Burkert 6524 User manual

Operating Instructions
Type 6524/6525
3/2-, 2x3/2- or 5/2-way solenoid valve for pneumatics

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1 OPERATING INSTRUCTIONS
The operating instructions contain important information.
▶Carefully read these instructions and follow the safety
information.
▶Keep the manual and make it available to every user.
▶People who work on the device must read and understand these
instructions.
1.1 Symbols
DANGER!
Immediate danger! Fatal or serious injuries.
WARNING!
Potential danger! Fatal or serious injuries.
CAUTION!
Danger! Moderate or minor injuries.
NOTE!
Warns of damage.
▶Indicates instructions to avoid danger.
→Indicates a procedure you need to carry out.
Inhaltsverzeichnis
1 Operating instructions.................................................................. 2
2 Intended use ............................................................................... 3
3 Basic safety instructions .............................................................. 3
4 Structure and description ............................................................ 5
5 Technical data ............................................................................. 6
6 Assembly / installation ................................................................. 8
7 Start-up..................................................................................... 14
8 Maintenance, troubleshooting ................................................... 15
9 Disassembly .............................................................................. 16
10 Transportation, storage, disposal............................................... 16
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3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not take into account any unforeseen
circumstances and events which occur during installation, oper-
ation and maintenance. The operator is responsible for observing
the location-specic safety regulations, also with reference to
personnel.
Risk of injury due to high pressure and any escaping media.
▶Switch o the pressure before working on the device or system.
Vent or empty the lines.
Danger of injury due to unconnected compressed-air hoses
whipping around
▶Check all hose connections are seated properly before applying
compressed air to the valve.
Risk of injury from electric shock.
▶Switch o the power supply before working on the device or
system. Secure against reactivation.
▶Observe the applicable accident prevention and safety regula-
tions for electrical devices.
2 INTENDED USE
The device serves exclusively as a 3/2-, 2x3/2- or 5/2-way
solenoid valve for the media that is permitted based on the data
sheet for the corresponding type.
▶Do not use the device outdoors.
▶Use the device only in conjunction with third-party devices and
components that are recommended or approved by Bürkert.
▶Prerequisites for safe and trouble-free operation include correct
transportation, correct storage, installation, start-up, operation and
maintenance.
▶Observe the permissible data, operating conditions and conditions
of use of the respective devices or products. These specications
can be found in the contract documents, operating instructions
and on the type label.
▶Use the device only as intended. Improper use of the device may
be dangerous to people, nearby equipment and the environment.
2.1 Denition of terms
Term Denition for these instructions
Device Solenoid Valve Type 6524 or Type 6525
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Risk of burns or re from hot device surfaces due to longer duty
cycles.
▶Only touch the device when wearing protective gloves.
▶Keep the device away from highly ammable substances and media.
General hazardous situations.
Observe the following to prevent injuries:
▶Observe the general rules of technology.
▶In a potentially explosive atmosphere, only use devices that are
approved for this purpose. These devices are identied by a separate
“Ex” type label. Before use, note the information on the separate
Ex type label and the Ex additional instructions or the separate Ex
operating Instructions.
▶Only use the device when it is in a perfect state and in accordance
with the operating instructions.
▶Secure the device or system to prevent unintentional activation.
▶After an interruption in the power supply, ensure that the process is
restarted in a controlled manner.
▶Do not modify the device.
▶Do not mechanically load the device.
▶Only trained technicians may perform installation and maintenance
work.
▶Only use suitable tools to perform installation and maintenance
work.
▶To avoid pressure drops during switching, make the pressure
supply volume is as large as possible.
▶Operate the device only with direct current.
▶Install the device according to the regulations applicable in the
respective country.
3.1 Variant PF34 for safety-related shutdown
DANGER!
Risk of injury from uncontrolled process
▶The system operator must ensure that the safety-related shut-
down does not trigger a dangerous, uncontrolled process.
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NOTE!
