Type 8644 AirLINE with I/O System 750 (Wago) Operating Instructions Bedienungsanleitung Manuel d‘utilisation
We reserve the right to make technical changes without notice. Technische Änderungen vorbehalten. Sous réserve de modifications techniques.
Typ 8644 Type 8644 AirLINE - Wago Contents 1. Operating Instructions.........................................................................................................................................................6 1.1. 2. Symbols.......................................................................................................................................................................................6 Authorized use....................................................................
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.
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......................
Typ 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.
Typ 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.
Typ 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.
Typ 8644 General Information 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 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.
Typ 8644 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.
Typ 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.
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. All components are connected by a locking mechanism.
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, • 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.
Typ 8644 System Description 5.5.
Typ 8644 System Description 5.6. Exploded drawing 5.6.1.
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 Figure 5: Exploded drawing - add-on dimension 16.
Typ 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 ...
Typ 8644 Technical Data Max. power consumption Logic current I_Log = I_Log_FBKN + Σ I_Module 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: Documentation Wago I/O - System 750 www.wago.
Typ 8644 Technical Data Valve locations (max.) 64 32 32 Electrical modules 2-fold, 8-fold monostable 2-fold 2 x monostable 8-fold 2 x monostable 2-fold, 8-fold bistable Pneumatic modules 2-fold, 8-fold 2-fold 2-fold bistable Ambient temperature 0 ... +55 °C 0 ... +55 °C 0 ...
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. if the feed of a vehicle is brought into a closed room.
Typ 8644 Technical Data 6.4.2.
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 monostable ME02 / 2-fold 2 x monostable 22 x 70.5 x 52 mm 22 x 70.5 x 52 mm 38 g 38 g Storage temperature -20 ... +60° C -20 ... +60° C Nominal load voltage DC 24 V DC 24 V 2 2x2 Power consumption per valve location during switching 43 mA 2 x 43 mA Power consumption per valve location after approx.
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 monostable ME02 / 8-fold 2 x monostable 88 x 70.5 x 52 mm 88 x 70.5 x 52 mm 94 g 94 g Storage temperature -20 ... +60° C -20 ... +60° C Nominal load voltage DC 24 V DC 24 V 8 8x2 Power consumption per valve location during switching 43 mA 2 x 43 mA Power consumption per valve location after approx.
Typ 8644 Technical Data 6.5.3. Electronic base module ME02 / 2-fold bistable, ME02 / 8-fold bistable Technical Data ME02 / 2-fold bistable ME02 / 8-fold bistable 22 x 70.5 x 52 mm 88 x 70.5 x 52 mm 38 g 94 g Storage temperature -20 ... +60° C -20 ... +60° C Nominal load voltage DC 24 V DC 24 V 2x2 8x2 Power consumption per valve location during switching 41 mA 41 mA Power consumption from the backplane bus max. 15 mA max.
Typ 8644 Technical Data 6.5.4. Electronic base module ME03 / 2-fold monostable, ME03 / 2-fold bistable Technical Data ME03 / 2-fold monostable ME03 / 2-fold bistable 33 x 93 x 60 mm 33 x 93 x 60 mm 54.4 g 49.1 g Storage temperature -20 ... +60° C -20 ... +60° C Nominal load voltage DC 24 V DC 24 V 2 2x2 Power consumption per valve location during switching 85 mA 41 mA Power consumption per valve location after approx. 400 ms 52 mA - Power consumption from the backplane bus max.
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 10 mm monostable ME03 / 4-fold monostable 33 x 93 x 60 mm 66 x 93 x 60 mm 51 g 91.2 g Storage temperature -20 ... +60° C -20 ... +60° C Nominal load voltage DC 24 V DC 24 V 3 4 Power consumption per valve location during switching 43 mA 85 mA Power consumption per valve location after approx. 65 ms (for ME03 / 4-fold monostable after approx.
Typ 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), Connector module left Figure 6: Electrical interface Feed on right Valve disc 2-fold Intermediate feed Valve disc 2-fold Valve disc 8-fold Feed on left Electrical interface • Valve discs (working connections, various valves).
Typ 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 Connector module left Intermediate feed Connector module 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.
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. 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.
Typ 8644 Structure and function of the modules 7.2. Connection modules 7.2.1.
Typ 8644 Structure and function of the modules The feeds differ e.g.
Typ 8644 Structure and function of the modules 7.2.2.
Typ 8644 Structure and function of the modules 7.2.3.
Typ 8644 Structure and function of the modules 7.2.4.
Typ 8644 Structure and function of the modules 7.2.5.
Typ 8644 Structure and function of the modules 7.2.6.
Typ 8644 Structure and function of the modules 7.2.7.
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. For detailed information see Chapter 10.Start-Up.
Typ 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 8-fold monostable 11 mm 8 6524 3/2-way 6525 5/2-way 8-fold bistable 11 mm 8 0460 5/3-way 8-fold 2 x monostable 11 mm 8 6524 2 x 3/2-way 2-fold monostable 16.
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.
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.
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.
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.
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.
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.
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 ME03 2-fold monostable Add-on dimension Valve locations Valve type Operating prinziple 16.
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 ME03 / 2-fach bistable Add-on dimension Valve locations Valve type Operating prinziple 16.
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.
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 ME03 / 4-fold monostable Add-on dimension Valve locations Valve type Operating principle 16.
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.
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, • An integrated P shut-off is also available for the modules MP11 (2-fold mono and 8-fold mono).
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 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.
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. Pilot valve and valve housing are clamped or bolted to each other.
Typ 8644 Structure and function of the modules Valves Operating prinziple 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) Control assist air (External) D (NO) 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
Typ 8644 Structure and function of the modules Valve switching time TON Figure 29: TOFF t 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.
Typ 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.
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. The valve block is bolted securely onto the standard rail.
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. 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.
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! • Before dismounting pneumatic lines and valves, turn off the pressure and vent the lines.
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. • 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.
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.
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.
Typ 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.
Typ 8644 Maintenance, Troubleshooting Malfunction Valves switch with a delay or blow off at the deaeration connections Possible cause 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.
Typ 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.
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.
Typ 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. 12. Storage Note! Incorrect storage may damage the device. • Store the device in a dry and dust-free location! • Storage temperature: -20 ... +60°C.
Typ 8644 Disposal 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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