Burkert 8644 AirLINE User manual

Quickstart
English Deutsch Français
Type 8644
AirLINE
Modular valve island for pneumatics
Modulare Ventilinsel für Pneumatik
Îlot de distributeurs modulaires pour la pneumatique

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co. KG, 2011 - 2023
Operating Instructions 2307/02_EU-ML_00809514 / Original DE

3
1 THE QUICKSTART ................................................................ 4
1.1 Denitionofterms ....................................................... 4
1.2 Symbols used.............................................................. 4
2 INTENDED USE .................................................................... 5
3 BASIC SAFETY INSTRUCTIONS.......................................... 5
4 NOTES ON COMPATIBILITY AND REVISION LEVELS ........ 7
4.1 Overview of revision levels .......................................... 7
4.2 Notes on valve islands revision 2
(only applies to “WAGO” valve islands)....................... 8
4.3 Distinguishing features between valve islands
REV.1 and REV.2 ......................................................... 9
4.4 Distinguishing features between individual valves
REV.1 and REV.2 ......................................................... 9
5 GENERAL INFORMATION .................................................. 10
5.1 Contact address........................................................ 10
5.2 Warranty .................................................................... 10
5.3 Information on the Internet........................................ 10
6 TECHNICAL DATA............................................................... 10
6.1 Standards and guidelines.......................................... 10
6.2 General technical data............................................... 10
7 CONNECT VALVES ............................................................. 12
7.1 Single valves width per station 11 mm...................... 12
7.2 Double valves width per station 11 mm.................... 12
7.3 Single valves width per station 16 mm...................... 13
8 REMOVING THE VALVE BLOCK FROM THE
STANDARD RAIL................................................................. 13
9 INSTALLATION OF THE VALVE ISLAND IN THE
CONTROL CABINET........................................................... 14
9.1 Safety instructions..................................................... 14
9.2 Installation on standard rail ....................................... 15
9.3 Installation with AirLINE Quick .................................. 16
10 INSTALLATION .................................................................... 18
10.1 Fluidic installation...................................................... 18
10.2 Electrical installation.................................................. 21
11 START-UP............................................................................ 21
11.1 Safety instructions..................................................... 21
11.2 Fluidic start-up .......................................................... 21
11.3 Electrical start-up ...................................................... 22
12 MAINTENANCE................................................................... 22
13 SPARE PARTS..................................................................... 22
14 TRANSPORT, STORAGE, PACKAGING ............................. 23
Contents
Type 8644
English

4
The Quickstart
1 THE QUICKSTART
The Quickstart contains a short summary of the most important
information and instructions for use of the device. The detailed
description can be found in the operating instructions for Type
8644.
Keep the Quickstart in an easily accessible location for every
user. The Quickstart must be available to each new owner of the
device.
Important safety information!
▶Carefully read these instructions.
▶Above all, observe the safety instructions, intended use and
operating conditions.
▶Persons who work on the device must read and understand
these instructions.
Operating instructions and data sheets for Bürkert
products can be found on the Internet at:
country.burkert.com
1.1 Denition of terms
Term in these instructions, refers to
Device, valve
island
Valve island Type 8644
Actuator pneumatic consumer controlled by the valve
island
Plant Machine with pneumatic consumers actuated
by the valve island
1.2 Symbols used
DANGER!
Warns of an immediate danger.
▶Failure to observe these instructions will result in death or
serious injuries.
WARNING!
Warns of a potentially hazardous situation.
▶Failure to observe these instructions may result in serious
injuries or death.
CAUTION!
Warns of a potential danger.
▶Failure to observe these instructions may result in moderate
or minor injuries.
NOTE!
Warns of damage.
Important tips and recommendations.
Refers to information in these operating instructions or in
other documentation.
▶Designates instructions to avoid danger.
→Highlights a work step which you must carry out.
Type 8644
English

