Burkert 8644 AirLINE User manual

Type 8644 AirLINE
with Point I/O System (Rockwell)
mit Point I/O System (Rockwell)
avec Point I/O System (Rockwell)
Operating Instructions
Bedienungsanleitung
Instructions de service

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous resérve de modification techniques.
© 2002 Bürkert Werke GmbH & Co. KG
Operating Instructions 0605/06_EU-EN_00804718

Add-on dimension 11 mm

Add-on dimension 16,5 mm
Rockwell-Field bus node
Me03
Me03
Me03 Accessories
Syst
Syst
Syst
Me03
Valves
Cover
Cover plate
Accessories
6524 6525 0461
Mp12
Syst
6527
6526

8644/Rockwell - 1
CONTENTS
deutsch
List of contents
Type 8644 AirLINE -Rockwell
GENERAL NOTES................................................................................................................................................................................................................................. 3
Symbols..................................................................................................................................................................................................................................................... 4
General safety notes ................................................................................................................................................................................................................ 4
Scope of delivery........................................................................................................................................................................................................................... 6
Warranty conditions.................................................................................................................................................................................................................... 6
Approvals................................................................................................................................................................................................................................................. 6
Assembly note.................................................................................................................................................................................................................................. 6
Information of the Internet ................................................................................................................................................................................................... 6
INSTALLATION/COMMISSINONING ....................................................................................................................................................................... 7
Installation instructions........................................................................................................................................................................................................... 8
Illustration of the Valve block........................................................................................................................................................................................... 8
Removing the valve block from the top-hat rail....................................................................................................................................... 9
Installation of the AirLINE system........................................................................................................................................................................ 10
Fluidic installation ...................................................................................................................................................................................................................... 11
Labelling of the connections ........................................................................................................................................................................................ 12
Elektrical installation.............................................................................................................................................................................................................. 13
Fluidic commissioning......................................................................................................................................................................................................... 13
Electrical commissioning................................................................................................................................................................................................. 13
MAINTENANCE AND TROUBLESHOOTING........................................................................................................................................ 15
Troubleshooting............................................................................................................................................................................................................................ 16

2 - 8644/Rockwell
CONTENTS
deutsch
SYSTEM DESCRIPTION......................................................................................................................................................................................................... 17
Bürkert-AirLINE modulare elektrical / pneumatic automation system................................................................... 19
Valve block (variable configuration)................................................................................................................................................................... 22
Valve units .......................................................................................................................................................................................................................................... 23
Connector modules................................................................................................................................................................................................................. 26
Basic electrical module...................................................................................................................................................................................................... 40
Basic pneumatic module.................................................................................................................................................................................................. 51
Valves....................................................................................................................................................................................................................................................... 53
Limitations for use in Zone 2........................................................................................................................................................................................ 55
ANNEX................................................................................................................................................................................................................................................................. A1
EC Declaration of Conformity................................................................................................................................................................................... A2
Certificate of Conformity ................................................................................................................................................................................................. A3

8644/Rockwell - 3
GENERAL NOTES
General Notes
SYMBOLS .......................................................................................................................................................................................................................................................... 4
GENERAL SAFETY NOTES ............................................................................................................................................................................................. 4
Protection from damage by electrostatic charging .......................................................................................................................................... 4
Safety notes for the valve................................................................................................................................................................................................................ 5
SCOPE OF DELIVERY ................................................................................................................................................................................................................ 6
WARRANTY CONDITIONS ................................................................................................................................................................................................. 6
APPROVALS .............................................................................................................................................................................................................................................. 6
ASSEMBLY NOTE .............................................................................................................................................................................................................................. 6
INFORMATION ON THE INTERNET ..................................................................................................................................................................... 6

