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Operating Instructions Type 8644 AirLINE

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2. 1 1 Not used 2 Valve ED 3 Valve 2 3 4 FE 4 Figure 23 Electronic base module ME03 2 fold monostable 17555 burkert Structure and function of the modules FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 7 3 9 Electronic base module 2 fold bistable Structure An electrical base module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve types Base module type Add on Valve Valve Operating dimension locations type prinziple ME03 2 fach bistable 16 5 mm 2 0461 5 3 way 5 2 way Impulse Function display of the LEDs 4 function Yellow LED on valve coil A powered 1 Yellow LED on valve coil B powered Pin assignment of valve plug 1 Valve coil A 2 24V 3 1 2 3 Valve coil B Figure 24 Electronic base module ME03 2 fold bistable 47 burkert 355655 FLUID CONTROL SYSTEMS Structure and function of the modules 7 3 10 Electronic base module MEO3 3 fold 10 mm monostable Structure An electrical base module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve ty
3. R S 3 5 X Pneumatic connections Figure 10 Side feed on left Variants Supply connection P 1 Connection X Exhaust air connection R S 3 5 G 1 4 M5 G 1 4 D10 D4 D10 NPT 1 4 M5 NPT 1 4 Version available with and without pressure gauge Connection X Operation Configuration of X Standard Exhaust air pilot valve Control assist air Connection for control assist air Operation with control assist air is optional 2777 burkert Structure and function of the modules FLUID CONTROL SYSTEMS 7 2 3 Connection modules pneumatic in middle Type MEO2 Variant drawing Pressure gauge Pneumatic connections Figure 11 Intermediate feed Variants Supply connection P 1 Connection X Exhaust air connection R S 3 5 G 1 4 M5 G 1 4 D10 D4 D10 NPT 1 4 M5 NPT 1 4 Version available with and without pressure gauge MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Connection X Operation Configuration of X Standard Exhaust air pilot valve Control assist air Connection for control assist air Operation with control assist air is optional 33 burkert FLUID CONTROL SYSTEMS Typ 8644 Structure and function of the modules MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 34 7 2 4
4. 1405557 burkert Authorized use FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 2 AUTHORIZED USE Non authorized use of the AirLINE may be dangerous to people nearby equipment and the environment The device is designed for use in an environment where there is a risk of explosion Pneumatically operated devices may be used for control Do not use the device outdoors unprotected Use according to the authorized data operating conditions and conditions of use specified in the contract documents and operating instructions These are described in the chapter entitled 6 Technical Data The device may be used only in conjunction with third party devices and components recommended and authorized by B rkert Correct transportation correct storage and installation and careful use and maintenance are essential for reli able and faultless operation Use the device only as intended The AirLINE System Type 8644 was developed with due consideration given to accepted safety rules and is state of the art Nevertheless dangerous situations may occur Failure to observe this operating manual and its operating instructions as well as unauthorized tampering with the device release us from any liability and also invalidate the warranty covering the devices and accessories 2 1 Restrictions If exporting the system device observe any existing restriction
5. burkert 5577 FLUID CONTROL SYSTEMS Technical Data 6 5 3 Electronic base module MEO2 2 fold bistable 2 8 fold bistable Technical Data MEO2 2 fold MEO2 8 fold bistable bistable Dimensions BxHxT 22 x 70 5 x 52 mm 88 x 70 5 x 52 mm Weight 38 g 94g Storage temperature 20 460 C 20 460 C Nominal load voltage 24V DC 24V Number of valve outputs 2x2 8x2 Power consumption per valve location during 41 mA 41 mA switching Power consumption from the backplane bus max 15 mA max 15 mA Display of the valve status 2 yellow LED per valve 2 yellow LED per valve location location Power loss of the module at the point of switching 1 8W 7 2 W MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 24 Typ 8644 Technical Data burkert FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 6 5 4 2 fold bistable Electronic base module 2 fold monostable Technical Data 2 fold monostable 2 fold bistable Dimensions BxHxT 33 x 93 x 60 mm 33 x 93 x 60 mm Weight 54 4g 4919 Storage temperature 20 60 C 20 60 C Nominal load voltage 24V 24 V Number of valve outputs 2 2x2 Power consumption per valve location during 85 mA 41 mA switching Power consumpti
6. ab For exact specification see data sheet of the particular valves 55 burkert 557 FLUID CONTROL SYSTEMS Installation 8 INSTALLATION 8 1 Safety instructions DANGER Risk of injury from high pressure in the equipment Before dismounting pneumatic lines and valves turn off the pressure and vent the lines Risk of injury due to electrical shock Before reaching into the device or the equipment switch off the power supply and secure to prevent reactivation Observe applicable accident prevention and safety regulations for electrical equipment Electronic modules and valves may also be replaced while the power supply is on 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 an uncontrolled restart Secure system from unintentional activation Following installation ensure a controlled restart CAUTION Escape of medium and malfunction If the seals are not seated correctly leaks and malfunctions may occur due to pressure losses Ensure that the seals are seated correctly in the area of the electronics and pneumatics Short circuit malfunction The electrical connection requires exact contacting Do not bend contacts MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2
7. 12 STORAGE NOTE Incorrect storage may damage the device Store the device in a dry and dust free location Storage temperature 20 60 C 67 burkert Uu FLUID CONTROL SYSTEMS Disposal MAN 1000010109 EN Version 1 Status RL released 1 freigegeben printed 20 01 2015 68 13 DISPOSAL Dispose of the device and packaging in an environmentally friendly manner NOTE Damage to the environment caused by device components contaminated with media Observe applicable disposal regulations and environmental regulations Observe national waste disposal regulations 9102 LO OZ pajuud uaqababiay peseeje TY 5 1215 U01S19 NA 6010100001 NYW burkert FLUID CONTROL SYSTEMS LO c S N 2 c o 9 www burkert com
8. 4 fold monostable 49 burkert FLUID CONTROL SYSTEMS Typ 8644 Structure and function of the modules 7 4 Pneumatic base module 7 4 1 General Description The pneumatic base module features the working connections for the following applications Several modules can be placed in rows by connecting them The seal on the outside is retained The P connection can be sealed by using a bulkhead This allows movement in one valve block with different operating pressures Variants The variant versions differ in add on dimension number of valve locations wiring diagram of the valves version of the working connections and optional use of non return valves Not all conceivable variants have been implemented 3 O RS in R 3 1 P shut off 5 RS in S 5 Figure 27 Example of a pneumatic base module Type ME11 2 fold Add on dimension Larger valves also require wider base modules This allows a higher flow rate to be implemented Currently the fol lowing add on dimensions are available MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 50 Variants Add on 2 fold 2 fold 3 fold 4 fold 8 fold dimension mono bistable mono mono mono mm MP11 11 x X x MP12 16 5 X x x x Also with P shut off Number of valve locations per module As module optimization is based on low granularity cost
9. 66 11 PACKAGING TRANSPORT mma a 67 13 DISPOSAL La aa kaaa 68 burkert 555775 FLUID CONTROL SYSTEMS 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 these instructions 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 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 MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Indicates important additional information tips and recommendations a5 Refers to information in these operating instructions or in other documentation designates a procedure which you must carry out
10. MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 4 20Ncm 30 Necm Figure 32 Tightening the screws 59 burkert 25777 FLUID CONTROL SYSTEMS Installation 8 5 Fluid Installation AN DANGER Risk of injury from high pressure in the equipment Before dismounting pneumatic lines and valves turn off the pressure and vent the lines Design the connections with the largest possible volume Close the open connections not required with lock screws The connections for the pilot control exhaust air x must not be sealed Check that connections 1 and 3 or 5 have been configured correctly these must not be mixed up 8 5 1 Pneumatic connections feed R S 3 5 Exhaust air X channel Standard version Deaeration of the control valves Control assist air version P connection for control valves P 1 Pressure supply connection Figure 33 Pneumatic connections Procedure Depending on the version insert D10 or screw G1 4 NPT 1 4 the connections to the corresponding working connections MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 NOTE For the plug in connections the hose pipes must meet the following requirements Minimum hardness of 40 Shore D in accordance with DIN 53505 or ISO 868 Outer diameter in accordance with DIN 73378 max permitted deviation 0 1 mm of the
11. r Wago field bus node ME03 4 fold valve disc 2 fold valve disc fold valve disc 3 fold valve disc 2 ME03 VVago termination module 2 6527 1 9851 55 ls 5 6524 Cover plate 9102 1003 pajund p se l i TY SMEIS 40 6 NI 6010100001 NVW Exploded drawing add on dimension 16 5 mm Figure 5 16 deutsch 1105607 burkert Technical Data FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 6 TECHNICAL DATA 6 1 WARNING Operating Conditions Risk of injury Malfunction if used outside Do not use Type 8644 AirLINE system outdoors and avoid heat sources which may cause the permitted tem perature range to be exceeded Permitted temperatures Storage temperature Permitted air humidity Permitted air pressure Operation Storage transport Protection class Protection class 6 2 Electrical power supply Nominal voltage Tolerance Valve Types 0460 0461 Valve Type 6524 2 x 3 2 way Current carrying capacity 20 60 C 75 on average 85 occasionally 80 kPa to 106 kPa up to 2 000 m above sea level 70 kPa to 106 kPa up to 3 000 m above sea level Class 3 in accordance with VDE 106 IEC 60536 IP20 in accordance with IEC 60529 24V DC 15 20 10 10 15 10 Technical data
12. 3 10 Electronic base module 3 fold 10 mm 48 7 3 11 Electronic base module 4 fold 2 49 4 nai burkert FLUID CONTROL SYSTEMS 7 4 Pneumatic base module ss az azad yaaa GARA AAKALA RS s n aa 50 TAA 7 4 2 Pneumatic base module with integrated P shut off 7 9 Valvesu ee ee EN 53 7 5 1 General 53 8 1 1 5 5 5 5 56 81 Safety Instructions maan Aa a asdaa k d ayqdazb asidasal sasbabasmk s ba bisa 56 8 2 Removing the valve block from the top hat 5 57 8 3 Installing the AirLINE system e g in the control cabinet 58 8 4 Changing the electrical function module nnneennenneonnnenneunnennnunnnunnsennennnnennunnnnnnnun
13. 4 No function Yellow LED on valve coil A powered 4 Yellow LED on valve coil B powered Pin assignment of valve plug 24V Valve coil B Figure 20 Electronic base module MEO2 8 fold 2 x monostable 43 burkert mp ses FLUID CONTROL SYSTEMS Structure and function of the modules 7 3 6 Electronic base module MEO2 2 fold bistable Structure An electrical base module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve types Base module type Add on Valve Valve Operating dimension locations type prinziple 2 2 fold bistable 11 mm 2 0460 5 3 way 5 2 way Impulse Function display of the LEDs 4 function lt 1 Yellow LED on valve coil A powered Yellow LED on valve coil B powered Pin assignment of valve plug 1 Valve coil A 2 24V 3 Valve coil B Figure 21 Electronic base module MEO2 2 fold bistable MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 44 27775 burkert Structure and function of the modules FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 7 3 7 Electronic base module MEO2 8 fold bistable Structure An electrical b
14. Connection modules pneumatic on right Type MEO2 Variant drawing Pressure gauge Pneumatic connections Electrical interface B rkert VVago 1 0 System 750 in the valve block AirLINE Figure 12 Side feed on right Variants Supply connection P 1 Connection X Exhaust air connection R S 3 5 G 1 4 M5 G 1 4 D10 D4 D10 NPT 1 4 M5 NPT 1 4 Version available with and without pressure gauge Connection X Operation Configuration of X Standard Exhaust air pilot valve Control assist air Connection for control assist air Operation with control assist air is optional 7757 burkert Structure and function of the modules FLUID CONTROL SYSTEMS 7 2 5 Connection modules pneumatic on left Type Variant drawing Pressure gauge Electrical interface B rkert VVago I O System 750 in the valve block AirLINE Pneumatic connections Figure 13 Side feed on left Variants Supply connection P 1 Connection X Exhaust air connection R S 3 5 G 3 8 G 1 8 G 3 8 NPT 3 8 NPT 1 8 NPT 3 8 Version available with and without pressure gauge MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Connection X Operation Configuration of X Standard Exhaust air pilot valve Control assist air Connection for control assist a
15. Protection class 3 in accordance with VDE 0580 Total current depends on electrical connection technology expansion stage and control Add on dimension 11mm Operating principle C D 3 2 way 2xC 2 x 3 2 way L N 5 3 vvay Valve Type 6524 Type 6524 Type 0460 Operating principle H 5 2 way H 5 2 impulse Valve Type 6525 Type 0460 Flow rate 300 l min 300 I min 200 l min Pressure range 2 5 7 bar 2 5 7 bar 2 5 7 bar with P shut off 5 7 bar Output 1W 2x1W 0 9 W i with power reduction Current before 43 mA 2 x43 mA 41 mA power reduction Current after 28 mA 2x18 mA power reduction 18 Typ 8644 por Technical Data burkert Valve locations max 64 32 32 Electrical modules 2 fold 8 fold 2 fold 2 x monostable 2 fold 8 fold monostable 8 fold 2 x monostable bistable Pneumatic modules 2 fold 8 fold 2 fold 2 fold bistable Ambient temperature 0 55 C 0 55 C 50 C Operating voltage 24 V DC 15 20 Yo tolerance Residual ripple for field bus interface 5 Power reduction in the module For the Ex version maximum 10 The following restrictions apply to the power supply tolerances of the entire system see Technical Data of the entire system Valve type 0460 10 LO S Add on dimension 16 5 mm 5 E Operating principle CID 3 2 way L N 5 3 way Valve Type 6526 Ty
16. Valve discs are modular in design and consist of Electronic base modules Pneumatic base modules Valves Valve Electronic base module Pneumatic base module Working connections outputs Figure 8 Modular design of the valve discs Typ 8644 Structure and function of the modules burkert FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 On the electronic base module the digital outputs are switched where the valves are located Depending on the operating principle of the valve these outputs switch the internal P channel to the working connections outputs of the pneumatic base modules NOTE Do not change attached valves until Air LINE has been depressurized f a P shut off is used the valves can also be changed under pressure Variants Thanks to the modular design of the valve disc there are several variants Types MP11 MEO2 MP12 MEO3 Pneumatic Electronic Add on dimension 11 mm 16 5 mm Valve types 6524 6526 6525 6527 0460 0461 Number of valve locations on 2 fold 2 fold electronic base module 3 fold 8 fold 4 fold Number of valve locations on 2 fold 2 fold pneumatic base module 3 fold 4 fold 8 fold Connection version D6 D8 Pneumatic base module D4 G1 8 D1 4 NPT 1 8 M5 D4 M7 D1 4 D6 M5 M7 Non return valves optional without non r
17. and function of the modules MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 42 7 3 4 Electronic base module MEO2 8 fold monostable Structure An electrical base module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve types Base module type Add on Valve Valve Operating dimension locations type prinziple 2 8 fold monostable 11 mm 8 6524 3 2 way 6525 5 2 way Function display of the LEDs No function 4 Yellow LED on valve coil powered Pin assignment of valve plug 2 Not used 3 Valve Figure 19 Electronic base module MEO2 8 fold monostable 7757 burkert Structure and function of the modules FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 7 3 5 Electronic base module MEO2 8 fold 2 x monostable Structure An electrical base module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve types Base module type Add on Valve Valve Operating dimension locations type prinziple 2 8 fold 2 x monostable 11 mm 8 6524 2 x 3 2 way Function display of the LEDs