5
Intended use
2 INTENDED USE
The valve island Type 8644 has been designed to control
pneumatic consumers in automation systems. The valve
island must only be used for controlling suitable pneumatic
consumers.
▶Use the device only as intended. Non-intended use of the
device may be dangerous to people, nearby equipment and
the environment.
▶In explosion hazardous areas, only use devices that are
approvedfortheseareas.Thesedevicesareidentiedby
additional approval data on the type label. When used in
explosionhazardousareas,alwaysobservethespecica-
tions on the type label and the “Additional information for
use in the Ex area” included in the scope of delivery.
▶Device must not be used outdoors unprotected.
▶When using the device, observe the authorised data, ope-
ratinganddeploymentconditionsspeciedinthecontract
documents and in the operating instructions. These are
described in Chapter “Technical data”.
▶Use the device only in conjunction with third-party devices
and components recommended or approved by Bürkert.
▶Correct transport, storage and installation as well as careful
use and maintenance are essential for safe and faultless
operation.
▶Use the device only when it is in perfect condition.
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not take account of any
• contingencies or events which may occur during installation,
operation and maintenance of the devices;
• local safety regulations that are within the operator’s scope
of responsibility, including those relating to the installation
personnel.
Risk of injury from high pressure, escaping medium and
uncontrolled movement of the actuators.
▶Secure the actuators against shifting before working on the
device or plant.
▶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 it against reactivation.
▶Observe any applicable accident prevention and safety regu-
lations for electrical devices.
Risk of burns/re due to hot device surface if device ope-
rated continuously.
▶Keepthedeviceawayfromhighlyammablesubstances
and media and do not touch with bare hands.
Type 8644
English

6
Basic safety instructions
Risk of injury due to improper installation and maintenance.
▶Only allow trained technicians to perform installation and
maintenance work.
▶Perform installation and maintenance work using suitable
tools only.
Risk of injury due to unintentional activation of the device
and system and uncontrolled restart.
▶Secure the device and system against unintentional
activation.
▶Ensure that the system starts up in a controlled manner only.
Risk of injury due to allergic reaction to lubricants.
▶Avoid skin contact with lubricants.
▶Wear protective gloves.
General hazardous situations.
To prevent injuries, observe the following:
▶Do not feed any aggressive or combustible media into the
media connections of the device.
▶Do not place the housing under mechanical stress (e.g. by
placing objects on it or standing on it).
▶Note that pipes and valves must not be released in pressu-
rised systems.
▶Alwaysswitchothepowerbeforeworkingonthesystem.
▶Make the pressure supply as large-volume as possible to
avoid pressure drops during switching.
▶The system cannot be activated unintentionally.
▶Installation and maintenance work may only be carried out
by authorised specialist personnel using suitable tools.
▶Only restart the process in a controlled manner following
disruptions.
Observe sequence:
1. Apply electrical supply.
2. Pressurise with medium.
▶Operate the device only when it is in perfect condition and in
accordance with the operating instructions.
▶Observe the general rules of technology.
NOTE!
Avoid pressure drops!
To avoid a pressure drop, provide the device’s pressure supply
to the greatest extent possible.
Electrostatically sensitive components and assemblies.
The device contains electronic components that are susceptible
totheeectsofelectrostaticdischarging(ESD).Components
that come into contact with electrostatically charged persons
or objects are at risk. In the worst case scenario, these compo-
nents will be destroyed immediately or fail after start-up.
▶MeettherequirementsspeciedbyEN61340-5-1tomini-
mise or avoid the possibility of damage caused by a sudden
electrostatic discharge.
▶Do not touch electronic components when the supply voltage
is connected.
Type 8644
English

