Burkert 8644 AirLINE User manual

Operating Instructions
Type 8644
AirLINE
with I/O System 750 (Wago)

We reserve the right to make technical changes without notice.
© Bürkert Werke GmbH & Co. KG, 2002 - 2023
Operating Instructions 2311/14_ENen_00804090 / Original DE
These operating instructions apply to device variants REV.1 and REV.2.
Information about the distinguishing features of the device variants can be found in chapter “5.6 Information
on compatibility and revision status” on page 20.

3
Inhalt
1 OPERATING INSTRUCTIONS ................................................................................................................6
1.1 Symbols........................................................................................................................................6
1.2 Denitionofterms........................................................................................................................7
2 INTENDED USE ......................................................................................................................................8
3 BASIC SAFETY INSTRUCTIONS ...........................................................................................................9
4 GENERAL NOTES.................................................................................................................................11
4.1 Contactaddress.........................................................................................................................11
4.2 Warranty .....................................................................................................................................11
4.3 Informationonline ......................................................................................................................11
4.4 Standardsanddirectives...........................................................................................................11
5 PRODUCT DESCRIPTION....................................................................................................................12
5.1 Applicationrange .......................................................................................................................12
5.2 Generaldescription....................................................................................................................12
5.3 Systemstructure........................................................................................................................13
5.4 Explodedview............................................................................................................................15
5.4.1 Exploded view - width per station 11mm, REV.1 .......................................................15
5.4.2 Exploded view - width per station 11 mm, REV.2 ......................................................16
5.4.3 Exploded view - width per station 16 mm, REV.1 ......................................................17
5.5 Locationanddescriptionofthetypelabels .............................................................................18
5.5.1 Valve island type label ................................................................................................18
5.5.2 UL type label...............................................................................................................18
5.5.3 Valve type label...........................................................................................................19
5.6 Informationoncompatibilityandrevisionstatus .....................................................................20
5.6.1 Overviewofrevisionstatutesforthedierentwidthsperstation ..............................20
5.6.2 Information on Revision 2 (REV.2) ..............................................................................22
5.6.3 Distinguishing features between REV.1 and REV.2 ....................................................22
6 TECHNICAL DATA ................................................................................................................................23
6.1 Operatingconditions .................................................................................................................23
6.2 Technicaldataoftheoverallsystem.........................................................................................23
6.3 Technicaldataofthevalveblock..............................................................................................25
6.4 Electricaldata ............................................................................................................................27
6.4.1 Performance characteristics from the perspective of the overall system...................27
Type8644AirLINE-Wago
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6.4.2 Electrical basic module ME02 / 2-fold monostable,
ME02 / 2-fold 2 x monostable ....................................................................................28
6.4.3 Electrical basic module ME02 / 8-fold monostable,
ME02 / 8-fold 2 x monostable ....................................................................................29
6.4.4 Electronic base module ME02 / 2-fold bistable,
ME02 / 8-fold bistable
....................................................................................................................................30
6.4.5 Electronic base module ME03 / 2-fold monostable,
ME03 / 2-fold bistable ................................................................................................31
6.4.6 Electronic base module ME03 / 3-fold 10 mm monostable,
ME03 / 4-fold monostable..........................................................................................32
7 STRUCTURE AND FUNCTION OF THE MODULES ............................................................................33
7.1 Valveblock .................................................................................................................................33
7.2 Electricalconnectionmodules ..................................................................................................34
7.3 Electronicbasemodules ...........................................................................................................35
7.3.1 Electronic base module ME02 / 2-fold monostable ...................................................37
7.3.2 Electronic base module ME02 / 2-fold 2 x monostable .............................................38
7.3.3 Electronic base module ME02 / 8-fold monostable ...................................................39
7.3.4 Electronic base module ME02 / 8-fold 2 x monostable .............................................40
7.3.5 Electronic base module ME02 / 2-fold bistable .........................................................41
