BURKERT 20135258 is an AirLINE SP Type 8647 modular electropneumatic automation system configured as a 24-bank valve island with an 11 mm station pitch. The island integrates 24 individual 3/2-way servo-controlled pilot solenoid valves in Circuit Function C (normally closed) on pneumatic base modules. Developed specifically for direct mechanical and electrical integration into the Siemens SIMATIC ET 200SP and SIMATIC ET 200SP HA distributed I/O systems, the assembly links pneumatic actuators directly to process controllers via PROFINET IO or PROFIBUS DP.

Each valve position features integrated pneumatic HotSwap functionality at port 1 (P), allowing valves to be serviced or exchanged under continuous system operating pressure. The exhaust ports 3 (R) and 5 (S) are equipped with integrated check valves (RSV) to suppress transient backpressures in shared exhaust headers. Due to the air volume requirements across 24 active valve functions, this assembly includes one factory-configured intermediate supply feed unit (PSU-M) positioned within the valve train.

System Integration and Architecture

Type 8647 AirLINE SP combines Siemens distributed peripheral components and pneumatic control into a unified terminal mounted on a common standard rail. Communication and DC load power interface through the backplane bus system of SIMATIC ET 200SP / ET 200SP HA without external discrete wiring harness runs between the controller outputs and solenoid coils.

Configuration tools operate identically to native Siemens I/O:

• TIA Portal: Integration via Hardware Support Package (HSP0225) or standard PROFINET GSDML files located under Pneumatics (Burkert).
• STEP 7 Classic: Configured through HSP2105 (v5.5 SP4 or higher) or PROFIBUS GSD files.
• SIMATIC PCS 7: Engineering integration achieved through Hardware Update Package (HUP) starting from version 9.0 SP2, supporting plant asset management diagnostics.
• Commissioning Tools: Compatible with Siemens PRONETA (version 2.5 or higher) and SIMATIC Automation Tool (version 3.1 SP2 or higher) for fast topology scanning and loop checking.

Load Voltage Planning

The permissible load voltage tolerance for pilot valves is 24 V DC ±10%, which is narrower than standard digital I/O defined by IEC 61131-2. To prevent voltage drops across large configurations, place a light-colored Siemens BaseUnit (BU...D or BU...D/T) immediately to the left of the valve block to provide dedicated power rail feeding.

Revision 2 Features and Valve Configuration

Article 20135258 is built according to Bürkert Revision 2 (REV.2) specifications. REV.2 introduces unified pneumatic interfaces across all 11 mm station platforms, optimizing channel geometries and flow dynamics.

Technical Distinguishing Feature	Revision 1 (REV.1)	Revision 2 (REV.2 - 20135258)
Release Ring Color on Push-In Ports	Black	Blue
Working Port Channel Arrangement	Parallel	Wavy (optimized air paths)
Flow Reduction with Integrated P Shut-Off	Up to 50%	Approximately 20%
Pilot Valve Flange Profile	FM14 (Single 3/2 and 5/2) / FM20 (Double)	Standardized FM20 across all 6524/6525 valves
Type Label Revision Marking	Without "Rev." text	Marked with "Rev.2"

The pilot valves utilized on this island are Type 6524 Circuit Function C, combining a Type 6144 flipper solenoid armature with an elastomer-sealed poppet valve seat. Each pilot valve includes a manual override as standard, allowing manual activation during commissioning.

Technical Specifications

Operational Parameter	Specified Value
Article Number (Ident Number)	20135258
System Type	8647 AirLINE SP
Generation / Revision	Revision 2 (REV.2)
Number of Valve Stations	24 stations (24 single valve functions)
Valve Circuit Function	Circuit Function C (3/2-way, normally closed)
Width per Station	11 mm
Medium	Lubricated or oil-free dry compressed air, neutral gases
Compressed Air Quality	ISO 8573-1:2010, Class 7.4.4 (5 µm filtration recommended)
Operating Pressure Range	2.5 bar to 10.0 bar (relative pressure)
Flow Rate (QNn value air)	300 l/min (at +20 °C, 6 bar inlet, 1 bar pressure differential)
Effective Flow with P Shut-Off	Approx. 240 l/min (20% flow reduction)
Valve Body Material	Polyamide (PA)
Base Module / Enclosure Materials	Polyamide (PA), Polycarbonate (PC)
Seal Materials	NBR, FKM, and PUR
Supply Connections 1 (P), 3 (R), 5 (S)	G 1/4 female thread
Working Ports 2 (A)	D6 mm push-in coupling (bottom-facing orientation)
Auxiliary Pilot Air Port (X)	M5 female thread
Operating Voltage	24 V DC (±10%, max. residual ripple 2.4 Vss)
Nominal Power per Coil	0.8 W
Current per Valve	40 mA nominal (28 mA holding current after 120 ms)
Duty Cycle	100% ED (continuous operation)
Switching Times (ISO 12238)	Opening: 15 ms, Closing: 28 ms
Ambient Operating Temperature	0 °C to +55 °C
Medium Temperature Range	0 °C to +50 °C
Storage Temperature	-20 °C to +60 °C
Permissible Ambient Humidity	75% average, 85% occasional (non-condensing)
Total System Width Limit	Max. 858 mm for standalone valve block
Total System Weight	Up to 10 kg depending on installed base units
Degree of Protection	IP20 (IP65 in closed industrial control cabinet)
Protection Class	Class 3 (DIN EN 61140 / VDE 0140) with FE ground rail

Pneumatic Connections and Port Assignment

The valve block is supplied and deaerated through lateral connection units (PSU-L on the left, PSU-R on the right) and an intermediate supply module (PSU-M). The intermediate supply module is mandatory in this assembly because total air throughput exceeds single-port limits past 24 valve functions.

