Burkert 8644 AirLINE User manual

Quickstart
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Type 8644
AirLINE

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© 2011 Bürkert Werke GmbH
Operating Instructions 1103/00_EU-ML_00809514 / Original DE

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1. QUICKSTART .....................................................................................................4
2. SYMBOLS ............................................................................................................4
3. INTENDED USE ................................................................................................5
3.1. Foreseeable misuse ......................................................................... 5
4. GENERAL SAFETY INFORMATION ........................................................6
5. GENERAL INFORMATION ...........................................................................7
5.1. Contact address ...............................................................................7
5.2. Warranty ............................................................................................. 7
5.3. Informations in the Internet .............................................................7
6. SYSTEM DESCRIPTION ...............................................................................8
6.1. Application area ................................................................................ 8
6.2. System description ..........................................................................8
7. TECHNICAL DATA ...........................................................................................9
7.1. Conformity ......................................................................................... 9
7.2. Standards ........................................................................................... 9
7.3. General Technical Data ..................................................................9
7.4. Technical Data of Valves ................................................................. 9
8. STRUCTURE AND INSTALLATION ......................................................11
8.1. Safety instructions .........................................................................11
8.2. Structure ..........................................................................................12
8.3. Assembly ..........................................................................................13
8.4. Removing the valve block from the standard rail ....................16
9. INSTALLATION ...............................................................................................17
9.1. Safety instructions .........................................................................17
9.2. Fluid Installation ..............................................................................17
9.3. Electrical Installation ......................................................................19
10. START-UP ......................................................................................................19
10.1. Safety instructions .......................................................................19
10.2. Fluid start-up .................................................................................19
10.3. Electrical start-up .........................................................................20
11. TRANSPORT, STORAGE, DISPOSAL .............................................. 20
Contents
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Quickstart
1. QUICKSTART
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.
Important Safety Information!
Read Quickstart carefully and thoroughly. Study in particular the
chapters entitled "General safety information" and "Intended use".
• Quickstart must be read and understood.
The Quickstart explains, for example, how to install and start-up the
device.
A detailed description of the device can be found in the operating
instructions for Type 8644.
The operating instructions can be found on the enclosed CD
and on the Internet at:
www.burkert.com
2. SYMBOLS
The following symbols are used in these instructions.
DANGER!
Warns of an immediate danger!
• Failure to observe the warning may result in a fatal or serious
injury.
WARNING!
Warns of a potentially dangerous situation!
• Failure to observe the warning may result in serious injuries or death.
CAUTION!
Warns of a possible danger!
• Failure to observe this warning may result in a moderately severe
or minor injury.
NOTE!
Warns of damage to property!
Important tips and recommendations.
Refers to information in these operating instructions or in
other documentation.
→designates a procedure which you must carry out.
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Intended use
3. INTENDED USE
Non-intended use of the AirLINE Type 8644 may be a hazard
to people, nearby equipment and the environment.
• The device is designed for use in an environment where there is a
risk of explosion (only Type 8644 Siemens and Wago). Pneumati-
cally operated devices may be used for control.
• Do not use the device outdoors unprotected.
• Use according to the authorized data, service and operating condi-
tions specified in the contract documents and operating instruc-
tions. These are described in the chapter entitled "Technical data".
• The device may be used only in conjunction with third-party devices
and components recommended and authorized by Bürkert.
• Correct transportation, storage, and installation, as well as care-
ful use and maintenance are essential for reliable and faultless
operation.
• Use the device only as intended.
3.1. Foreseeable misuse
• Do not supply the medium connectors of the system with aggressive
or flammable media.
• Do not physically stress the housing (e.g. by placing objects on it
or standing on it).
• Note that pipes and valves must not become detached in systems
which are under pressure.
• Before reaching into the system, always switch off the power supply.
• Design the pressure supply with the largest possible volume to
prevent a pressure drop when the system is switched on.
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General safety information
4. GENERAL SAFETY INFORMATION
This safety information does not cover:
• Haphazard situations that can arise during installation, operation and
maintenance of the use.
• Locally applicable safety regulations which the operator and instal-
lation personnel are obligated to follow.
Danger – high pressure!