7
Notes on compatibility and revision levels
4 NOTES ON COMPATIBILITY AND REVISION LEVELS
The valve island Type 8644 is available in combination with decentralised peripheral devices from the cooperation partners “WAGO”,
“Phoenix Contact”, “Siemens” and “Rockwell Automation”.
The “WAGO” variant was revised (see Chapter 4.1).
The variants “Phoenix Contact”, “Siemens” and “Rockwell Automation” were not revised.
4.1 Overview of revision levels
Valve island width per station 11 mm*
REV.1 REV.2
Electronic modules REV.1
Pneumatic base modules REV.1 Pneumatic base modules REV.2
Connection modules REV.1 Connection modules REV.2
Solenoid valve Types 6524 and 6525 REV.1
• 1angepatternfordoublevalves
Type 6524 2 x 3/2-way
• 1angepatternforsinglevalves
Type 6524 3/2-way
Type 6525 5/2-way
Solenoid valve Types 6524 and 6525 REV.2
• 1angepatternfordoublevalvesandsinglevalves
Type 6524 2 x 3/2-way
Type 6524 3/2-way
Type 6525 5/2-way
Solenoid valve Type 0460
1angepatternforpulsevalvesandbistablevalves
Type 0460 5/2-way
Type 0460 5/3-way
AirLINE Quick REV.1 AirLINE Quick REV.2
*)only applies to the “WAGO” variant valve islands
Type 8644
English

8
Notes on compatibility and revision levels
Valve island width per station 16 mm*
REV.1 REV.2
Electronic modules REV.1
Pneumatic base modules REV.1 Pneumatic base modules REV.2
Connection modules REV.1 Connection modules REV.2
Solenoid valve Types 6526, 6527 and 0461
• 1angepatternforsinglevalves
Type 6526 3/2-way
Type 6527 5/2-way
1angepatternforpulsevalvesandbistablevalves
Type 0461 5/2-way
Type 0461 5/3-way
AirLINE Quick REV.1 AirLINE Quick REV.2
*)only applies to the “WAGO” variant valve islands
4.2 Notes on valve islands revision 2 (only
applies to “WAGO” valve islands)
The single valves of Types 6524 and 6525, the pneumatic base
modules and connection modules as well as the control cabinet
base adaptation AirLINE Quick have been revised due to various
optimisations. Compatibilities must therefore be taken into
account in the following cases:
• Valve replacement (see operating instructions for details)
• Extension, repair or conversion of valve blocks (see operating
instructions for details)
Revision2(REV.2)onlyaectspneumaticcomponentsofvalve
island8640.Notaectedbytherevision:
– Electrical data
–Conguration
- Outer dimensions
Type 8644
English

9
Notes on compatibility and revision levels
4.3 Distinguishing features between valve
islands REV.1 and REV.2
Only applies to the “WAGO” variant valve islands.
Colour of release rings (push-in connectors)
REV.1 REV.2
black blue
Channel arrangement of the working connections
REV.1 REV.3
parallel undulating
Note on the type label of the valve island
REV.1 REV.2
without note “REV.” with note “REV.2”
4.4 Distinguishing features between
individual valves REV.1 and REV.2
Only applies to the “WAGO” variant valve islands.
Single valves REV.1:
The single valves Type 6524 3/2-way and Type 6525 5/2-way
havethesameangepatternasthepneumaticbasemodule.
Thissinglevalveangepatterndiersfromthatofthedouble
valve Type 6524 2 x 3/2-way.
Single valves REV.2:
ComparedtotheREV.1,theangepatternsofthevalveshave
been standardised with regard to the pneumatic base modules.
The single valves 3/2-way and 5/2-way as well as the double
valves 2x3/2-way now have the same/standardised pneumatic
angepattern.
various channel sizes
Single valves REV.1
withangepattern
“FM14”
Single valves REV.2
withangepattern
“FM20”
Figure 1: Dierences between ange patterns of REV.1 and REV.2 for
single valves Type 6524 and Type 6525
Type 8644
English

10
General information
5 GENERAL INFORMATION
5.1 Contact address
Germany
Bürkert Fluid Control Systems
Sales Centre
Christian-Bürkert-Str.13–17
D-74653Ingelngen
Tel.+49(0)7940-1091111
Fax+49(0)7940-1091448
Email: [email protected]
International
The contact addresses can be found on the back pages of the
printed Quickstart.
They are also available online at: country.burkert.com
5.2 Warranty
A precondition for the warranty is that the device is used as
intendedinconsiderationofthespeciedoperatingconditions.
5.3 Information on the Internet
OperatinginstructionsanddatasheetsforType8644canbe
found on the Internet at:
country.burkert.com → 8644
6 TECHNICAL DATA
6.1 Standards and directives
The device complies with the relevant EU harmonisation legis-
lation. In addition, the device also complies with the require-
ments of the laws of the United Kingdom.
The harmonised standards that have been applied for the con-
formity assessment procedure are listed in the current version of
the EU Declaration of Conformity/UK Declaration of Conformity.
6.2 General technical data
NOTE!
To avoid damage to the device, use only direct current to
power the device.
Degree of pro-
tection (according
to EN 60529)
veriedbyBürkert,
not evaluated
byUL
IP20
IP65 in closed control cabinets
4X in combination with AirLINE Quick
(see chapter 9.3 on page 16) in closed
control cabinets
Type 8644
English

