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.
© Bürkert Werke GmbH & Co. KG, 2011 - 2017
Operating Instructions 1804/01_EU-EN_00809514 / Original DE

3
1. QUICKSTART .....................................................................................................4
1.1. Definition of the term "Device" ......................................................4
1.2. Symbols .............................................................................................. 4
2. INTENDED USE ................................................................................................5
2.1. Restrictions ........................................................................................ 5
3. GENERAL SAFETY INFORMATION ........................................................5
4. GENERAL INFORMATION ...........................................................................6
4.1. Contact address ...............................................................................6
4.2. Warranty ............................................................................................. 6
4.3. Informations in the Internet .............................................................6
5. TECHNICAL DATA ...........................................................................................7
5.1. Conformity .........................................................................................7
5.2. Standards ........................................................................................... 7
5.3. General Technical Data ..................................................................7
6. ASSEMBLY ..........................................................................................................8
6.1. Safety instructions ...........................................................................8
6.2. Assembly ............................................................................................9
6.3. Removing the valve block from the standard rail ....................12
7. INSTALLATION ...............................................................................................13
7.1. Fluid Installation ..............................................................................13
7.2. Fluid deinstallation .........................................................................15
7.3. Electrical Installation ......................................................................15
8. START-UP .........................................................................................................16
8.1. Safety instructions .........................................................................16
8.2. Fluid start-up ...................................................................................16
8.3. Electrical start-up ...........................................................................16
9. MAINTENANCE .............................................................................................. 16
10. TRANSPORT, STORAGE, DISPOSAL .............................................. 16
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
1.1. Definition of the term "Device"
In these instructions, the term "device" always refers to the system
AirLINE type 8644.
1.2. 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
2. 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 supply the medium connectors of the system with
aggressive or flammable media.
• Do not use the device outdoors unprotected.
• Do not physically stress the housing (e.g. by placing objects on
it or standing on it).
• 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.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
3. 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.
General Hazardous Situations.
To prevent injuries:
• Ensure that the system cannot be activated unintentionally.
• 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.
• 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.
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General information
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.
NOTE!
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!
4. GENERAL INFORMATION
4.1. 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
4.2. Warranty
The warranty is only valid if the AirLINE Type 8644 is used as intended
in accordance with the specified application conditions.
4.3. 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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Technical data
5. TECHNICAL DATA
5.1. Conformity
The system AirLINE type 8644 conforms with the EC Directives
according to the EC Declaration of Conformity.
5.2. Standards
The applied standards, which verify conformity with the EC Direc-
tives, can be found on the EC-Type Examination Certificate and / or
the EC Declaration of Conformity.
5.3. General Technical Data
Technical Data Pilot valve type 0460,
6524, 6525
Pilot valve type 0461,
6526, 6527
Pressure range Vac. up to 10 bar Vac. up to 10 bar
Operating
voltage
24 V DC 24 V DC
Voltage tolerance +20 % / -15 %
(when using
Type 0460: ± 10 %)
+20 % / -15 %
(when using
Type 0461: ± 10 %)
Ambient
temperature
0 ... +55 °C
(when using Type 0460 and 0461: 0 ... +50 °C)
5.3.1. 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. 1: Location and description of the rating plate
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Assembly
5.3.2. 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. 2: Fluid connection. Types 6524 and 6525
5.3.3. Fluid and electrical connection
Type 6524
(2 x 2/3-way valve)
12
14
- Pin coil 12
controlled via bit “n+1”
- Pin coil 14
controlled via bit
“n”
+ Pin
X*
5/R
4/A
1/P
2/B
3/S Bit “n+1”
Bit “n”
Observe pin
assignment!
X* - pilot control
exhaust air
Hand lever
assignment
Fig. 3: Fluid and electrical connection. Type 6524
6. ASSEMBLY
6.1. 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.
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Assembly
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.
6.2. Assembly
DANGER!
Danger of explosion!
If systems in the explosion-protected area 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!
6.2.1. Installation on standard rail
Field bus
Converter Module Module
Converter Terminator
Fig. 4: Installation of a valve block into a control cabinet
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Assembly
→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
6.2.2. 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
“Tab. 1: Dimensions of the flange images for AirLINE Quick”.
The distances to the left, right, front and top depend on the selected
valve terminal configuration.
Recommended distance in the control cabinet to the valve
terminal:
left right front top
30 mm 60 mm 30 mm 50 mm
HINWEIS!
The opening on the control cabinet must be burr-free to
prevent damage to the seal of the AirLINE Quick adapter.
