Burkert AirLINE 8652 User manual

Operating Instructions
Type 8652
AirLINE
Modular valve terminal for pneumatics

We reserve the right to make technical changes without notice.
© Bürkert Werke GmbH & Co. KG, 2017 - 2019
Operating Instructions 1902/06_EUen_00810541 / Original DE

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Type 8652
Contents
1THE OPERATING INSTRUCTIONS ........................................................................................................6
1.1 Symbols........................................................................................................................................6
1.2 Denitionofterms........................................................................................................................7
2INTENDED USE ......................................................................................................................................8
3BASIC SAFETY INSTRUCTIONS ...........................................................................................................9
4GENERAL INFORMATION....................................................................................................................11
4.1 Contactaddress.........................................................................................................................11
4.2 Warranty .....................................................................................................................................11
4.3 InformationontheInternet........................................................................................................11
5PRODUCT DESCRIPTION....................................................................................................................12
5.1 Intendedapplicationrange........................................................................................................12
5.2 Characteristics ...........................................................................................................................12
5.3 Valveterminaldesign.................................................................................................................13
5.3.1 Fieldbus gateway ME43 .............................................................................................13
5.3.2 Connection module ....................................................................................................13
5.3.3 Electronic module.......................................................................................................13
5.3.4 Pneumatic slide valve type 6534 ................................................................................14
5.3.5 Supply manifold..........................................................................................................14
5.3.6 Adapter plate AirLINE Quick.......................................................................................14
5.3.7 Terminating resistor ....................................................................................................14
6TECHNICAL DATA ................................................................................................................................15
6.1 Conformity..................................................................................................................................15
6.2 Standards ...................................................................................................................................15
6.3 Operatingconditions .................................................................................................................15
6.4 Generaltechnicaldata...............................................................................................................17
6.4.1 Pneumatic slide valve type 6534 ................................................................................17
6.4.2 Pilot pressure diagram................................................................................................17
6.5 Circuitfunction(CF) ...................................................................................................................18
6.6 Typelabelstandard(example)...................................................................................................18
6.7 TypelabelUL(example).............................................................................................................19
6.8 SpecicationsofindustrialEthernet .........................................................................................20
6.8.1 PROFINET IO .............................................................................................................20
6.8.2 EtherNet/IP.................................................................................................................20
6.8.3 ModbusTCP ..............................................................................................................21
6.8.4 EtherCAT ....................................................................................................................21
6.9 SpecicationsPROFIBUSDPV1 ...............................................................................................21
ValveterminalAirLINEtype8652
Type 8652
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Type 8652
7ASSEMBLING THE VALVE TERMINAL IN THE CONTROL CABINET.................................................22
7.1 AssemblingontheoororwallofthecontrolcabinetwithAirLINEQuick ............................23
7.1.1 DimensionsofangettingAirLINEQuick................................................................. 24
7.1.2 Assembling the valve island in the control cabinet .................................................... 25
7.2 Assemblingonstandardrail......................................................................................................26
7.3 Connectingthefunctionalearth................................................................................................27
8ELECTRICAL CONNECTION................................................................................................................28
8.1 Electricalconnectioneldbusgateway ....................................................................................28
8.1.1 Gateway with CANopen interface / büS interface .......................................................28
8.1.2 Gateway with industrial Ethernet interface .................................................................29
8.1.3 Gateway with PROFIBUS DPV1 interface ..................................................................30
8.2 Electricalconnectionelectronicmodulewithdigitalinputs ....................................................31
8.3 ElectricalconnectionType6534valvesfor
safety-relatedshut-o(SIAvariant) ..........................................................................................32
9PNEUMATIC CONNECTION.................................................................................................................34
9.1 Assignmentofthepneumaticconnections ..............................................................................34
9.1.1 Allocation of valve outputs to the pneumatic connections of the valve terminal .......35
9.1.2 External and internal auxiliary pilot air........................................................................35
10 MICRO SD CARD .................................................................................................................................36
11 DESIGNING VIA THE BÜRKERT COMMUNICATOR...........................................................................37
11.1 UserinterfaceoftheBürkertCommunicator............................................................................37
