Burkert 8640 User manual

Quickstart
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Type 8640
AirLINE

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co. KG, 2009 - 2019
Operating Instructions 1901/11_EU-ML_00804431 / Original DE

3
1 THE 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 DEVICE REVISION ..........................................................................................6
6 TECHNICAL DATA ...........................................................................................7
6.1 Conformity .........................................................................................7
6.2 Standards ........................................................................................... 7
6.3 General Technical Data .................................................................. 7
7 ASSEMBLY ..........................................................................................................8
7.1 Safety instructions ...........................................................................8
7.2 Assembly ............................................................................................ 9
8 INSTALLATION ............................................................................................... 12
8.1 Fluid Installation ..............................................................................12
8.2 Fluid deinstallation .........................................................................15
8.3 Electrical Installation ......................................................................15
9 START-UP ......................................................................................................... 19
10 MAINTENANCE .............................................................................................. 19
11 TRANSPORT, STORAGE, DISPOSAL .................................................19
Contents
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The Quickstart
1 THE QUICKSTART
The Quickstart contains the most important information and notes
regarding the use of the device. A detailed description can be found
in the operating instructions for Type 8640.
Keep the Quickstart in an easily accessible location for each user.
The Quickstart must be available to each new owner of the device.
Important safety information!
▶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.
The operating instructions and data sheets for Bürkert
devices can be found 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 8640.
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 an instruction which you must follow to prevent
a hazard.
→designates a procedure which you must carry out.
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Intended use
2 INTENDED USE
Non-intended use of the AirLINE Type 8640 may be a hazard to
people, nearby equipment and the environment.
▶The device may be used for the control of pneumatically oper-
ated units.
▶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
conditions specified in the contract documents and operat-
ing instructions. These are described in the chapter entitled “6
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.
▶Do not supply the medium connectors of the system with
aggressive or flammable media.
▶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 sys-
tems 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 applica-
tion planning and operation of the device.
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.
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Type 8640

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General safety information
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 8640 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 8640 can be found
on the Internet under: www.burkert.com
5 DEVICE REVISION
The hardware and firmware for the device have been revised.
The revised version REV.2 is largely compatible with the previous
version. Differences to be taken into account for the user relate to
the EthernetIP and ModbusTCP Ethernet variants. The details are
described in the operating instructions.
The operating instructions can be found on the Internet at:
www.burkert.com
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Type 8640