18. bistable mono 10 mm mono mono bistable mono mono MEO2 x x x x x x MEO3 x x x x Typ 8644 Structure and function of the modules burkert FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Combination options electronic base module valve Base module type Add on Valve Valve Operating dimension locations type prinziple ME02 2 fold 11 mm 2 6524 3 2 way monostable 6525 5 2 way 2 fold 11 mm 2 0460 5 3 way bistable 5 2 way impulse 2 fold 11 mm 2 6524 2 x 3 2 way 2 x monostable 8 fold 11 mm 8 6524 3 2 way monostable 6525 5 2 way 8 fold 11 mm 8 0460 5 3 way bistable 5 2 way impulse 8 fold 11 mm 8 6524 2 x 3 2 way 2 x monostable ME03 2 fold 16 5 mm 2 6526 3 2 way monostable 6527 5 2 way 2 fold 16 5 mm 2 0461 5 3 way bistable 5 2 way impulse 3 fold 11 mm 3 6524 3 2 way monostable 6525 5 2 way 4 fold 16 5 mm 4 6526 3 2 way monostable 6527 5 2 way with 10 mm valves 39 burkert 355557 FLUID CONTROL SYSTEMS Structure and function of the modules 7 3 2 Electronic base module MEO2 2 fold monostable Structure An electrical base module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve types Base module type Add on Valve Va
19. consist of a pilot control solenoid valve and a pneumatic valve Pilot valve and valve housing are clamped or bolted to each other The active principle allows high pressures to be switched at low power consumption and short switching times The valves operate maintenance free Go Ex license l 3 G Ex nA Il T4 for Types 6524 6525 and Types 6526 6527 Type 6524 2 x 3 2 way Type 6524 Type 6525 Figure 28 Example of a valve Types 6524 2 x 3 2 way 6524 and 6525 Variants In the case of Air LINE Type 8644 valves can be integrated with the following operating principles Valves Operating prinziple Operation Width Type 3 2 way C NC Internal control air 10 6524 D NO C NC Control assist air D NO External C vacuum NC 2 x 3 2 way 2 x C NC Internal control air 2xC NC Control assist air External 53 MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 54 maa Typ 8644 burkert FLUID CONTROL SYSTEMS Structure and function of the modules Valves Operating prinziple Operation 3 2 way C NC Internal control air D NO C NC Control assist air D NO External C vacuum NC 5 2 way H Internal control air Control assist air External Internal control air Control assist air External 5 3 way L Lock middle Internal control air position N Deaerated L L
20. of the entire system Valve block via connection module on front max 2 5 A Valve type Valve flow Before power reduction After power reduction 6524 43 mA 28 mA 6524 2 x 3 2 way 43 mA 18 mA 6525 43 mA 28 mA 6526 85 mA 52 mA 6527 85 mA 52 mA 0460 41 mA 2 0461 41 mA 17 burkert 5577 FLUID CONTROL SYSTEMS Technical Data Max power consumption Logic current Log Log FBKN Z1 Module Log Power consumption in the 5 V logic area Log FBKN Proportionate current in the field bus node see relevant explanation in Wago documentation type an Further product specific information on Wago field bus nodes terminals can be found on the Internet under www wago com gt Documentation gt Wago I O System 750 _Module Proportionate current in the 5 V logic area of the electronic base modules max 15 mA _Valve Valve flow before and after power reduction Feld bus node see Wago handbook The permitted ambient temperature depends on the modules used The most critical module is essential during assembly Module with Valve Type 6524 6525 6526 6527 O 55 C Module with Valve Type 0460 0461 0 450 C 6 3 Technical Data of the valve block Nominal operating mode Long term operation 100 ED Protection class in terminal design IP20 MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015
21. pneumatic lines and valves turn off the pressure and vent the lines Risk of electric shock Before reaching into the device or the equipment switch off the power supply and secure to prevent reactivation Observe applicable accident prevention and safety regulations for electrical equipment Risk of burns risk of fire if used continuously through hot device surface Keep the device away from highly flammable substances and media and do not touch with bare hands General hazardous situations To prevent injury ensure That the system cannot be activated unintentionally Installation and repair work may be carried out by authorized technicians only and with the appropriate tools After an interruption in the power supply or pneumatic supply ensure that the process is restarted in a defined or controlled manner The device may be operated only when in perfect condition and in consideration of the operating instructions The general rules of technology apply to application planning and operation of the device NOTE Operate system with direct current only To prevent damage to the system use only direct current for the system power supply Prevent a pressure drop To prevent a pressure drop design the system pressure supply with the largest possible volume MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Electrostatic sensitive components assemblies The device
22. screws clockwise Mount all other modules terminals on the standard rail 58 Ma saa burkert Installation FLUID CONTROL SYSTEMS NOTE Alternative for large valve blocks Remove the predecessor module Snap the valve block onto the standard rail Slide the block to its final position Snap on the predecessor module again 8 4 Changing the electrical function module DANGER Danger high pressure Before dismounting pneumatic lines and valves turn off the pressure and vent the lines Risk of short circuit Do not insert any foreign objects into the base module 24 V supply bus The function module is a component of the electronic base module It can be replaced in consideration of the points listed below Depressurize AirLINE system Using a screwdriver loosen the fastening screws of the valves Remove valve from the valve plug Flange seal and O ring 3 2 Way valve must not be soiled Detach function module above rear catch mechanism and remove vertically without tilting it from the distributor module backplane bus Place new function module vertically on the distributor module backplane bus and press down until it clicks into position Connect valve with the cleanly inserted flange seals O rings to the valve slot and tighten the screws according to the following assembly diagram see Figure 32 Tightening the screws
23. 015 If connections are damaged or bent replace the affected components Do not switch on the system unless the components are in perfect condition NOTE Operate the system with direct current only To prevent damage to the system use only direct current for the system power supply Prevent a pressure drop To prevent a pressure drop design the system pressure supply with the largest possible volume 56 Mp aa burkert Installation FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 8 2 Removing the valve block from the top hat rail DANGER Risk of electric shock Before reaching into the device or the equipment switch off the power supply and secure to prevent reactivation Observe applicable accident prevention and safety regulations for electrical equipment The valve block of the AirLINE system Type 8644 is combined with the I O system 750 from Wago The valve block is bolted securely onto the standard rail Additional electrical modules terminals can be aligned in rows on the sides of the valve block Procedure Detach the adjacent modules terminals if fitted Release the attachment of the valve block on the standard rail To do this turn the fastening screws all the way counter clockwise Lift the valve block vertically off the standard rail oo f x m a a22 er
24. 6 36 5 7 2 7 Connection modules pneumatic on right Type MEO 1211m an ana 37 gt 7 3 Electronic base module ssnssssesesnnsesssenesnmnussssensennnnnssssssesnnnnesssessssnunssenssesennnnsenssenesnnnsnssssnesnnnnnsnsnenennnnnensnennnnnnnanenen 38 7 3 1 General 38 2 7 3 2 Electronic base module 2 2 fold 6 40 S 2 7 3 3 Electronic base module 2 2 fold 2 x 6 41 lt 7 3 4 Electronic base module 2 8 fold monostable 5 2 42 7 3 5 Electronic base module 2 8 fold 2 x monostable unnnemmennenennennnennennennenennen 43 7 3 6 Electronic base module MEO2 2 fold 44 7 3 7 Electronic base module 2 7 8 fold bistable nnneenennnennnennennnennnennennenennen 45 7 3 8 Electronic base module 2 fold monostable nnmennenennnennennennnennnen nennen 46 7 3 9 Electronic base module 2 fold bistable unnneenenennnennennennnennnennennenennen 47 7
