ms
Closing: 45 ms

28
Pneumatic valve type 6526/6527
Technical data
Stacking size 16.5 mm
Material PA (Housing)
Gasket material NBR
Media
dry compressed air, oiled or oil-free
neutral gases (10 µm lter
recommended)
Line connection Flange MP13
Pneumatic
module
Type MP13 with G 1/8“, NPT 1/8“ or
Type MP13 with plug connector Ø 8
mm
Manual actu-
ation Yes (alternative versions without)
Rated power 0.3 W
Rated operating
mode 100 % continuous operation
Elec. connec-
tion at the valve rectangular plug RM 5.08 mm
Installation with 2 screws M3 x 30
Orice 6
QNn value air 700 l/min
Rated power 0.3 W
Pressure range 2 ... 8 bar
1 ... 8 bar (with auxiliary control air)
Switching times Opening: 80 ms
Closing: 90 ms
29
INSTALLATION
Safety Precautions
DANGER!
hazard due to high pressure!
Interference with the system will result in an acute risk
of injury.
•Switch o the pressure and depressurise the system
before loosening pipes and modules!
Hazard due to electrical voltage!
Interference with the system will result in an acute risk
of injury.
•Always switch o the power supply before starting
work!
•Observe all applicable accident prevention and safety
regulations for electrical equipment.
WARNING!
Hazard situations!
Unintentional operation or impermissible damage can
lead to dangerous situations including physical injury.
•Take suitable measures to prevent unintentional opera-
tion or inadmissible damage!
•Ensure that the process is restarted in a dened and
controlled manner after an interruption in the electrical or
pneumatic power supply!
30
WARNING!
During installation and maintenance operations, haz-
ardous situations may arise.
This work may only be carried out by authorised spe-
cialist personnel who have been trained for working in
explosive atmospheres and using suitable tools!
CAUTION!
Power supply!
The device may only be operated with direct current.
Otherwise damage may be caused to the system.
•Ensure that the device is connected only to a DC
power supply!
Pressure drop!
The pressure in the system may drop during switching.
•Prevent pressure drops. Design the pressure supply
system with as large a volume as possible.
Seating of the seals!
If the seals are not seated correctly, leaks can occur re-
sulting in malfunctions due to pressure losses.
•During installation, pay particular attention to the proper
seating of the seals in the area of the electronics and
pneumatics.
31
CAUTION!
Components / assemblies in the system susceptible
to electrostatic charges!
•Observe the regulations of the EMC Act. The regula-
tions of the EMC Act are only satised with correct
FE and PA connections.
Electrical connection!
A reliable electrical connection requires exact contact-
ing.
•Do not bend the contacts!
•If connections are bent or damaged, replace the com-
ponents concerned before switching on the system.
Possible limitations!
Observe the applicable limitations when converting /
expanding systems. Information can be found in the
section Intended use / Limitations).
• Ensure a dened and controlled restarting of the
process after an interruption in the electrical or
pneumatic power supply!
• Always pick up a preassembled system at the
pneumatic supply modules and then remove it
from the packaging.

32
Tools and torques
Application Type and size of
the tool
Torque
Actuation of the locking
elements
Plain screwdriver,
size 5
-
Screwing on the clamping
bolts onto the supply
modules,
bolts of the terminal mod-
ule - Pneumatic module
Plain screwdriver,
size 7
1.3 ...
1.5 Nm
Installation / removal
of the valves with 11 mm
stacking size
Cross-head
screwdriver,
size 0
0.2 Nm
Installation / removal
of the valves with 16.5
mm stacking size
Cross-head
screwdriver,
size 1
0.3 Nm
Tightening the inclined tie
rods
3 mm Allen Key 0.6 Nm
33
Removing /hooking a preassembled system
from an S7 prole rail
Illustration:
Hooking onto the prole rail
Removing:
→Loosen (by turning in anti-clockwise direction) all the
clamping bolts (11) on the supply modules.
→Now swing the system out of the prole rail.
Hooking:
→Move all clamping bolts (11) on the supply modules
into their starting position by turning in anti-clockwise
direction up to the stop.
→Now hook the system onto the upper edge of the pro-
le rail at the desired position and swing it into place.
→Then tighten all the clamping bolts (11) by turning in
clockwise direction (prescribed torque 1.5 Nm).
34
Installation / removal of the ET 200iSP™
modules
on S7 prole rail
11 Clamping bolts
15 Releasing slide
Illustration:
Clamping bolts
11
11
11
15
Installation
→The ET 200iSP™ modules (terminal modules) can be
placed onto the prole rail and latched to the AirLINE
Ex System.
Lock modules tted on the right-hand supply slice with
the supply slice.
Disassembly
→For disassembly, prise out the releasing slide
(15) on the supply slice using a plain screwdriver.
This will release the latched module. Push it away to
the right.
35
Expansion of an existing system
with individual slices
Illustration:
Adding slices
Two inclined tie rods (19) connect each of the modules.
→When you have tted two modules onto the prole
rail and pushed them together, screw the right-hand
module to the left-hand module with two inclined tie
rods. (3mm Allen key: 0.6 Nm)
→Further modules can be added on the right in the
same way.
→Finally retighten the clamping bolts of the modules as
described above.

