BURKERT 20120692 Type 8647 AirLINE SP is a modular electro-pneumatic automation system designed for direct backplane integration into the Siemens SIMATIC ET 200SP distributed peripheral architecture. Configured with a 24-valve bank capacity at an 11 mm station pitch, this assembly integrates 3/2-way and 5/2-way pilot solenoid valves to operate process valves, pneumatic cylinders, and single- or double-acting pneumatic actuators. The system includes an AirLINE Quick cabinet floor adaptation plate machined from stainless steel (VA), which routes pneumatic pressure supply, exhaust lines, and D6 working connections through the control cabinet base plate to eliminate external bulkheads.

Hardware revision REV.2 incorporates blue release rings on the push-in connectors, a wavy geometric channel arrangement on the working ports, and standardized pneumatic flange profiles (FM20) across single and double valve bodies. Pneumatic safety features include integrated check valves in exhaust ducts 3 (R) and 5 (S) to block back pressure accumulation during simultaneous exhaust, alongside an integrated pneumatic HotSwap shutoff mechanism in supply duct 1 (P). The HotSwap check valve isolates air pressure when a pilot valve is unbolted, permitting live valve servicing under full system operating pressure without process interruption.

System Architecture & Modular Design

Type 8647 combines Siemens electrical peripheral components with Bürkert fluid technology into a unified terminal rail assembly. The assembly consists of two primary module groups: supply connection units and working valve units.

• Connection Units (PSU): Positioned at the left (PSU-L, 44 mm width), center (PSU-M, 33 mm width), and right (PSU-R, 44 mm width) of the valve island. Connection units supply compressed air via G 1/4 ports, vent exhaust media through integrated silencers or threaded G 1/4 ducts, provide M5 auxiliary pilot air connections, and mechanically secure the terminal assembly to the mounting rail. Ident number 20120692 includes one PSU-M intermediate feed unit to prevent pressure drops across the 24 valve positions.
• Valve Units: Consist of an electronic base module (PQ module), a pneumatic base module, and plug-in pilot solenoid valves (Type 6524 or Type 6525). Electronic base modules are configured in 4-slot (PQ4) or 8-slot (PQ8/PQ16) segments, housing the driver electronics, backplane communication circuitry, LED indicators, and alphanumeric LC displays.
• Pneumatic Sub-bases: Accommodate valve modules, house integrated non-return check valves, contain the P-channel HotSwap check seats, and channel working air directly to the stainless steel push-in fittings.

Module Designation	Ident Number	Slot Count	Width [mm]	Compatible Valve Types	EVS Option
PSU-L	285088	—	44	Supply / Exhaust Left	No
PSU-M	285091	—	33	Intermediate Supply	No
PSU-R	285092	—	44	Exhaust / Terminating Right	No
PQ4VS4	284935	4	44	Type 6524 3/2-way / Type 6525 5/2-way	No
PQ8VS4	284936	4	44	Type 6524 2x3/2-way / Type 0460	No
PQ8VS8	283166	8	88	Type 6524 3/2-way / Type 6525 5/2-way	No
PQ16VS8	284806	8	88	Type 6524 2x3/2-way / Type 0460	No

Mechanical Installation & AirLINE Quick Cabinet Floor Adaptation

Burkert 20120692 utilizes the AirLINE Quick mounting method. Instead of mounting the standard DIN rail directly to the control cabinet back wall, the valve island secures to the cabinet floor via a stainless steel floor adapter plate. The adapter plate supports the entire assembly, including the standard rail and all attached Siemens ET 200SP modules.

Installation requires a rectangular cutout on the base plate of the control cabinet. The perimeter must be deburred before mounting to prevent cutting the elastomer sealing element.

1. Insert the flat seal free of twists or defects into the perimeter groove of the AirLINE Quick stainless steel base plate.
2. Position the valve terminal assembly from inside the cabinet over the prepared floor cutout.
3. Position the external stability counter-flange from the outside bottom of the cabinet enclosure.
4. Fasten the assembly using M5x10 screws tightened in sequence to a torque of 2.0 Nm.

