Burkert 8821 Operating Instructions Manual
Operating Instructions
Bedienungsanleitung
Manuel d‘utilisation
Type 8821
Functional unit comprising MasterJet air unit and base construction
Funktionseinheit bestehend aus MasterJet mit Lufteinheit und Sockelaufbau
Unité fonctionnelle comprenant le MasterJet avec unité pneumatique et socle
We reserve the right to make technical changes without notice.
Technische Änderungen vorbehalten.
Sous réserve de modifications techniques.
© Bürker t Werke GmbH & Co. KG, 2012 - 2017
Operating Instructions 1805/01_EU-EN_00810012 / Original DE
Type 8821
english
Contents
OPERATING INSTRUCTIONS ..................................................................5
1.
1.1. Symbols ..........................................................................................5
1.2. Definitions of terms .....................................................................5
2. AUTHORIZED USE........................................................................................6
2.1. Restrictions ....................................................................................6
3. BASIC SAFETY INSTRUCTIONS ...........................................................6
4. GENERAL INFORMATION ..........................................................................7
4.1. Contact address ...........................................................................7
4.2. Warranty..........................................................................................7
4.3. Information on the Internet ..........................................................7
5. SYSTEM DESCRIPTION .............................................................................8
5.1. Intended application area............................................................8
5.2. General description ...................................................................... 8
5.3. Functions ........................................................................................8
6. TECHNICAL DATA ..........................................................................................9
6.1. Conformity ...................................................................................... 9
6.2. Standards ....................................................................................... 9
6.3. Operating conditions ...................................................................9
6.4. General technical data ................................................................9
6.5. Schematic circuit ........................................................................12
7. ASSEMBLY
7.1. Safety instructions ......................................................................13
7.2. Assembly of the functional unit ................................................13
..................................................................................................... 13
8. INSTALLATION
8.1. Safety instructions ......................................................................15
8.2. Pneumatic installation ................................................................15
8.3. Hydraulic installation ..................................................................16
8.4. Parts list for the screw connections .......................................16
8.5. Overview of MasterJet screw connections
with the pneumatic unit .............................................................17
8.6. Electrical installation ...................................................................18
8.7. Electrical installation ...................................................................19
9. START-UP
9.1. Safety instructions ......................................................................20
9.2. Starting-up the pneumatic unit ................................................20
9.3. Starting-up Type 8821 ..............................................................21
10. OPERATION
10.1. Safety instructions ......................................................................22
10.2. Manual operation of the MasterJet .........................................23
10.3. Automatic operation of the MasterJet ....................................23
10.4. Sensor programming .................................................................24
11. MAINTENANCE
11.1. Safety instructions ......................................................................26
12. SPARE PARTS .............................................................................................. 27
.............................................................................................15
.......................................................................................................20
................................................................................................... 22
............................................................................................ 26
3
13. REPAIRS .......................................................................................................... 28
english
13.1. Replacing pilot valve Type 6014 .............................................28
13.2. Replacing pilot valve Type 0450 .............................................29
13.3. Replacing flow-rate sensor SE12 ...........................................30
13.4. Replacing the display and evaluation unit
(electronics module SE32) .......................................................31
13.5. Replacing drive DM63 and DM50 ..........................................32
13.6. Replacing expansion cylinder DM63 .....................................33
13.7. Replacing the pneumatic unit ..................................................34
14. SHUTDOWN...................................................................................................35
14.1. Safety instructions ......................................................................35
14.2. Disassembly of Type 8821 .......................................................35
15. TRANSPORTATION, STORAGE, DISPOSAL .................................36
Type 8821
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Type 8821
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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.
The operating instructions contain important safety
information!
Failure to observe these instructions may result in hazardous
situations.
• The operating instructions must be read and understood.
1.1. Symbols
DANGER!
Warns of an immediate danger!
• Failure to observe the warning will result in a fatal or serious
injury.
WARNING!
Warns of a potentially dangerous situation!
• Failure to observe the warning may result in serious injuries or
death.
CAUTION!
Warns of a possible danger!
• Failure to observe this warning may result in a moderate or
minor injury.
NOTE!
Warns of damage to property!