11.2 EstablishingaconnectionbetweenthedeviceandtheBürkertCommunicator....................38
11.3 Basesettingsofthevalveterminal ...........................................................................................38
11.4 Basesettingsofindustrialcommunication ..............................................................................38
11.4.1 Selectingtheeldbusprotocol...................................................................................38
11.4.2 PROFIBUS DPV1 settings ..........................................................................................38
11.4.3 CCLink settings ..........................................................................................................39
11.4.4 Industrial Ethernet settings.........................................................................................39
11.5 Furtherpossiblesettings ...........................................................................................................40
11.5.1 Congurationarea“UnitX” ........................................................................................40
11.5.2 Congurationarea“Industrialcommunication”..........................................................41
11.5.3 Congurationarea“Generalsettings” ........................................................................42
11.6 Usingextensionmodules(EM)..................................................................................................45
11.6.1 Congurationoftheeldbus ......................................................................................45
11.6.2 Conguringthevalveislandwithextensionmodules.................................................46
11.6.3 ConguringthebüSnetwork......................................................................................46
12 SETTINGS OF THE FIELDBUS GATEWAY ..........................................................................................48
12.1 OperatingelementsofeldbusgatewayME43........................................................................48
12.2 Operationviathedisplayattheeldbusgateway ...................................................................48
12.2.1 Description of the keys...............................................................................................48
12.3 DisplayelementsofeldbusgatewayME43............................................................................49
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Type 8652
12.3.1 LEDs for displaying the network connection to the industrial Ethernet......................49
12.3.2 LED for displaying the device status ..........................................................................50
12.4 Settingoptionsoftheeldbusgateway ...................................................................................51
13 DESIGNING VIA FIELDBUS .................................................................................................................52
13.1 CablingofbüSnetworks ...........................................................................................................52
13.2 Start-uplesanddescriptionofprocessdataandparameters..............................................52
13.3 Bit-by-bitcompilationoftheinputsandoutputs .....................................................................53
13.3.1 Examples of bit-by-bit allocations of valve units........................................................ 53
14 EXTENDED GATEWAY FUNCTIONALITIES.........................................................................................54
15 START-UP .............................................................................................................................................55
15.1 Safetyinstructions .....................................................................................................................55
15.2 Startingupviamanualoverride ................................................................................................55
15.2.1 Additionalelement“MOlocking” ...............................................................................56
15.3 Displayelementsoftheelectronicmodule ..............................................................................56
15.4 Displayviews .............................................................................................................................57
15.5 Markingthevalveslots..............................................................................................................58
16 MAINTENANCE, TROUBLESHOOTING...............................................................................................59
16.1 Safetyinstructions .....................................................................................................................59
16.2 Replacingavalve.......................................................................................................................59
16.2.1 Replacing a valve with the correct minimum distance ...............................................60
16.2.2 Replacing a valve without minimum distance ............................................................61
16.3 Replacingthelter.....................................................................................................................62
16.4 ReplacingtheeldbusgatewayME43......................................................................................63
16.5 Troubleshooting .........................................................................................................................64
16.6 LCdisplayoftheelectronicmodules........................................................................................65
17 DISASSEMBLY .....................................................................................................................................66
17.1 Safetyinstructions .....................................................................................................................66
18 ACCESSORIES.....................................................................................................................................67
19 PACKAGING, TRANSPORT..................................................................................................................68
20 STORAGE .............................................................................................................................................68
21 DISPOSAL ............................................................................................................................................68
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The operating instructions
Type 8652
1 THE OPERATING INSTRUCTIONS
The operating instructions describe the entire life cycle of the device.
→Keep these instructions ready to hand at the operation site.
Importantsafetyinformation!
▶Carefully read these instructions.
▶Observe in particular the safety instructions, intended use and operating conditions.
▶Persons, who work on the device, must read and understand these instructions.
1.1 Symbols
DANGER
Warnsofanimmediatedanger.
▶Failure to observe the warning will result in a fatal or serious injury.
WARNING
Warnsofapotentiallydangeroussituation.
▶Failure to observe the warning may result a fatal or serious injury.
CAUTION
Warnsofapossibledanger.
▶Failure to observe the warning may result in a moderate or minor injury.
NOTE
Warnsofdamagetoproperty.
▶Failure to observe the warning may result in damage to the device or other equipment.
Indicates important additional information, tips and recommendations.
Refers to information in these operating instructions or in other documentation.