36
Conversion, expansion and assembly of
an existing system with individual slices
19 Inclined tie rod
Illustration:
Swing in the slice 19
Conversion and expansion
→First loosen the clamping bolts (11) on the right-hand
supply slice.
→After loosening the two inclined tie rods (19), push the
supply slice to the right.
→You can move the other slices in the same way until you
reach the point at which the system is to be modied.
→If a slice is to be added, rst hook it into the upper
edge of the prole rail. Swing in the slice and push it
to the left up to the existing part-system.
Assembly
→Reassemble the system in the reverse order.
37
Removal of individual slices
Supply slice
→Release the desired module
by actuating the locking
element and swing out the
module.
→Note in the case of the pres-
sure gauge module that the
hose has to be disconnected
from the pneumatic module
(see illustration Hose connec-
tion of the pressure gauge
module).
Illustration:
Supply slice
Valve slice
→Remove the valves (either
pressure-free or all locations
equipped with P shut-o) and
remove any caps from the
plug contacts.
→Release the electronics mod-
ule by actuating the locking
element in the direction of
the arrow and swing out the
module.
Illustration:
Valve slice
38
Installation of individual slices
Illustration:
Hose connection of the
pressure gauge module
Supply slice
→Hook the module in question into the terminal module
and swing it down until it engages.
→Note with the pressure gauge module that the hose
must rst be connected to the pressure pneumatic
module (see illustration: Hose connection of the pres-
sure gauge module).
Valve slice
→Hook the electronic module into the terminal module.
→Actuate the locking element in the direction of the arrow
and swing it in the module completely.
→Screw on the valves (either pressure-free or all posi-
tions equipped with P shut-o).
39
Removal / installation of the cover aps
Installation
→For installation, position the
cover ap in the half-open
position and then push it into
the hinge contour.
Illustration:
Fitting the cover ap
Disassembly
→For disassembly, swing open
the cover flap and lift the
hinge tab carefully over the
hinge contour (e. g. with a
small plain screwdriver).
Illustration:
Engaging the cover ap

40
Replacement of a terminal or pneumatic module
Important note!
•When converting or expanding the system, pay
attention that the sal rings of the pneumatic
modules are coated with a lm of suitable
grease (e. g. with Centoplex 2 from Klüber
Lubrication). Otherwise the seal rings may be
damaged or installation made more dicult.
•In the case of modication or expansion of pre-
fabricated systems, the system serial numbers
and system identication numbers on the front
side lose their validity.
•In such cases we recommend that you remove
the identication sign or provide the device with
a suitable identication.
During installation of the terminal or pneumatics module,
the modules are aligned with one another during produc-
tion. It ensures compliance with all the tolerances at the
interfaces (prole mounting - plug - uid channels).
If you install the pneumatic module on a terminal mod-
ule yourself, pay attention during integration into the
system that all interfaces (prole mounting - plug - uid
channels) engage in one another correctly.
Otherwise proceed as follows:
→Remove the assembly from the system again.
→Loosen the three screws on the rear of the terminal
module.
41
→Realing the pneumatic module on the terminal module.
→Tighten the three screws again.
42
Replacement of a valve
DANGER!
Hazards due to pressure changes!
During removal of the valve, only the P channel is shut
o in each case. This means that any pressure at the
working outlet ports A or B is relieved during disman-
tling. This means also that an actuator connected to
this port is also depressurised. This can result in move-
ment.
•With large volumes on the actuator side, provide a
shut-o possibility for the working ports in order to
prevent any movement of the actuator.
• We recommend that the system be brought to a
correspondingly safe basic condition electrically
before replacing the valve.
• If the corresponding valve position is not tted with
a P shut-o, rst depressurise the system!
• If you replace valves tted to modules with P shut-
o, no more than four valves may be removed at
the same time.
43
During removal of the valve, a relatively large amount of
air is initially blow o due to the function. The P shut-o
can only close when the necessary pressure diference
has been reached. The automatic shut-o signicantly
reduces the exhaust air, however, so that only a slight
residual leakage occurs with the P shut-o closed.
→Ensure that the gasket is correctly tted when installing
the valve.
→Tighten the valve to the tightening torques indicated
in the chapter Tools and torques.
→Pay attention during installation of the valve that the
working ports are also pressurised in the correspond-
ing rest position of the valve until it switches over. This
allows a connected actuator to make a movement
according to the pressurisation.
→Ensure that these movements do not cause any dam-
age or undesirable actions in the system.

