Burkert 8644 AirLINE Operating Instructions Manual
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Burkert 8644 AirLINE Operating Instructions Manual

Burkert 8644 AirLINE Operating Instructions Manual

With i/o system 750 wago, remote process actuation control system
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Type 8644
AirLINE
with I/O System 750 (Wago)
Operating Instructions
Bedienungsanleitung
Manuel d'utilisation

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Summary of Contents for Burkert 8644 AirLINE

  • Page 1 Type 8644 AirLINE with I/O System 750 (Wago) Operating Instructions Bedienungsanleitung Manuel d‘utilisation...
  • Page 2 We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous réserve de modifications techniques. © Bürkert Werke GmbH & Co. KG, 2002 - 2018 Operating Instructions 1805/13_EU-EN_00804090 / Original DE...

  • Page 3: Table Of Contents

    Typ 8644 Type 8644 AirLINE - Wago ontents Operating instructiOns ................................6 1.1. symbols ......................................6 authOrized use .....................................7 2.1. restrictions ....................................7 2.1.1. Explosion protection approval ........................ 7 2.2. predictable Misuse ................................7 Basic safety instructiOns ..............................8 general infOrMatiOn ................................9 4.1. scope of supply ..................................9 4.2. contact addresses ................................9 4.3. Warranty ......................................9 4.4. licenses ......................................9 4.5. information on the internet .
  • Page 4 Typ 8644 6.3. technical data of the valve block ..........................18 6.4. pneumatic data of the connection modules ......................20 6.4.1. Dimensioning of the connection modules ..................20 6.4.2. Performance features from the point of view of the entire system..........21 6.5. electrical data ..................................22 6.5.1. Electronic base module ME02 / 2-fold monostable, ME02 / 2-fold 2 x monostable....22 6.5.2.
  • Page 5 Typ 8644 7.4. pneumatic base module ..............................50 7.4.1. General Description ..........................50 7.4.2. Pneumatic base module with integrated P shut-off ................51 7.5. Valves ......................................53 7.5.1. General Description ..........................53 installatiOn ....................................56 8.1. safety instructions ................................56 8.2. removing the valve block from the top-hat rail ....................57 8.3. installing the airline system (e.g. in the control cabinet) ................58 8.4. changing the electrical function module .......................59 8.5. fluid installation ..................................60 8.5.1. Pneumatic connections - feed ......................60 8.5.2.

  • Page 6: Operating Instructions

    Typ 8644 Operating Instructions 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.

  • Page 7: Authorized Use

    Typ 8644 Authorized use 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. •...

  • Page 8: Basic Safety Instructions

    Typ 8644 Basic Safety Instructions Basic safeTy insTrucTiOns These safety instructions do not make allowance for any: • ontingencies 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.

  • Page 9: General Information

    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 Bürkert Company Locations 4.3. Warranty This document contains no promise of guarantee.

  • Page 10: Information On The Internet

    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 Documentation Datasheets/Operating Instructions Type 8644 Wago The complete documentation is also available on CD and can be ordered by quoting part no. 804625.

  • Page 11: System Description

    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 Figure 1: Type 8644 AirLINE Wago deutsch...

  • Page 12: Structure Of The System

    Typ 8644 System Description The Type 8644 Bürkert AirLINE is an electrical and pneumatic automation system which was developed for use in 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.

  • Page 13: Characteristic Features And Advantages

    Typ 8644 System Description 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, •...

  • Page 14: Diagram Of The Valve Block

    Typ 8644 System Description 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 Bürkert AirLINE system deutsch...

  • Page 15: Exploded Drawing

    Typ 8644 System Description 5.6. exploded drawing 5.6.1. exploded drawing - add-on dimension 11 mm Wago field bus node ME02 8-fold valve disc 2-fold valve disc ME02 2-fold valve disc ME02 ME02 Wago termination module MP11 Bulkhead 6524 (2 x 3/2-way) 6524 6525 Cover plate...

  • Page 16: Exploded Drawing - Add-On Dimension 16.5 Mm

    Typ 8644 System Description 5.6.2. exploded drawing - add-on dimension 16.5 mm Wago field bus node ME03 4-fold valve disc 2-fold valve disc ME03 3-fold valve disc 2-fold valve disc ME03 ME03 Wago termination module MP12 Accessories 6526 6527 6524 Cover plate 6525 0461...