• Before loosening lines or valves, turn off the pressure and vent
the lines.
Risk of electric shock!
• Before reaching into the device or the equipment, switch off the
power supply and secure to prevent reactivation!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
Risk of burns/risk of fire if used continuously through hot
device surface!
• Keep the device away from highly flammable substances and media
and do not touch with bare hands.
General Hazardous Situations.
To prevent injuries:
• Ensure that the system cannot be activated unintentionally.
• Installation and maintenance work may be carried out only by
authorized technicians with the appropriate tools.
• After an interruption in the power supply or pneumatic supply,
ensure that the process is restarted in a defined or controlled
manner.
• The device may be operated only when in perfect condition and
in consideration of the operating instructions.
• The general rules of technology must be observed for application
planning and operation of the device.
The Type 8644 AirLINE was developed with due consideration
given to accepted safety rules and is state-of-the-art. Never-
theless, dangerous situations may occur.
Failure to observe this operating manual and its operating instructions
as well as unauthorized tampering with the device release us from
any liability and also invalidate the warranty covering the devices
and accessories!
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General information
NOTE!
Operate the system with direct current only!
To prevent damage to the system, use only direct current for the
system power supply.
Prevent a pressure drop!
To prevent a pressure drop, design the system pressure supply
with the largest possible volume.
Electrostatic sensitive components/modules!
The device contains electronic components, which react sensitively
to electrostatic discharge (ESD). Contact with electrostatically
charged persons or objects is hazardous to these components. In
the worst case scenario, they will be destroyed immediately or will
fail after start-up.
• Observe the requirements in accordance with EN 61340-5-1
and 5-2 to minimize/avoid the possibility of damage caused by a
sudden electrostatic discharge!
• Also, ensure that you do not touch electronic components when
the power supply voltage is present!
5. GENERAL INFORMATION
5.1. Contact address
Germany
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. + 49 (0) 7940 - 10 91 111
Fax + 49 (0) 7940 - 10 91 448
E-mail: [email protected]
International
Contact addresses are found on the final pages of this operating
manual.
And also on the Internet under: www.burkert.com
5.2. Warranty
The warranty is only valid if the AirLINE Type 8644 is used as intended
in accordance with the specified application conditions.
5.3. Informations in the Internet
The operating manual and the data sheets on Type 8644 can be found
on the Internet under: www.burkert.com
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System Description
6. SYSTEM DESCRIPTION
6.1. Application area
The AirLINE system is designed for decentralized use in industrial
environments. Electronics and fluidics can be combined particularly
easily and efficiently thanks to the modular design.
DANGER!
Danger of explosion!
If systems in the explosion-protected area (Type 8644 Siemens and
Wago) are installed in a control cabinet, the following requirements
must be met:
• The control cabinet must be authorized for use in the explosion-
protected area.
• The control cabinet must be large enough to allow the resulting lost
heat to be dissipated in a suitable manner to the outside.
• The internal temperature of the control cabinet must not exceed
the max. permitted ambient temperature for the device.
Risk of electric shock!
• Before reaching into the device or the equipment, switch off the
power supply and secure to prevent reactivation!
• Observe applicable accident prevention and safety regulations for
electrical equipment!
6.2. System description
Fig. 1: Type 8644 AirLINE
The Type 8644 AirLINE is an electrical and pneumatic automation
system which was developed for use in the control cabinet or switch
box. In a continuous system all electronic and pneumatic components
are standardized, enabling pneumatic, electric and electronic modules
with various functions to be combined very easily with each other by
the observation of simple rules.
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Technical data
7. TECHNICAL DATA
7.1. Conformity
The AirLINE system Type 8644 conforms to the EC Directives
according to the Declaration of Conformity.