Electrostatically sensitive components / assemblies
The device contains electronic components that are susceptible
to the eects of electrostatic discharging (ESD). Components are
at risk if they come into contact with electrostatically charged
persons or objects. In the worst-case scenario, they will be
destroyed immediately or will fail after start-up.
▶Observe the requirements for minimising or avoiding the pos-
sibility of damage caused by sudden electrostatic discharge in
accordance with EN 61340-5-1.
▶Do not touch electronic components when the supply voltage is
connected.
4 STRUCTURE AND DESCRIPTION
Type 6524
3/2-way valve
Type 6524
2 x 3/2-way valve
Type 6525
5/2-way valve
The valves consist of a rocker pilot solenoid valve (Type 6144) and
a pneumatic seat valve. Pilot valve and body are clamped together.
The principle allows the switching of high pressures together with
low power consumption and fast switching times.
The valves can be lined up and with plug connections at the rear
are preferably used for valve islands; with tag connectors at the
front they are preferably used on valve blocks to control pneumatic
actuators.
All pilot valves are equipped with a manual override as a standard.
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4.1 Variant PF34 for safety-related shutdown
The PF34 variant of the Type 6524 and 6525 valves is equipped
with an additional cable. It allows the valve circuit to be interrupted
by an external switch or sensor.
The PF34 variant has no manual override.
Type 6524
3/2-way valve
Type 6524
2 x 3/2-way valve
Type 6525
5/2-way valve
Fig. 1: Variant PF34 for safety-related shutdown
5 TECHNICAL DATA
5.1 Operating conditions
WARNING!
Risk of injury due to malfunction if used outdoors.
▶Do not use the device outdoors.
▶Avoid heat sources that could lead to the permissible tempera-
ture range being exceeded.
NOTE!
Operate valve at temperatures below 0 °C only with dry air.
Ambient temperature –10...+55°C
Medium temperature –10...+50°C
Medium • Filtered compressed air (max. particle
size 5 µm), preferably oil-free and dry
(operation with oiled air is possible)
• Neutral gases, air
Compressed air quality ISO 8573-1:2010
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Degree of protection IP40 with rectangular plug
Installation position Any, preferably actuator face up
Manual override Standard
Protection class III according to VDE 0580
Switching times [ms]
See data sheet
Measurement at valve outlet at 6 bar and
+20 °C:
Opening pressure build-up 0...90 %
Closing pressure reduction 100...10 %
Materials See data sheet
5.2 Electrical data
Operating voltage 24V
Voltage tolerance ±10%
Nominal power 1W
Nominal operating
mode
Continuous operation (100% duty cycle)
Electrical connection:
On valve
Valve island
Valve block
Rectangular connector
With grid 5.08 mm
With integrated plug socket
IP40 with rectangular connector
5.3 Type label (example)
Germany
6524 C
2,5—10bar
24VBA0,8W
W1XAW
00123456
1
4
3
2
Fig. 2: Example of a type plate inscription
Items Text Description
16524 Device type
CCircuit function
22,5–10 bar Permitted pressure range
324VBA0 Voltage (±10 %)
8 W Power
400123456 Order number of the device
Table 1: Description of the type plate inscription
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5.4 Circuit functions (CF)
4
15
14
2
13
12
C, 2 x 3/2-way
Outlet 2 and outlet 4
vented when idle.
2
1 3
12
C, 3/2-way valve
Output 2 vented when idle
2
1 3
10
D, 3/2-way valve
Pressure port 1 connected to outlet 2 when
idle
14
12
4 2
513
H, 5/2-way valve
Pressure port 1 connected to outlet 2 when
idle, outlet 4 vented
6 ASSEMBLY / INSTALLATION
WARNING!
Risk of injury due to improper installation
▶Only trained technicians may perform installation work.
▶Only carry out installations with suitable tools.
▶Secure the system against unintentional activation.
▶Following installation, ensure a controlled restart.
WARNING
Risk of injury due to uncontrolled movement of the actuators
Back pressure in the exhaust air ducts can cause uncontrolled
movements of the actuators.
▶Use large-volume silencers.
Prior to installation
→Clean pipelines.