11
Technical data
when using the pilot valve Types
6524, 6525, 6526, 6527 0460, 0461
Pressure range Vac. to 10 bar
UL devices: Vac. to 8 bar
Operating voltage* 24VDC
Voltage tolerance +20%/–15% ± 10%
Ambient
temperature
0...+55°C 0...+50°C
*)
UL approved Versions must be supplied by one of the following:
a. Limited Energy Circuit (LEC) according to UL/ IEC 61010-1
b. Limited Power Source (LPS) according to UL/ IEC 60950
c. SELV/ PELV with UL Recognized Overcurrent Protection
dimensioned according to UL/ IEC 61010-1 Table 18
d. NEC Class 2 power source
6.2.1 Valve island type label
Manufacture
code
Device type
Revision marking
Serial number
Order number
Figure 2: Location and description of the type label (example)
6.2.2 UL type label
Device type, internal code
Supply voltage, current
Operating pressure
Figure 3: Location and description of the UL type label (example)
Type 8644
English

12
Connect valves
6.2.3 Valve type label
Germany
6524 C
2,5—10bar
24VBA0,8W
W1XAW
00123456
Device type
Circuit function
permitted pressure range
Order number
Operating voltage
(± 10%), power
Manufacture code
Figure 4: Location and description of the type label (example Type 6524)
7 CONNECT VALVES
7.1 Single valves width per station 11 mm
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-volume
as possible!
X* – pilot exhaust air
Figure 5: Fluid connection single valves Type 6524 and Type 6525
7.2 Double valves width per station 11 mm
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
Figure 6: Fluid and electrical connection double valves Type 6524
Type 8644
English

13
Removing the valve block from the standard rail
7.3 Single valves width per station 16 mm
Make the pressure
supply as large-
volume as
possible!
X* – pilot exhaust air
Type 6526
3/R
X*
2/A
1/P
no
connections
Type 6527
X*
5/R
4/A
1/P
2/B
3/S
Flange pattern “FM17”
Figure 7: Fluid connection single valves Type 6526 and Type 6527
8 REMOVING THE VALVE BLOCK
FROM THE STANDARD RAIL
DANGER!
Danger due to electrical voltage!
▶Beforereachingintothedeviceorthesystem,switchothe
power supply and secure it against reactivation.
Thevalveblockisrmlyscrewedontothestandardrail.Other
electrical modules/terminals can be attached to its sides.
Procedure:
→Loosen the adjacent modules/clips (if any).
→Unlock the attachment of the valve block to the standard rail.
Turn the fastening screws anticlockwise until they stop.
→Liftthevalveblockverticallyothestandardrail.
Figure 8: Unlocking the valve block attachment to the standard rail
Type 8644
English