• Failure to observe the warning may result in damage to the
device or the equipment.
Indicates important additional information, tips and
recommendations.
Refers to information in these operating instructions or in
other documentation.
→ Designates a procedure which you must carry out.
1.2. Definitions of terms
In these instructions, the maximized version of the term "functional
unit" comprises the following components:
MasterJet, pneumatic unit and base construction.
While the minimum version only comprises
the pneumatic unit and base construction.
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Authorized Use
2. AUTHORIZED USE
Non-authorized use of the functional unit may be dangerous
to people, nearby equipment, and the environment.
• The functional unit is designed to control and monitor the cooling circuits on industrial production systems.
• The functional unit must not be used in potentially explosive
areas.
• Use according to the authorized data, operating conditions, and
conditions of use specified in the contract documents and operating instructions. These are described in the chapter entitled
"Technical Data".
• The functional unit must only be used in conjunction with thirdparty devices and components recommended and approved by
Bürkert.
• Correct transportation, storage, and installation, as well as careful use and maintenance are essential for reliable and faultless
operation.
• Do not make any external modifications to the device housings.
Do not paint housing parts or screws.
• Only use the functional unit as intended.
2.1. Restrictions
If exporting the system/device, observe any existing restrictions.
3. BASIC SAFETY INSTRUCTIONS
These safety instructions do not make allowance for any
• Contingencies and events which may arise during the installation,
operation, and maintenance of the devices.
• Local safety regulations – the operator is responsible for observing
these regulations, also in relation to the installation personnel.
Danger – high pressure!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Risk of electric shock!
• Switch off the power supply and secure it against reactivation
before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
General hazardous situations!
To prevent injuries:
• Do not supply the medium connectors of the system with
aggressive or flammable media.
• Do not supply the compressed-air connections with any liquids.
• The impact protection on the top of the device must not be
loaded with more than 70 kg.
• Ensure that the system cannot be activated unintentionally.
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General Information
• Installation and repair work may be carried out by authorized
technicians only and with the appropriate tools.
• After an interruption in the electrical or pneumatic supply,
ensure that the process is restarted in a defined or controlled
manner.
• The device must only be operated when in a perfect condition
and in consideration of the operating instructions.
• The general rules of technology apply to application planning
and operation of the device.
NOTE!
Electrostatic sensitive components/modules!
The device contains electronic components which react sensitively
to electrostatic discharge (ESD). Contact with electrostatically
charged persons or objects are hazardous to these components.
In the worst case scenario, they will be destroyed immediately or
will fail after start-up.
• Observe the requirements in accordance with EN 61340-5-1
and -5-2 to minimize/avoid the possibility of damage caused by
a sudden electrostatic discharge!
• Also, ensure that you do not touch electronic components when
the power supply voltage is present!
4. GENERAL INFORMATION
4.1. Contact address
Germany
Bürkert Fluid Control Systems
Technik Center
Christian-Bürkert-Str. 13-17
D-74653 Ingelfingen
Germany
Tel. + 49 (0) 7940 - 10 91 110
Fax + 49 (0) 7940 - 10 91 448
E-mail: 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. Warranty
The warranty is only valid if the functional unit is used as intended in
accordance with the specified application conditions.
4.3. Information on the Internet
The operating instructions and data sheets for Type 8821 can be found
on the Internet at:
www.burkert.com
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System Description
5. SYSTEM DESCRIPTION
5.1. Intended application area
Type 8821 is intended for the use in industrial systems, especially
robot applications used for resistance spot welding for controlling
and monitoring cooling water circuits.
5.2. General description
Type 8821 is used to control and monitor the flow of coolant in
industrial robot applications used for resistance spot welding.
The coolant circuit is controlled by the unit and the required coolant
quantity is monitored.
Additionally, the water pressure within the system is reduced when
the flow of cooling water is switched off.
This is advantageous when replacing the welding electrodes as this
prevents any cooling water from escaping.
5.3. Functions
• The main valve (NC) for the feed and return of the cooling circuit is
controlled via pilot valve Type 6014.
• During shutdown, the pressure in the cooling system is automatically
reduced by the delayed drive control in the return.