Highlights instructions to avoid a danger.
Designates a procedure which you must carry out.
Indicates a result.
MENUE Symbol for software interface texts.
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The operating instructions
Type 8652
1.2
Term In these instructions representative for
Device, valve terminal Valve terminal AirLINE type 8652
Valve Pneumatic slide valve that can be integrated in the valve block
Actuator, process valve Pneumatic consumers that are controlled by the valve terminal
SIA variant Variantforsafety-relatedshut-o
büS Bürkert system bus, a communication bus developed by Bürkert based on
the CANopen protocol
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Intended use
Type 8652
2 INTENDED USE
ThevalveterminalAirLINEtype8652isdesignedforcontrollingpneumaticallyoperatedprocess
valvesandforrecordingtheswitchingstatusesofthesevalves.
▶Use the device for its intended purpose only. Non-intended use of the device may be dangerous to
people, nearby equipment and the environment.
▶In areas at risk of explosion, only use devices approved for use in those areas. These devices are
labeled with a separate Ex type label. When utilized in a potentially explosive atmosphere, always pay
attention to the details on the separate Ex type label and the Ex additional instructions contained in the
scope of delivery.
▶Theprerequisitesforsafeandecientoperationarecorrecttransport,storage,assembly,installation,
start-up, operation, and maintenance.
▶When using the device, observe the permitted data, operating conditions and application conditions.
This information can be found in the contractual documents, the operating instructions and on the type
label.
▶Use the device only in conjunction with third-party devices and components recommended and autho-
rized by Bürkert.
▶In outdoor areas, make sure the device is installed in a control cabinet that provides a degree of protec-
tion of at least IP 65.
▶In indoor areas, make sure the device is installed in a control cabinet that provides a degree of protec-
tion of at least IP 20.
▶Makesurethedeviceisinecientworkingorderbeforeuse.
The valve terminal is intended only for use in industrial areas.
The valve terminal is not suitable for use in applications where there is a risk to life and limb.
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Basic safety instructions
Type 8652
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not consider any contingencies or incidents which occur during assembly,
operationandmaintenance.Theoperatorisresponsibleforobservingthelocation-specicsafetyregulations,
also with reference to the personnel.
Riskofinjuryduetohighpressureanduncontrolledmovementoftheactuators.
▶Before working on the device or system, secure the actuators against moving.
▶Beforeworkingonthedeviceorsystem,switchothepressure.Ventordrainlines.
Riskofinjuryfromelectricshock.
▶Beforeworkingonthedeviceorsystem,switchothepowersupply.Secureagainstreactivation.
▶Observe applicable accident prevention and safety regulations for electrical equipment.
Riskofburnsduetohotdeviceparts.
▶Keepthedeviceawayfromhighlyammablesubstancesandmedia.
Riskofinjuryduetoimproperinstallationandmaintenance.
▶Only trained technicians may perform installation and maintenance work.
▶Perform installation and maintenance with suitable tools only.
Riskofinjuryduetounintentionalactivationanduncontrolledstart-upofthedeviceandsystem.
▶Secure the device and system to prevent unintentional activation.
▶Ensure that the system does not start up in an uncontrolled manner.
Generalhazardoussituations.
To prevent injury, ensure the following:
▶Install the device according to the regulations applicable in the country.
▶Donotsupplyaggressiveorammablemediatothemediaconnectionsofthedevice.
▶Do not supply liquids to the media connections of the device.
▶After the process is interrupted, restart in a controlled manner.
Observe sequence:
1. Connect the power supply.
2. Connect the pneumatic supply (with an external pressure supply, initially the external auxiliary pilot air
[X/12/14]andthenthemediumpressure[P/1]).
▶Donotcarryoutmodicationsatthedevice.
▶Do not subject the device to mechanical loads.
▶Observe the general rules of technology.
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Basic safety instructions
Type 8652
NOTE
Electrostatically sensitive components and assemblies.
Thedevicecontainselectroniccomponentsthataresusceptibletoelectrostaticdischarging(ESD).Com-
ponents that come into contact with electrostatically charged people or objects are at risk. In the worst
case scenario, these components are destroyed immediately or fail after start-up.
▶MeettherequirementsspeciedbyEN61340-5-1tominimizeoravoidthepossibilityofdamagecaused
by sudden electrostatic discharge.