  • Page 17: Technical Data

    Operating conditions WArNINg! 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: -20 ... +60 °C Permitted air humidity:...

  • Page 18: Technical Data Of The Valve Block

    Typ 8644 Technical Data Max. power consumption I_Log = I_Log_FBKN + Σ I_Module Logic current I_Log Power consumption in the 5 V - logic area I_Log_FBKN Proportionate current in the field bus node (see relevant explanation in Wago documentation type) Further product-specific information on Wago field bus nodes / terminals can be found on the Internet under: www.wago.com Documentation...
  • Page 19 Typ 8644 Technical Data Valve locations (max.) 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 0 ... +50 °C Operating voltage 24 V / DC, -15 % / +20 % tolerance**, Residual ripple for field bus interface 5 % Power reduction (in the module)

  • Page 20: Pneumatic Data Of The Connection Modules

    Typ 8644 Technical Data 6.4. pneumatic data of the connection modules Permitted temperature (storage / transport) -20 ... +60° C Permitted air humidity (operation) 75 % on average, 85 % occasionally CAuTIoN! In the range of 0 – +55 °C take suitable measures against increased air humidity (> 85 %). Slight condensation may occasionally occur on the external housing for a brief period, e.g.

  • Page 21: Performance Features From The Point Of View Of The Entire System

    Typ 8644 Technical Data 6.4.2. performance features from the point of view of the entire system connection module on left (Me02, Me03) The connection module on left is electrically passive → logical no process image, therefore no address is required → mechanical ME02 - 43 mm installation dimension ME03 - 56 mm installation dimension →...

  • Page 22: Electrical Data

    Typ 8644 Technical Data 6.5. electrical data 6.5.1. electronic base module Me02 / 2-fold monostable, Me02 / 2-fold 2 x monostable technical data Me02 / 2-fold Me02 / 2-fold monostable 2 x monostable Dimensions BxHxT 22 x 70.5 x 52 mm 22 x 70.5 x 52 mm Weight 38 g 38 g...

  • Page 23: Electronic Base Module Me02 / 8-Fold Monostable, Me02 / 8-Fold 2 X Monostable

    Typ 8644 Technical Data 6.5.2. electronic base module Me02 / 8-fold monostable, Me02 / 8-fold 2 x monostable technical data Me02 / 8-fold Me02 / 8-fold monostable 2 x monostable Dimensions BxHxT 88 x 70.5 x 52 mm 88 x 70.5 x 52 mm Weight 94 g 94 g Storage temperature -20 ...

  • Page 24: Electronic Base Module Me02 / 2-Fold Bistable, Me02 / 8-Fold Bistable

    Typ 8644 Technical Data 6.5.3. electronic base module Me02 / 2-fold bistable, Me02 / 8-fold bistable technical data Me02 / 2-fold Me02 / 8-fold bistable bistable Dimensions BxHxT 22 x 70.5 x 52 mm 88 x 70.5 x 52 mm Weight 38 g 94 g Storage temperature -20 ...

  • Page 25: Electronic Base Module Me03 / 2-Fold Monostable, Me03 / 2-Fold Bistable

    Typ 8644 Technical Data 6.5.4. electronic base module Me03 / 2-fold monostable, Me03 / 2-fold bistable technical data Me03 / 2-fold Me03 / 2-fold monostable bistable Dimensions BxHxT 33 x 93 x 60 mm 33 x 93 x 60 mm Weight 54.4 g 49.1 g Storage temperature -20 ...

  • Page 26: Electronic Base Module Me03 / 3-Fold 10 Mm Monostable, Me03 / 4-Fold Monostable

    Typ 8644 Technical Data 6.5.5. electronic base module Me03 / 3-fold 10 mm monostable, Me03 / 4-fold monostable technical data Me03 / 3-fold Me03 / 4-fold 10 mm monostable monostable Dimensions BxHxT 33 x 93 x 60 mm 66 x 93 x 60 mm Weight 51 g 91.2 g Storage temperature -20 ...

  • Page 27: Structure And Function Of The Modules

    Typ 8644 Structure and function of the modules 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), •...