7.3.6 Electronic base module ME02 / 8-fold bistable .........................................................42
7.3.7 Electronic base module ME03 / 2-fold monostable ...................................................43
7.3.8 Electronic base module ME03 / 2-fold bistable .........................................................44
7.3.9 Electronic base module ME03 / 3-fold 10 mm monostable .......................................45
7.3.10 Electronic base module ME03 / 4-fold monostable ...................................................46
7.4 Pneumaticconnectionmodules................................................................................................47
7.5 Pneumaticbasemodules ..........................................................................................................49
7.6 Valves .........................................................................................................................................50
7.6.1 Valves Type 6524 and Type 6525 for valve islands width per station 11 mm ............50
7.6.2 Valves Type 0460 for valve islands width per station 11 mm .....................................55
7.6.3 Valves Type 6526 and Type 6527 for valve islands width per station 16 mm ............56
7.6.4 Valves Type 0461 for valve islands width per station 16 mm .....................................58
8 INSTALLATIONANDSTART-UPOFTHEVALVEISLANDINTHECONTROLCABINET....................59
8.1 Safetyinstructions .....................................................................................................................59
8.2 Removingthetransportlockfromthevalveblock ..................................................................60
8.3 Installationonstandardrail .......................................................................................................61
8.4 Fluidicinstallation ......................................................................................................................62
8.4.1 Pneumatic installation of the connection units...........................................................62
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8.4.2 Pneumatic installation of the valve units ....................................................................63
8.5 InstallationwithAirLINEQuick(onlyvalveislandswidthperstation11mm).........................64
8.5.1 AirLINE Quick in a potentially explosive atmosphere .................................................64
8.5.2 Installation of AirLINE Quick .......................................................................................65
8.5.3 DimensionsoftheangepatternsforAirLINEQuick .................................................66
8.5.4 Assignment of the pneumatic connections for AirLINE Quick ...................................67
8.6 Electricalinstallation..................................................................................................................67
9 MAINTENANCE, TROUBLESHOOTING...............................................................................................68
9.1 Safetyinstructions .....................................................................................................................68
9.2 Troubleshooting .........................................................................................................................68
9.3 Maintenanceofcomponents.....................................................................................................69
9.3.1 UL handling.................................................................................................................69
10 START-UP .............................................................................................................................................70
10.1 Safetyinstructions .....................................................................................................................70
10.2 Fluidicstart-up ........................................................................................................................... 70
10.3 Electricalstart-up....................................................................................................................... 70
10.3.1 SelectionofmodulesintheGSDle..........................................................................71
11 ACCESSORIES, SPARE PARTS...........................................................................................................72
11.1 Accessories,sparepartsforwidthperstation11mm ............................................................72
12 PACKAGING, TRANSPORT, STORAGE ...............................................................................................73
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Operating instructions
1 OPERATING INSTRUCTIONS
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 them available to every new owner of the device.
WARNING!
Theoperatinginstructionscontainimportantsafetyinformation!
Failure to observe these instructions may result in hazardous situations.
▶The operating instructions must be read and understood.
1.1 Symbols
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toproperty!
▶Failure to observe these instructions may result in damage to the device or the equipment.
Indicates important additional information, advice and recommendations.
Refers to information in these operating instructions or in other documentation.
▶Highlights instructions to avoid a danger.
→Highlights a procedure which you must carry out.
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Operating instructions
1.2 Denition of terms
Term in these instructions stands for
Device, valve block Valve island Type 8644, variant WAGO
Valve island Valve block Type 8644 in combination with modules from the decen-
tralised “I/O System 750” from WAGO
Valve, pilot valve Pneumatic solenoid valve integrated in the valve block
Actuator pneumatic consumer controlled by the valve island
Equipment Machine whose pneumatic consumers are controlled by the valve island
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Intended use
2 INTENDED USE
ThevalveislandType8644Wagohasbeenbuilttocontrolpneumaticconsumersinautomation
systems.Thedevicemustonlybeusedtocontrolsuitablepneumaticconsumers.
►The device must only be used for its intended purpose. Improper use of the device may be dangerous
to people, nearby equipment and the environment.
►In potentially explosive 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potentiallyexplosiveareas,
observe the information on the type label and the additional instructions for the potentially explosive
area included in the scope of delivery.
►Install the device in a suitable control cabinet or housing. The requirements for the control cabinet or
housing correspond to those of the “I/O System 750” from WAGO.