25. B rkert 8644 monostable 4 DO 2 8 fold monostable B rkert 8644 monostable 8 DO V1 ID 00148843 corresponds to 4 times 2 DO 2 8 fold monostable B rkert 8644 monostable 8 DO V2 ID 00218237 2 8 fold 2 x monostable Burkert 8644 monostable 16 DO 2 2 fold bistable B rkert 8644 bistable 4 DO B rkert 8644 bistable 4 DO 2 8 fold bistable B rkert 8644 monostable 16 DO ME03 2 fold monostable Burkert 8644 monostable 2 DO B rkert 8644 monostable 2 DO 6 mm 3 fold 10 mm Burkert 8644 monostable 3 DO Burkert 8644 monostable 3 DO 4 fold monostable B rkert 8644 monostable 4 DO B rkert 8644 monostable 4 DO 2 fold bistable B rkert 8644 bistable 4 DO B rkert 8644 bistable 4 DO Module is combined with predecessor module for utilization of the data byte One bit remains unassigned Connection modules and intermediate feeds are not bus users and are not considered Typ 8644 Packaging and Transport FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 11 PACKAGING AND TRANSPORT NOTE Transport damages Inadequately protected equipment may be damaged during transport During transportation protect the device against wet and dirt in shock resistant packaging Avoid exceeding or dropping below the allowable storage temperature
26. MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 burkert FLUID CONTROL SYSTEMS Type 8644 AirLINE with I O System 750 Wago Operating Instructions Bedienungsanleitung Manuel d utilisation MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 We reserve the right to make technical changes without notice Technische Anderungen vorbehalten Sous reserve de modifications techniques 2002 2010 Burkert Werke GmbH Operating Instructions 1004 13 EU ML 00804090 Original DE Typ 8644 burkert FLUID CONTROL SYSTEMS Type 8644 AirLINE Wago CONTENTS 1 6 1 Symbols aaa AA BA AA AA Aa 6 2 AUTHORIZED USE aaa NAAANINAG 7 2 1 esiric ons 7 2 1 1 Explosion protection 5 ernennen nen 7 2 2 Predictable Misuse 7 m 3 BASIC ya an ke aba a medaka ygb s is 8 a 2 4 GENERAL 1 1 Gana saman 9 3 4 1 5 of Supply AA AA AA 9 4 2 Contact
27. Version Status RL released freigegeben printed 20 01 2015 Operation Configuration of X Standard Exhaust air pilot valve Control assist air Connection for control assist air Operation with control assist air is optional 37 burkert FLUID CONTROL SYSTEMS Typ 8644 Structure and function of the modules MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 38 7 3 7 3 1 Electronic base module General Description The electronic base module is connected to the adjacent modules via its electrical interface In this way it receives both the power supply and the control signals for the valves on the slots The electronic base modules and therefore the valve discs can be controlled as digital output modules terminals For detailed information see Chapter 70 Start Up Variants The valves used for AirLINE Type 8644 have different wiring diagrams valve dimensions and control properties Accordingly the electronic base modules exist in different versions Ejector hooks Valve slot Mechanical connection to the pneumatic base module Inscription area LED display Function module Distributor module Electrical interface Figure 16 Example of an electronic base module Type ME02 2 fold Available variants Variants 2 fold 2 fold 2 fold 2x 3 fold 4 fold 8 fold 8 fold 8 fold 2x mono
28. alve location location Power loss of the module at the point of switching 2 W 4 W Power loss of the module 65 ms after the switching 1 W z process 2 x 0 25 VV power loss on resistors 2 x 0 25 W on valve coils Power loss of the module 110 ms after the switching 2 1 VV process Typ 8644 Technical Data burkert FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 6 5 2 MEO2 8 fold 2 x monostable Electronic base module MEO2 8 fold monostable Technical Data MEO2 8 fold monostable MEO2 8 fold 2 x monostable Dimensions BxHxT 88 x 70 5 x 52 mm 88 x 70 5 x52 mm Weight 94g 94g Storage temperature 20 60 C 20 60 C Nominal load voltage 24V 24 V Number of valve outputs 8 8x2 Power consumption per valve location during 43 mA 2 x43 mA switching Power consumption per valve location after 28 mA 2x18 mA approx 65 ms Power consumption from the backplane bus max 15 mA max 15 mA Display of the valve status 1 yellow LED per valve 2 yellow LED per valve process location location Power loss of the module at the point of switching 8 W 16 W Power loss of the module 65 ms after the switching 4 W z process 8 x 0 25 VV povver loss on resistors 8 x 0 25 VV on valve coils Povver loss of the module 110 ms after the svvitching 4VV 23
29. ase module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve types Base module type Add on Valve Valve Operating dimension locations type prinziple 2 8 fold bistable 11 mm 8 0460 5 3 way 5 2 way Impulse Function display of the LEDs 4 No function lt 1 Yellow LED on valve coil A powered Yellow LED on valve coil B powered Pin assignment of valve plug 1 Valve coil A 2 24V 3 Valve coil B Figure 22 Electronic base module MEO2 8 fold bistable 45 burkert 3555555 FLUID CONTROL SYSTEMS Structure and function of the modules MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 46 7 3 8 Electronic base module 2 fold monostable Structure An electrical base module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve types Base module type Add on Valve Valve Operating dimension locations type prinziple ME03 2 fold monostable 16 5 mm 2 6526 3 2 way 6527 5 2 way Function display of the LEDs No function 4 Yellow LED on valve coil powered Pin assignment of valve plug
30. ased freigegeben printed 20 01 2015 10 burkert System Description FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 5 SYSTEM DESCRIPTION 5 1 Application area The AirLINE system is designed for decentralized use in industrial environments Electronics and fluidics can be combined particularly easily and efficiently thanks to the modular design DANGER Danger of explosion If systems in the explosion protected area are installed in a control cabinet the following requirements must be met The control cabinet must be authorized for use in the explosion protected area The control cabinet must be large enough to allow the resulting lost heat to be dissipated in a suitable man ner to the outside The internal temperature of the control cabinet must not exceed the max permitted ambient temperature for the device Risk of electric shock Before reaching into the device or the equipment switch off the power supply and secure to prevent reactivation Observe applicable accident prevention and safety regulations for electrical equipment 5 2 Description of the system x 1 2 Figure 1 Type 8644 AirLINE Wago 1g burkert FLUID CONTROL SYSTEMS System Descri ption Typ 8644 The Type 8644 B rkert AirLINE is an electrical and pneumatic automation system which was developed for use in
31. ble 2 fold bistable 25 6 5 5 Electronic base module ME03 3 fold 10 mm monostable MEO3 4 fold monostable 26 2 7 STRUCTURE AND FUNCTION OF THE 5 5 27 7 1 Valve block issssctscssccicaisccccsestcesestcssertoasertcosertccsetecaectonsertceserbocsereceseroooserecosnroocsetecaseeboodeeccoserbocsetocaserbooserccosnrbossetccaserbosdeeccaserocs 27 S 7 1 1 Connection modules feeds 5 27 7 1 2 Valve disces nenne AANGAL 28 8 7 2 Connection 165 aaa aaa aaa aaa aa aaa ee aaa aa aa aaa r aaa m mt aa m tararisen 30 7 2 1 Structure of the connection module s s l s i s s s i i s s ssi i s s isis s ss3ss318 30 7 2 2 Connection modules pneumatic on left Type MEO 2 cence tenses n sl 32 3 7 2 3 Connection modules pneumatic in middle Type 2 33 7 2 4 Connection modules pneumatic on right Type MEO2 unnsnesssesesnsnneenennsunennnnennennnnnennennnnn 34 3 7 2 5 Connection modules pneumatic on left Type 35 2 7 2 6 Connection modules pneumatic in middle Type
32. contains electronic components which react sensitively to electrostatic discharge ESD Contact with electrostatically charged persons or objects is hazardous to these components In the worst case scenario they will be destroyed immediately or will fail after start up Observe the requirements in accordance with EN 61340 5 1 and 5 2 to minimize or avoid the possibility of damage caused by sudden electrostatic discharge Also ensure that you do not touch electronic components when the power supply voltage is present 27777 burkert General nformation FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 4 GENERAL INFORMATION 4 1 Scope of Supply Check immediately upon receipt of the delivery that the contents are not damaged and that the type and scope agree with the delivery note and packing list If there are any discrepancies please contact us immediately 4 2 Contact Addresses Germany B rkert Fluid Control Systems Sales Center Chr B rkert Str 13 17 D 74653 Ingelfingen Tel 49 0 7940 10 91 111 Fax 49 0 7940 10 91 448 E mail info de buerkert com International Contact addresses can be found on the final pages of the printed operating instructions And also on the Internet at www burkert com gt Burkert gt Company gt Locations 4 3 Warranty This document contains no promise of guarantee Please refer to our genera