→If necessary, connect a dirt trap (5 µm) upstream.
Installation position
Any installation position, preferably with the actuator facing up.
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6.1 Installation of the valve on the valve block
→Place the valve on the valve block, ensuring that the ange seal
is correctly inserted (see “Fig. 3”).
→Screw on the valve (for sequence and tightening torques see
“Fig. 3”).
2
20 Ncm
20 Ncm
1
30 Ncm
3
4
30 Ncm
Flange seal
Fig. 3: Installation of the valve on the valve block, tightening torques
6.2 Electrical installation pilot valve
DANGER!
Risk of injury from electric shock.
▶Switch o the power supply before working on the device or
system. Secure against reactivation.
▶Observe the applicable accident prevention and safety regula-
tions for electrical devices.
NOTE!
▶Observe voltage.
▶In case of alternating voltage, a rectier must be connected in
series.
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Rectangular
connector
Circular plug Strand
connection
Fig. 4: Connection options Type 6144 pilot valve
→Observe the type plate information on voltage, electrical power
and current type. Voltage tolerance ±10 %.
At 100% duty cycle and maximum ambient temperature the coil
heats up
in single assembly to approx. +105 °C
in block assembly to approx. +120 °C
6.2.1 Pin assignment
3/2- and 5/2-way valve 2 x 3/2-way valve
(+)
(–)JB17 (–) (+)JB18
14(–)12(–) (+)
JB20
14(+)12(+) (–)
JB21
14( )12( ) ( )
JF79
Fig. 5: Pin assignment 3/2-, 5/2- and 2 x 3/2-way valves
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2 x 3/2-way valve variant MA06
12(–)14(–) (+)
JB20
12(+)14(+) (–)
JB21
12( )14( ) ( )
JF79
Fig. 6: Pin assignment 2 x 3/2-way valve variant MA06 with electrical
connection rotated by 180°.
6.2.2 Pin assignment variant PF34 for safety-
related switch-o
Single valve (12)
3/2-way valve WWC (Type 6524)
5/2-way Valve WWH (Type 6525)
Wire colours
BK = black; RD = red
24V
12 (–)
12
BK RD
(+)
(–)JB17
BK, RD
Fig. 7: Pin assignment variant PF34, 3/2- and 5/2-way valve
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Double valve (12, 14)
2 x 3/2-way valve WWC
(Type 6524)
Wire colours
BK = black; BN = brown;
BU = blue; GY = grey
14 (–)
24V
12 (–)
14
12
BK
BU
BN
GY
14(–)12(–) (+)
JB20
14: BK, BN
12: BU, GY
Fig. 8: Pin assignment variant PF34, 2 x 3/2-way valve
6.3 Pilot valve manual override
To operate the valve manually, turn the manual override 90° in the
direction of the arrow on gure 1.
This puts the valve into the switched state.
The valve remains xed in the switched state until the manual
override is turned back to its original position.
For the double valve 2 x 3/2-way, the upper manual override
switches output 2 (A) while the lower manual override switches
output 4 (B).
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1
Fig. 9: Manual override of the pilot valve
Pos. Designation
1Manual override
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6.4 Pneumatic installation
DANGER!
Risk of injury due to high pressure and any escaping media.
▶Switch o the pressure before working on the device or system.
Vent or empty the lines.
Make the pressure supply as large-volume as possible.
Type 6524
3/R
X*
2/A
1/P
Type 6525
X*
5/R
4/A
1/P
2/B
3/S
Make the pressure
supply as large as
possible!
X* - pilot exhaust air
Fig. 10: Position of the connections, Type 6524 3/2-way valve and
Type6525 5/2-way valve
Type 6524
(2 x 2/3-way valve)
12
14
— pole coil 12
actuated via bit “n+1”
— pole coil 14
actuated via bit “n”
Flange pattern "FM20"
+ pole
X*
5/R
4/A
1/P
2/B
3/S Bit “n+1”
Bit “n”
Observe pin
assignment!
X* - pilot exhaust air
Hand lever
assignment
Fig. 11: Position of the connections, 2x 3/2-way valve Type 6524
NOTE!
