Burkert 8821 User manual

Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 8821
Functional unit comprising MasterJet air unit and base construction
Funktionseinheit bestehend aus MasterJet mit Lufteinheit und Sockelaufbau
Unité fonctionnelle comprenant le MasterJet avec unité pneumatique et socle

We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürkert Werke GmbH & Co. KG, 2012 - 2017
Operating Instructions 1805/01_EU-EN_00810012 / Original DE

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1. OPERATING INSTRUCTIONS ..................................................................5
1.1. Symbols ..........................................................................................5
1.2. Definitions of terms .....................................................................5
2. AUTHORIZED USE........................................................................................6
2.1. Restrictions ....................................................................................6
3. BASIC SAFETY INSTRUCTIONS ...........................................................6
4. GENERAL INFORMATION ..........................................................................7
4.1. Contact address ...........................................................................7
4.2. Warranty.......................................................................................... 7
4.3. Information on the Internet .......................................................... 7
5. SYSTEM DESCRIPTION .............................................................................8
5.1. Intended application area............................................................8
5.2. General description ......................................................................8
5.3. Functions ........................................................................................8
6. TECHNICAL DATA ..........................................................................................9
6.1. Conformity ...................................................................................... 9
6.2. Standards .......................................................................................9
6.3. Operating conditions ...................................................................9
6.4. General technical data ................................................................9
6.5. Schematic circuit ........................................................................12
7. ASSEMBLY .....................................................................................................13
7.1. Safety instructions ......................................................................13
7.2. Assembly of the functional unit ................................................13
8. INSTALLATION .............................................................................................15
8.1. Safety instructions ......................................................................15
8.2. Pneumatic installation ................................................................15
8.3. Hydraulic installation ..................................................................16
8.4. Parts list for the screw connections .......................................16
8.5. Overview of MasterJet screw connections
with the pneumatic unit .............................................................17
8.6. Electrical installation ...................................................................18
8.7. Electrical installation ...................................................................19
9. START-UP .......................................................................................................20
9.1. Safety instructions ......................................................................20
9.2. Starting-up the pneumatic unit ................................................20
9.3. Starting-up Type 8821 ..............................................................21
10. OPERATION ................................................................................................... 22
10.1. Safety instructions ......................................................................22
10.2. Manual operation of the MasterJet .........................................23
10.3. Automatic operation of the MasterJet ....................................23
10.4. Sensor programming .................................................................24
11. MAINTENANCE ............................................................................................26
11.1. Safety instructions ......................................................................26
12. SPARE PARTS ..............................................................................................27
Contents
Type 8821
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Type 8821
13. REPAIRS ..........................................................................................................28
13.1. Replacing pilot valve Type 6014 .............................................28
13.2. Replacing pilot valve Type 0450 .............................................29
13.3. Replacing flow-rate sensor SE12 ...........................................30
13.4. Replacing the display and evaluation unit
(electronics module SE32) .......................................................31
13.5. Replacing drive DM63 and DM50 ..........................................32
13.6. Replacing expansion cylinder DM63 .....................................33
13.7. Replacing the pneumatic unit ..................................................34
14. SHUTDOWN................................................................................................... 35
14.1. Safety instructions ......................................................................35
14.2. Disassembly of Type 8821 .......................................................35
15. TRANSPORTATION, STORAGE, DISPOSAL .................................36
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Operating Instructions
Type 8821
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 these instructions available to every new owner
of the device.
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 the warning will 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 moderate or
minor injury.
NOTE!
Warns of damage to property!
• Failure to observe the warning may result in damage to the
device or the equipment.
Indicates important additional information, tips and
recommendations.
Refers to information in these operating instructions or in
other documentation.
→Designates a procedure which you must carry out.
1.2. Definitions of terms
In these instructions, the maximized version of the term "functional
unit" comprises the following components:
MasterJet, pneumatic unit and base construction.
While the minimum version only comprises
the pneumatic unit and base construction.
