BURKERT 20025930 (Type 8652 AirLINE) is a 16-station modular valve island engineered for process automation environments. Configured as a high-density pneumatic automation node, this assembly integrates 16 valve slots accommodating 32 total valve pilot functions, 32 digital inputs across four 8DI electronic modules, and an integrated central pneumatic intermediate feed module. Fieldbus connectivity is established through a dedicated ME43 PROFIBUS DPV1 communication interface with a 9-pin Sub-D socket, providing cyclic process command exchange as well as clear-text and symbolic diagnostic alarms readable directly via an on-board LC display or transmitting to the higher-level PLC.

Process safety and system availability are central to the 20025930 configuration. The first 13 valve slots are populated with Type 6534 dual 3/2-way normally closed valves (CF-C) with manual override, while positions 14 through 16 are equipped with Type 6534 SIA variants designed for safety-related hardware shutdown via external potential-free contacts. Integrated check valves in exhaust air ducts 3 (R) and 5 (S) prevent back-pressure surges from causing unintended process valve movements. In addition, pneumatic HotSwap capability in supply channel 1 (P) permits valve replacement under full line pressure without interrupting adjacent operating loops.

Factory Configuration (Article 20025930)

Configuration Parameter	Factory Setting / Specified Hardware
Base Type	Type 8652 AirLINE Standard
Article Number (MPN)	20025930
Number of Valve Slots	16 valve slots (accommodating 32 discrete valve functions)
Valve Positions 1 to 13	2x 3/2-way CF-C (normally closed, servo-controlled, with manual override)
Valve Positions 14 to 16	2x 3/2-way CF-C SIA (normally closed, safety-related shut-off)
Digital Inputs	32 DI (El. module 1, 2, 3, and 4 equipped with DI)
Fieldbus Communication	PROFIBUS DPV1 (ME43 architecture, Sub-D 9-pin interface)
AirLINE Quick Adapter Plate	Anodised aluminium (for control cabinet base or wall mounting)
Supply Connection 1 (P)	Push-in D10 mm (nickel-plated brass)
Working Ports 2 & 4	Push-in D6 mm (nickel-plated brass)
Auxiliary Pilot Air	Internal supply (3 to 10 bar)
Pneumatic Intermediate Feed	1 unit integrated (intermediate supply/exhaust module)
Exhaust Check Valves	Integrated in exhaust channels 3 (R) and 5 (S)
Pneumatic HotSwap	Integrated in supply port 1 (P)

Technical Specifications

Specification Parameter	Value / Technical Requirement
Operating Medium	Oil-free or lubricated compressed dry air, neutral gases (5 μm filtration recommended)
Compressed Air Quality	ISO 8573-1:2010, Class 7.4.4
Operating Pressure Range	Vacuum to 10 bar (-1.0 to 10.0 bar) overpressure to atmospheric
Auxiliary Pilot Pressure	3 to 10 bar
Standard Flow Rate $Q_{\text{Nn}}$ (Air)	310 l/min (measured at +20 °C, 6 bar inlet pressure, 1 bar pressure drop)
Flow Rate with HotSwap Function	Approx. 3% flow reduction ($Q_{\text{Nn}} \approx 300\text{ l/min}$)
Switching Times (ISO 12238)	Opening: 15 to 20 ms; Closing: 15 to 25 ms (varies by circuit function)
Nominal Operating Mode	Continuous operation (100% duty cycle)
Station Width	11 mm per valve slice
Body / Seal Materials	Polyamide (PA) housing; NBR and PUR seals
Operating Voltage	24 V DC (±10%, residual ripple 1 Vss)
Nominal Power per Valve	0.7 W (drops to 0.175 W after electronic power reduction)
Nominal Current per Valve	29 mA (drops to 10 mA after electronic power reduction)
Degree of Protection	IP20 bare mounting; IP65 inside closed cabinet with AirLINE Quick
Ambient / Medium Temperature	-10 °C to +55 °C
Storage Temperature	-20 °C to +60 °C
Electrical Protection Class	Class III according to DIN EN 61140, VDE 0140

AirLINE Quick Adapter Interface

Direct cabinet integration is achieved through the AirLINE Quick adapter plate, eliminating the need for bulkheads and intermediate cabinet fittings by mounting the valve island directly onto the control cabinet floor or wall cutout.