7.2. Standards
The conformity with EC guidelines is guaranteed in accordance with
standards:
• EN 61000-6-6, EN 61000-6-2, EN 61000-6-4, EN 61000-3-3,
EN 60079-0, EN 60079-15
7.3. General Technical Data
Technical Data Pilot valve type 0460,
6524, 6525
Pilot valve type 0461,
6526, 6527
Add-on
dimension
11 mm 16.5 mm
Pressure range Vac. up to 10 bar Vac. up to 10 bar
Max. number of
valves
64
(when using
Type 0460: 32)
32
(when using
Type 0461: 24)
Operating
voltage
24 V DC 24 V DC
Voltage tolerance +20 % / -15 %
(when using
Type 0460: ± 10 %)
+20 % / -15 %
(when using
Type 0461: ± 10 %)
Residual ripple 1 Vss 1 Vss
Nominal power
per valve
1 W
(0.5 W nominal power
after 120 ms)
2 W
(1 W nominal power
after 120 ms)
Nominal current
per valve
43 mA
(28 mA holding current
after 120 ms)
41 mA
(when using Type 0460)
85 mA
(52 mA holding current
after 120 ms)
41 mA
(when using Type 0461)
Ambient
temperature
Storage
temperature
0 ... +55 °C
(when using Type 0460 and 0461: 0 ... +50 °C)
-20 ... +60 °C
Protection class IP20 acc. to IEC 60529
IP65 in closed switch box
7.4. Technical Data of Valves
Type Operating principle Add-on
dimension
(mm)
Flow-rate
(l/min)
6524 3/2-way valve 11 300
2 x 3/2-way valve
6525 5/2-way valve 11 300
6526 3/2-way valve 16.5 700
6527 5/2-way valve 16.5 700
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Technical data
0460 5/2-way impulse valve 11 200
0460 5/3-way valve 11 200
0461 5/2-way impulse valve 16.5 450
0461 5/3-way valve 16.5 450
7.4.1. Rating plate
MADE IN GERMANY
W14UN
450000Y
24 V DC 1W
PN 2,5 - 7 bar
6525 H 4,0
Type
Operating principle
Orifice
Identification number
Voltage (±10 %), capacity
Pressure range
Fig. 2: Location and description of the rating plate
7.4.2. Fluid connection
Type 6524
3/R
X*
2/A
1/P
Type 6525
X*
5/R
4/A
1/P
2/B
3/S
Design the pressure supply
with the largest possible
volume!
X* - pilot control exhaust air
Fig. 3: Fluid connection. Types 6524 and 6525
7.4.3. Fluid and electrical connection
Type 6524
(2 x 2/3-way valve)
12
14
- Pin coil 12
controlled via bit 1
- Pin coil 14
controlled via bit 2
+ Pin
X*
5/R
4/A
1/P
2/B
3/S Bit 2
Bit 1
Observe pin
assignment!
X* - pilot control
exhaust air
Fig. 4: Fluid and electrical connection. Type 6524
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Structure and installation
8. STRUCTURE AND INSTALLATION
8.1. Safety instructions
DANGER!
Risk of injury from high pressure in the equipment!
• Before loosening lines or valves, turn off the pressure and vent
the lines.
Risk of injury due to electrical shock!
• Before reaching into the device or the equipment, switch off the
power supply and secure to prevent reactivation!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
WARNING!
Risk of injury from improper assembly!
• Installation may only be carried out by authorized technicians with
the appropriate tools!
Risk of injury from unintentional activation of the system and
uncontrolled restart!
• Secure system from unintentional activation.
• Following assembly, ensure a controlled restart.
CAUTION!
Escape of medium and malfunction!
If the seals are not seated correctly, leaks and malfunctions may occur
due to pressure losses.
• Ensure that the seals are seated correctly in the area of the elec-
tronics and pneumatics.
Short-circuit, malfunction!
The electrical connection requires exact contacting.
• Do not bend contacts.
• If connections are damaged or bent, replace the affected
components.
• Do not switch on the system unless the components are in perfect
condition.
NOTE!
Operate the system with direct current only!
To prevent damage to the system, use only direct current for the
system power supply.
Prevent a pressure drop!
To prevent a pressure drop, design the system pressure supply with
the largest possible volume.
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Structure and installation
8.2. Structure
Supply and vent connections
Working connections
4-fold / 8-fold valve disc
2-fold valve disc
Intermediate feed
Connection module on right
Panel (optional pressure gauge to indicate operating pressure on the station)
2-fold valve disc
Connection module on left
Fig. 5: Diagram of the modules of the Bürkert AirLINE system
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Structure and installation
8.3. Assembly
8.3.1. Installation on standard rail
DANGER!