33. 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 operate the equipment the device 10 2 Fluid start up NOTE Switch on the supply pressure Only then switch on the power supply Procedures before fluid start up Check connections voltage and operating pressure Ensure that max operating data see type plate are not exceeded Check that connections 1 and 3 or 5 have been configured correctly these must not be mixed up Release manual actuation during electrical operation 10 3 Electrical start up Information on electrical start up may be found on the Internet under www wago com 3 Documentation gt Wago I O System 750 65 burkert FLUID CONTROL SYSTEMS Typ 8644 Start Up MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 66 10 3 1 The module designations of the different electrical base modules in the GSD file can be found in the following table Selection of the modules in the GSD file Add on dimension Module designation MEO2 2 fold monostable Entry in GSD file B rkert 8644 monostable 2 DO Burkert 8644 monostable 2 DO monostable 11 mm MEO2 2 fold 2x monostable B rkert 8644 monostable 4 DO
34. esponding working connections Connection nipples can be used for threaded versions Inscription of the connections Label the inscription areas with the data of the valve connections 8 6 Electrical Installation DANGER Risk of injury due to electrical shock Before reaching into the device or the equipment switch off the power supply and secure to prevent reactivation Observe applicable accident prevention and safety regulations for electrical equipment Information on electrical installation may be found on the Internet under www wago com gt Documentation gt Wago I O System 750 MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 62 50777 burkert Maintenance Troubleshooting FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 9 MAINTENANCE TROUBLESHOOTING 9 1 Safety instructions AN DANGER Risk of injury from high pressure in the equipment Before dismounting pneumatic lines and valves turn off the pressure and vent the lines Risk of injury due to electrical shock Before reaching into the device or the equipment switch off the power supply and secure to prevent reactivation Observe applicable accident prevention and safety regulations for electrical equipment N WARNING Risk of injury from improper maintenance Maintenance may be carried out by autho
35. eturn valve non return valve in R channel non return valve in R S channel P shut off optional with P shut off not available Special design 3 fold 10 mm valves Available for certain valve types and with function restriction only See also 6 2 Technical data of the entire system and 7 4 Pneumatic base module Overall width of electronic pneumatic base module 33 mm with 3 slots for 10 mm valves 29 burkert 355653 FLUID CONTROL SYSTEMS Structure and function of the modules 7 2 Connection modules 7 2 1 Structure of the connection module Panel Assembly variant with pressure gauge Electrical connection module Pneumatic feed Type MEO2 MEOS left right Type MP11 MP12 left middle right Interface to electrical part of the automation system field bus nodes electrical modules terminals Shunting socket on left plug on right Electrical interface for data shunting within the Burkert AirLINE system Type 8644 Clamps Fastening clamps for rail assembly Catch hook Mechanical attachment for pneumatic base modules MP11 MP12 Screws X Pilot control exhaust air Fastening screws for rail connection assembly R 3 Exhaust air connection Cover plate P 1 Pressure supply connection R 3 9 5 S 5 Exhaust air connection X Pilot control exhaust P 1 air connection control Pressure supply connection ass
36. f the P shut off is used there are some restrictions with respect to the operating data of the complete system The flow rate of the valves Type 6524 6525 is reduced to approx 6000 The operating pressure range must be between 5 and 7 bar if the P shut off is used otherwise there may be problems with the P shut off As the pressure supply for the pilot valves is not shut off if valves are used with external control assist air the P shut off can be used only in conjunction with the valves with internal control air within the restricted pressure range The P shut off can be combined with the integrated non return valves NOTE If using the P shut off base modules ensure that the pressure supply of the valve clusters is designed with a cor respondingly large volume minimum hose diameter 8 6 mm Mean value from measurements 51 burkert FLUID CONTROL SYSTEMS Structure and function of the modules Procedure when replacing a valve CAUTION Only one valve may be removed at the same time During removal observe that only the P channel is shut off This means that a pressure on the working out puts A or B is released when the valve is removed This also means that a connected actuator is also depres surized and a movement may be triggered as a result If there is a larger volume on the actuator side attach a shut off option for the working connections to prevent the actuator
37. from moving When the valve is removed a relatively large amount of air is initially blown into the open for functional reasons as the P shut off cannot close until the required pressure difference is reached However as the automatic shut off reduces the exhaust air significantly only a residual leakage remains when the P shut off is closed When installing the valve ensure that the seal is inserted correctly Install the valve at the tightening torques indicated in the operating instructions When installing the valve ensure that the working connections are also pressurized in the corresponding rest position of the valve until it is switched over The pressurization may cause a connected actuator to move gt Ensure that these movements of the actuator do not cause any damage or unwanted actions in the system Q Before changing the valve we recommend bringing the system into an electrically safe basic state MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 52 Typ 8644 Structure and function of the modules burkert FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 7 5 Valves 7 5 1 General Description Automation systems are being used increasingly in all areas in which open and closed loop tasks are to be managed The valves form the interface between electronics and pneumatics The valves
38. g Figure 30 Releasing the attachment of the valve block on the standard rail There must be adequate space between valve block and predecessor module 5 6 mm Detach the modules terminals from the standard rail according to the manufacturer s description 57 burkert DRAR FLUID CONTROL SYSTEMS Installation NOTE The interface of the left connection module contains elements which may break off if force is used Never place the valve block on its sides and observe the permitted installation positions Figure 31 Detach the module terminals from the standard rail 8 3 Installing the AirLINE system e g in the control cabinet NOTE Before installation check that the fastening rail is anchored firmly in the control cabinet or in the system Observe the specifications in the configuration file for the installation sequence The valve block is not connected securely to the standard rail before the fastening screws are tightened During the entire installation ensure that it cannot fall down Connect all electrical modules terminals on the left of the valve block to the standard rail according to the manu facturer s specifications MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Slide the valve block onto the rail along the interface of the predecessor module Screw the valve block to the rail by tightening the fixing