▶Do not touch electronic components when the supply voltage is connected.
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General information
Type 8652
4 GENERAL INFORMATION
4.1
Germany
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Strasse 13–17
D-74653Ingelngen
Tel.+49(0)7940-1091111
Fax+49(0)7940-1091448
Email: [email protected]
International
The contact addresses can be found on the last pages of the printed Quickstart.
And also on the Internet at: www.burkert.com
4.2
The warranty is only valid if the deviceis used as intended in accordance with the specied application
conditions.
4.3
The operating instructions and data sheets for Bürkert products can be found on the Internet at:
www.burkert.com
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Product description
Type 8652
5 PRODUCT DESCRIPTION
Due to the compact and modular design in terms of pneumatic and electric interfaces, the valve terminal
AirLINEtype8652providesaexiblesolutionforvariedandcomplexcontrolactivities.Thevalveterminal
design is optimized for use in control cabinets. The AirLINE Quick adapter plate is already part of the basic
valve terminal version. Using AirLINE Quick, the valve terminal can be positioned directly at a cut-out on
theoororwallofthecontrolcabinet.Alternatively,astandardrailenablesassemblyontherearwallofthe
control cabinet.
Whenconguredtoamaximumdegree,thevalveterminalallowsapplicationofupto48valvefunctions.
A clear operating and display concept facilitates installation and maintenance work. The supply manifold is
madeofaluminumandprovidesthenecessarystability.Itisusedtoattachtheuidicelements,thepneu-
matic slide valves, and the electronic modules.
TheelectricalconnectiontechnologyoccursviatheeldbusgatewayME43,althoughvariouseldbuspro-
tocols can be used.
5.1
The valve terminal AirLINE type 8652 is designed to control and record the switching statuses of pneumati-
cally operated process valves.
5.2
•Fast and easy tubing through AirLINE Quick
•Valve change possible during operation due to hot swap function
•Integrated check valves
•Fast information on the device status due to two-line LCD with alphanumeric display
•Displaynumberofswitchingcyclesandpredenedwarningthresholds
•RedundantringtopologywithMediaRedundancyProtocol(MRP)orDeviceLevelRing(DLR)
•OptionalconnectiontoBürkert’sEcientDeviceIntegrationPlatform(EDIP):
CongurationandparameterizationwiththeuniversalsoftwaretoolBürkertCommunicator
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Product description
Type 8652
5.3
Fieldbus gateway
ME43
Connection module
with feed
Connection module
without supply
Pneumatic slide valves
Adapter plate
AirLINE Quick
Electronic module
Electronic module with
digital inputs
Supply manifold
complete(hotswap)
Terminating resistor
Figure 1: Design of the valve terminal type 8652
5.3.1
TheeldbusgatewaytypeME43isusedasaeldbusconverterbetweenbüS/CANopenandindustrialEth-
ernet or PROFIBUS DPV1.
5.3.2
The connection module is used for the internal distribution of the pilot pressure on the pilot valves. Through
a seal in the connection module it is possible to switch to internal or external pilot pressure supply. The con-
nection module enables the additional pressure supply of medium pressure and pilot pressure.
5.3.3
The electronic module shows the valve status via an LC display.
If electronic modules with digital inputs are used, they supply electric power to the connected position feed-
backs. Thanks to the position feedbacks, error messages, maintenance intervals or other information on the
device status can be displayed on the LC display of the electronic module.
Standard 3-wire sensors and 2-wire sensors with voltages between 10...30 V as well as mechanical limit
switches can be used.
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Product description
Type 8652
The following data may be output depending on the sensor used:
Possibledata 3-wiresensors 2-wiresensors Mechan.limitswitches
Sensor actuated XXX
Sensor not actuated XXX
Short circuit X– –
Broken wire – X–
Examplesofapplicablepositionfeedbacks
3-wire sensors:
Bürkerttype8697(3-wire)
TurckNi1,5-BKT-AP7X
BalluBES-M08EA
2-wire sensors:
Bürkerttype8697(2-wire)
Turck Ni5-K11-Y1
TurckBi2-EG08-AG41X
TurckBi3-M12-AD4X
Mechanical limit switch:
Bürkerttype8697(microswitch)
5.3.4
Operation of the pneumatic slide valves is based on a soft-seated slide principle. The individual technical
values and the various circuit functions of the pneumatic slide valves are described on the valve terminal
type8652datasheet(seewww.burkert.com).