7
Technical data
6 TECHNICAL DATA
6.1 Conformity
The AirLINE system Type 8640 conforms with the EC Directives
according to the EC Declaration of Conformity.
6.2 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.
6.3 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 ± 10 % ± 10 %
Ambient
temperature
0 ... +55 °C
(when using Type 0460 and 0461: 0 ... +50 °C)
6.3.1 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
6.3.2 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
Fig. 2: Fluid connection. Types 6524 and 6525
6.3.3 Fluid and electrical connection
Hand lever
assignment
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
Fig. 3: Fluid and electrical connection. Type 6524
7 ASSEMBLY
7.1 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.
7.2 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!
7.2.1 Installation on standard rail
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
7.2.2 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
“7.2.3 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
NOTE!
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.
Valve terminal
Type 8640
AirLINE Quick
adapter
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
7.2.3 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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Installation
Version
4-fold 8-fold 12-fold 16-fold 24-fold
Feature
––––on request
M111 ±0.4 155 ±0.4 199 ±0.4 243 ±0.4 331 ±0.4
N1 114 ±0.4 54 ±0.3 68 ±0.3 123 ±0.4 66 ±0.3
N2 – 158 ±0.4 202 ±0.4 246 ±0.4 200 ±0.4
N3 – – – – 334 ±0.4
N4 –––––
O (Number of
bores) 6 8 8 10 12
G148 192 236 280 368
Tab. 1: Dimensions of the flange images for AirLINE Quick.
8 INSTALLATION
8.1 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.
8.1.1 Pneumatic connections - feed
Pressure supply connection P/1
Exhaust air R/3, S/5
X channel:
Standard version:
Deaeration of the control valves
Control assist air version:
P connection for control valves
Fig. 8: Pneumatic connections
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Installation
Procedure:
→Depending on the version, plug the connections in the corre-
sponding working connections or screw them in.
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.
8.1.2 Removing the plug-in connections
→To detach the pipes, press in the thrust ring and pull out the hose
pipe.
8.1.3 Pneumatic connections -
AirLINE standard
Working connections
for 3/2-way valves
Working connections
for 5/2-way and
2 x 3/2-way valves
Fig. 9: Pneumatic connections - valve discs
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.
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Installation
8.1.4 Pneumatic connections -
AirLINE Quick
Fig. 10: Pneumatic connections – AirLINE Quick
Procedure:
→Depending on the version, plug the connections in the corre-
sponding working connections.
8.1.5 Fluid connection AirLINE Quick
Air discharge connection R/S
Example of
connection adapter
Supply connection P
Fig. 11: Fluid connection AirLINE Quick
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!
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Installation
8.2 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.
8.3 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!
8.3.1 Conventional connection technology
(multipole and multiple connection)
Module Configuration
Multiple connection – Ground
Functional earth
Multi-pole connection
for valve outputs
Pin 1 Valve 1
Pin 241) Valve 24
Pin 25 Ground
Multipole circuit
feedback indicator
inputs
Pin 1 Input 1
Pin 32 Input 32
Pin 43 24 V
Pin 44 Ground
1) In manual/automatic mode Pin 24 is constantly supplied with 24 V.
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Installation
8.3.2 Field bus technology connections
Please observe section “5 Device revision”, page 6.
Pin Profibus DP CanOpen / DeviceNet Profinet,
Ethernet/
IP,
Modbus
TCP
IP20 IP54 IP20 IP54
1n. c. +5 V n. c. Drain TX+
2n. c. RxD/TxD-N/A-
line
CAN LOW n. c. TX–
3RxD/TxD-P/B-
line
DGND GND GND RX+
4CNTR-P
(RTS)
RxD/TxD-P/B-
line
n. c. CAN HIGH n. c.
5DGND Shield n. c. CAN LOW n. c.
6+5 V n. c. RX–
7n. c. CAN HIGH n. c.
8RxD/TxD-N/A-
line
n. c. n. c.
9n. c. n. c.
D-SUB 9 5-pole M12 D-SUB 9 5-pole RJ45
female female
(Reverse-Key)
male Micro 12 female
male
female
D-SUB 9
IP20
Pin 1 Pin 4
12345678
Socket RJ45
8.3.3 Power supply connections
Pin All models
IP20 IP54
1 GND Outputs 24 V DC Outputs
2 24 V DC Outputs 24 V DC Logic
3 GND Logic GND Logic
4 24 V DC Logic GND Outputs
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Installation
8.3.4 DIP switch settings
Profibus-DP
12345678
Address of the profibus DP subscriber - 125 OFF
DeviceNet / CanOpen
12345678
Address of the field bus module 0 – 63 Baud rate
Baud rate
DIP 7/8 DVN COP
0 125 kB 20 kB
1 250 kB 125 kB
2 500 kB 250 kB
3 - 500 kB
8.3.5 RIO - internal bus extension
Electronics Inputs Outputs
24 V DC (2)
Outputs
24 V DC (4)
Logic
GND (3)
Logik
GND (1)
Outputs
Fig. 12: Power supply
Internal field bus: 4-pole socket M8 42
13
CAN LOW
CAN HIGH
Field bus settings:
DIP switches
1234567 8
Address on the in-
ternal RIO bus
Mode inputs Reserve
always OFF
Terminating
resistors
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Installation
8.3.6 Address on the internal RIO bus:
DIP switches 1 to 3
Each peripheral terminal has a unique address. This address is set
on the valve terminal via DIP switches 1 to 3.
DIP 1 DIP 2 DIP 3 Address Peripheral
terminal
OFF OFF OFF 0 0
ON OFF OFF 1 1
OFF ON OFF 2 2
ON ON OFF 3 3
OFF OFF ON 4 4
ON OFF ON 5 5
OFF ON ON 6 6
ON ON ON 7 7
8.3.7 Mode inputs: DIP switches 4 and 5
NOTE!
The input modes allow the entries (feedback indicator) to be
assigned in different ways in the process image of the inputs
(PAE).
DIP 4 DIP 5
No entries available OFF OFF
Normal mode ON OFF
Mode: shifted inputs OFF ON
Mode: halved inputs ON ON
CAUTION!
If there are no inputs available, both switches must be set to OFF.
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Start-Up
9 START-UP
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.
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.
10 MAINTENANCE
See “8.2 Fluid deinstallation”, page 15.
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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Type 8640