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Authorized Use
Type 8821
2. AUTHORIZED USE
Non-authorized use of the functional unit may be dangerous
to people, nearby equipment, and the environment.
• The functional unit is designed to control and monitor the cool-
ing circuits on industrial production systems.
• The functional unit must not be used in potentially explosive
areas.
• Use according to the authorized data, operating conditions, and
conditions of use specified in the contract documents and oper-
ating instructions. These are described in the chapter entitled
"Technical Data".
• The functional unit must only be used in conjunction with third-
party devices and components recommended and approved by
Bürkert.
• Correct transportation, storage, and installation, as well as care-
ful use and maintenance are essential for reliable and faultless
operation.
• Do not make any external modifications to the device housings.
Do not paint housing parts or screws.
• Only use the functional unit as intended.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
3. BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
• Contingencies and events which may arise during the installation,
operation, and maintenance of the devices.
• Local safety regulations – the operator is responsible for observing
these regulations, also in relation to the installation personnel.
Danger – high pressure!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Risk of electric shock!
• Switch off the power supply and secure it against reactivation
before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
General hazardous situations!
To prevent injuries:
• Do not supply the medium connectors of the system with
aggressive or flammable media.
• Do not supply the compressed-air connections with any liquids.
• The impact protection on the top of the device must not be
loaded with more than 70 kg.
• Ensure that the system cannot be activated unintentionally.
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General Information
Type 8821
• Installation and repair work may be carried out by authorized
technicians only and with the appropriate tools.
• After an interruption in the electrical or pneumatic supply,
ensure that the process is restarted in a defined or controlled
manner.
• The device must only be operated when in a perfect condition
and in consideration of the operating instructions.
• The general rules of technology apply to application planning
and operation of the device.
NOTE!
Electrostatic sensitive components/modules!
The device contains electronic components which react sensitively
to electrostatic discharge (ESD). Contact with electrostatically
charged persons or objects are 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
Technik Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Germany
Tel. + 49 (0) 7940 - 10 91 110
Fax + 49 (0) 7940 - 10 91 448
E-mail: [email protected]
International
Contact addresses can be found on the final pages of the printed
operating instructions.
And also on the Internet at:
www.burkert.com
4.2. Warranty
The warranty is only valid if the functional unit is used as intended in
accordance with the specified application conditions.
4.3. Information on the Internet
The operating instructions and data sheets for Type 8821 can be found
on the Internet at:
www.burkert.com
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System Description
Type 8821
5. SYSTEM DESCRIPTION
5.1. Intended application area
Type 8821 is intended for the use in industrial systems, especially
robot applications used for resistance spot welding for controlling
and monitoring cooling water circuits.
5.2. General description
Type 8821 is used to control and monitor the flow of coolant in
industrial robot applications used for resistance spot welding.
The coolant circuit is controlled by the unit and the required coolant
quantity is monitored.
Additionally, the water pressure within the system is reduced when
the flow of cooling water is switched off.
This is advantageous when replacing the welding electrodes as this
prevents any cooling water from escaping.
5.3. Functions
• The main valve (NC) for the feed and return of the cooling circuit is
controlled via pilot valve Type 6014.
• During shutdown, the pressure in the cooling system is automatically
reduced by the delayed drive control in the return.
• The residual pressure is released via delayed switched pilot valve
Type 0450 and pneumatic expansion cylinder DM63 in the closed
cooling circuit.
• An optical cooling water flow sensor Type 8012 DN8, comprising
evaluation electronics with integrated impeller SE12, fitting SO30
and electronics module SE32 monitors the flow rate and sends
signal outputs to the overriding control or robot in accordance with
the programmed monitoring windows.
• The flow-rate sensor comprises a flow direction detector.
• The flow quantity of the cooling water can be limited via a manual
adjusting screw on the pneumatic feed drive.
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Technical Data
Type 8821
6. TECHNICAL DATA
6.1. Conformity
Type 8821 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. Operating conditions
WARNING!
Risk of injury!
Malfunction if used outside!
• Do not use Type 8821 outdoors and avoid heat sources which
may cause the permissible temperature range to be exceeded.