Installation Limits with AirLINE Quick

When mounting via AirLINE Quick, the projection of the standard rail beyond the valve block must not exceed 10 cm on either side. Only short Siemens BaseUnits can be installed on the rail. Combination of AirLINE Quick with SIMATIC ET 200SP HA is not possible due to profile rail geometry.

If removing or remounting on a DIN rail, all fastening screws must be turned counter-clockwise completely before tilting the block upward. When mounted inside an enclosure, maintain a minimum clearance of 5 cm (8 cm if EVS terminals are wired) between the top of the valve island and adjacent components to permit dissipation of thermal exhaust and access to releases.

Pneumatic Connections & Integrated Safety Functions

The pneumatic interfaces on the 20120692 assembly are located on the connection blocks and beneath the pneumatic base sub-modules via the stainless steel floor plate.

Port Number	Marking	Function	Thread / Dimension	Recommended Torque [Nm]	Max Torque [Nm]
1	P / 1	Primary Compressed Air Supply	G 1/4	4 to 7	20
3 / 5	R/3, S/5	Exhaust Ducts (R and S)	G 1/4	4 to 7	20
2	X	Auxiliary Pilot Air (EXT) / Pilot Exhaust (INT)	M5	1.0 to 1.2	3
2, 4	Bottom	Actuator Working Lines	D6 push-in	1.75 to 2.25 (M7)	4

Port Connection Verification

Check and verify port assignments 1 (P) and 3/5 (R/S) before charging the line. Ports 1 and 3/5 must never be interchanged under any circumstances, as reverse pressurization will cause uncontrolled actuator movements and structural damage.

In standard 3/2-way single valve operation (Type 6524), working air discharges through lower port 2 (port 4 remains unused). In 5/2-way (Type 6525) or 2x3/2-way (Type 6524 double valve) configurations, upper port 2 and lower port 4 operate alternately as working outlets.

Exhaust Duct Check Valves

Exhaust channels 3 (R) and 5 (S) integrate spring-loaded check valves. In multi-valve manifolds, simultaneous venting of large actuators can generate brief pressure spikes in shared exhaust corridors. The integrated non-return valves isolate individual working paths, eliminating unwanted pilot flapper unseating and preventing unintended actuator displacement during safety stops.

Valve Maintenance & HotSwap Replacement

Ident number 20120692 features pneumatic HotSwap shutoff seats in port 1 (P). When a pilot valve is unbolted from the pneumatic sub-base, an internal valve seat automatically seals the supply air port for that specific station, retaining full system line pressure (up to 10 bar) across all remaining 23 valve slots.

HotSwap Servicing Rules

When unseating a valve under pressure, a brief burst of air escapes until the internal shutoff mechanism seals the differential opening. Operators must wear safety glasses. Do not loosen more than one valve simultaneously from the same pneumatic base module.

1. Secure connected process actuators against accidental motion before servicing.
2. Loosen the two diagonal fastening screws of the solenoid valve using an appropriate screwdriver.
3. Lift the defective valve vertically away from the sub-base, checking that the sub-base profile seal seat is clean.
4. Fit the replacement valve (ensuring REV.2 flange compatibility FM20) with new elastomeric profile seals.
5. Tighten both fastening screws alternately in diagonal pairs to ensure uniform compression of the profile seal.

Hardware Revision Compatibility

REV.1 and REV.2 single valves possess distinct flange profiles and channel arrangements. Replace REV.2 valves only with REV.2 spare valves. Mixing REV.1 single valves onto REV.2 pneumatic sub-bases will result in seal failure.

Electrical Connection & Siemens Automation Integration

Type 8647 connects directly to the backplane communication bus of the Siemens SIMATIC ET 200SP system. Electrical contacts for digital control, module supply, and bus logic engage automatically when the valve terminal is snapped into place against the left-hand Siemens BaseUnit.