14
Installation of the valve island in the control cabinet
Theremustbesucientspacebetweenthevalveblock
and the predecessor module (> 6 mm).
→Detach modules/clips from the standard rail according to the
manufacturer’s description.
NOTE!
The interface of the left connection module contains ele-
ments that can break o if force is applied.
▶Never place the valve block on its side.
▶Observe the permissible installation position of the valve block.
Figure 9: Detaching the modules/clips from the standard rail
NOTE!
▶When re-screwing the valve block on the standard rail,
observe a max. torque of 2 Nm!
9 INSTALLATION OF THE VALVE
ISLAND IN THE CONTROL CABINET
9.1 Safety instructions
DANGER!
Risk of explosion!
For devices in the potentially explosive atmosphere, which are
installed in a control cabinet, ensure the following:
• The control cabinet must be approved for use in the poten-
tially explosive atmosphere.
• The control cabinet must be dimensioned in such a way that
the resulting heat loss can be discharged to the outside using
suitable means.
• The internal temperature of the control cabinet must not
exceed the maximum permitted ambient temperature for the
device.
Risk of injury from electric shock.
▶Switchothepowersupplybeforeworkingonthedeviceor
system. Secure it against reactivation.
WARNING!
Risk of injury due to improper installation.
▶Only trained specialist personnel may carry out assembly
and disassembly work.
▶Only carry out assembly work using suitable tools.
Type 8644
English

15
Installation of the valve island in the control cabinet
CAUTION!
Medium leakage and malfunction.
If seals are not properly positioned, leaks and functional impair-
ments may arise due to pressure loss.
▶Ensure the seals are properly positioned in the electronics
assemblies and pneumatics.
Short circuit, loss of function.
The electrical connection requires exact contacting.
▶Do not bend the contacts.
▶Replacetheaectedcomponentsifconnectionsaredama-
ged or bent.
▶Only activate the device when the components are in perfect
condition.
Risk of injury due to falling heavy equipment.
During transportation or installation work, a heavy device may
fall and cause injuries.
▶Heavy equipment must only be transported, installed and
removed with the help of a second person and using suitable
equipment.
Thevalveblockisnotrmlyconnectedtothestandardrail
before tightening the fastening screws.
▶Make sure that the valve block cannot fall during the entire
installation.
Risk of injury due to sharp edges.
Sharp edges can cause cuts.
▶Wear suitable protective gloves.
NOTE!
Valve island Type 8644 is supplied as a fully assembled device.
ModicationsmayonlybemadebyBürkert.
The valves are excluded from this and may be exchanged by
the user for valves of the same variant.
9.2 Installation on standard rail
Fieldbus Converter Module Module Converter Conclusion
Figure 10: Installation on standard rail in the control cabinet
→Installthestandardrailrmlyinthecontrolcabinet.
→Establish a short, wide PE connection between the standard
rail and the control cabinet.
The valve island must be freely accessible from above.
Ensure good heat dissipation.
Type 8644
English

16
Installation of the valve island in the control cabinet
Recommended distance when installing in the control cabinet:
A30 mm C30 mm
B30 mm D60 mm
9.3 Installation with AirLINE Quick
ForinstallationwithAirLINEQuick,acut-outmustrstbepro-
vided in the control cabinet base or wall. This can be done, for
example, with a laser or punch.
Forthedimensionsofthecorrespondingangepattern,see
Chapter “9.3.1 Dimensions of the ange patterns for AirLINE
Quick”.
The distances to the left, right, front and top depend on the
selectedvalveislandconguration.
Recommended distance between the control cabinet and
valve island:
left right front top
30 mm 60 mm 30 mm 50 mm
NOTE!
The cut-out in the control cabinet must be burr-free so that the
AirLINE Quick adapter seal is not damaged.
→Insert the seal of the AirLINE Quick Adapter into the groove of
theangeopeningwithoutdamagingit.
→Position the valve island on the cut-out made in the control
cabinet.
→Install the stabilising plate from the outside to avoid warping
and secure it with M 5 x 10 screws from the supplied
attachment set.
AirLINE Quick
Adapter
Valve island
Type8644
Control cabinet
Figure 11: Positioning the valve island in the control cabinet
Stabilising plate
Screws M 5 x 10
Figure 12: Fixing the stabilising plate
Type 8644
English

17
Installation of the valve island in the control cabinet
9.3.1 Dimensions of the ange patterns for AirLINE Quick
Control cabinet inner wall
Space requirement for external reinforcing frame
G
N4
N3
N2
N1
M
only with O= 6 and O = 10
(O = number of holes)
Ø 5.3 ± 0.2
59±0.3 73±0.3
(96)
R 6.5
t >= 1.5
>= 8
Figure 13: Flange pattern AirLINE Quick – for dimensions, see table Tab. 1 on page 18
Type 8644
English