• The residual pressure is released via delayed switched pilot valve
Type 0450 and pneumatic expansion cylinder DM63 in the closed
cooling circuit.
• An optical cooling water flow sensor Type 8012 DN8, comprising
evaluation electronics with integrated impeller SE12, fitting SO30
and electronics module SE32 monitors the flow rate and sends
signal outputs to the overriding control or robot in accordance with
the programmed monitoring windows.
• The flow-rate sensor comprises a flow direction detector.
• The flow quantity of the cooling water can be limited via a manual
adjusting screw on the pneumatic feed drive.
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Technical Data
6. TECHNICAL DATA
6.1. Conformity
Type 8821 conforms with the EC Directives according to the EC
Declaration of Conformity.
6.2. Standards
The applied standards, which verify conformity with the EC Directives, can be found on the EC-Type Examination Certificate and / or
the EC Declaration of Conformity.
6.3. Operating conditions
WARNING!
Risk of injury!
Malfunction if used outside!
• Do not use Type 8821 outdoors and avoid heat sources which
may cause the permissible temperature range to be exceeded.
Permitted temperatures
Ambient temperature: +5 to +55°C
Medium temperature: +5 to +90°C
Media: Aggressive and neutral fluids
Protection class: IP65 in accordance with EN 60529
6.4. General technical data
Weight: 9.5 kg
Housing material: VA / brass
External sealing material: EPDM
6.4.1. Dimensions
271,3
199,5
6
5
199,8
85,6
276,3
Fig. 1: Type 8821, MasterJet with pneumatic unit and base construction;
rear view
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Type 8821
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Technical Data
199,5
216,1
Fig. 2: Type 8821, MasterJet with pneumatic unit and base construction;
bottom view
216
192,6
Fig. 3: Type 8821, MasterJet with pneumatic unit and base construction;
left side view
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Technical Data
6.4.2. Pneumatic data
Control medium: Quality classes in accordance with DIN ISO 8573-1
Dust content: Class 5: max. particle size 40 μm,
max. particle density 10 mg/m
3
Water content: Class 3: max. pressure dew point -20°C or
min. 10°C below the lowest
operating temperature
Oil content: Class 5: max. 25 mg/m
3
Temperature range
of compressed air: -10 to +50°C
Pressure range 3.0 to 9.5 bar
Air flow rate IN/min
(for aeration and deaeration) (QNn value according to definition for
pressure drop from 7 to 6 bar absolute)
Connections Plug-in hose connector
Ø 6 mm / 1/4"
6.4.3. Hydraulic data
Medium: Water, cooling water
Max. operating pressure: 9.5 bar
Ambient temperature: +5 to +55°C
Water connections
on the block: See “Fig. 7”, page 17
6.4.4. Electrical data
Valve
Connection: DIN 43650 form B with M12 adapter
Power supply: 24 V DC
Sensor:
Connection: M12 connector
Power supply: 12 - 30 V DC
Measuring precision: +/- 1% of the final value, 3% of the mea-
sured value at a flow rate of 0.3 to 10 m/s
Output: 1 impulse /revolution, transistor NPN
700 mA
11
6.5. Schematic circuit
english
Type 8821
Technical Data
P customer's pressure
installation
P 5-10 bar
Pneumatic
leading to
the robot
3
1
3/2-way valve
(6014) 24VDC
ø 0.05
5/2-way valve (0450)
pneumatically controlled
Connector
4
3 1
Supply line
Customer's
supply
Return travel
ø 0.5
2
Valve supply 1
(2031) DN15
Valve return 2
(2031) DN15
ø 0.5
Deaeration
Air
Water
Flow-rate sensor
SE12 DN08
2
Supply line
Spot-welding gun
Return travel
Display SE32
Fig. 4: Schematic circuit
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Assembly
7. ASSEMBLY
7.1. Safety instructions
DANGER!
Risk of injury from high pressure in the system!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Risk of injury due to electrical shock!
• Switch off the power supply and secure it against reactivation
before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
WARNING!
Risk of injury from improper assembly!
• Installation must only be carried out by authorized technicians
and with the appropriate tools!
Risk of injury from unintentional activation of the system and
uncontrolled restart!
• Secure system from unintentional activation.
