BURKERT 20099403 is an 8-bank pneumatic valve island belonging to the Type 8647 AirLINE SP electropneumatic automation system family, built for direct integration into Siemens SIMATIC ET 200SP and ET 200SP HA distributed I/O systems. Operating on an 11 mm width per station grid, this Revision 2 (REV.2) assembly features a mixed valve population with 3/2-way pilot functionality, G 1/4 primary supply ports, and bottom-oriented push-in D6 working ports. The unit incorporates integrated check valves in exhaust ducts 3 (R) and 5 (S), as well as pneumatic HotSwap non-return functionality in channel 1 (P).

Engineered for process plant automation, the assembly mechanically and electrically docks to standard DIN mounting rails directly adjacent to Siemens ET 200SP electronic base units. Pilot solenoid valves control actuators, hygienic process valves, and pneumatic cylinders while feeding visual feedback into dedicated graphic LC displays and backplane fieldbus registers. The assembly carries ATEX and IECEx Zone 2 approvals for industrial hazardous atmosphere deployment.

System Overview and Siemens Integration

Type 8647 AirLINE SP merges electrical signal processing and pneumatic actuation into a single rack format. The valve island consists of lateral connection units (PSU), electronic base modules (PQ), pneumatic base modules, and plug-in pilot solenoid valves. Power and communication lines link through the Siemens ET 200SP backplane bus without external inter-module wiring.

Key integration properties include:

• Seamless connection to Siemens SIMATIC ET 200SP and ET 200SP HA backplane bus systems.
• Full configuration via Siemens TIA Portal (HSP), SIMATIC STEP 7 (HSP2105), and PCS 7 (HUP).
• Fieldbus communication options via PROFINET IO (GSDML) and PROFIBUS DP (GSD).
• Support for channel-level diagnostics, switching cycle counter registers, and PROFIenergy commands.
• Integrated graphic LC display on electronic modules indicating switching status, wire break, short circuit, and position feedback.

Revision 2 (REV.2) Features and Distinctions

Article 20099403 is manufactured to the Revision 2 (REV.2) hardware architecture. REV.2 introduces structural pneumatic optimizations that differentiate it from early REV.1 models:

Distinguishing Feature	Revision 1 (REV.1)	Revision 2 (REV.2) — Model 20099403
Release ring colour on push-in connectors	Black	Blue
Working connection channel arrangement	Parallel alignment	Wavy offset alignment
Pilot valve pneumatic flange pattern	Separate FM14 (single) and FM20 (double)	Unified FM20 interface across single and double valves
Flow restriction with integrated P-shutoff (HotSwap)	Reduction up to 50%	Reduction approx. 20%
Type label identification	Without "Rev." marking	Explicitly marked "Rev.2"

Flange Interface Compatibility Restriction

Single valves from REV.1 (FM14 flange pattern) and REV.2 (FM20 flange pattern) are mechanically non-interchangeable. When replacing pilot valves on 20099403, only REV.2 certified valves with FM20 pattern or double valves may be fitted.

Modular Structure: Connection and Valve Units

Type 8647 consists of functional blocks assembled side-by-side along the DIN rail:

1. Left Connection Unit (PSU-L): Provides the left pneumatic supply inputs, main exhaust deaeration ports, and contacts for the ET 200SP power bus. Contains a "PWR OK" diagnostic LED.
2. Electronic Base Module (PQ Module): Houses electrical terminal interfaces, switching transistors, diagnostic monitoring circuitry, and status LC displays for 4 or 8 stations.
3. Pneumatic Base Module: Distributes pressure supply 1 (P) and exhaust pathways 3/5 (R/S) to the individual sub-base valve seats, housing push-in output ports 2 (A) and 4 (B).
4. Pilot Solenoid Valves: Rocker/flipper pilot valves (Type 6524/6525) fitted with manual overrides.
5. Right Connection Unit (PSU-R): Terminates the pneumatic and structural assembly.