18
Installation
Variant 8-valve 12-valve 16-valve
Special
feature –––
M155 ± 0.4 199 ± 0.4 243 ± 0.4
N1 54 ± 0.3 68 ± 0.3 123 ± 0.4
N2 158 ± 0.4 202 ± 0.4 246 ± 0.4
N3 –––
N4 –––
O
(number of holes) 8 8 10
G192 236 280
Variant 16-valve 24-valve 24-valve
Special
feature
with interme-
diate feed –with interme- diate feed
M276 ± 0.4 331 ± 0.4 364 ± 0.4
N1 140 ± 0.4 66 ± 0.3 73 ± 0.3
N2 279 ± 0.4 200 ± 0.4 219 ± 0.4
N3 – 334 ± 0.4 367 ± 0.4
N4 –––
O
(number of holes) 10 12 12
G313 368 401
Tab. 1: Dimensions of the ange pattern AirLINE Quick
10 INSTALLATION
10.1 Fluidic installation
DANGER!
Risk of injury from high pressure in the system.
▶Beforelooseninglinesorvalves,switchothepressure!Vent
or empty the lines.
▶Make the pressure supply as large-volume as possible.
▶Close open connections that are not required with lock
screws.
▶Connections for pilot exhaust air (x) must not be closed.
▶Check the connections 1 and 3 or 5 are correctly assigned.
These must not be interchanged under any circumstances.
NOTE!
The hose lines must meet the following requirements for the
working connections:
• Minimum hardness of 40 Shore D (according to DIN 53505
or ISO 868)
• Outer diameter according to DIN 73378 (max. permissible
deviation ± 0.1 mm from nominal dimension)
• Burr-free,cutoatrightanglesandundamagedonthe
external diameter surface
▶Insert the hose lines into the working connections as far as
they will go.
Type 8644
English

19
Installation
10.1.1 Connect feed
Exhaust air R/3, S/5
Pressure port P/1
X channel
Standard device:
Venting the control valves
Auxiliary pilot air version:
P connection for control valves
Figure 14: Pneumatic connections feed
→Screw the G1/4 connection adapter onto the P and R/S
connections.
→Insert or screw the hose lines into the corresponding connec-
tions (depending on the variant).
NOTE!
Risk of leakage if the screw connection is too strong!
▶WheninstallingtheuidicconnectionadaptersontheP,R/S
connections, observe the maximum tightening torque of 12
Nm.
Irreversible damage to the seal in the thread of the tting!
▶When screwing or unscrewing the connection adapters, pre-
vent the corresponding connection from twisting by holding
it with a suitable tool.
10.1.2 Connecting the working ports
Labellingelds
Working connections for
3/2-way valves
Working connections
for 5/2-way valves
Figure 15: Pneumatic connections – Working connections
→Insert or screw the hose lines into the corresponding working
connections (depending on the variant).
Connection nipples can be used for threaded variants.
Labelling of connections:
→Labelthelabellingeldswiththedataofthevalve
connections.
Type 8644
English

20
Installation
10.1.3 Connecting the feed with AirLINE Quick
Exhaust port R/S
Example of
connection adaptor
Supply connection P
Figure 16: Connecting the feed with AirLINE Quick
→Screw the G1/4 connection adapter onto the P and R/S
connections.
→Insert the hose lines into the corresponding connections.
NOTE!
Risk of leakage if the screw connection is too strong!
▶WheninstallingtheuidicconnectionadaptersontheP,R/S
connections, observe the maximum tightening torque of 12
Nm.
Irreversible damage to the seal in the thread of the tting!
▶When screwing or unscrewing the connection adapters, pre-
vent the corresponding connection from twisting by holding
it with a suitable tool.
10.1.4 Connecting working ports with AirLINE
Quick
Figure 17: Pneumatic connections – AirLINE Quick
→Plug the hose lines into the corresponding working
connections.
10.1.5 Loosen hose lines
→To loosen the hose lines, press in the pressure ring on the
working connection and pull out the hose line.
Type 8644
English