• Following assembly, ensure a controlled restart.
7.2. Assembly of the functional unit
WARNING!
Risk of injury from a sudden discharge of cooling water due
to improper installation!
If the installation position is incorrect (horizontal orientation or
upside down), the discharge function of the expansion cylinder is
no longer guaranteed. This can cause cooling water to suddenly
escape from the spot-welding gun when the electrode caps are
being replaced.
• Only install the functional unit vertically.
• The installation position must be observed.
Procedure:
→ Connect the MasterJet to a base plate or fixture using the desig-
nated bores (see “Fig. 5” and “Fig. 6”).
NOTE!
• Pay attention to the installation position of the functional unit. If
installed correctly, the impact protection plate is at the top!
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Assembly
88
88
Fig. 5: Screwing bores in the base plate
A fixture that matches the screw hole pattern on the robot can be
supplied for mounting on the base of the robot.
Item designation and order number:
Angled bracket, complete 771338
See section “12. Spare Parts”, page 27
14
Fixture for installation of
the base of the robot
Fig. 6: MasterJet including fixture for mounting on the base of the robot
7.2.1. Mounting options:
Generally, various options are available for mounting the MasterJet.
Recommendation:
Mount the unit as close as possible to the process (e.g. spot-welding
gun).
Long hose lengths are required with large distances. This has the following consequences:
• The amount of coolant increases, which means that a correspondingly larger expansion cylinder has to be selected.
• Delayed reaction times when it comes to changes in the flow rate
caused, for example, by an electrode cap breaking on the spotwelding gun.
The detection of these and other error conditions are therefore
also delayed.
Type 8821
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Installation
8. INSTALLATION
8.1. Safety instructions
DANGER!
Risk of injury from high pressure in the system!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Risk of injury due to electrical shock!
• Switch off the power supply and secure it against reactivation
before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
WARNING!
Risk of injury from improper installation!
• Installation may be carried out by authorized technicians only
and with the appropriate tools!
Risk of injury from unintentional activation of the system and
uncontrolled restart!
• Secure system from unintentional activation.
• Following installation, ensure a controlled restart.
8.2. Pneumatic installation
DANGER!
Risk of injury from high pressure in the system!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Procedure:
→ Following the mechanical mounting of the MasterJet, establish
a pneumatic connection between the pneumatic unit and
MasterJet:
→ Connect the factory-provided air supply to the pneumatic unit.
See “Fig. 7: Overview of the hose system Type 8821”
Observe the air volume requirements in the robot
application.
The MasterJet requires a plug-in hose connection with a
6 mm diameter. The robot application requires a 1/2" connection (1/2" on M22 x 1.5 or equivalent is standard in most
structural work applications).
→ Connect the connecting hose leading to the base of the robot or
stationary welding gun to the output side of the T-fitting on the
maintenance unit.
→ Tighten the screws.
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Installation
NOTE!
Damage caused by high inlet pressure!
• The air pressure provided on site must not exceed the maximum
permissible pressure on the functional unit.
• Use a suitable pressure reducer if the inlet pressure is higher
than permissible!
8.3. Hydraulic installation
NOTE!
Damage caused by improper tightening of the screws!
• When tightening the universal rotary joint observe the maximum
torque or the 1/4 revolution tightening otherwise the screw connection can tear.
Procedure:
→ Connect the warehouse cooling water supply and return on the
input side of the MasterJet using the screws provided.
NOTE!
Malfunction of the MasterJet due to the supply and return
being mixed up!
The existing water flow is not measured if the flow direction is
mixed up.
• Observe the flow direction when connecting the cooling water
supply.
→ Cut the supplied plug-in hoses to length in accordance with the
distance between the MasterJet output and the connection point
on the base of the robot.
Cut the hoses to such a length that they can be laid with
large bending radii. Bending radii that are too tight can hinder
the water flow.
→ Then connect the prepared houses to the output side of the
MasterJet and the base of the robot.
Match the color of the hose with the color-coded connections
on the base of the robot: supply = green; return = red.