Permitted temperatures
Ambient temperature: +5 to +55°C
Medium temperature: +5 to +90°C
Media: Aggressive and neutral fluids
Protection class: IP65 in accordance with EN 60529
6.4. General technical data
Weight: 9.5 kg
Housing material: VA / brass
External sealing material: EPDM
6.4.1. Dimensions
271,3
199,5 85,6
199,8
276,3
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Fig. 1: Type 8821, MasterJet with pneumatic unit and base construction;
rear view
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Technical Data
Type 8821
199,5
216,1
Fig. 2: Type 8821, MasterJet with pneumatic unit and base construction;
bottom view
216
192,6
Fig. 3: Type 8821, MasterJet with pneumatic unit and base construction;
left side view
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Technical Data
Type 8821
6.4.2. Pneumatic data
Control medium: Quality classes in accordance with DIN ISO 8573-1
Dust content: Class 5: max. particle size 40 μm,
max. particle density 10 mg/m3
Water content: Class 3: max. pressure dew point -20°C or
min. 10°C below the lowest
operating temperature
Oil content: Class 5: max. 25 mg/m3
Temperature range
of compressed air: -10 to +50°C
Pressure range 3.0 to 9.5 bar
Air flow rate IN/min
(for aeration and deaeration) (QNn value according to definition for
pressure drop from 7 to 6 bar absolute)
Connections Plug-in hose connector
Ø 6 mm / 1/4"
6.4.3. Hydraulic data
Medium: Water, cooling water
Max. operating pressure: 9.5 bar
Ambient temperature: +5 to +55°C
Water connections
on the block: See “Fig. 7”, page 17
6.4.4. Electrical data
Valve
Connection: DIN 43650 form B with M12 adapter
Power supply: 24 V DC
Sensor:
Connection: M12 connector
Power supply: 12 - 30 V DC
Measuring precision: +/- 1% of the final value, 3% of the mea-
sured value at a flow rate of 0.3 to 10 m/s
Output: 1 impulse /revolution, transistor NPN
700 mA
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Technical Data
Type 8821
6.5. Schematic circuit
Display SE32
P customer's pressure
installation
P 5-10 bar
Supply line Customer's
supply Return travel
3/2-way valve
(6014) 24VDC Valve supply 1
(2031) DN15
Valve return 2
(2031) DN15
Flow-rate sensor
SE12 DN08
Deaeration
Air Water
Connector
5/2-way valve (0450)
pneumatically controlled
Spot-welding gun
Pneumatic
leading to
the robot
Supply line Return travel
3
1
ø 0.5
2
ø 0.05 2
3 1
4
ø 0.5
Fig. 4: Schematic circuit
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Assembly
Type 8821
7. ASSEMBLY
7.1. Safety instructions
DANGER!
Risk of injury from high pressure in the system!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Risk of injury due to electrical shock!
• Switch off the power supply and secure it against reactivation
before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
WARNING!
Risk of injury from improper assembly!
• Installation must only be carried out by authorized technicians
and 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.
7.2. Assembly of the functional unit
WARNING!
Risk of injury from a sudden discharge of cooling water due
to improper installation!
If the installation position is incorrect (horizontal orientation or
upside down), the discharge function of the expansion cylinder is
no longer guaranteed. This can cause cooling water to suddenly
escape from the spot-welding gun when the electrode caps are
being replaced.
• Only install the functional unit vertically.
• The installation position must be observed.
Procedure:
→Connect the MasterJet to a base plate or fixture using the desig-
nated bores (see “Fig. 5” and “Fig. 6”).
NOTE!
• Pay attention to the installation position of the functional unit. If
installed correctly, the impact protection plate is at the top!
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Assembly
Type 8821
88
88
Fig. 5: Screwing bores in the base plate
A fixture that matches the screw hole pattern on the robot can be
supplied for mounting on the base of the robot.