39. ir Operation with control assist air is optional 35 burkert FLUID CONTROL SYSTEMS Typ 8644 Structure and function of the modules MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 36 7 2 6 Connection modules pneumatic in middle Type Variant drawing Pressure gauge Pneumatic connections Figure 14 Intermediate feed Variants Supply connection P 1 Connection X Exhaust air connection R S 3 5 G 3 8 G 1 8 G 3 8 NPT 3 8 NPT 1 8 NPT 3 8 Version available with and without pressure gauge Connection X Operation Configuration of X Standard Control assist air Exhaust air pilot valve Connection for control assist air Operation with control assist air is optional 77257 burkert Structure and function of the modules FLUID CONTROL SYSTEMS 7 2 7 Connection modules pneumatic on right Type Variant drawing Pressure gauge Electrical interface B rkert VVago I O System 750 in the valve block AirLINE Pneumatic connections P 1 Figure 15 Side feed on right Variants Supply connection P 1 Connection X Exhaust air connection R S 3 5 G 3 8 G 1 8 G 3 8 NPT 3 8 NPT 1 8 NPT 3 8 Version available with and without pressure gauge Connection X MAN 1000010109 EN
40. ist air connection Figure 9 Structure of the connection module MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Variants The feeds were designed in different variants to meet diverse requirements To facilitate start up and diagnosis feeds are available with a pressure gauge You receive the fluid connections with straight or conical screw connections as well as with quick connect systems The fluid connections can be used differently for special functions For example the vent connection for the pilot valve can be used as a connection for the control assist air and different pressures can be applied for supplying and controlling the valve 30 Typ 8644 Structure and function of the modules FLUID CONTROL SYSTEMS The feeds differ e g by Pressure gauge Connection version MP11 MP12 G 1 4 G 3 8 D10 NPT 3 8 NPT 1 4 Control assist air yes no MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 31 burkert FLUID CONTROL SYSTEMS Typ 8644 Structure and function of the modules MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 32 7 2 2 Connection modules pneumatic on left Type MEO2 Variant drawing Panel Electrical interface B rkert VVago I O System 750 in the valve block AirLINE Pressure gauge
41. k also includes valves of Type 0461 5 2 way impulse valve 5 3 way valve a profile rail EN 50022 35 x 15 must be used In all other cases this profile rail is also recommended 7 1 1 Connection modules feeds Feeds in the form of pneumatic connection modules form the fluid interface between supply line and internal supply structure The fluid is conveyed from one valve disc to the next via the feed To ensure that the supply pressure remains almost constant over the entire route additional feeds may be required It is recommended to place an additional feed after 24 ME02 or 16 ME03 valve locations The use of intermediate feeds also allows segments to be established if the pneumatic conduits between individual valve discs are sealed 27 MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 28 agila Typ 8644 burkert FLUID CONTROL SYSTEMS Structure and function of the modules Electrical Electrical Electrical connection module 1 1 Shunting connection module Pneumatic feed Pneumatic feed Pneumatic feed module module module Connector module Intermediate Connector module left feed right Figure 7 Schematic representation of feed 7 1 2 Valve discs MKO3 DANGER Danger high pressure Before dismounting pneumatic lines and valves turn off the pressure and vent the lines Structure
42. l terms of sales and delivery The war ranty is only valid if the device is used as intended in accordance with the specified application conditions The warranty extends only to defects in the AirLINE System Type 8644 and its components We accept no liability for any kind of collateral damage which could occur due to failure or malfunction of the device 4 4 Licenses The approval rating on the B rkert labels refers to B rkert products To ensure that the complete valve cluster is authorized a gateway with a Type Examination Certificate must also be used In this case a valve cluster can be expanded up to 64 valves with authorized type tested units burkert 1355755 FLUID CONTROL SYSTEMS General Information 4 5 Information on the Internet The operating instructions and data sheets for Type 8644 can be found on the Internet at www burkert com gt Documentation gt Datasheets Operating Instructions gt Type 8644 Wago The complete documentation is also available on CD and can be ordered by quoting part no 804625 Technical data configuration files and a detailed description of bus terminals and electrical function terminals by the Wago company are available on the Internet web site www wago com gt Documentation gt Wago I O System 750 B rkert has no influence on the reliability of this homepage or on technical or presentation changes to the linked pages MAN 1000010109 EN Version Status RL rele
43. lve Operating dimension locations type prinziple 2 2 fold monostable 11 mm 2 6524 3 2 way 6525 5 2 way Function display of the LEDs No Function 2 Yellow LED on valve coil powered Pin assignment of valve plug 2 Not used 3 Valve Figure 17 Electronic base module MEO2 2 fold monostable MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 40 7757 burkert Structure and function of the modules FLUID CONTROL SYSTEMS 7 3 3 Electronic base module MEO2 2 fold 2 x monostable Structure An electrical base module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve types Base module type Add on Valve Valve Operating dimension locations type prinziple MEO2 2 fold 2 x monostable 11 mm 2 6524 2 x 3 2 way Function display of the LEDs 4 No function Yellow LED on valve coil A powered vo Yellow LED on valve coil B powered Pin assignment of valve plug 1 Valve coil A 2 24V 3 Valve coil B Figure 18 Electronic base module MEO2 2 fold 2 x monostable MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 41 burkert FLUID CONTROL SYSTEMS Structure
44. m Permitted air pressure Operation Storage transport Protection class Protection class 80 kPa to 106 kPa up to 2 000 m above sea level 70 kPa to 106 kPa up to 3 000 m above sea level Class 3 in accordance with VDE 106 IEC 60536 IP20 in accordance with IEC 60529 MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 20 6 4 1 Dimensioning of the connection modules MEO2 2 2 ME03 left left middle middle right right Housing dimensions 61 x 73 x 74 x 95 x 52x 71 x 66 x 93 x 54 x 73 x 63 x 95 x i 124 mm 142 mm 119 mm 142 mm 121 mm 142 mm width x height x i i depth including including including including a catch hook catch hook catch hook catch hook Weight 220g 400g 118g 335 g 220g 390g Typ 8644 Technical Data FLUID CONTROL SYSTEMS 6 4 2 Performance features from the point of view of the entire system Connection module on left MEO2 ME03 The connection module on left is electrically passive logical no process image therefore no address is required mechanical MEO2 43 mm installation dimension ME03 56 mm installation dimension electrical no power consumption fluid left restriction of the valve block left feed Connection module in middle ME02 ME03 The intermediate feed is electrically passive logical no process image therefore no add
45. n dimension 11 2 15 5 6 2 Exploded drawing add on dimension 16 5 mm naasa msaaananaanamsasaasanaanannans 16 6 TECHN CAL 17 6 1 Operating Conditions a aad oa asa 17 6 2 Technical data of the entire system s ss sssssssssssss ssessse 148888 assa nasa arar nananana 17 burkert 2 FLUID CONTROL SYSTEMS 6 3 Technical Data of the valve block tacis aaa 18 6 4 Pneumatic data of the connection 1 5 nananaannnananananaaaaaa nananana nanaaananaaaaaanaaaaaanaaasaaaaaaaasaaann 20 6 4 1 Dimensioning of the connection 0 165 20 6 4 2 Performance features from the point of view of the entire system scence 21 6 5 Electrical paaa AA aaa 22 6 5 1 Electronic base module MEO2 2 fold monostable 2 2 fold 2 x monostable 22 6 5 2 Electronic base module MEO2 8 fold monostable 2 8 fold 2 x monostable 23 6 5 3 Electronic base module 2 2 fold bistable MEO2 8 fold bistable 24 6 5 4 Electronic base module 2 fold monosta
46. nnennnunnnnnnnunnunnnennnunnnennnunnen 59 8 5 Fluid Installation a maamaamananamanaaamananaaanaaamanaaaaanagaana ikain 60 8 5 1 Pneumatic connections feed unnsnnsennneenennnnnnnnnnnnnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnnnn nenn nenn 60 8 5 2 Removing the plug in 5 22 61 8 5 3 Pneumatic connections valve 05 5 22 61 8 6 Electrical InstallatiON sssssssssssssmn a 62 9 MAINTENANCE 1 5 1 asaan 63 9 1 Safety instructions aaa AA AA AA aa 63 9 2 5 a a a a R aa a a aaa nenne naziri 63 9 3 Maintenance of components MAN 1000010109 EN Version 1 Status RL released 1 freigegeben printed 20 01 2015 9 3 1 UL 5 7 En arne here 10 a a nd a ns al m s id ek 65 10 1 Safety instructions s ss sssssssssssss sssssse assa sy saya sy 148850822688266 65 10 2 Fluid start p a DD AA DA a y asian ba 65 10 3 Electrical startup aaah a o za R B R NAAN AANO 65 10 3 1 Selection of the modules in the GSD 22222222