8.4. Parts list for the screw connections
Position Material number Quantity
1. GE15LREDOMDCF 1
2. 3C382-15-8 1
3. EVGE22LR3/4KEGMS 1
4. GE22LR3/4KEGMSX 1
5. 3D082-22-12B 1
6. 3C382-22-12B 1
7. EVGE15LR1/2KEGMS 1
8. GE15LR1/2KEGMSX 1
9. 3D082-15-8B 1(2)
10. 3C382-15-8B 1
11. 35C82-15-8B (2)
12. H898202 (1)
Tab. 1: Parts list for the screw connections
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Installation
8.5. Overview of MasterJet screw connections with the pneumatic unit
On the base of the robot On the functional unit/output On the functional unit/input
Pneumatic connections
Universal sealing head H898202 *) Double nipple GE15LREDOMDCF
35C82-15-8B + universal sealing head 3C382-15-8
Cooling water connections
Universal sealing head 35C82-15-8B *) Supply double nipple EVGE15LR1/2KEGMS Return double nipple EVGE22LR3/4KEGMS
+ hose coupling 3D082-15-8B + hose coupling 3D082-22-12B
Universal sealing head 3D082-15-8B *) Return double nipple GE15LR1/2KEGMSX Supply double nipple GE22LR3/4KEGMSX
+ universal sealing head 3C382-15-8B + universal sealing head 3C382-22-12B
*) included in the equipment pack
Tab. 2: Overview of the screw connections
Bending radius
When laying
the hoses,
ensure there
are sufficient
bending radii!
Fig. 7: Overview of the hose system Type 8821
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Installation
8.6. Electrical installation
DANGER!
Risk of injury due to electrical shock!
• Switch off the power supply and secure it against reactivation before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations for electrical equipment!
Overview: Electrical plug configuration
SE12
Not used
4
5
1
V+ (12-36 VDC)
Connection of the 5-pole M12 plastic
device plug
Fig. 8: Electrical connection; overview of the plugs
18
0 V DC
3
Max. cable length 10 m
2
Impulse output
(default NPN)
SE32
0 V DC
3
2
Impulse input
(default NPN)
Connection of the 4-pole
M12 metal plug
Not used
4
1
V+ (sensor)
PNP transistor
output
4
5
1
V+ (12-36 V DC)
Connection of the 5-pole plastic
device plug
3
2
NPN transistor
output
0 V DC
Type 8821
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Installation
Classification of wire colors:
Pin Wire color
1 brown
2 white
3 blue
4 black
5 gray
Tab. 3: Electrical connection; wire colors
8.7. Electrical installation
DANGER!
Risk of injury due to electrical shock!
• Switch off the power supply and secure it against reactivation
before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
Procedure:
→ Connect the flow-rate sensor SE12 DN08 with the display and
evaluation unit (electronics module SE32) via the connection
cable (ID number 555676). To do so, unscrew the standard M12
plug pin including the screw lock.
The display and evaluation unit (electronics module SE32) can
be mechanically mounted anywhere along the length of the connection cable (e.g. on the safety fence).
→ Connect the supply voltage for the display and evaluation unit
(electronics module SE32) to the 5-pole M12 device plug pin
(see “Fig. 8: Electrical connection; overview of the plugs”).
→ In the event of an alarm, etc., the unit's evaluation signals on the
same plug pin can be transferred to the overriding control or the
robot via the corresponding cable (see connection diagram with
NPN and PNP output).
NOTE!
Observe the maximum load capacity on the outputs!
• Failure to do so can overload the device and damage the
electronics.
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Start-Up
9. START-UP
9.1. Safety instructions
WARNING!
Risk of injury from improper operation!
Improper operation may result in injuries as well as damage to the
device and the surrounding area.
• Before start-up, ensure that the operating personnel are familiar
with and completely understand the contents of the operating
instructions.
• Observe the safety instructions and intended use.
• Only adequately trained personnel may start up the equipment/
the device.
9.2. Starting-up the pneumatic unit
To test the MasterJet, the pneumatic unit must first be placed into
operation as the control valve and expansion cylinder of the MasterJet
are controlled by compressed air.
DANGER!
Risk of injury from moving compressed air hoses that are not
connected!
• Check all of the hose connections are secured tightly before
charging the pneumatic unit with compressed air.