Risk of electric shock!
• Before reaching into the device or the equipment, switch off the
power supply and secure to prevent reactivation!
Field bus
Converter Module Module
Converter Terminator
Fig. 6: Installation of a valve block into a control cabinet
→Fasten the standard rail firmly in the control cabinet.
→Establish a short, wide PE connection between the standard rail
and the control cabinet.
The valve terminal must be freely accessible from above.
Ensure good heat dissipation!
Recommended distance when installing in a control cabinet:
A30 mm C30 mm
B30 mm D60 mm
8.3.2. Installation of AirLINE Quick
To install AirLINE Quick, a notch must be first of all provided on the
base or the wall of the control cabinet, e.g. through lasing or punching.
For the dimensions of the relevant flange image, refer to chapter
"8.3.3. Dimensions of the flange images for AirLINE Quick".
NOTE!
The notch on the control cabinet base must be burr-free for the seal
of the AirLINE Quick adapter not to become damaged.
→Place the valve terminal in the control cabinet on the prepared
notch.
AirLINE Quick
adapter
Valve terminal
Type 8644
Control cabinet
Fig. 7: Placing the valve terminal in the control cabinet
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Structure and installation
NOTE!
The seal of the AirLINE Quick adapter must be placed into the
groove without being damaged before installing the adapter on the
control cabinet base.
→Attach the stability plate from the outside to the control cabinet
base or wall to prevent distortion and fix with M5 screws.
Stability plate
Screws
Fig. 8: Attaching the stability plate
8.3.3. Dimensions of the flange images for
AirLINE Quick
158 ± 0.4
54 ± 0.3
t >= 1.5
(192)
(96)
73 ± 0.3
59 ± 0.3
155 ± 0.4
R 6.5
Space requirements
for reinforcing frame
on the outside
Fig. 9: Dimensions: 8-fold adapter
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Structure and installation
246 ± 0.4
123 ± 0.4
t >= 1.5
(280)
243 ± 0.4 Space requirements
for reinforcing frame
on the outside
(96)
73 ± 0.3
59 ± 0.3
R 6.5
Fig. 10: Dimensions: 16-fold adapter
279 ± 0.4
140 ± 0.4
(313)
R 6.5
73 ± 0.3 59 ± 0.3
t >= 1.5
276 ± 0.4
(96)
Space require-
ments for rein-
forcing frame on
the outside
Fig. 11: Dimensions: 16-fold adapter with intermediate feed module
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Structure and installation
8.4. Removing the valve block from the
standard rail
DANGER!
Risk of electric shock!
• Before reaching into the device or the equipment, switch off the
power supply and secure to prevent reactivation.
The valve block is bolted securely onto the standard rail. Additional
electrical modules / terminals can be aligned in rows on the sides of
the valve block.
Procedure:
→Detach the adjacent modules/terminals (if fitted).
→Release the attachment of the valve block on the standard rail. To
do this, turn the fastening screws all the way counter-clockwise.
Fig. 12: Releasing the attachment of the valve block on the standard rail
→Lift the valve block vertically off the standard rail.
There must be adequate space between valve block and pre-
decessor module > 6 mm.
→Detach the modules/terminals from the standard rail according to
the manufacturer’s description.
NOTE!
The interface of the left connection module contains elements
which may break off if force is used.
• Never place the valve block on its side and observe the permitted
installation position.
Fig. 13: Detaching the modules/terminals from the standard rail
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Installation
9. INSTALLATION
9.1. Safety instructions
DANGER!
Risk of injury from high pressure in the equipment!
• Before loosening lines or valves, turn off the pressure and vent
the lines.
Risk of injury due to electrical shock!
• Before reaching into the device or the equipment, switch off the
power supply and secure to prevent reactivation!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
WARNING!
Risk of injury from improper installation!
• Installation may only be carried out by authorized technicians with
the appropriate tools!
Risk of injury from unintentional activation of the system and
uncontrolled restart!
• Secure system from unintentional activation.
• Following installation, ensure a controlled restart.
9.2. Fluid Installation
DANGER!