44
Connection of the air inlet and exhaust lines
36 Exhaust air
37 Pilot control air /
auxiliary control air
38 Compressed
air supply
Illustration: Connection of the
air inlet and exhaust lines
36
37
38
Connection of the pressure supply
→Connect the compressed air supply to the ports P/1
of the supply modules.
The largest possible lines should be used for the supply
in order to avoid pressure drops. With larger AirLINE Ex
systems and applications with high consumptions, the com-
pressed air supply should be connected to the right-hand
and left-hand supply slices, optionally also to additional
middle supply slices.
→Close P/1 ports not used with plugs.
Connection of the exhaust air
→Connect the exhaust air to the ports R/S-3/5 of the
supply modules.
This connection should be made with the largest possible
lines and possibly silencers with high ow rates in order to
avoid back-pressures. Connect the exhaust air preferably
to the right-hand and left-hand supply slice, optionally also
to an additional middle supply slice.
45
Pilot exhaust air / auxiliary control air
Depending on which valves you operate on the AirLINE
Ex System, port X is used as follows:
Standard valves:
In this case the exhaust air from the pilot control valves is
discharged 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 connection should be
made with the largest possible lines and possibly silenc-
ers with high ow rates in order to avoid back-pressures.
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.
Bulkhead
As an option, the pressure supply of the system can be seg-
ment by means of a bulkhead in the central P channel be-
tween two pneumatic modules. This allows dierent pres-
sure levels or dierent media to be used in the same system.
In the case of preassembled systems, the position of a
bulkhead is marked on the corresponding pneumatic
module.
46
COMMISSIONING, MAINTENANCE,
SERVICE, DIAGNOSIS OF ERROR
Decommissioning
DANGER!
Hazard due to high pressure!
Interference with the system will result in an acute risk
of injury.
•Switch o the pressure and depressurise the system
before loosening pipes and modules!
Hazard due to electrical voltage!
Interference with the system will result in an acute risk
of injury. Always switch o the power supply before
starting work!
•Observe all applicable accident prevention and safety
regulations for electrical equipment.
Shut down the system as follows:
→Depressurise the system.
→Switch o the power supply.
→Dismantle the modules.
→Store the modules in the original packaging.
47
Cleaning
Use only a damp, lint-free cloth for cleaning the system.
Solvents or alcohol are not suitable for cleaning. They
may attack the platic parts.
DANGER!
Sparking due to electrostatic discharge!
In the case of friction on plastic surfaces, sparks my
be caused by electrostatic discharges.
•Use only damp cloths for cleaning the device sur-
faces!
Further information for Commissioning, Mainte-
nance, Service and Diagnosis of errors nd you in
the operating instruction on the enclosed CD.
Information on the Internet:
Operating manual and data sheets on Type 8650
can be found on the Internet under:
www.burkert.com Technical data manuals /
data sheet Type 8690

48
PACKAGING, TRANSPORT, STORAGE
CAUTION!
Transport damage!
Inadequately protected devices may be damaged
during transport.
•Transport the device in a protective packaging to
avoid moisture and dirt.
•Avoid exposure to excessively high or low tempera-
tures that could lead to the permissible storage
temperatures being exceeded.
Damage due to incorrect storage!
Incorrect storage can result in damage to the Pneumatic
Controller.
•Store the device in a dry and dust-free location!
•Storage temperature: -20 ... +65 °C.
49
DISPOSAL
CAUTION!
Environmental damage due to device components
contaminated with media!
•Observe the relevant waste disposal and environ-
mental protection regulations.
→Dispose of the device and the packaging in an envi-
ronmentally safe manner.
→Observe the national waste disposal regulations.