• Ensure that the exhaust shut-off valve remains closed during
initial start-up.
Procedure:
→ Open the air supply line on the input side of the pneumatic unit.
→ Check the compressed air connections and resolve any existing
air leaks with suitable measures.
→ Open the exhaust shut-off valve if there are no existing air leaks.
→ Also check the compressed air connections and components of
the pneumatic unit for leaks.
→ Ensure that there are no leaks.
→ Then check the electric feedback from the pressure switch.
→ Check that the input on the connected PLC or robot control is
set to the logic "1" switching status.
Observe the correct supply pressure on the input of the
pneumatic unit. It should be between 3 and 6 bar.
→ After deactivating the exhaust shut-off valve, the electric input of
the connected PLC or robot control should change to the logic
"0" switching status.
Start-up of the pneumatic unit is then complete.
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Start-Up
9.3. Starting-up Type 8821
Once
• the connected line system has been charged with compressed air
and cooling water and
• the pneumatic unit has been placed into operation,
• the functional unit can be started up.
Procedure:
→ After opening the cooling water flow, check the line feed on the
input side of the MasterJet for leaks.
→ Repair any leaks on the hose connections of the cooling water
circuit.
→ Start the cooling circuit via manual valve actuation on pilot
valve 6014 (see “Fig. 9”).
→ Check the screws on the output side for leaks.
→ A red LED indicates if the preset limit has been exceeded.
→ If all of the conditions are correct, the current flow rate is shown
on the display of the evaluation unit (electronics module SE32)
in liters or gallons per minute, depending on the settings when
the cooling water is running.
→ The maximum flow rate can be reduced to the required value
using the setting screw on the return valve of the MasterJet by
opening the lock nut and then turning the flat-blade screw.
NOTE!
Suitable tools for setting the flow rate:
• To reduce the flow rate, the setting screw can be slightly
adjusted with a large hexagon screwdriver. Counter this with an
open-end wrench.
→ Set the limit values for the flow rate monitor in the programming
menu of the evaluation unit (electronics module SE32)
(see “10.4.1. Programming menu of the evaluation unit (electronics module SE32)”).
The settings for other parameters, switching process, and measuring units are provided in the operating instructions for the
electronics module SE32.
→ To check the electrical functions, deactivate the cooling circuit
via the manual valve actuator on pilot valve 6014 (see “Fig. 9”).
→ To check the electrical functions, first of all set the corre-
sponding switching output of the PLC or robot control to the
logic "1" switching status.
Pilot valve 6014 is controlled with switching command "1" that
pneumatically opens the supply and return valves of the MasterJet and establishes the cooling circuit.
At the same time, the pneumatic side in the expansion cylinder
is pressed forward by means of a cover plate in the pneumatic
control circuit of the switching valve. The water in the expansion
cylinder is pressed into the cooling circuit.
→ Then reset the switching status of the switch output.
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Operation
This closes the cooling circuit and the air chamber in the
expansion cylinder is vented after a time delay.
The remaining pressure in the cooling circuit for the spotwelding gun is released into the expansion cylinder.
WARNING!
Risk of injury from ejected cooling water or steam!
If the expansion cylinder malfunctions when the electrode cap is
removed, this can cause cooling water or steam to escape.
• Only remove the electrode caps using the intended tools.
• Wear protective glasses and clothing when removing the electrode caps.
→ Remove the electrode caps from the spot-welding gun to test
the functionality of the MasterJet.
If the MasterJet is operating correctly, water must not spray out
of the electrode shaft when pressure is applied.
Start-up is completed following the function test of the expansion
cylinder.
10. OPERATION
10.1. Safety instructions
WARNING!
Danger due to improper operation!
Improper operation may result in injuries as well as damage to the
device and the area around it.
• The operating personnel must know and have understood the
contents of the operating instructions.
• Observe the safety instructions and intended use.
• Only adequately trained personnel may operate the equipment/
the device.
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Operation
10.2. Manual operation of the MasterJet
There are two ways to activate the cooling circuit:
• Either connect pilot valve Type 6014 with +24 VDC or
• Move the manual lever on the valve
(90° clockwise).