Pneumatic slide valves type 6534 come with manual override. The manual override operates without the
valve terminal being connected to the power supply and enables manual switching of the valves (see
chapter“15.2”).
Manual override provides both spring-return and latching action as standard. Use of the additional element
“MOlocking”limitsthemanualoverridefunction(justspringreturnorblocked).
5.3.5
The supply manifold is used to supply the individual valves. The supply manifold is available with or without
checkvalves.TheapplicationofPshuto(HotSwap)enablestheswappingofindividualvalvesduring
operation. The check valves in the exhaust ducts help to avoid unwanted actuator switching (e.g. due to
uncontrolledpressurepeaks).
The supply manifold is designed to allow the valve terminal to be mounted on the standard rail or directly on
theoororwallofthecontrolcabinetasAirLINEQuick.
5.3.6
The stainless steel adapter plate AirLINE Quick enables, e.g., utilization of the valve terminal in hygienic
applications without extensive installation work. The adapter plate guarantees simple and secure assembly
ontheoororwallofthecontrolcabinet.
5.3.7
Eachtype8652valveislandhas1terminatingresistorupondelivery(see“Fig.1”).Ifseveralvalveislands
are connected in series, only the last device within this series can have a terminating resistor. The termi-
nating resistors of the other devices must be extracted from the devices by pulling them to the right.
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Technical data
Type 8652
6 TECHNICAL DATA
6.1
ThedeviceconformstotheECdirectivesaspertheECDeclarationofConformity(ifapplicable).
6.2
The applied standards, which are used to demonstrate conformity with the EC Directives, are listed in the EC
typeexaminationcerticateand/ortheECDeclarationofConformity(ifapplicable).
6.3
NOTE
▶Usesafetyextra-lowvoltageinaccordancewithprotectionclass3EN61140,VDE0140.
Condition Permissiblerange
Ambient temperature –10…+55 °C
Storage temperature –10…+60 °C
Altitude Restricted to max. 2000 m above sea level for UL approved versions
Compressed air
quality
ISO 8573-1:2010, Class 7.4.4
Nominal operating
mode
Continuousoperation(100%dutycycle)
Operating voltage 24VDC±10%residualrippleateldbusinterface1Vss1)
Protection class 3inaccordancewithEN61140,VDE0140
1) UL approved Versions must be supplied by one of the following:
a) Limited Energy Circuit (LEC) according to UL/ IEC 61010-1
b) Limited Power Source (LPS) according to UL/ IEC 60950
c) SELV/ PELV with UL Recognized Overcurrent Protection dimensioned according to UL/ IEC 61010-1 Table 18
d) NEC Class 2 power source
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Technical data
Type 8652
Condition Permissiblerange
Current consumption Currentconsumptiondependsonthevalveterminalconguration.
Thetotalcurrentfortheeldbusinterfaceiscalculatedusingtheformula:
Itotal= Ibackgr.+(nxIvalve)+(mxIpos. feedback)+(kxIdisplay mod.)
Itotal: Total current
Ibackgr.: Backgroundcurrentdependentontheeldbussystem
PROFINET IO: 135 mA
EtherNet/IP: 135 mA
Modbus TCP: 135 mA
PROFIBUS DPV1: 100 mA
DeviceNet: 35 mA
CANopen: 35 mA
n: Number of valves
Ivalve:Nominalcurrentofthevalve(35mA)
m: Number of position feedbacks
Ipos. feedback.:Currentconsumptionofpositionfeedbacks(max.22mA)
k: Number of display modules
Idisplay mod.:Currentconsumptiondisplaymodules(10mA)
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Technical data
Type 8652
6.4
Valve slots Max. 24
Position feedback Max. 48
Degree of protection IP20
6.4.1
Circuitfunction(CF) 2xCFC*
NC(normallyclosed)
2 x 3/2-way
2xCFD
NO(normallyopen)
2 x 3/2-way
CFH*
5/2-way monostable
CFZ
5/2-way bistable
CFL*
5/3-way locked
CFM
5/3-way pressurized
CFN
5/3-way exhausted
Flow rate QNn Up to 310 lN/min
(seedatasheetforexactowratevaluesforthevariouscircuitfunctions)
Medium pressure** 0...10 bar
Pilot pressure*** 3...10 bar
Electr. power before/
after power reduction
2x0.7W/2x0.175W 0.7W/0.175W 0.7W/0.175W
Power before/after
power reduction
2x29mA/2x≤10mA 29mA/≤10mA
*) AlsoavailableasSIAvariant(seechapter“8.3”onpage32).