Property	AirLINE Quick Specification
Adapter Plate Material	Anodised aluminium (optional stainless steel 1.4301 available)
Pneumatic Port Material	Nickel-plated brass (push-in)
Supply / Exhaust Ports	Push-in coupling D10 mm (or 3/8")
Working Outlets	Push-in coupling D6 mm (or 1/4")
Mounting Position	Control cabinet floor or control cabinet wall
Ingress Protection	IP65 achieved within enclosed control cabinets

Modular Assembly Architecture

The 8652 architecture combines pneumatic base modules, electrical backplane slices, electronic I/O modules, and the main fieldbus gateway into a unified rail-mountable structure.

Pneumatic Circuit Functions

The Type 6534 pilot valves mounted on the island provide high-speed servo-assisted switching:

• Circuit Function C (CF C): Dual 3/2-way servo-controlled solenoid valve, normally closed in de-energised state. Standard versions feature mechanical manual overrides.
• Circuit Function C SIA (CF C SIA): Dual 3/2-way servo-controlled solenoid valve, normally closed, configured without manual override for safety-instrumented shutdown circuits.
• Alternative 6534 Functions: Type 8652 also supports CF D (dual 3/2-way NO), CF H (5/2-way monostable), CF Z (5/2-way bistable/impulse), CF L (5/3-way closed center), CF M (5/3-way pressurized center), and CF N (5/3-way exhausted center).

Safety-Related Shut-Off (SIA) Implementation

Valve positions 14, 15, and 16 on article 20025930 are fitted with Type 6534 SIA valves. These valves feature dedicated, physically separate connection terminals allowing external hardware interlocks to cut valve coil power independently of the bus master communications.

Feature	SIA Technical Specification
Valve SIA Terminal Type	Pluggable, coded 2-pin screw terminals ($0.14\text{ to }1.5\text{ mm}^2$, AWG 28–16)
Module Shutdown Terminal	Pluggable spring-loaded terminal strip, 12-pin ($0.14\text{ to }1.5\text{ mm}^2$, AWG 26–16)
Switching Capacity	0.5 A / 24 V DC (individual valve); 1.5 A / 24 V DC (module shutdown)
Factory Delivery State	Bridged with factory jumper clips for direct commissioning without SIA
Control Contact Requirement	External potential-free dry contact (safety relay or mechanical switch)

Safety Terminal Preparation

Before wiring an external safety shut-off contact to the SIA terminals, the yellow coded jumper clips pre-installed at delivery must be removed. Connecting voltage to these potential-free inputs will damage the shutdown circuitry.

Electrical and Fieldbus Connections

Communication and Display Power Supply (5-Pin Spring Terminal)

Terminal	Wire Color	Assignment
1	Red	+24 V DC (electronics power)
2	White	CAN_H (internal büS connection)
3	Green	Shielding (PE)
4	Blue	CAN_L (internal büS connection)
5	Black	0 V DC (GND)

Pneumatic Valve Power Supply (2-Pin Spring Terminal)

Pin	Wire Color	Assignment
1	Red	AUX +24 V DC (pneumatic coil load power)
2	Black	0 V DC (GND)

Isolated Power Supplies

The pneumatic valves must be supplied via their own dedicated 2-pin AUX 24 V power connection on the interface plate. This keeps solenoid coil load noise isolated from the sensitive display and PROFIBUS digital communications.

PROFIBUS DPV1 Sub-D 9-Pin Interface

Sub-D Pin	Signal Name	Description
1	SHIELDING	Cable shielding connection
2	M24	Optional 24 V ground return
3	RxD / TxD-P	B-line (receive/transmit data positive)
4	CNTR-P	Control signal P (repeater direction control, optional)
5	DGND	Data ground (0 V reference for terminating resistors)
6	+5 V	+5 V DC power for active bus terminating resistors
7	+24 V	Optional +24 V DC feed
8	RxD / TxD-N	A-line (receive/transmit data negative)
9	CNTR-N	Control signal N (optional)

8DI Digital Input Electronic Modules

Article 20025930 includes four 8DI electronic modules, providing 32 total digital sensor inputs across the 16 valve stations (2 inputs per valve position). Current consumption is limited to 30 mA per digital input channel.