Manual lever
Fig. 9: Pilot valve Type 6014 with a lever for manual valve activation
Manual operation is used when starting up the system so that the
parameters for the flow monitor can be set for the first time, and to
ensure that the current flow rate is monitored simultaneously.
The correct functionality of the expansion cylinder can be checked via
a manual activation lever on pilot valve Type 0450.
10.3. Automatic operation of the
MasterJet
To activate the cooling circuit, the coil of pilot valve Type 6014 is
switched via a 24 V DC output of a PLC or robot control, which pneumatically activates the drives in the supply and return of the cooling
circuit, thus activating the cooling circuit.
At the same time as activating the cooling circuit, expansion cylinder
DM63 is pneumatically activated with a delay via pilot valve Type 0450
and a cover plate in the control circuit. When activated, the expansion
cylinder that is built into the supply line of the cooling water circuit
presses the cooling water in the cylinder into the cooling circuit.
If the cooling circuit is closed by the control (control of the 24 V DC
output on pilot valve Type 6014), the activation of the expansion cylinder
is also switched off via its pilot valve Type 0450. The existing water
pressure is dispelled in the expansion cylinder.
The dimensions of the expansion cylinder are dependent
on the length and diameter of the cooling circuit hoses. The
standard design is preferentially used with the MasterJet on
the base of the robot.
When the cooling circuit is activated, cooling water passes through
the flow-rate sensor SE12 located in the return.
Depending on the flow rate, the flow-rate sensor SE12 sends impulses
to the display and evaluation unit (electronics module SE32).
Based on the incoming impulses, the evaluation unit calculates the
flow rate and compares this with the minimum and maximum values
specified by the user.
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Operation
Following a programmable fade-out time, during which the current high
flow values are ignored until they are stabilized, an output is set on
the PLC or robot control when the correct flow rate is achieved. This
output is only reset in the event of a malfunction.
10.4. Sensor programming
Flow-rate sensor SE12 is connected to the display and evaluation
unit (electronics module SE32) by means of a connection cable.
Fig. 10: Flow-rate sensor including connection cable and evaluation unit
(electronics module SE32)
The maximum length of the connection cable is 10 m.
10.4.1. Programming menu of the evaluation
unit (electronics module SE32)
The following parameters can be set in this menu:
• Quantity unit: Liter/second or liter/minute.
• K-factor for the flow-rate sensor: Number of impulses per liter:
• Output action (MODE): Specification of the lower and upper limit
of the limit switch and the switching delay time.
• Filter effect: Adjustable range from 0 to 9.
• Bar graph scaling: Specification of the lower and upper limit.
Accessing the programming menu:
When the operating voltage is applied, the evaluation unit (electronics
module SE32) is in the read level. Switch to the calibration level for
programming purposes.
Changing to the calibration level:
Press and hold both of the
buttons simultaneously for approx.
5 seconds.
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Operation
Function of the buttons in the calibration level:
Switches to the previous menu option
Enter values
Increase value
Press both of the buttons simultaneously to
move the decimal point.
Switches to the next
menu option
Change by one
position to the left
• Confirm menu
option
• Take over
settings
• Change to the
read level
Tab. 1: Function of the buttons in the calibration level
Menu structure:
Specify the measurement unit
UNIT
L/S
L/M
Set the K-factor for the flow-rate sensor
K-FAC
NO TEACH
144
Enter
value (144)
Set the output action (MODE)
OUT
MODE
Enter switching threshold
7500
OLO
Lower limit
Enter switching delay
00
Measurement unit in seconds
DEL
Set the filter
FILT
5
FILT
Scale the bar graph
BRGR
0.600
BGLO
Lower limit
8500
OHI
Upper limit
Setting value 0 to 9
12.00
BGHI
Upper limit
INV
Inversion
YES / NO
OUT
END
Fig. 11: Menu structure; programming SE32
Return to the read level
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Maintenance
Further information on operating and programming the display and
evaluation unit (electronics module SE32) is included in the operating
instructions.
11. MAINTENANCE
11.1. Safety instructions
DANGER!
Risk of injury from high pressure in the system!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Risk of injury due to electrical shock!
• Switch off the power supply and secure it against reactivation
before reaching into the device or equipment!