Item designation and order number:
Angled bracket, complete 771338
See section “12. Spare Parts”, page 27
Fixture for installation of
the base of the robot
Fig. 6: MasterJet including fixture for mounting on the base of the robot
7.2.1. Mounting options:
Generally, various options are available for mounting the MasterJet.
Recommendation:
Mount the unit as close as possible to the process (e.g. spot-welding
gun).
Long hose lengths are required with large distances. This has the fol-
lowing consequences:
• The amount of coolant increases, which means that a correspond-
ingly larger expansion cylinder has to be selected.
• Delayed reaction times when it comes to changes in the flow rate
caused, for example, by an electrode cap breaking on the spot-
welding gun.
The detection of these and other error conditions are therefore
also delayed.
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Installation
Type 8821
8. INSTALLATION
8.1. Safety instructions
DANGER!
Risk of injury from high pressure in the system!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Risk of injury due to electrical shock!
• Switch off the power supply and secure it against reactivation
before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
WARNING!
Risk of injury from improper installation!
• Installation may be carried out by authorized technicians only
and with the appropriate tools!
Risk of injury from unintentional activation of the system and
uncontrolled restart!
• Secure system from unintentional activation.
• Following installation, ensure a controlled restart.
8.2. Pneumatic installation
DANGER!
Risk of injury from high pressure in the system!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Procedure:
→Following the mechanical mounting of the MasterJet, establish
a pneumatic connection between the pneumatic unit and
MasterJet:
→Connect the factory-provided air supply to the pneumatic unit.
See “Fig. 7: Overview of the hose system Type 8821”
Observe the air volume requirements in the robot
application.
The MasterJet requires a plug-in hose connection with a
6 mm diameter. The robot application requires a 1/2" con-
nection (1/2" on M22 x 1.5 or equivalent is standard in most
structural work applications).
→Connect the connecting hose leading to the base of the robot or
stationary welding gun to the output side of the T-fitting on the
maintenance unit.
→Tighten the screws.
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Installation
Type 8821
NOTE!
Damage caused by high inlet pressure!
• The air pressure provided on site must not exceed the maximum
permissible pressure on the functional unit.
• Use a suitable pressure reducer if the inlet pressure is higher
than permissible!
8.3. Hydraulic installation
NOTE!
Damage caused by improper tightening of the screws!
• When tightening the universal rotary joint observe the maximum
torque or the 1/4 revolution tightening otherwise the screw con-
nection can tear.
Procedure:
→Connect the warehouse cooling water supply and return on the
input side of the MasterJet using the screws provided.
NOTE!
Malfunction of the MasterJet due to the supply and return
being mixed up!
The existing water flow is not measured if the flow direction is
mixed up.
• Observe the flow direction when connecting the cooling water
supply.
→Cut the supplied plug-in hoses to length in accordance with the
distance between the MasterJet output and the connection point
on the base of the robot.
Cut the hoses to such a length that they can be laid with
large bending radii. Bending radii that are too tight can hinder
the water flow.
→Then connect the prepared houses to the output side of the
MasterJet and the base of the robot.
Match the color of the hose with the color-coded connections
on the base of the robot: supply = green; return = red.
8.4. Parts list for the screw connections
Position Material number Quantity
1. GE15LREDOMDCF 1
2. 3C382-15-8 1
3. EVGE22LR3/4KEGMS 1
4. GE22LR3/4KEGMSX 1
5. 3D082-22-12B 1
6. 3C382-22-12B 1
7. EVGE15LR1/2KEGMS 1
8. GE15LR1/2KEGMSX 1
9. 3D082-15-8B 1(2)
10. 3C382-15-8B 1
11. 35C82-15-8B (2)
12. H898202 (1)
Tab. 1: Parts list for the screw connections
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Installation
Type 8821
8.5. Overview of MasterJet screw connections with the pneumatic unit
On the base of the robot On the functional unit/output On the functional unit/input
Pneumatic connections
Universal sealing head H898202 *) Double nipple GE15LREDOMDCF
35C82-15-8B + universal sealing head 3C382-15-8
Cooling water connections
Universal sealing head 35C82-15-8B *) Supply double nipple EVGE15LR1/2KEGMS Return double nipple EVGE22LR3/4KEGMS
+ hose coupling 3D082-15-8B + hose coupling 3D082-22-12B
Universal sealing head 3D082-15-8B *) Return double nipple GE15LR1/2KEGMSX Supply double nipple GE22LR3/4KEGMSX
+ universal sealing head 3C382-15-8B + universal sealing head 3C382-22-12B
*) included in the equipment pack
Tab. 2: Overview of the screw connections
When laying
the hoses,
ensure there
are sufficient
bending radii!