• Port 1 (P): Main pressure supply (G 1/4). Delivers filtered air to the common gallery.
• Ports 3 (R) and 5 (S): Common deaeration ports (G 1/4). Integrated check valves prevent exhaust pulses from entering adjacent non-actuated lines.
• Port X: Auxiliary pilot air control and exhaust (M5 thread).

For 3/2-way single valves (Type 6524 Circuit Function C), port connections are arranged as follows:

• Upper connection (Position 1): Not used / closed.
• Lower connection (Position 2): Working port 2 (A), fitted with D6 mm push-in couplings directed downwards through the bottom pneumatic module plate.

Exhaust Air Silencing and Sizing

Ensure unrestricted exhaust venting on ports 3 (R) and 5 (S) by installing appropriately sized silencers or piping exhaust out of the cabinet. Inadequate exhaust venting generates backpressures that can cause unintended actuator movement or delayed valve shut-off.

Pneumatic Push-In Tubing Handling (ISO 14743:2020)

To ensure positive sealing on D6 mm push-in connections:

• Use calibrated polyamide (PA) tubing (external diameter tolerance ±0.08 mm) or polyurethane (PU) tubing (tolerance ±0.1 mm).
• Cut tubing strictly square. Beveled cuts degrade collet gripping force and compromise O-ring seating.
• Minimum tensile retention force for D6 tubing is 120 N for PA and 100 N for PU. When using flexible PU tubing in demanding applications, insert internal brass support sleeves (ID 20099400).

Electrical Integration and Safety Shutdown

Article 20135258 receives power and control logic through the electronic base modules (PQ modules). Each 4-slot or 8-slot PQ module features an LC display and front status LEDs (PWR green, DIAG red/green).

• Switching Cycle Counter: Each channel maintains two separate non-volatile counters—one for the internal pilot valve and one for the external actuator. Warning thresholds can be parameterized in TIA Portal or STEP 7 to trigger preventive maintenance warnings on the display and fieldbus master.
• Visual Diagnostics: Graphic LC displays provide channel switching states, text alerts for wire break, short circuit, or missing load voltage.

Safety Shut-Off Architecture

Electrical de-energization causes Type 6524 valves to return instantly to their normally closed rest position:

1. External Valve Shutdown (EVS): Electronic base modules with EVS terminals permit group shutdown via an external potential-free dry contact (max. line length 2 m inside the same cabinet). Never connect external voltage or link multiple EVS contacts together.
2. Siemens F-PM-E Power Module: For safety-assessed emergency stop applications according to DIN EN ISO 13849-1, operate the valve island in the potential group of a Siemens F-PM-E 24VDC/8A PPM ST fail-safe power module. All installed modules must bear the "FC" marking. Set the F-PM-E dark test readback time between 1.5 ms and 2.5 ms, and the switch-on test readback time to 0.8 ms to prevent unwanted valve cut-off during cyclic testing.

Installation and Cabinet Assembly

Type 8647 is supplied fully assembled and tested. Mount the terminal onto a rigid DIN standard rail (TH 35-7.5 or TH 35-15) inside an IP54 or higher industrial enclosure.

Installation Rules:

1. Overhead Clearance: Maintain a minimum clearance of 5 cm between the top edge of the valve block and the control cabinet ceiling or cable tray (8 cm minimum if EVS screw terminals are utilized) to facilitate module disassembly and prevent thermal build-up.
2. Rail Fastening: Tighten all terminal clamping screws clockwise to approximately 1.8 Nm.
3. Interface Engagement: Slide the adjacent Siemens SIMATIC ET 200SP BaseUnits along the DIN rail toward the valve island until the locking mechanism clicks firmly into place.
4. Connection Tightening Torques:
   • G 1/4 pneumatic ports (P, R, S): 4.0 Nm to 7.0 Nm (maximum permitted 20.0 Nm).
   • M5 auxiliary port (X): 1.0 Nm to 1.2 Nm (maximum permitted 3.0 Nm).
   • Valve retaining screws (M2): Tighten in diagonal pairs to 0.25 Nm.

Maintenance, Replacement Valves, and Accessories

Thanks to pneumatic HotSwap shut-off seals in the 1 (P) gallery, individual valves can be replaced while the system is pressurized without interrupting operation of adjacent valves. When loosening valve retaining screws under pressure, an initial blast of air occurs until the differential shut-off element seals the base port.

Replacement Compatibility

REV.1 and REV.2 single valves are mechanically and fluidically incompatible. Always verify the flange profile before installation. Article 20135258 requires REV.2 replacement valves with FM20 flange patterns.

Supported Replacement Parts for REV.2 Valve Train:

• Replacement Pilot Valve (REV.2, 3/2-way NC, 2.5-10 bar, 24 V DC): Article no. 20029918
• Blanking Cover Plate (covers unused REV.2 valve slot): Article no. 661092
• Electrical Connection Cover (protects unused PCB socket): Article no. 653670
• Valve Profile Seal Kit (FM24/FM20 for Type 6524 3/2-way REV.2, 12 pcs): Article no. 20024336
• Intermediate Base Module Seal Kit (Type MP16, 4 pcs): Article no. 20024339
• D6 mm Push-in Fitting Replacement (Brass, 8 pcs): Article no. 20024340
• D6 mm Push-in Fitting Replacement (Stainless Steel VA, 8 pcs): Article no. 20024341