►Do not use the device outdoors.
►The prerequisites for safe and trouble-free operation are correct transportation, correct storage, installa-
tion, commissioning, operation and maintenance.
►To use the device, observe the permitted data, operating conditions and usage conditions. These speci-
cationscanbefoundinthecontractdocuments,theoperatinginstructionsandonthetypelabel.
►Use the device only in conjunction with third-party devices and components recommended or approved
by Bürkert.
►Use the device only when it is in technically perfect condition.
The valve island is intended exclusively for use in the industrial sector.
The valve island is only permitted in applications where there is a danger to life and limb if the SIA and
EVS functions provided for this purpose are used with appropriate, approved equipment (safety relays,
etc.).
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Basic safety instructions
3 BASIC SAFETY INSTRUCTIONS
These safety instructions do not take into account any unforeseen circumstances or events that occur
during installation, operation and maintenance. The operator is responsible for observing the location-spe-
cicsafetyregulations,includingstasafety.
Riskofinjuryfromhighpressure,mediumleakageanduncontrolledmovementoftheactuators.
►Secure the actuators against adjusting before working on the device or system.
►Switchothepressurebeforeworkingonthedeviceorsystem.Ventordrainthepipes.
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 regulations for electrical devices.
Riskofburnsfromhotdeviceparts.
►Keepthedeviceawayfromhighlyammablesubstancesandmedia.
Riskofinjuryduetoimproperinstallationandmaintenance.
►Only trained technicians may perform installation and maintenance work.
►Perform installation and maintenance work using suitable tools only.
Riskofinjuryfromunintentionalactivationanduncontrolledstart-upofthedeviceandsystem.
►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:
►Transport, install and dismantle a heavy device only with the aid of a second person and using suitable
equipment.
►Install the device in accordance with the regulations applicable in the respective country.
►Do not feed any aggressive or combustible media into the media connections of the device.
►Do not feed any liquids into the media connections of the device.
►Following interruption of the process, ensure that the process is restarted in a controlled manner.
Observe sequence:
1. Connect electrical power supply.
2. Pressurise with medium.
►Do not modify the device.
►Do not to subject the device to mechanical stress.
►Observe the general rules of the technical equipment.
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Basic safety instructions
ATTENTION
Electrostaticallysensitivecomponentsandassemblies.
Thedevicecontainselectroniccomponentsthataresensitivetotheeectsofelectrostaticdischarge
(ESD). Components are at risk if they come into contact with electrostatically loaded persons or objects.
In the worst case scenario, these components will be destroyed immediately or fail after start-up.
►MeettherequirementsspeciedbyEN61340-5-1tominimiseoravoidthepossibilityofdamage
caused by sudden electrostatic discharge.
►Do not touch electronic components when the supply voltage is connected.
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General notes
4 GENERAL NOTES
4.1 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
4.2 Warranty
Apreconditionforthewarrantyisthatthedeviceisusedasintendedandthatthespeciedusagecondi-
tions are taken into account.
4.3 Information online
OperatinginstructionsanddatasheetsforType8644canbefoundonlineat:country.burkert.com
Technicalspecications,congurationlesandadetaileddescriptionofbuscouplesandelectrical
function terminals from Wago can be found online at:
www.wago.com Downloads Documentation WAGO I/O System 750
Bürkert has no control over the currency or technical or presentative changes of the linked pages.
4.4 Standards and directives
The device complies with the valid EU harmonisation legislation. In addition, the device also complies with
the requirements of the laws of the United Kingdom.
The harmonised standards that have been applied for the conformity assessment procedure are listed in the
current version of the EU Declaration of Conformity/ UK Declaration of Conformity.
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Product description
5 PRODUCT DESCRIPTION
5.1 Application range
ThevalveislandType8644isbuiltfordecentraliseduseinindustrialenvironments.Electronicsanduidics
canbeeasilyandecientlycombinedduetothemodularstructure.
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 regulations for electrical devices.