  • Page 28: Valve Discs Mk03

    Typ 8644 Structure and function of the modules Electrical Electrical Electrical 1:1-Shunting connection module 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 MK03 DANgEr! danger – high pressure! •...
  • Page 29 Typ 8644 Structure and function of the modules 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.

  • Page 30: Connection Modules

    Typ 8644 Structure and function of the modules 7.2. connection modules 7.2.1. structure of the connection module Panel Assembly variant with pressure gauge Pneumatic feed Electrical connection module Type MP11/MP12 (left, middle, right) Type ME02/ME03 (left, right) Interface to electrical part of the automation system (field Shunting bus nodes;...
  • Page 31 Typ 8644 Structure and function of the modules the feeds differ e.g. by: • Pressure gauge • Connection version Mp11 Mp12 G 1/4" G 3/8" NPT 3/8" NPT 1/4" • Control assist air yes / no deutsch...

  • Page 32: Connection Modules, Pneumatic - On Left Type Me02

    Typ 8644 Structure and function of the modules 7.2.2. connection modules, pneumatic - on left Type Me02 Variant drawing Pressure gauge Panel Electrical interface Bürkert/Wago I/O-System-750 in the valve block (AirLINE) Pneumatic connections Figure 10: Side feed on left Variants supply connection (p) 1 connection X exhaust air connection (r/s) 3/5...

  • Page 33: Connection Modules, Pneumatic - In Middle Type Me02

    Typ 8644 Structure and function of the modules 7.2.3. connection modules, pneumatic - in middle Type Me02 Variant drawing Pressure gauge Panel Pneumatic connections Figure 11: Intermediate feed Variants supply connection (p) 1 connection X exhaust air connection (r/s) 3/5 G 1/4 G 1/4 NPT 1/4 NPT 1/4 •...

  • Page 34: Connection Modules, Pneumatic - On Right Type Me02

    Typ 8644 Structure and function of the modules 7.2.4. connection modules, pneumatic - on right Type Me02 Variant drawing Pressure gauge Panel Electrical interface Bürkert/Wago I/O-System-750 in the valve block (AirLINE) Pneumatic connections Figure 12: Side feed on right Variants supply connection (p) 1 connection X exhaust air connection (r/s) 3/5...

  • Page 35: Connection Modules, Pneumatic - On Left Type Me03

    Typ 8644 Structure and function of the modules 7.2.5. connection modules, pneumatic - on left Type Me03 Variant drawing Pressure gauge Panel Electrical interface Bürkert/Wago I/O- System-750 in the valve block (AirLINE) Pneumatic connections Figure 13: Side feed on left Variants supply connection (p) 1 connection X...

  • Page 36: Connection Modules, Pneumatic - In Middle Type Me03

    Typ 8644 Structure and function of the modules 7.2.6. connection modules, pneumatic - in middle Type Me03 Variant drawing Pressure gauge Panel 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 •...

  • Page 37: Connection Modules, Pneumatic - On Right Type Me03

    Typ 8644 Structure and function of the modules 7.2.7. connection modules, pneumatic - on right Type Me03 Variant drawing Pressure gauge Panel Electrical interface Bürkert/Wago I/O-System-750 in the valve block (AirLINE) Pneumatic connections Figure 15: Side feed on right Variants supply connection (p) 1 connection X exhaust air connection (r/s) 3/5...

  • Page 38: Electronic Base Module

    Typ 8644 Structure and function of the modules 7.3. electronic base module 7.3.1. 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.
  • Page 39 Typ 8644 Structure and function of the modules Combination options (electronic base module / valve) Base module type add-on Valve Valve Operating dimension locations type prinziple ME02 2-fold 11 mm 6524 3/2-way monostable 6525 5/2-way 2-fold 11 mm 0460 5/3-way bistable 5/2-way impulse 2-fold 11 mm 6524...

  • Page 40: Electronic Base Module Me02 / 2-Fold Monostable

    Typ 8644 Structure and function of the modules 7.3.2. electronic base module Me02 / 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...

  • Page 41: Electronic Base Module Me02 / 2-Fold 2 X Monostable

    Typ 8644 Structure and function of the modules 7.3.3. electronic base module Me02 / 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...