47. nominal dimension Burr free cut off at right angles and undamaged on the outer diameter The hose pipes must be pressed all the way into the plug in connections 60 Typ 8644 Installation burkert FLUID CONTROL SYSTEMS 8 5 2 Removing the plug in connections To detach the pipes press in the thrust ring and pull out the hose pipe 8 5 3 Pneumatic connections valve discs NOTE For 3 2 way valves the upper connections remain free Inscription areas OCS OOS OG z O NG 7 A NQS NO 8 fold valve discs or 4 x 2 fold valve discs Working connections for 5 2 and 2 x 3 2 Way valves Working connections for 3 2 way valves Variants 5 2 way valve 2 x 3 2 way valve Figure 34 Pneumatic connections valve discs MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Variant 1 Variant 2 Variant 3 Working connection upper 2 M5 M7 D6 D4 D1 4 Working connection lower 4 M5 M7 D6 D4 D1 4 3 2 way valve Variant 1 Variant 2 Variant 3 Working connection upper 0 Sealed internally Sealed internally Sealed internally Working connection lower 2 M5 M7 D6 D4 D1 4 61 BEB E Typ 8644 burkert FLUID CONTROL SYSTEMS Installation Installation Depending on the version insert D6 D4 D1 4 or screw M5 M7 the connections to the corr
48. ock middle position N Deaerated 5 2 way impulse H Internal control air NOTE Valves with control assist air If valves are used with control assist air the exhaust air escapes from the pilot valve into the environment Valves with control assist air cannot be combined on the valve cluster with valves with internal control air as the con nection X see Chapter 7 2 Connection modules is used differently Valves 6524 and 6525 Exception Type 6524 2 x 3 2 way Go The assembly of the valve cluster Type 8644 with the valves 6524 and 6525 is authorized for use in Zone 2 in accordance with Il 3 G Ex nA Il T4 with the number PTB 02 ATEX 2048 Restrictions for use in Zone 2 CAUTION For valve types 6526 and 6527 the valve switch off time restriction Topp 2 0 2 s must be observed for use in Zone 2 with temperature class T4 under the following conditions at quick switch on cycles valve switch on time Toy lt 3 s maximum ambient temperature of 55 C maximum permitted overvoltage of U ina 10 Yo 777 burkert Structure and function of the modules FLUID CONTROL SYSTEMS Valve switching time Ton Torr t MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Figure 29 Valve switching time If the valve is switched on for longer than 3 seconds there are no restrictions for the duration until the valve is switched on again
49. on per valve location after 52 mA approx 400 ms Power consumption from the backplane bus max 15 mA max 15 mA Display of the valve status 1 yellow LED per valve 1 yellow LED per valve on valve coils process 2 x 0 5 W power loss on resistors 2 x 0 5 W location location Power loss of the module at the point of switching 4W 1 8 VV Povver loss of the module 400 ms after the svvitching 2W 25 burkert FLUID CONTROL SYSTEMS Typ 8644 Technical Data MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 26 6 5 5 Electronic base module 3 fold 10 mm monostable 4 fold monostable Technical Data 3 fold 10 mm monostable 4 fold monostable Dimensions BxHxT 33x93x60 mm 66 x 93x 60 mm Weight 51g 91 2g Storage temperature 20 460 C 20 60 C Nominal load voltage DC 24V DC 24 V Number of valve outputs 3 4 Power consumption per valve location during 43 mA 85 mA switching Power consumption per valve location after 28 mA 52 mA approx 65 ms for 4 fold monostable after approx 400 ms Power consumption from the backplane bus max 15 mA max 15 mA Display of the valve status 1 yellow LED per valve 1 yellow LED per valve process 4 x 0 5 W power loss on resistors 4 x 0 5 W on valve coils location location Powe
50. pe 0461 3 Operating principle H 5 2 way H 5 2 impulse 8 Valve Type 6527 Type 0461 2 Flow rate 700 I min 500 I min b g Pressure range 2 10 bar 2 5 7 bar m vvith P shut off 2 Output 1w 2W 0 9 W 5 Current before 42 mA 85 mA 41 mA E power reduction g Current after 33 mA 52 mA 2 power reduction Valve locations max 32 24 o 5 o S Electrical modules 2 fold 3 fold 4 fold 2 fold bistable monostable lt Pneumatic modules 2 fold 3 fold 4 fold 2 fold bistable Ambient temperature 455 C 50 C Operating voltage 24 V DC 15 20 tolerance Residual ripple for field bus interface 5 3 x 10 mm valves for add on dimension of 16 5 For the Ex version maximum 10 The following restrictions apply to the power supply tolerances of the entire system see Technical Data of the entire system Valve type 0461 10 19 burkert FLUID CONTROL SYSTEMS Typ 8644 Technical Data 6 4 Permitted temperature storage transport Permitted air humidity operation CAUTION 20 22 60 C Pneumatic data of the connection modules 75 on average 85 occasionally In the range of 0 55 C take suitable measures against increased air humidity gt 85 Slight condensation may occasionally occur on the external housing for a brief period e g if the feed of a vehicle is brought into a closed roo
51. pes Base module type Add on Valve Valve Operating dimension locations type prinziple 3 fold 10 mm 11 mm 3 6524 3 2 way monostable 6525 5 2 way Function display of the LEDs No function 4 Yellow LED on valve coil powered Pin assignment of valve plug 1 Valve 123 2 Not used 3 Valve Figure 25 Electronic base module ME03 3 fold 10 mm monostable MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 48 2777 burkert Structure and function of the modules FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 7 3 11 Electronic base module 4 fold monostable Structure An electrical base module consists of a distributor module backplane bus and a function module Both modules are contacted via a 14 pole board to board plug Combination options with valve types Base module type Add on Valve locations Valve type Operating principle dimension 4 fold monostable 16 5 mm 4 6526 3 2 way 6527 5 2 way Function display of the LEDs No function Yellow LED on valve coil powered Pin assignment of valve plug Not used Valve Valve 2 3 FE Io n Figure 26 Electronic base module ME03
52. propriately sized silencers or inadequate due to too small or dirty expansion tanks Clean dirty silencers silencers back pressures Impurities or foreign objects in the Change the valve pilot valve or main valve Leaking valve blocks Missing or crushed O rings Determine the leaks or missing seals between the modules Missing or incorrectly positioned profile seals between valve and pneumatic base module Insert missing seals or replace damaged seals 9 3 Maintenance of components 9 3 1 UL Handling Valve clusters of Type 8644 with UL license may be converted by UL certified production installation or service centers only Do not reach into the system This refers in particular to Damage of components Expansion of the valve clusters by modules the catch mechanism of the pneumatic modules must be released for this NOTE Replacement of the valves is a permitted maintenance operation follow the general safety instructions MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 64 Typ 8644 Start U FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 10 START UP 10 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 area around it Before start up
53. r loss of the module at the point of switching 3W 8W Power loss of the module 65 ms after the switching 1 5 W 5 process 3 x 0 25 W power loss on resistors 3 x 0 25 W on valve coils Power loss of the module 400 ms after the switching 2 4W Typ 8644 zu burkert Structure and function of the modules FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 7 STRUCTURE AND FUNCTION OF THE MODULES 7 1 Valve block The valve block is composed of the following assemblies Connection modules feeds grouped connections for supply exhaust air and control assist air Valve discs working connections various valves o 9 Valve disc Intermediate o g b 8 fold feed T 2 5 2 a N O o D amp 2 Q o 5 5 o 5 8 3 R 2 5 8 o o i gt gt Na Connector module Connector module left right Figure 6 Example of valve block schematic The electric automation system pneumatically forms a complete unit externally Thanks to the modular design the number of internal bus users as well as the power consumption of the valve block can vary Externally the valve block like any electrical module terminal provides a standardized electrical interface If the configuration of the valve bloc
