Type 8644 AirLINE With decentralized peripheral system ET200S (Siemens) Operating Instructions Bedienungsanleitung Manuel d‘utilisation
We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous resérve de modification techniques.
Type 8644 Type 8644 AirLINE - Siemens Table 1. Contents Operating Instructions.........................................................................................................................................................6 1.1. 2. of Symbols.......................................................................................................................................................................................6 Authorized use.....................................................
Type 8644 6.4.1. Dimensioning of the connection modules..........................................................................................19 6.4.2. Performance features from the point of view of the entire system...............................................20 6.5. Electrical Data........................................................................................................................................................................21 6.5.1.
Type 8644 7.5.1. General Description.................................................................................................................................50 8. Installation....................................................................................................................................................................................53 8.1. Safety instructions.....................................................................................................................
Type 8644 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.
Type 8644 Authorized use 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.
Type 8644 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. Danger – high pressure! • Before dismounting pneumatic lines and valves, turn off the pressure and vent the lines.
Type 8644 General Information 4. General Information 4.1. Contact Addresses Germany Bürkert Fluid Control Systems Sales Center Chr.-Bürkert-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 4.2.
Type 8644 System Description 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.
Type 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. All components are connected by a locking mechanism.
Type 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 • 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.
Type 8644 System Description 5.5.
Type 8644 System Description 5.6. Exploded drawing 5.6.1.
Type 8644 System Description 5.6.2. Exploded drawing - add-on dimension 16.5 mm  Siemens field bus node Siemens power module ME03 4-fold valve disc 2-fold valve disc ME03 3-fold valve disc 2-fold valve disc ME03 ME03 Siemens termination module MP12 Accessories Cover Cover plate Type 6526 Type 6527 Type 6524 Type 0461 Type 6525 Figure 5: Exploded drawing - add-on dimension 16.
Type 8644 Technical Data 6. Technical Data 6.1. 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 temperature range to be exceeded. Permitted temperatures Storage temperature: -20 ...
Type 8644 Technical Data Max. power consumption Logic current I_Log I_Log_FBKN I_Module I_Log = I_Log_FBKN + Σ I_Module Power consumption in the logic area Proportionate current in the field bus node ET200S max. 150 mA Proportionate current in the logic area of the electronic base modules max 10 mA each Field bus node see Siemens handbook The permitted ambient temperature depends on the modules used.
Type 8644 Technical Data Ambient temperature 0 ... +55 °C Operating voltage 0 ... +55 °C 0 ... +55 °C 24 V / DC, -15 % / +20 % 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 % Add-on dimension 16.
Type 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. if the feed of a vehicle is brought into a closed room.
Type 8644 Technical Data 6.4.2.
Type 8644 Technical Data 6.5. Electrical Data 6.5.1. Electronic base module ME02, ME03 / 2-fold monostable Technical Data ME02 / 2-fold monostable ME03 / 2-fold monostable 22 x 70.5 x 52 mm 33 x 93 x 60 mm 35 g 47 g Storage temperature -20 ... +60° C -20 ... +60° C Nominal load voltage DC 24 V DC 24 V 2 2 Power consumption per valve location during switching 43 mA 85 mA Power consumption per valve location after approx. 120 ms (for ME03 approx.
Type 8644 Technical Data 6.5.2. Electronic base module ME02, ME03 / 4-fold monostable Technical Data ME02 / 4-fold monostable ME03 / 4-fold monostable 44 x 70.5 x 52 mm 66 x 93 x 60 mm 56 g 75 g Storage temperature -20 ... +60° C -20 ... +60° C Nominal load voltage DC 24 V DC 24 V 4 4 Power consumption per valve location during switching 43 mA 85 mA Power consumption per valve location after approx. 120 ms (for ME03 approx.
Type 8644 Technical Data 6.5.3. Electronic base module ME02, ME03 / 2-fold bistable Technical Data ME02 / 2-fold bistable ME03 / 2-fold bistable 22 x 70.5 x 52 mm 33 x 93 x 60 mm 35 g 44 g Storage temperature -20 ... +60° C -20 ... +60° C Nominal load voltage DC 24 V DC 24 V 2 2 41 mA 41 mA max. 10 mA max. 10 mA 2 yellow LED per valve location 2 yellow LED per valve location Power loss of the module (Type 0460) 1.8 W - Power loss of the module (Type 0461) - 1.
Type 8644 Technical Data 6.5.4. Electronic base module ME02 / 2-fold 2 x monostable Technical Data Dimensions WxHxD Weight ME02 / 2-fold 2 x monostable 22 x 70.5 x 52 mm 38 g Storage temperature -20 ... +60° C Nominal load voltage DC 24 V Number of valve outputs 2x2 Power consumption per valve location 2 x 43 mA Power consumption per valve location after 110 ms 2 x 18 mA Power consumption from the backplane bus Display of the valve status max.
Type 8644 Technical Data 6.5.5. Electronic base module ME03 / 3-fold 10 mm monostable Technical Data Dimensions WxHxD Weight ME03 / 3-fold 10 mm monostable 33 x 93 x 60 mm 45 g Storage temperature -20 ... +60° C Nominal load voltage DC 24 V Number of valve outputs 3 Power consumption per valve location during switching 43 mA Power consumption per valve location after approx. 120 ms 28 mA Power consumption from the backplane bus max.