  • Page 42: Electronic Base Module Me02 / 8-Fold Monostable

    Typ 8644 Structure and function of the modules 7.3.4. electronic base module Me02 / 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...

  • Page 43: Electronic Base Module Me02 / 8-Fold 2 X Monostable

    Typ 8644 Structure and function of the modules 7.3.5. electronic base module Me02 / 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...

  • Page 44: Electronic Base Module Me02 / 2-Fold Bistable

    Typ 8644 Structure and function of the modules 7.3.6. electronic base module Me02 / 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...

  • Page 45: Electronic Base Module Me02 / 8-Fold Bistable

    Typ 8644 Structure and function of the modules 7.3.7. electronic base module Me02 / 8-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...

  • Page 46: Electronic Base Module Me03 / 2-Fold Monostable

    Typ 8644 Structure and function of the modules 7.3.8. electronic base module Me03 / 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...

  • Page 47: Electronic Base Module Me03 / 2-Fold Bistable

    Typ 8644 Structure and function of the modules 7.3.9. electronic base module Me03 / 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...

  • Page 48: Electronic Base Module Me03 / 3-Fold 10 Mm Monostable

    Typ 8644 Structure and function of the modules 7.3.10. electronic base module Me03 / 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 types Base module type add-on...

  • Page 49: Electronic Base Module Me03 / 4-Fold Monostable

    Typ 8644 Structure and function of the modules 7.3.11. electronic base module Me03 / 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...

  • Page 50: Pneumatic Base Module

    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.

  • Page 51: Pneumatic Base Module With Integrated P Shut-Off

    Typ 8644 Structure and function of the modules 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, •...
  • Page 52 Typ 8644 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.

  • Page 53: Valves

    Typ 8644 Structure and function of the modules 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 consist of a pilot control solenoid valve and a pneumatic valve.
  • Page 54 Typ 8644 Structure and function of the modules Valves Operating prinziple Operation Width type 3/2-way C (NC) Internal control air 6526 D (NO) C (NC) Control assist air (External) D (NO) C - vacuum (NC) 5/2-way Internal control air 6525 Control assist air (External) Internal control air 6527...
  • Page 55 Typ 8644 Structure and function of the modules Valve switching time 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. For exact specification see data sheet of the particular valves.

  • Page 56: Installation

    Typ 8644 Installation 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! •...

  • Page 57: Removing The Valve Block From The Top-Hat Rail

    Typ 8644 Installation 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.

  • Page 58: Installing The Airline System (E.g. In The Control Cabinet)

    Typ 8644 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.

  • Page 59: Changing The Electrical Function Module

    Typ 8644 Installation 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! •...

  • Page 60: Fluid Installation

    Typ 8644 Installation 8.5. fluid installation 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. •...

  • Page 61: Removing The Plug-In Connections

    Typ 8644 Installation 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 Working connections for 5/2- and 2 x 3/2-Way valves Working connections for...

  • Page 62: Electrical Installation

    Typ 8644 Installation installation → Depending on the version, insert (D6, D4, D1/4) or screw (M5, M7) the connections to the corresponding 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.

  • Page 63: Maintenance, Troubleshooting

    Typ 8644 Maintenance, Troubleshooting MainTenance, TrOuBleshOOTing 9.1. 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! •...

  • Page 64: Maintenance Of Components

    Typ 8644 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 ≥ 2.5 bar...

  • Page 65: Start-Up

    Typ 8644 Start-Up 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, ensure that the operating personnel are familiar with and completely understand the contents of the operating instructions.

  • Page 66: Selection Of The Modules In The Gsd File

    Typ 8644 Start-Up 10.3.1. selection of the modules in the gsd file The module designations of the different electrical base modules in the GSD file can be found in the following table. add-on dimension Module designation entry in gsd file ME02 / 2-fold monostable Bürkert 8644 monostable 2 DO *Bürkert 8644 monostable 2 DO ME02 / 2-fold 2 x monostable Bürkert 8644 monostable 4 DO...

  • Page 67: Packaging And Transport

    Typ 8644 Packaging and Transport 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. sTOrage NoTE! incorrect storage may damage the device.

  • Page 68: Disposal

    Typ 8644 Disposal 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 regul ations and environmental regulations. Observe national waste disposal regulations. deutsch...
  • Page 70 www.burkert.com...

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