→Without damaging the seal of the AirLINE Quick adapter, insert it
into the groove of the flange opening.
→Position the valve terminal in the control cabinet on the prepared
opening.
→From outside attach the stability plate to prevent distortion and
secure with screws M 5 x 10 from the enclosed fastening set.
AirLINE Quick
adapter
Valve terminal
Type 8644
Control cabinet
Fig. 5: Placing the valve terminal in the control cabinet
Stability plate
Screws M 5 x 10
Fig. 6: Attaching the stability plate
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Assembly
6.2.3. Dimensions of the flange images for AirLINE Quick
Inside wall control cabinet
Space requirements reinforcing frame outside
G
N4
N3
N2
N1
M
only at O= 6 and O = 10
Ø 5.3 ± 0.2
59 ± 0.3 73 ± 0.3
(96)
R 6.5
t>=1.5
>=8
Fig. 7: Dimensions of the flange images for AirLINE Quick – for dimensions see “Tab. 1”, page 12
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Assembly
Version
8-fold 12-fold 16-fold 16-fold 20-fold
Feature
–––1) 2)
M155 ±0.4 199 ±0.4 243 ±0.4 276 ±0.4 287 ±0.4
N1 54 ±0.3 68 ±0.3 123 ±0.4 140 ±0.4 145 ±0.4
N2 158 ±0.4 202 ±0.4 246 ±0.4 279 ±0.4 290 ±0.4
N3 –––– –
N4 –––– –
O (Number of
bores) 8 8 10 10 10
G192 236 280 313 324
20-fold 24-fold 24-fold 32-fold
Feature
3) –1) 3)
M320 ±0.4 331 ±0.4 364 ±0.4 452 ±0.4
N1 65 ±0.3 66 ±0.3 73 ±0.3 65 ±0.3
N2 193 ±0.4 200 ±0.4 219 ±0.4 195 ±0.4
N3 323 ±0.4 334 ±0.4 367 ±0.4 325 ±0.4
N4 –––455 ±0.4
O (Number of
bores) 12 12 12 16
G357 368 401 489
Tab. 1: Dimensions of the flange images for AirLINE Quick
1) with intermediate feed
2) on request
3) with intermediate feed on request
6.3. 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. 8: Releasing the attachment of the valve block on the standard rail
→Lift the valve block vertically off the standard rail.
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Installation
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. 9: Detaching the modules/terminals from the standard rail
NOTE!
• When screwing the valve block back onto the standard rail,
observe a max. torque of 2 Nm!
7. INSTALLATION
7.1. 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.
7.1.1. 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
Fig. 10: Pneumatic Connections
Procedure:
→Depending on the version, plug the connections in the corre-
sponding working connections or screw them in.
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Installation
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.
7.1.2. Removing the plug-in connections
→To detach the pipes, press in the thrust ring and pull out the hose
pipe.
7.1.3. Pneumatic connections –
AirlINE standard
Inscription areas
Working connections
for 3/2-way valves
Working connections
for 5/2-way valves
Fig. 11: Pneumatic connections - valve discs
Procedure:
→Depending on the version, plug the connections in the corre-
sponding working connections or screw them in.
→Connection nipples can be used for threaded versions.
Inscription of the connections:
→Label the inscription areas with the data of the valve
connections.
7.1.4. Pneumatic connections –
AirLINE Quick
Fig. 12: Pneumatic connections – AirLINE Quick
Procedure:
→Depending on the version, plug the connections in the corre-
sponding working connections.
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Installation
7.1.5. Fluid connection AirLINE Quick
Air discharge connection R/S
Example of
connection adapter
Supply connection P
Fig. 13: Fluid connection AirLINE Quickk
Procedure:
→Screw connection adapter G1/4" or NPT 1/4" to connections P
and R/S.
NOTE!
Risk of leakage if screw connection is too tight!
• When fitting the fluid connection adapters to the connections
P, R/S, observe the max. torque of 12 Nm. In doing so, counter
with a suitable tool to prevent the connections from turning!
7.2. Fluid deinstallation
NOTE!
Irreversible damage to the seal in the thread of the screw
connection!
• When loosening the connection adapters, use a suitable tool to
prevent the corresponding supply or air discharge connection
from turning.
7.3. 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.
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Start-Up
8. START-UP
8.1. 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.
8.2. 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.
8.3. 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.
9. MAINTENANCE
See“7.2. Fluid deinstallation”, page 15.
10. 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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Type 8644

www.burkert.com