• Observe applicable accident prevention and safety regulations
for electrical equipment!
WARNING!
Risk of injury from improper maintenance!
• Maintenance may be carried out by authorized technicians only
and with the appropriate tools!
Risk of injury from unintentional activation of the system and
uncontrolled restart!
• Secure system from unintentional activation.
• Following maintenance, ensure a controlled restart.
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Spare Parts
12. SPARE PARTS
Order numbers for spare parts:
Position Part designation Order no.
1 Sensor SE12 558777
2 Fitting DN08 444571
3 Electronics module SE32 563940
4 Pilot valve 6014 153771
5
6 Expansion cylinder 211861
7 Pilot valve release Type 0450 904258
8 Drive WWA/DM50 246737
9 Drive WWA/DM63 246738
10 Max stroke limit 637866
11 M12 4-pole plug (not pictured) 448856
12 Complete pneumatic unit, right 904230
13 Diaphragm 677664
Tab. 4: Overview of spare parts
Cable for the sensor / electronics
module SE32
555676
1
12
2
8
4
6
9
7
5
3
10
13
Fig. 12: Overview of spare parts
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Repairs
13. REPAIRS
13.1. Replacing pilot valve Type 6014
DANGER!
Risk of injury from high pressure in the system!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Removing the pilot valve:
NOTE!
Malfunction caused by mixing up the plug-in hose
connections
• Before disconnecting the plug-in hoses identify the affiliation of
the hose and connection, to prevent the connections from being
mixed up when being reconnected.
Before replacing the pilot valve,
disconnect the pneumatic supply
as described below.
→ Push back the lock ring on the
plug-in connector and simultaneously pull the plug-in hose
from the plug-in connector.
Fig. 13: Replacing pilot valve
Type 6014
→ Loosen and remove all of the
other plug-in hose connectors
in the same way.
Fig. 14: Removing the plug-in
hoses
Once all of the plug-in hose connections have been removed:
→ Unscrew the plug pin for the electrical M12 control from the
valve coil.
Then remove the pilot valve Type 6014 as described below.
→ Loosen and remove the
through bolt using a suitable
flat or box wrench.
→ Remove the valve.
Fig. 15: Removing pilot valve
Type 6014
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Repairs
Installation of the new pilot valve:
→ Attach the valve.
→ Caution!
Replace the O-ring before pushing the through bolt through.
→ Insert the through bolt and tighten to a torque of 1 Nm using a
flat or box wrench.
The torque must be observed!
The valve housing may be damaged if the bolt is tightened
excessively.
→ Reestablish all of the plug-in hose connections. Ensure that the
hose and connector are assigned correctly.
→ Connect the plug pin for the electrical M12 control to the valve
coil.
13.2. Replacing pilot valve Type 0450
DANGER!
Risk of injury from high pressure in the system!
• Turn off the pressure and vent the lines before loosening lines
or valves.
Dismantling pilot valve Type 0450:
→ Loosen and remove both of
the fastening screws on the
fixing bracket using a flatblade screwdriver.
Fig. 16: Removing pilot valve
Type 0450
NOTE!
Malfunction caused by mixing up the plug-in hose
connections
• Before disconnecting the plug-in hoses identify the affiliation of
the hose and connection, to prevent the connections from being
mixed up when being reconnected.
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Repairs
→ Now remove all three of the
connected plug-in hoses.
Fig. 17: Loosening the plug-in
hoses on pilot valve
Type 0450
Installation of the new valve:
→ Reestablish all of the plug-in hose connections. Ensure that the
hose and connector are assigned correctly.
→ Disconnect the locking piece on the unused connection from the
removed pilot valve Type 0450 and connect it to the new valve.
→ Screw the valve to the fixing bracket using both of the fastening
screws.
13.3. Replacing flow-rate sensor SE12
Removing the flow-rate sensor:
→ Unscrew the M12 plug pin on
the top of the sensor housing.
Fig. 18: Unscrewing the M12
plug pin on the flow-rate
sensor
→ Loosen and remove the 4
fastening screws on the
sensor head using a suitable
hex-wrench.
→ Remove the sensor head.
Fig. 19: Removing the sensor
head
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