▶Before the pneumatic installation, check the compatibility with
the valve island in question by means of the valve’s article
number (see the operating instructions of the corresponding
valve island).
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Type 6524
(2 x 3/2-way valve
variant MA06)
12
14
— pole coil 14
Coil 14
— pole coil
12
Coil 12
Flange pattern FM20
Connection assignment
see “Fig. 11”
+ Pol
Observe pin
assignment!
Hand lever
assignment
Fig. 12: Position of the connections, 2 x 3/2-way valve variant MA06 with
electrical connection rotated by 180
7 START-UP
WARNING!
Risk of injury due to improper operation.
▶Prior to start-up, it must be ensured that the operating personnel
are familiar with and fully understand the contents of the operat-
ing instructions.
▶Only authorised technicians may start up the device or system.
→Check correct connection of pressure and tension.
→For electrical operation, unlock the manual override (0-position).
→Create print rst.
→Then apply voltage.
→Make sure that the maximum operating data (type label) are not
exceeded.
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Fault Possible cause Remedy
Valves
switch
with a
delay or
blow o
at the
exhaust
ports
Pressure supply insuf-
cient or not available
Set up large-volume pressure
supply (also for upstream
devices such as pressure
regulators, maintenance units,
on/o valves, etc.)
Valves are not in home
position (de-ener-
gized) during pressure
build-up
Apply pressure to the valve
block before the valves are
switched.
Insucient ventilation
of the exhaust air
ducts due to too small
or dirty silencers (back
pressure)
Use suitably sized silencers
or expansion vessels. Clean
the dirty silencers.
Impurities or foreign
matter in the pilot or
main valve
Apply pulsed pressure to the
exhaust air ducts to blow out
the impurities.
Install a new pilot or main
valve.
8 MAINTENANCE, TROUBLESHOOTING
WARNING!
Risk of injury due to improper maintenance work.
▶Only trained technicians may perform maintenance work.
▶Secure the system against unintentional activation.
▶Ensure a controlled restart after maintenance is completed.
The valves are maintenance-free when operated according to the
instructions in this manual.
Fault Possible cause Remedy
Valves do
not switch
No operating voltage
or operating voltage
too low
Check electrical connection
Ensure operating voltage
according to type label
Manual override not in
neutral position
Bring manual override to zero
position.
Pressure supply insuf-
cient or not available
Set up large-volume pressure
supply (also for upstream
devices such as pressure
regulators, maintenance units,
on/o valves, etc.)
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9 DISASSEMBLY
DANGER!
Risk of injury due to high pressure and any escaping media.
▶Switch o the pressure before working on the device or system.
Vent or empty the lines.
Risk of injury from electric shock.
▶Switch o the power supply before working on the device or
system. Secure against reactivation.
▶Observe the applicable accident prevention and safety regula-
tions for electrical devices.
WARNING!
Risk of injury due to improper disassembly.
▶Only trained technicians may perform disassembly work.
→Loosen the two fastening screws.
→Carefully pull the valve o the valve block.
10 TRANSPORTATION, STORAGE,
DISPOSAL
NOTE!
Damage in transit due to inadequately protected devices.
▶Protect the device against moisture and dirt in shock-resistant
packaging during transportation.
▶Observe permitted storage temperature.
Incorrect storage may damage the device.
▶Store the device in a dry and dust-free location.
Permitted storage temperature: –20…+65°C.
Damage to the environment caused by device parts that are
contaminated with media.
▶Dispose of the device and packaging in an environmental-
ly-friendly manner.
▶Observe applicable disposal and environmental regulations.
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Manuals and data sheets on the Internet: www.burkert.com
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Manuels d'utilisation et fiches techniques sur Internet : www.burkert.fr
© Bürkert Werke GmbH & Co. KG, 2001 - 2022
Operating Instructions 2208/12_EUml_00803840 / Original DE
Bürkert Fluid Control Systems
Sales Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Tel. + 49 (0) 7940 - 10-91 111
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