4 - 8644/Rockwell
GENERAL NOTES
ATTENTION
EXERCISECAUTION ON
HANDLING!
ELECTROSTATICALLY
SENSITIVE COMPONENTS /
MODULES
The unit contains electronic components that are very sensitive to
electrostaticdischarge(EDS).Contacttoelectrostaticallycharged
persons or objects will endanger these components. In the worst case,
they will be immediately destroyed or will fail after commissioning.
Observe the requirements of EN 100 015 - 1 in order to minimize the
possibility of, or avoid, damage from instantaneous electrostatic
discharge. Also take care not to touch components that are under
supply voltage.
Please observe the notes in these operating instructions together with the conditions of use and permitted
data that are specified in the data sheet, in order that the device will function perfectly and remain operab-
le for a long time:
• Keepto standardengineering rules in planningthe use of and operatingthe device!
• Installation and maintenance work are only allowed by specialist personnel using suitable tools!
• Observe the current regulations on accident prevention and safety for electrical devices during
operation,maintenance and repairof the device!
• Always switch off the power supply before intervening in the system!
• Note that in systems under pressure, piping and valves may not be loosened!
• Takesuitable precautions topreventinadvertentoperation or damagebyunauthorizedaction!
• After interruption of the electrical or pneumatic supply, make sure the process is restarted in a well-
defined,controlled manner!
• Onnon-observance of these notes and unauthorized interferencewiththe device, we will refuse all
liability and the warranty on device and accessories will become void!
Protection from damage by electrostatic charging
SYMBOLS
The following symbols are used in these operating instructions:
marks a work step that you must carry out
ATTENTION!
marks notes on whose non-observance your health or the functioning of the device will
beendangered
NOTE
marks importantadditionalinformation, tipsand recommendations
GENERAL SAFETY NOTES

8644/Rockwell - 5
GENERAL NOTES
Safety notes for the valve
ATTENTION!
• Keepto standardengineering rulesin planning theuse of and operatingthe device!
• Takesuitable precautions topreventinadvertentoperation or damagebyunauthorizedaction!
• Note that in systems under pressure, piping and valves may not be loosened!
0 bar, psi, kPa
• Always switch off the power supply before intervening in the system!
• To avoid pressure drop on switching, make the volume of the pressure supply as large as
possible!
• The device shall only be operated on direct current !
• Risk of injury!
In continuous operation, the coil can become very hot!

6 - 8644/Rockwell
GENERAL NOTES
WARRANTY CONDITIONS
This document contains no warranty statements. In this connection we refer to our general sales and
business conditions. A prerequisite for validity of the warranty is use of the device as intended with
observance of the specified conditions of use.
ATTENTION!
The warranty covers only faultless condition of the automation system and the
attached valves supplied. No liability will be accepted for consequential damage of any
kind that may arise from failure or malfunctioning of the device.
SCOPE OF DELIVERY
Immediately after receipt of the goods, make sure the contents are undamaged and agree with the scope of
delivery stated on the packing slip.
In case of irregularities, contact our customer service department at once:
Bürkert Fluid Control Systems
ServiceDepartment
Chr.-Bürkert-Str.13-17
D-76453Ingelfingen
Tel.:[phone]
Fax:[phone]
E-mail:inf[email protected]ert.com
Or to your Bürkert Sales Center
INFORMATION ON THE INTERNET
Operating instructions and data sheets for type 8644 may be found on the Internet under:
www.buerkert.com Germany Produkte Downloads Betriebsanleitungen Typ 8644 Rockwell
Furthermore, a complete documentation is available on CD.The complete Operating instructions may be
orderedunder thefollowing indentificationnumber: 804718
NOTE
Technical data, configuration files and a detailed description of bus terminals and electrical
function terminals by the Rockwell company are available on the Internet web site:
www.ab.com Manuals On-Line I/O 1734 Point I/O
Bürkert has no influence upon the update status of the latter home page or on changes in
technicaldata or presentation on the pageslinkedthereto.
ASSEMBLY NOTE
If the configuration of the valve block also provides ofType 0461 (5/2- way pulsed valve, 5/3- way valve), a
profilerail EN 50022-35x15 mustbe used.
APPROVALS
The approval marks on Bürkert rating plates refer to the Bürkert products.In order that the complete valve
island is approved, a gateway with a design inspection certificate must be used.In this case, a valve
island may be extended with approved units having design inspection certificates up to 64 valves.
More detailed information on the approvals of the valves is to be found in the chapterValves.