Risk of injury from high pressure in the equipment!
• Before loosening lines or valves, turn off the pressure and vent
the lines.
• Design the connections with the largest possible volume.
• Close the open connections not required with lock screws.
• The connections for the pilot control exhaust air (x) must not be
sealed.
• Check correct assignment of the connections 1 and 3 or 5. They
may by no means be interchanged.
9.2.1. Pneumatic connections - feed
Exhaust air
Pressure supply connection
X channel:
Standard version:
Deaeration of the control valves
Control assist air version:
P connection for control valves
(R/S) 3/5
(P) 1
Fig. 14: Pneumatic Connections
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Installation
Procedure:
→Depending on the version, plug the connections in the corre-
sponding working connections (D10) or screw them in (G 1/4,
NPT 1/4).
NOTE!
For the plug-in connections the hose pipes must meet the following
requirements:
• Minimum hardness of 40 Shore D (in accordance with DIN
53505 or ISO 868);
• Outer diameter in accordance with DIN 73378 (max. permitted
deviation ± 0.1 mm of the nominal dimension);
• Burr-free, cut off at right angles and undamaged on the outer
diameter;
The hose pipes must be pressed all the way into the plug-in
connections.
9.2.2. Removing the plug-in connections
→To detach the pipes, press in the thrust ring and pull out the hose
pipe.
9.2.3. Pneumatic connections - valve discs
NOTE!
For 3/2-way valves the upper connections remain free.
Inscription areas
8/4/2-fold valve discs
Working connec-
tions for 3/2-way
valves
Working connec-
tions for 5/2-way
valves
Fig. 15: Pneumatic connections - valve discs
5/2-way valve variants
Working connection Variant 1 Variant 2
Top (2) M7 D6, D1/4
Bottom (4) M7 D6, D1/4
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Start-Up
3/2-way valve variants
Working connection Variant 1 Variant 2
Top (0) Sealed internally Sealed internally
Bottom (2) M7 D6, D1/4
Procedure:
→Depending on the version, plug the connections in the corre-
sponding working connections (D6, D1/4) or screw them in (M7).
→Connection nipples can be used for threaded versions.
Inscription of the connections:
→Label the inscription areas with the data of the valve
connections.
9.3. Electrical Installation
DANGER!
Risk of injury due to electrical shock!
• Before reaching into the device or the equipment, switch off the
power supply and secure to prevent reactivation!
The electrical installation of the AirLINE system corresponds to the
installation of the decentralized peripheral device (depending on the
relevant cooperation partner Siemens, Wago, Phoenix or Rockwell).
Refer to the manuals provided by the cooperation partners for a more
detailed description.
10. START-UP
10.1. Safety instructions
WARNING!
Risk of injury from improper operation!
Improper operation may result in injuries as well as damage to the
device and the area around it.
• Before start-up, ensure that the operating personnel are familiar
with and completely understand the contents of the operating
instructions.
• Observe the safety instructions and intended use.
• Only adequately trained personnel may start up the equipment/
the device.
10.2. Fluid start-up
NOTE!
• Switch on the supply pressure.
• Only then switch on the power supply!
Procedures before fluid start-up:
→Check connections, voltage and operating pressure.
→Ensure that max. operating data are not exceeded.
→Check correct assignment of the connections 1 and 3 or 5. They
may by no means be interchanged.
→Release manual actuation during electrical operation.
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Transport, Storage, Disposal
10.3. Electrical start-up
The start-up of the AirLINE system corresponds to the installation of the
decentralized peripheral device (depending on the relevant cooperation
partner Siemens, Wago, Phoenix or Rockwell).
Refer to the manuals provided by the cooperation partners for a more
detailed description.
11. TRANSPORT, STORAGE, DISPOSAL
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 exceeding or dropping below the permitted storage
temperature.
Incorrect storage may damage the device!
• Store the device in a dry and dust-free location!
• Storage temperature: -20 ... +60 °C.
Damage to the environment caused by device components
contaminated with media!
• Ensure the device and packaging are disposed of in an environ-
mentally sound manner.
• Observe applicable regulations relating to refuse disposal and
the environment.
• Observe the national waste disposal regulations.
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