Type 8644 Structure and function of the modules 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),  Connection module on left Figure 6: Electrical interface Feed on right Valve discs 2-fold Intermediate feed Valve discs 2-fold Valve discs 4-fold Feed on left Electrical interface • Valve discs (working connections, various valves).
Type 8644 Structure and function of the modules Electrical connection module Electrical 1:1 shunting Electrical connection module Pneumatic feed module Pneumatic feed module Pneumatic feed module Connection module on left Intermediate feed Connection module on right  Figure 7: Schematic representation of feed 7.1.2. Valve discs MK03 Danger! Danger – high pressure! • Before dismounting pneumatic lines and valves, turn off the pressure and vent the lines.
Type 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. Note! • Do not change attached valves until AirLINE has been depressurized. • If a P shut-off is used, the valves can also be changed under pressure.
Type 8644 Structure and function of the modules 7.2. Connection modules 7.2.1.
Type 8644 Structure and function of the modules 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.
Type 8644 Structure and function of the modules 7.2.2.
Type 8644 Structure and function of the modules 7.2.3.
Type 8644 Structure and function of the modules 7.2.4.
Type 8644 Structure and function of the modules 7.2.5.
Type 8644 Structure and function of the modules 7.2.6.
Type 8644 Structure and function of the modules 7.2.7.
Type 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. For detailed information see Chapter “10. Start-Up”.
Type 8644 Structure and function of the modules Combination options (electronic base module / valve) Base module type ME02 ME03 Add-on dimension Valve locations Valve type 2-fold monostable 11 mm 2 6524 3/2-way 6525 5/2-way 2-fold bistable 11 mm 0460 5/3-way 2-fold 2 x monostable 11 mm 2 6524 2 x 3/2-way 4-fold monostable 11 mm 4 6524 3/2-way 6525 5/2-way 2-fold monostable 16.5 mm 6526 3/2-way 6527 5/2-way 2-fold bistable 16.
Type 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. The bus signals on the distributor module are protected from interference by a shield support.
Type 8644 Structure and function of the modules 7.3.3. Electronic base module ME02 / 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. The bus signals on the distributor module are protected from interference by a shield support.
Type 8644 Structure and function of the modules 7.3.4. 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. The bus signals on the distributor module are protected from interference by a shield support.
Type 8644 Structure and function of the modules 7.3.5. 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. The bus signals on the distributor module are protected from interference by a shield support.
Type 8644 Structure and function of the modules 7.3.6. 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. The bus signals on the distributor module are protected from interference by a shield support.
Type 8644 Structure and function of the modules 7.3.7. 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. The bus signals on the distributor module are protected from interference by a shield support.
Type 8644 Structure and function of the modules 7.3.8. 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. The bus signals on the distributor module are protected from interference by a shield support.
Type 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. The bus signals on the distributor module are protected from interference by a shield support.
Type 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.
Type 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, • An integrated P shut-off is also available for the modules MP11 (2-fold mono and 8-fold mono).
Type 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 outputs A or B is released when the valve is removed. This also means that a connected actuator is also depressurized and a movement may be triggered as a result.
Type 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. Pilot valve and valve housing are clamped or bolted to each other.
Type 8644 Structure and function of the modules Valves Operating principle Operation Width Type C (NC) Internal control air 16 6526 10 6525 16 6527 10 0460 16 0461 10 0460 16 0461 3/2-way D (NO) C (NC) D (NO) Control assist air (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 position Internal control air N Deaerated L Lock middle position N Deaerated 5/2-way impulse
Type 8644 Structure and function of the modules Valve switching time TON TOFF t  Figure 27: 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.
Type 8644 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.
Type 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 decentralized peripheral system ET200S from Siemens. The valve block is bolted securely onto the standard rail.
Type 8644 Installation →→Detach the modules / terminals from the standard rail according to the manufacturer's description. Note! The interface of the left connection module contains elements which may break off if force is used. Ensure that the power module has been detached correctly and that there is adequate clearance in between.
Type 8644 Installation 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. →→Connect all electrical modules/terminals on the left of the valve block to the standard rail according to the manufacturer's specifications.
Type 8644 Installation →→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 30: Tightening the screws”). 20 Ncm 30 Ncm  Figure 30: Tightening the screws 8.5.
Type 8644 Installation 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  Figure 31: Pressure supply connection Pneumatic connections Procedure →→Depending on the version, insert (D10) or screw (G1/4, NPT 1/4) the connections to the corresponding working connections.
Type 8644 Installation 8.5.3.
Type 8644 Installation →→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.
Type 8644 Maintenance, Troubleshooting 9. 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.
Type 8644 Maintenance, Troubleshooting Malfunction Possible cause Valves switch with a delay or blow off at the deaeration connections Inadequate or no pressure supply Remedial action 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 ≥ 2.
Type 8644 Start-Up 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, 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.
Type 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.
Type 8644 Packaging and Transport 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.
Type 8644 Storage 12. Storage Note! Incorrect storage may damage the device. • Store the device in a dry and dust-free location! • Storage temperature: -20 ... +60°C 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.
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