Parameter	Digital Input Module Specification
Supported Sensors	Standard 3-wire PNP sensors, 2-wire sensors (10 to 30 V), mechanical limit switches
Switching Thresholds	$V_{\text{OFF}} = 0\text{ to }5\text{ V DC}$; $V_{\text{ON}} = 10\text{ to }30\text{ V DC}$
Input Current at $V_{\text{ON}}$	Maximum 5.7 mA per channel (typical at 24 V DC)
Input Impedance	$>4\text{ k}\Omega$
Galvanic Isolation	None (all channels share a common 0 V reference potential)
Conductor Cross-Section	Pluggable screw terminals, $\le 1.5\text{ mm}^2$ (AWG 28–16)
Maximum Cable Length	$<30\text{ m}$
Sensor Diagnostics	Wire-break detection on 2-wire sensors; short-circuit detection on 3-wire sensors

Dimensional Data

Dimensions are stated in millimetres (mm) for the 16-fold variant with integrated central intermediate air supply module.

Dimension Variable	16-Fold with Intermediate Feed	16-Fold without Intermediate Feed
Dimension A	112 mm	99 mm
Dimension B	224 mm	198 mm
Mounting Pattern C	10 × M5	10 × M5
Dimension D	114.3 mm	—
Increment m	7	15
Increment $m'$	7	—
Segment Number n	4	4

Control Cabinet Installation and HotSwap Servicing

When positioning the valve island on the control cabinet baseplate or cutout, observe minimum front clearance distances to permit valve module removal under operating conditions.

Maintenance Without Process Interruption

Pneumatic HotSwap enables replacement of an individual pilot valve while the manifold remains pressurized. Maintain at least the recommended front enclosure distance shown in the manual so technicians can unlock and dismount the valve body cleanly.

Hazardous Area Certification and Safety Limitations

Type 8652 assemblies carrying explosion-proof codes PU17 or PX68 comply with European ATEX, international IECEx, North American HazLoc, and Chinese CCC Ex directives for Category 3 equipment.

Standard / Certification	Protection Classification
ATEX Certificate (DEKRA BVS)	BVS 20 ATEX E 031 U; II 3G Ex ec IIC Gc / II 3D Ex tc IIIC Dc
IECEx Certificate	IECEx BVS 20.0024 U; Ex ec IIC Gc / Ex tc IIIC Dc
North America (cURus HazLoc)	Class I, Zone 2, AEx ec IIC Gc / Ex ec IIC Gc U; Class II, Zone 22, AEx tc IIIC Dc; Class I Div 2 Groups A, B, C, D; Class II/III Div 2 Groups F, G
China Compulsory Certification	CCC Ex certification according to GB/T 3836 series
Enclosure Requirement	Minimum IP54 for gas (Zone 2 / 3G); minimum IP6X for dust (Zone 22 / 3D)
Environmental Limitation	Pollution degree 2 or better per IEC 60664-1; indoor cabinet use only
Transient Protection	External transient protection must clamp surges to $\le 140%$ of nominal peak voltage

Explosion Hazard in Hazardous Locations

Do not connect or disconnect electrical terminals, fieldbus plugs, or SIA wiring while circuits are energized in an explosive atmosphere. The pneumatic HotSwap function must never be used in a potentially explosive atmosphere unless the environment is proven non-hazardous by calibrated gas detection equipment.

Replacement Valves and Key Ordering Information

Article Description	Ordering Code (Article No.)
20025930 Configured Valve Island (16-bank, PROFIBUS DPV1, ALQ AL)	20025930
Type 6534 Replacement Valve, 2x 3/2-way CF-C (standard with override)	301374
Type 6534 SIA Replacement Valve, 2x 3/2-way CF-C SIA (safety shutdown)	338802
8DI Electronic Module (with 8 digital input contacts)	384872
5-Pin Spring-Loaded Terminal Strip (display & electronics power)	920180
2-Pin Spring-Loaded Terminal Strip (auxiliary valve power AUX 24 V)	920442
ME43 Fieldbus Gateway Replacement — PROFIBUS DP	301803
ME43 Fieldbus Gateway Replacement — Industrial Ethernet	301799
M5 × 10 A2 DIN 6912 Base Screw Set (pack of 10 for cabinet mounting)	308661
Height Adapter Plate (16-fold with intermediate feed)	754962
Retaining Plate for External Cabinet Mounting (16-fold with feed)	60005568
Blind Plate (16-fold with intermediate feed)	754967