54. ress is required mechanical MEO2 33 mm add on dimension ME03 42 mm add on dimension electrical no power consumption fluid additional feed Connection module on right MEO2 MEO3 The connection module on right is electrically passive logical no process image therefore no address is required mechanical MEO2 47 mm installation dimension ME03 56 mm installation dimension electrical no power consumption fluid right restriction of the valve block right feed MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 21 burkert FLUID CONTROL SYSTEMS Typ 8644 Technical Data 6 5 Electrical Data 6 5 1 2 2 fold 2 x monostable Technical Data MEO2 2 fold monostable Electronic base module MEO2 2 fold monostable MEO2 2 fold 2 x monostable Dimensions BxHxT 22 x 70 5 x 52 mm 22 x 70 5 x52 mm MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 22 Weight 38g 38g Storage temperature 20 60 C 20 60 C Nominal load voltage DC 24 V DC 24 V Number of valve outputs 2 2x2 Power consumption per valve location during 43 mA 2 x43 mA switching Power consumption per valve location after 28 mA 2x18 mA approx 65 ms Power consumption from the backplane bus max 15 mA max 15 mA Display of the valve status 1 yellow LED per valve 2 yellow LED per v
55. rized technicians only and with the appropriate tools Risk of injury from unintentional activation of the system and an uncontrolled restart Secure system from unintentional activation Following maintenance ensure a controlled restart 9 2 Troubleshooting Malfunction Possible cause Remedial action Valves do not switch No or inadequate operating voltage Check the electrical connection Ensure the operating voltage according to type plate Manual actuation not in neutral Move manual actuation to zero position position Inadequate or no pressure supply Design the pressure supply with the largest possible volume even for upstream devices such as pressure controllers maintenance units shut off valves etc Minimum operating pressure gt 2 5 bar 63 8644 burkert FLUID CONTROL SYSTEMS Maintenance Troubleshooting Malfunction Possible cause Remedial action Valves switch with Inadequate or no pressure supply Design the pressure supply with the largest a delay or blow off possible volume even for upstream devices at the deaeration such as pressure controllers maintenance connections units shut off valves etc Minimum operating pressure gt 2 5 bar Valves are not in home position 3 Pressurize the valve block before you switch de energized during pressure the valves build up Deaeration of the exhaust air ducts Use ap
56. s 2 1 1 Explosion protection approval The explosion protection approval is only valid if you use the modules and components authorized by B rkert as described in these operating instructions The electronic modules may only be used in combination with the pneumatic valve types that have been approved by B rkert Otherwise the Ex approval will expire If you make unauthorized changes to the system the modules or components the explosion protection approval will also be terminated 2 2 Predictable Misuse Do not supply the medium connectors of the system with aggressive or flammable mediums Do not physically stress the housing e g by placing objects on it or standing on it Note that pipes and valves must not become detached in systems which are under pressure Before reaching into the system always switch off the power supply Design the pressure supply with the largest possible volume to prevent a pressure drop when the system is switched on burkert Hu r FLUID CONTROL SYSTEMS Basic Safety Instructions 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 with reference to the installation personnel A Danger high pressure Before dismounting
57. s node 2 Electronic base 3 module l m 2 a Field bus node J 4 kd 5 2 Field bus node n o f 2 z Pneumatic base z 2x is module O L si o Figure 2 Schematic diagram of the Burkert AirLINE system 6 2 4 12 burkert System Descri ption FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 5 4 Characteristic features and advantages 5 4 1 Characteristic features of AirLINE Easy to handle Function block oriented structure of the switch box or control cabinet Automatic setup of potential groups electric data and safety circuits Open flexible and modular structure Combination of the valve discs and terminals in different granularity 2 fold 4 fold for space optimized station structure 5 4 2 Advantages of AirLINE Flow optimized valve structure Pressure range of vacuum up to 10 bar Flow rate of approx 300 l min or 700 l min with a valve width of 10 mm or 16 mm Integration of non return valves in pneumatic base module optional Long service life thanks to flipper technology with oiled and unoiled air Simple combination of different functions configuration and expansion thanks to high modularity Numerous valve functions 3 2 5 2 monostable bistable and 5 3 way functions Mechanical emergency manual override Different pre
58. savings structure of valve discs and utilization of the elec tronics it is useful to have modules with a varying number of valve locations Type of working connections Whether quick plug in connections or thread you as the customer decide which is the optimum variant for you 2777 burkert Structure and function of the modules FLUID CONTROL SYSTEMS MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 Non return valve for the vent connections As certain applications require a functionality with non return valves there are also appropriate types for this purpose Without non return valve Non return valve in R Non return valve in R S An integrated P shut off is also available for the modules MP11 2 fold mono and 8 fold mono MP11 MP12 D6 D8 D4 G 1 8 D 1 4 NPT 1 8 M5 DE M7 M5 M7 D4 1 4 Special design 3 fold module with 10 mm valves 7 4 2 Pneumatic base module with integrated P shut off General Description The P shut off can be integrated in the module for the pneumatic base modules MP11 2 fold and 8 fold versions This option allows a defective valve to be changed under pressure without having to depressurize the complete valve cluster or system When the valve is changed by a mechanism the open cross section is reduced until only a slight residual leakage occurs Features and restrictions I
59. ssure stages possible in one chain Integration of pressure gauges to indicate operating pressure Centralized compressed air supply via connection modules on both sides as well as intermediate feed possible 13 burkert 5557 FLUID CONTROL SYSTEMS System Descri ption 5 5 Diagram of the valve block Manometer for indication of operating pressure at the station Connector 8 fold valve disc module left Intermediate feed 2 fold valve disc Connector module right Working connections Supply and vent connections Figure 3 Diagram of the modules of the Burkert AirLINE system MAN 1000010109 EN Version Status RL released freigegeben printed 20 01 2015 14 Typ 8644 FLUID CONTROL SYSTEMS System Description Exploded drawing 5 6 Exploded drawing add on dimension 11 mm 5 6 1 Wago field bus node fold valve disc 8 2 fold valve disc ME02 ME02 fold valve disc Wago termination module deutsch 2 PAG ROWAY 3 m m NG e F N o s Cover plate NG BN 4102 10 0Z pajuud uaqababiay peseeje TY 5 1215 U01s19 NA 6OLOLOOOOL NYW Exploded drawing add on dimension 11 mm Figure 4 15 Typ 8644 burkert FLUID CONTROL SYSTEMS System Description Exploded drawing add on dimension 16 5 mm 5 6 2
60. the control cabinet or switch box In a continuous system all electronic and pneumatic components are standardized enabling pneumatic electric and electronic modules with various functions to be combined very easily with each other by the observation of simple rules All components are connected by a locking mechanism At the same time the required electrical connections are also established For example valves and power outputs can be combined with one field bus connection only A large number of electrical modules terminals can be combined very easily with the valves mounted on special pneumatic modules valve discs The system consists in its minimum configuration of field bus nodes valve block and termination module Terminals may be placed before and after the valve block 5 3 Structure of the system Central control e g SPC lo Valve block R b 5 i oll Al Field bus DO DI 13 sn 2 node 1 5 SE Pa o 2 e g I s 1 1 PROFIBUS 5 T 9 Bi S 5 2 ng ils 8 ll 3 m 2x 4x cll 2x o o o 5 5 IJO 2x 4x 1 L fas fs el o m UcuxLULVLVU 7 77 PN Field bus A b a CF Field bu

Operating Instructions Type 8644 AirLINE

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