8644/Rockwell - 7
INSTALLATION / COMMISSIONING
Installation / Commissioning
Installation instructions..................................................................................................................... 8
Illustration of the Valve block............................................................................................................. 8
Removing the valve block from the top-hat rail..................................................................................9
Installation of the AirLINE system.................................................................................................... 10
Fluidicinstallation............................................................................................................................. 11
Labelling of the connections............................................................................................................. 12
Electrical installation ........................................................................................................................ 13
Fluidic commissioning...................................................................................................................... 13
Electrical commissioning ................................................................................................................. 13

8 - 8644/Rockwell
INSTALLATION / COMMISSIONING
Installation instructions
The valve block of the AirLINE-system Type 8644 is combined with the Point I/O System from the Rockwell
company.Please observe the respective installation notes.
ATTENTION!
Before starting installation work, switch off the voltage in the vicinity and secure it
againstbeing switched on again.
Illustration of the Valve block
Connector
moduleleft
Intermediatesupply
Connection
moduleright
2-fold valve units
8-fold valve unit
Supplyand exhaust
ports
Service ports
Service ports Supply and exhaust ports
Supplyand exhaust
ports
Illustration of the modules
of the Bürkert AirLINE system
Manometerfor indication ofoperating
pressure at the station

8644/Rockwell - 9
INSTALLATION / COMMISSIONING
Removing the valve block from the top-hat rail
If present, release the adjacent modules /
terminals!
Unlock theVavle block from the standard rail by
turning the fixing screws anticlockwise as far as
they will go.
Lift the Valve block vertically from the rail.
Disconnect the modules / terminals from the
standardrail followingthe manufacturer’s
instructions.
The valve block is firmly screwed to a standard rail. Additional electrical modules / terminals can be
mounted on this.
NOTE
The interface of the left-hand connection module contains elements that can be
damaged if force is used.
Never place the valve block on its side, and ensure that you use an approved
installationposition!

10 - 8644/Rockwell
INSTALLATION / COMMISSIONING
According to the manufacturer’s instructions (Chapter 2: Installing the Mounting Base /Wiring Base
Assembly, Installing I/O Modules), snap all electrical modules / terminals onto the standard rail to the
left of the valve block.
Installation of the AirLINE system (e.g. in a control cabinet)
During work in the control cabinet, observe the relevant safety regulations!
Beforemounting, check whether the mounting railis properly anchored in the control
cabinet or in the system.
Observe the sequence of installation specified in the configuration file(s).
Observe the notes for the connected system!
ATTENTION!
Mount all other modules / terminals on the rail.
NOTE
Alternative for large valve blocks:
- Removethe precedingmodule
- Snap the valve block onto the standard rail
- Slide the block to its final position
- Snapon thepreceding module again
Slide the valve block onto the standard rail along the interface of the previous module.
Screw the valve block to the rail by tightening the fixing screws clockwise.
ATTENTION!
The valve block is not securely fastened to the standard rail until the fixing screws have
been firmly tightened.Throughout the installation, you must ensure that it cannot fall.

8644/Rockwell - 11
INSTALLATION / COMMISSIONING
Fluidic installation
ATTENTION!
Thepneumatic connections shall not bepressurized during installation!
Make the connections with as large a volume as possible.
Close off unused, open ports with screw caps!
The ports for the pilot valve exhaust (x) shall not be closed off!
Check allocation according to instructions of ports 1 and 3 or 5: these shall under no
circumstancesbe swapped!
Procedure
Plug (D10) or screw (G 1/4, NPT 1/4) the connections, depending on the version, into the respective
service ports.
Safety notes
NOTE
For the plug connections the hoses must fulfil the following requirements:
• Minimum hardness of 40 Shore D (to DIN 53505 or ISO 868);
• Outside diameter to DIN 73378 (max. permissible deviation ± 0.1 mm from nominal
dimension);
• Free from burrs, cut off at right angles and undamaged over outer circumference;
• The hoses shall be pushed into the plug connectors as far as they will go.
Notes on plug connections
To release the hoses, depress the pressure ring and pull out the hose.
Disassembly of the plug connections
Pneumatic connections - supply units
Exhaust air
Standardmodel: Venting of the pilot valves
Auxiliary air control model: P-port for the pilot valves
Pressuresupply port
(R/S)3/5
X
(P)1
W
W
W