Technical Specifications

Parameter	Technical Specification
Grid spacing (Width per station)	11 mm
Total valve stations	8 valve slots
Valve functions supported	Mixed (Type 6524 3/2-way, 2×3/2-way, Type 6525 5/2-way, Type 0460 5/2 & 5/3)
Operating pressure range	2.5 to 10.0 bar (Vac. to 8 bar under UL, external pilot >2.5 bar)
Flow rate QNn (Air)	200 to 300 l/min (at 6 bar inlet, 1 bar differential pressure)
Operating voltage	24 V DC (±10%, SELV/PELV, max. 2.4 Vss ripple)
Power consumption per valve	0.8 W (single), 2 × 0.8 W (double valve with power reduction)
Nominal current per valve	40 mA pick-up (holding current drops to 28 mA after 120 ms)
Compressed air quality	ISO 8573-1:2010 Class 7.4.4 (filtered to 5 µm, dry, lubricated or non-lubricated)
Housing material	Polyamide (PA) and Polycarbonate (PC)
Seal material	NBR (Perbunan), FKM, and PUR
Enclosure class	IP20 (IP65 in closed control cabinet according to EN 60529)
Ambient operating temperature	0 °C to +55 °C (0 °C to +50 °C if Type 0460 valves are fitted)
Medium operating temperature	0 °C to +50 °C
Storage temperature	-20 °C to +60 °C
Relative humidity	75% annual average, 85% occasionally, non-condensing

Pneumatic Port Connections and Tightening Torques

Primary air supply and ventilation lines enter through the connection units, while individual working ports connect underneath the pneumatic base modules.

Connection Unit Port Allocations

• Port 1 (P): G 1/4 primary pressure supply.
• Port 3/5 (R/S): G 1/4 exhaust deaeration ports.
• Port X: M5 auxiliary control air (EXT) or pilot control exhaust (INT).

Valve Working Ports (Pneumatic Module Bottom)

• Port 2 (A) & Port 4 (B): Push-in coupling D6 (for 6 mm outside diameter tubing).
• When 3/2-way valves (Type 6524) are installed, upper ports remain unused while lower ports deliver working air.

Tightening Torques

Connection / Fastener	Thread Size	Recommended Torque	Maximum Permissible Torque
Supply & exhaust connections (P, R/S)	G 1/4	4.0 to 7.0 Nm	20.0 Nm
Auxiliary pilot connection (X)	M5	1.0 to 1.2 Nm	3.0 Nm
Push-in fittings AirLINE Quick	M7	1.75 to 2.25 Nm	4.0 Nm
Valve mounting screws (Type 6524/6525)	M2	0.25 to 0.30 Nm	0.35 Nm
Valve block rail locking screws	M4	approx. 1.8 Nm	2.0 Nm

Avoid Port Inversion

Ports 1 (P) and 3/5 (R/S) must never be interchanged. Connecting supply pressure to exhaust channels will damage pilot seats and cause uncontrolled valve movements.

Application Planning with ET 200SP and ET 200SP HA

When planning control cabinets with Bürkert Type 8647 and Siemens distributed I/O, distinct architectural guidelines apply:

Planning Parameter	In Combination with ET 200SP	In Combination with ET 200SP HA
Hardware mounting rail	Standard rail TH 35 (EN 60715)	Siemens ET 200SP HA profile rail
Upstream power BaseUnit	Light-colored BaseUnit (BU...D) recommended	Light-colored BaseUnit (BU...D) mandatory
Extension to the right of valve block	Permissible (requires new BU...D feed)	Not permissible (server module must terminate)
Multiple valve blocks in one station	Yes (with additional power infeed)	No (maximum 1 valve block per station)
Total module limit on station	Up to 64 modules / connection blocks	Up to 56 modules / connection blocks
Integration software	STEP 7 Classic, TIA Portal, PCS 7	PCS 7 (V9.0 SP2+ with HUP)

Separate Load Power Supply

Due to the ±10% voltage tolerance requirement of solenoid pilot coils, install a light-colored Siemens BaseUnit (BU...D or BU...D/T) immediately to the left of Type 8647 to create an independent potential group isolated from noisy peripheral loads.