• BaseUnit Power Separation: A light-colored Siemens BaseUnit (BU...D or BU...D/T) must be positioned directly to the left of the valve terminal connection unit PSU-L. This splits the load voltage group, ensuring dedicated 24 V DC supply lines (L+ and M) to the pneumatic pilot solenoids.
• Voltage Tolerance: Permissible load voltage tolerance is 24 V DC ±10% (21.6 V DC to 26.4 V DC). If voltage drops below 21.6 V DC, the left-hand PSU-L "PWR OK" LED turns off and the PQ modules issue a "No supply voltage L+" diagnostic interrupt.
• Fail-Safe Operation (Siemens F-PM-E): Type 8647 modules marked "FC" support installation within the potential group of a Siemens F-PM-E 24VDC/8A PPM ST fail-safe power module. When using F-PM-E, set the maximum readback time for dark test and switch-off test between 1.5 ms and 2.5 ms, and the switch-on test readback time to 0.8 ms.

Engineering, Configuration & Diagnostic Functions

Configuration is executed through Siemens TIA Portal (V13 or higher), SIMATIC STEP 7 (V5.5 SP4 or higher), or SIMATIC PCS 7 (V9.0 SP2 or higher). Configuration files are supplied as GSDML (PROFINET), GSD (PROFIBUS DP), HSP (Hardware Support Package HSP0225 / HSP2105), or HUP (Hardware Update Package for PCS 7).

Diagnostic & Status Display

Each valve module provides local optical feedback:

• PWR LED (Green): Illuminated when load voltage is within the valid 24 V DC operating window.
• DIAG LED: Displays module status (Green = operational, Flashing Green = unparameterized, Flashing Red = pending diagnostic condition).
• LC Graphic Display: 8-slot modules feature dual multi-character liquid crystal displays. Displays indicate individual channel actuation status, actuator position feedback (upper A / lower B), active PROFIenergy pauses, and diagnostic alarms (wire break, short circuit, switching limit reached).

Switching Cycle Counters

Each electronic base module records switching cycles independently for the pilot valve and the connected field actuator across every channel. Counter warning limits are parameterized via GSDML/HSP or written via SIMATIC STEP 7 runtime data blocks (WRREC/RDREC via data records DS 130 to DS 135). Counters are retained in non-volatile memory.

Diagnostic Code Hex (Dec)	Alarm Text	Underlying Cause	Corrective Action
0x09 (9)	Error	General internal hardware fault	Check mechanical seating; replace module
0x10 (16)	Parameterization error	Invalid configuration parameters	Check TIA Portal module slot mapping
0x11 (17)	No supply voltage	Supply voltage L+ below 21.6 V DC	Verify incoming 24 V DC power bus
0x1F (31)	Component unavailable	Firmware update executing	Await completion of update download
0x02F0 (752)	Pilot valve SCC limit	Pilot valve cycle threshold reached	Replace pilot valve; reset DS 132 bit
0x02F1 (753)	Actuator SCC limit	Field process valve cycle limit reached	Service field actuator; reset counter
0x02F3 (755)	Pilot valve: Wire break	Open circuit or unseated coil terminal	Check coil connection or seat cover
0x02F4 (756)	Pilot valve: Short circuit	Coil short circuit or terminal bridge	Clear short circuit; resettable fuse resets

Technical Specifications & Operating Limits

Technical Parameter	Specification / Limit
Operating Control Medium	Dry compressed air (oiled or unoiled), neutral inert gases
Compressed Air Quality	ISO 8573-1:2010 Class 7.4.4 (max. particle size 5 µm)
Operating Pressure Range	2.5 bar to 10 bar (without auxiliary pilot air)
Flow Rate (QnN value)	300 l/min (reduced by approx. 20% on REV.2 HotSwap sub-bases)
Medium Temperature	0 °C to +50 °C
Operating Ambient Temperature	0 °C to +55 °C
Relative Humidity	75% average, 85% maximum (non-condensing)
Atmospheric Pressure / Altitude	80 kPa to 106 kPa (maximum 2000 m above sea level)
Housing Materials	Polyamide (PA), Polycarbonate (PC); Valve body: PA / PPS / Aluminum
Sealing Material	Nitrile butadiene rubber (NBR)
Electrical Protection Class	Class 3 (DIN EN 61140 / VDE 0140); FE functional ground required
Cabinet Base Ingress Rating	IP20 base unit (IP65 in closed cabinet; UL Type 4X via AirLINE Quick)
Individual Valve Power Consumption	0.8 W per pilot solenoid (24 V DC)