12 - 8644/Rockwell
INSTALLATION / COMMISSIONING
Pneumatic connections - valve units
5/2-wayvalves
Variants
3/2-wayvalves
Assembly
Plug (D6, D4, D1/4) or screw (M 5, M7) the connections, depending on the version, into the respective
service ports.
With threaded versions, connecting nipples may be used.
NOTE
With 3/2-way valves, the upper ports remain free!
Labelling of the connections
Write the valve port data on the provided Labels
Labelling area
Service ports with 5/2-
way valves
Service ports with 3/2-
way valves
8-fold valve unit or
4 / 2-fold valve units
Variant 1 Variant 2 Variant 3
Service port above (2) M 5 M 7 D 6, D4, D1/4
Service part below (4) M 5 M 7 D 6, D4, D1/4
Variant 1 Variant 2 Variant 3
Service port above (0) internally closed off internally closed off internally closed off
Service port below (2) M 5 M 7 D 6, D4, D1/4

8644/Rockwell - 13
INSTALLATION / COMMISSIONING
bar
Switch on the pressure supply.
Only then switch on the voltage!
Fluidic commissioning
Checkthe connections, voltage andoperating pressure!
Make sure that the max. operating data (see rating plate) are not exceeded!
Check allocation according to instructions of ports 1 and 3 or 5:these shall under no circumstances be
swapped!
Forelectrical operation, unlock themanual override!
Measures to be taken before fluidic initialization
Fluidic commissioning
All the necessary steps for this should be taken from the Rockwell Operating Instructions Chapter 2 „Wiring
theAdapter“.
All the necessary steps for this should be taken from the Rockwell Operating Instructions Chapter 3 „How
toConfigure PointI/O Modules“.
Elektrical installation
Electrical commissioning

14 - 8644/Rockwell
INSTALLATION / COMMISSIONING
Special features of commissioning
On delivery, all valve islands possess a comparable configuration with regard to module addressing.
The first addressable module after the field bus node has the address 62,
allfollowing modules the address 63.
Reason:
If a passive DeviceNet node (1734-PDN) is used, then automatic addressing can only be performed via the
modules directly.Since it is difficult to remove the modules owing to the pneumatic design, the first module
wasassigned a different address(62).
NOTE
If an active DeviceNet node is used, automatic addressing must be performed.
Withtheactive Profibus node (1734-APB), this is performed automatically onpower-up.

8644/Rockwell - 15
MAINTENANCE AND TROUBLESHOOTING
Maintenance
and
troubleshooting
TROUBLESHOOTING .................................................................................................................................................................................................................. 16

16 - 8644/Rockwell
MAINTENANCE AND TROUBLESHOOTING
Remedy
Check the electrical connection.
Provide operating voltage acc. to
nameplate.
Turn knob to zero position.
Execute pressure supply with as large a
volume as possible (also for upstream
devices such as pressure controllers,
maintenance units, shut-off valves, etc.).
Minimum operating pressure
≥≥
≥≥
≥ 2,5 bar
Execute pressure supply with as large a
volume as possible (also for upstream
devices such as pressure controllers,
maintenance units, shut-off valves, etc.).
Minimum operating pressure
≥≥
≥≥
≥ 2,5 bar
Pressurize the valve block before the
valve switch!
Use matching, large-sized silencers or
expansion vessels.
Clean the contaminated silencers.
Change the valve
Determine the point of leakage or missing
seals.
Insert missing seals or replace damaged
seals.
TROUBLESHOOTING
Possible cause
Operating voltage not present or insufficient;
Manual override knob not in neutral position;
Pressure supply insufficient or not present.
Pressure supply insufficient or not present;
Valves not in basic position (no power) during
pressure build-up;
Venting of exhaust aire channels insufficient
because silencers are too small or
contaminated (backpressure);
Contamination or foreign bodies in pilot or
main valve.
O-rings missing or pinched between the
modules;
missing or wrongly positioned profile seals
between the valve and the basic pneumatic
module.
Fault
Valves do not switch:
Valves switch with
delay or blow out at the
vent connections:
Leaky valve blocks:
Service address:
Fluid Control Systems
Service-Department
Chr.-Bürkert-Str. 13-17
D-76453 Ingelfingen
Tel.: [phone]
Fax: [phone]
E-mail: [email protected]
or your Bürkert distribution center (see list of addresses on the last few pages)