Bending radius
Fig. 7: Overview of the hose system Type 8821
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Installation
Type 8821
8.6. Electrical installation
DANGER!
Risk of injury due to electrical shock!
• Switch off the power supply and secure it against reactivation before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations for electrical equipment!
Overview: Electrical plug configuration
2
3
4
1
5
Not used
NPN transistor
output
Impulse output
(default NPN)
0 V DC
V+ (12-36 VDC)
PNP transistor
output
2
34
1
V+ (sensor)
Impulse input
(default NPN)
0 V DC Not used
2
3
4
1
5
0 V DC
V+ (12-36 V DC)
SE12 SE32
Connection of the 5-pole M12 plastic
device plug
Max. cable length 10 m
Connection of the 4-pole
M12 metal plug Connection of the 5-pole plastic
device plug
Fig. 8: Electrical connection; overview of the plugs
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Installation
Type 8821
Classification of wire colors:
Pin Wire color
1 brown
2 white
3 blue
4 black
5 gray
Tab. 3: Electrical connection; wire colors
8.7. Electrical installation
DANGER!
Risk of injury due to electrical shock!
• Switch off the power supply and secure it against reactivation
before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
Procedure:
→Connect the flow-rate sensor SE12 DN08 with the display and
evaluation unit (electronics module SE32) via the connection
cable (ID number 555676). To do so, unscrew the standard M12
plug pin including the screw lock.
The display and evaluation unit (electronics module SE32) can
be mechanically mounted anywhere along the length of the con-
nection cable (e.g. on the safety fence).
→Connect the supply voltage for the display and evaluation unit
(electronics module SE32) to the 5-pole M12 device plug pin
(see “Fig. 8: Electrical connection; overview of the plugs”).
→In the event of an alarm, etc., the unit's evaluation signals on the
same plug pin can be transferred to the overriding control or the
robot via the corresponding cable (see connection diagram with
NPN and PNP output).
NOTE!
Observe the maximum load capacity on the outputs!
• Failure to do so can overload the device and damage the
electronics.
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Start-Up
Type 8821
9. START-UP
9.1. Safety instructions
WARNING!
Risk of injury from improper operation!
Improper operation may result in injuries as well as damage to the
device and the surrounding area.
• 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.
9.2. Starting-up the pneumatic unit
To test the MasterJet, the pneumatic unit must first be placed into
operation as the control valve and expansion cylinder of the MasterJet
are controlled by compressed air.
DANGER!
Risk of injury from moving compressed air hoses that are not
connected!
• Check all of the hose connections are secured tightly before
charging the pneumatic unit with compressed air.
• Ensure that the exhaust shut-off valve remains closed during
initial start-up.
Procedure:
→Open the air supply line on the input side of the pneumatic unit.
→Check the compressed air connections and resolve any existing
air leaks with suitable measures.
→Open the exhaust shut-off valve if there are no existing air leaks.
→Also check the compressed air connections and components of
the pneumatic unit for leaks.
→Ensure that there are no leaks.
→Then check the electric feedback from the pressure switch.
→Check that the input on the connected PLC or robot control is
set to the logic "1" switching status.
Observe the correct supply pressure on the input of the
pneumatic unit. It should be between 3 and 6 bar.
→After deactivating the exhaust shut-off valve, the electric input of
the connected PLC or robot control should change to the logic
"0" switching status.
Start-up of the pneumatic unit is then complete.
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