5.2 General description
Fig. 1: Type 8644 AirLINE Wago
The valve island Type 8644 is an electrical and pneumatic automation system that has been developed for
use in control cabinets or switch boxes. All electronic and pneumatic components are standardised in an
integrated system. By adhering to simple rules, pneumatic, electrical and electronic modules with various
functionalities can be combined very easily. All components are connected via a locking mechanism. As
a result, the required electrical connections are also made. For example, valves and power outlets can be
combinedwithjust1eldbusconnection.Alargenumberofelectronicmodules(terminals)canbecom-
bined very easily with the valves installed on special pneumatic modules (valve segments).
Initsminimumconguration,thesystemconsistsofeldbusnodes,avalveblockandaconnection
module. Terminals can be arranged before and after the valve block.
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Product description
5.3 System structure
Fieldbus
Central control
(e.g. PLC)
Fieldbus
node 1
(e.g.
PROFIBUS
DP)
DO
2x
Valve segment
4x
Fieldbus node 2
Fieldbus node ...
Fieldbus node n
Electrical
base module
Pneumatic
base module
AI
2x
DI
4x
Terminal module
Connection module
Valve segment
4x 8x
Valve segment
Valve block
Connection module
Valve Valve
Valve Valve
Fig. 2: Schematic representation of the Bürkert AIRLINE System
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Product description
4-fold valve segment
Right connection module
8-fold valve segment
Intermediate feed
Pressure gauge for operating
pressure indication on the station
Working ports
Supply and vent connections
Left connection module
Fig. 3: Representation of the modules of the Bürkert AIRLINE System
Additionalinformationandtechnicaldetailsontheelectricalanduidiccomponents:
Electricalmodules
see“7.2 Electrical connection modules” on page 34 and
“7.3 Electronic base modules” on page 35
Pneumaticmodules
see “7.4 Pneumatic connection modules” on page 47 and
“7.5 Pneumatic base modules” on page 49
Valves
see “7.6 Valves” on page 50
AirLINEQuick
see “8.5 Installation with AirLINE Quick (only valve islands width per station 11 mm)” on page 64
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Product description
5.4 Exploded view
5.4.1 Exploded view - width per station 11mm, REV.1
Wagoeldbusnode
ME02
8-fold valve segment
2-fold valve segment
ME02
2-fold valve segment
ME02
Wago terminal module
Bulkhead
MP11
ME02
Cover plate
6524
(2 x 3/2-way) 6524
6525
0460
Fig. 4: Exploded view - width per station 11 mm
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Product description
5.4.2 Exploded view - width per station 11 mm, REV.2
Type 6524
(2x3/2-way) Type 6524
Type 6525
Type 6524
*PF34 Type 0460
ME02
MP16
Accessories
Cover plate
Wagoeldbusnode
ME02
4-fold valve segment
ME02
ME02
8-fold valve segment
Wago terminal module
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Product description
5.4.3 Exploded view - width per station 16 mm, REV.1
Wagoeldbusnode
Wago terminal module
ME03
2-fold valve segment
ME03
4-fold valve segment
2-fold valve segment
ME03
ME03
MP12
Accessories
Cover plate
6526
6527
0461
Fig. 5: Exploded view - width per station 16 mm
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Product description
5.5 Location and description of the type labels
5.5.1 Valve island type label
Manufacture code
Device type
Revision marking
Serial number
Order number
Fig. 6: Location and description of a valve island type label (example)
5.5.2 UL type label
Device type, internal code
Supply voltage, current
Operating pressure
Fig. 7: Location and description of a UL type label (example)
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Product description
5.5.3 Valve type label
Germany
6524 C
2,5—10bar
24VBA0,8W
W1XAW
00123456
Device type
Mode of action
permitted pressure range
Order number
Voltage (± 10%), power
Production date (encrypted)
Fig. 8: Location and description of a valve type label (example Type 6524)
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Product description
5.6 Information on compatibility and revision status
5.6.1 Overview of revision statutes for the dierent widths per
station
REV.1 REV.2
• ElectronicmodulesREV.1
• PneumaticbasemodulesREV.1
• ConnectionmodulesREV.1
• 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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
• ElectronicmodulesREV.1
• PneumaticbasemodulesREV.2
• ConnectionmodulesREV.2
• 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.2
Valveislandwidthperstation11mm
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