**) Atlevelsofvacuumupto3barandpressurelevelsof8-10bar,observethepilotpressurediagramandsetthefeedofauxiliarypilotairto“external”
(see chapter “9.1.2Externalandinternalauxiliarypilotair”onpage35).
***) Withtheexternalauxiliarypilotairvariant,selectthepilotpressureinaccordancewiththepilotpressurediagram.
6.4.2
3 4 5 6 7 8 9 10
Pilotpressure[bar]
Mediumpressure[bar]
10
9
8
7
6
5
4
3
2
1
0
-1
Figure 2: Pilot pressure diagram for pneumatic slide valve type 6534
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Technical data
Type 8652
6.5
Circuitfunction(CF) Symbolinaccordancewith
ISO1219-1
Description
2 x CFC* 4
15
14
2
13
12
In idle position, port 2 and port 4 exhausted.
2 x CFD 4
15
14
2
13
12
In idle position, port 2 and port 4 vented.
CFH*
14
12
4 2
513
In idle position, pressure port 1 with port 2
connected, port 4 exhausted.
CFZ
14 12
4 2
513
5/2-way bistable valve;
depending on the switch position either
port 2 vented and port 4 exhausted
or
port 2 exhausted and port 4 vented.
CFL*
14 12
42
51 3
In idle position, all ports locked.
CFM(onrequest)
51 3
14 12
4 2 In idle position, port 2 and port 4 pressurized.
CFN(onrequest)
14 12
4 2
51 3
In idle position, port 2 and port 4
de-energized.
*)Type6534SIAvariant(variantforsafety-relatedshut-o)
Optionally,Type6534valvescanbeequippedwithasecondelectricalconnection(connectionterminal).Safety-relatedshut-oisthereforepossible
for each channel individually. The valve variants are without manual override. See also chapter “8.3”onpage32.
6.6
D-74653Ingelfingen
Type 8652 AirLINE
3–10 bar
–10...+55 °C
24 V
S/N 1002
00320501 W15MS
Operating voltage
Permitted ambient temperature range
Permitted pilot pressure range
Figure 3: Type label standard for valve terminal type 8652
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Technical data
Type 8652
6.7
For safety-relevant
information, see operating
instructions
MadeinGermany
D-74653Ingelfingen
Type 8652 AirLINE
3–10 bar
–10...+55 °C
24 V , 3A E238179
S/N 1002
Proc.Cont.Eq.
W18TT
00320501
Figure 4: Type label UL for valve terminal Type 8652
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Technical data
Type 8652
6.8
6.8.1 PROFINET IO
Topology recognition LLDP, SNMP V1, MIB2, physical device
Minimum cycle time 10 ms
IRT Not supported
MRP media redundancy MRP client is supported
Further supported functions DCP, VLAN priority tagging, shared device
Transmission speed 100 Mbit/s
Data transport network Ethernet II, IEEE 802.3
PROFINETIOspecication V2.3
Applicationrelations(AR) The device can simultaneously process up to 2 IO ARs, 1 Super-
visor AR, and 1 Supervisor DA-AR.
6.8.2 EtherNet/IP
Predenedstandardobjects IdentityObject(0x01)
MessageRouterObject(0x02)
AssemblyObject(0x04)
ConnectionManager(0x06)
DLRObject(0x47)
QoSObject(0x48)
TCP/IPInterfaceObject(0xF5)
EthernetLinkObject(0xF6)
DHCP Supported
BOOTP Supported
Transmission speed 10 and 100 Mbit/s
Duplex modes Half duplex, full duplex, auto negotiation
MDI modes MDI,MDI-X,autoMDI-X
Data transport network Ethernet II, IEEE 802.3
AddressConictDetection(ACD) Supported
DLR(ringtopology) Supported
Integrated switch Supported
CIP reset service Identity object reset service type 0 and type 1
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Other manuals for AirLINE 8652
3
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