Safety Functions: EVS, F-PM-E and HotSwap

Type 8647 accommodates several safety-related shut-off architectures:

1. External Valve Shutdown (EVS): Electronic base modules designated EVS include an isolated 2-pole plug-in terminal on the top surface. Opening this dry contact interrupts coil supply voltage to all valves on that module within 20 ms. Display and diagnostic communication remain active via the backplane bus.
2. Siemens F-PM-E Power Module Integration: Valve blocks containing FC-marked modules can be positioned in the power domain of a Siemens fail-safe power module (F-PM-E 24VDC/8A PPM ST). The module executes dark tests (recommended readback time 1.5 to 2.5 ms) and switch-off routines to shut down valve outputs according to DIN EN ISO 13849-1.
3. Pneumatic HotSwap in Port 1 (P): The pneumatic base module of 20099403 incorporates shut-off check valves under each seat. When a pilot valve is unscrewed during live operation, the P-channel closes automatically, enabling valve replacement without venting the whole valve block.
4. Integrated Exhaust Check Valves in 3 (R) and 5 (S): Backpressure check valves (RSV) prevent pressure surges in common exhaust ducts from inadvertently shifting unactuated single-acting cylinders.

Safety Notice for HotSwap Operations

When removing a valve from a live HotSwap base module, residual compressed air exhausts briefly, depressurizing working line 2 (A) or 4 (B). Connected process actuators will move to their unpressurized rest positions. Secure actuators against motion and wear protective safety glasses before loosening valve retaining screws.

Replacement Valves and Accessories

Only genuine Bürkert REV.2 spare valves and accessories should be fitted to article 20099403:

Article No.	Designation	Description / Function
20029918	Type 6524 3/2-way NC	REV.2 single valve, FM20 flange, 2.5–10 bar, 24 V DC, manual override
20029919	Type 6524 3/2-way NO	REV.2 single valve, FM20 flange, 2.5–10 bar, 24 V DC, manual override
20029920	Type 6525 5/2-way	REV.2 single valve, FM20 flange, 2.5–10 bar, 24 V DC, manual override
204710	Type 6524 2×3/2-way NC	Double valve, FM20 flange, 2.5–10 bar, 24 V DC, manual override
300817	Type 6524 2×3/2-way NC	Double valve with auxiliary pilot air, 1–10 bar, 24 V DC
661092	Cover plate REV.2	Covers unpopulated valve slots on 6524/6525 REV.2 pneumatic modules
653670	Electrical cover	Covers unused electrical sockets on PQ electronic modules
20024336	Valve seal set FM24	Pack of 12 spare flange seals for Type 6524 3/2-way REV.2 valves
20016305	Valve seal set FM20	Pack of 12 spare flange seals for Type 6524 2×3/2-way and 6525 REV.2 valves

Installation Guidelines and Clearances

Mount the valve island horizontally or vertically inside a suitable control cabinet rated at least IP54.

• Upper Clearance: Maintain a minimum distance of ≥5 cm between the upper edge of the valve block and cabinet trunking or walls to allow tool access and heat dissipation. If EVS modules are installed, maintain ≥8 cm for terminal access.
• Rail Attachment: Position the valve block on the standard TH 35 rail with screws loosened fully counter-clockwise, swing into place, and tighten clockwise to approx. 1.8 Nm.
• Push-in Tubing Insertion: Cut polyurethane (PU) or polyamide (PA) pneumatic hoses squarely. Fully push the D6 tubing past the internal stainless steel gripping claws to ensure leak-free sealing in compliance with ISO 14743.