BURKERT 20078061 (Type 8647 AirLINE SP) is a modular electropneumatic valve island configured with a 28-bank pneumatic base for direct integration into Siemens SIMATIC ET 200SP and ET 200SP HA distributed I/O systems. Equipped with 28 stations of Type 6524 dual 3/2-way pilot solenoid valves, the unit provides 56 independently operated, normally closed (Circuit Function C C) pneumatic control channels within an 11 mm grid. It features integrated check valves in the exhaust channels, a pneumatic HotSwap function in pressure supply channel 1 (P), push-in D6 working ports located at the bottom of the pneumatic module, and a dedicated intermediate air supply feed module.

Generation Revision 2 Distinguishing Features

Article 20078061 belongs to the Type 8647 Revision 2 (REV.2) generation. REV.2 introduces an updated pneumatic base module architecture and standardized valve mounting interfaces compared to earlier configurations:

• Working connection layout: Working ports 2 (A) and 4 (B) are arranged in an offset wavy pattern rather than parallel rows, facilitating tube insertion and release.
• Hose connector release rings: REV.2 pneumatic push-in fittings use blue release rings (REV.1 used black rings).
• P-shutoff flow optimization: Flow reduction caused by the integrated P-channel HotSwap check valve is limited to approximately 20% in REV.2, compared to up to 50% in REV.1.
• Standardized flange pattern: Single and double valves in REV.2 share a unified FM20 pneumatic flange interface across the base modules.

Pneumatic Configuration and Valve Assembly

Each of the 28 stations houses a Type 6524 dual 3/2-way solenoid valve. Each valve assembly incorporates two separate flipper pilot mechanisms (Type 6144) driving pneumatic seat valve amplifiers, enabling fast response times and low energy consumption.

Pneumatic Operating Parameters

Parameter	Specification
Operating Pressure Range	2.5 bar to 10.0 bar (gauge pressure)
Standard Air Flow Rate ($Q_{Nn}$)	300 l/min (measured at +20 °C, 6 bar inlet, 1 bar $\Delta p$)
Air Flow Rate with Integrated P-Shutoff	Approx. 240 l/min (reduced by ~20%)
Medium Temperature Range	0 °C to +50 °C
Medium Quality	Filtered compressed air (dry, oiled or unoiled) per ISO 8573-1:2010 Class 7.4.4; 5 µm filtration
Supply Port 1 (P)	G 1/4 female thread
Exhaust Ports 3 (R), 5 (S)	G 1/4 female thread with integrated non-return check valves (RSV)
Auxiliary / Pilot Exhaust (X)	M5 female thread
Working Ports 2 (A), 4 (B)	D6 (∅6 mm push-in coupling), bottom exit
Intermediate Supply Units	1 PCE (PSU-M G 1/4) installed within the valve bank

Intermediate Air Supply Requirement

In Type 8647 valve islands using Type 6524 dual 3/2-way valves, an intermediate feed unit (PSU-M) is required after every 16 valve functions to prevent internal pressure drops across large blocks. Article 20078061 incorporates 56 valve functions and includes 1 intermediate supply unit to ensure uniform pressure across all pneumatic stations.

Integrated Check Valves and P-HotSwap Function

The pneumatic base modules integrate non-return check valves (RSV) into the common exhaust lines 3 (R) and 5 (S). These check valves prevent pressure surges in the exhaust duct from triggering unintended movement in single-acting actuators during rapid venting.

The supply channel 1 (P) is equipped with a mechanical HotSwap shut-off valve. When a valve is removed from its station for servicing, the P channel automatically seals against supply pressure, leaving adjacent stations fully operational.

Depressurization on Valve Removal

While the integrated P shut-off stops supply pressure, removing a valve immediately vents remaining pressure in working ports 2 (A) and 4 (B). Connected actuators will depressurize and may change position. Always secure actuators mechanically before dismounting valves.

Siemens SIMATIC ET 200SP / ET 200SP HA Integration

Type 8647 mounts directly on the standard DIN rail adjacent to Siemens SIMATIC ET 200SP or ET 200SP HA distributed I/O modules, establishing electrical and backplane communication without external wiring.

Station Layout and Power Planning Rules

• Load Voltage Supply: The permissible tolerance for valve load voltage is 24 V DC ±10%, which is narrower than standard I/O voltage tolerances. A light-colored BaseUnit (type BU…D or BU…D/T) must be placed immediately to the left of the valve block to provide a separate, dedicated load potential group.
• ET 200SP HA Stations: When combining Type 8647 with SIMATIC ET 200SP HA on a profile rail, only one valve block is allowed per station, and it must be mounted at the far right of the rack. No additional ET 200SP I/O modules may be placed to the right of the valve block.
• ET 200SP Stations: Multiple valve blocks may be installed in a single station, provided the total width (maximum 975 mm without interface module) and module limits (64 total modules) are observed. If additional I/O modules are mounted to the right of the valve block, a new light-colored BaseUnit is required because the internal power bus does not pass through the right connection unit.

Software Configuration Methods

Software Environment	Configuration Tool	Integration Details
Siemens TIA Portal	HSP0225 (V14 SP1 or higher) / GSDML	Hardware Support Package enables drag-and-drop module setup and automatic rule checking
Siemens STEP 7 Classic	HSP2105 (V5.5 SP4 or higher) / GSD	Full integration via Hardware Support Package or device master file
Siemens PCS 7	HUP (V9.0 SP2 or higher)	Hardware Update Package supports integration with PCS 7 process control systems
Third-Party Fieldbus Masters	GSD (PROFIBUS) / GSDML (PROFINET)	Universal integration via standard device description files

Electrical Data and On-Board Diagnostics

Each electronic base module (PQ module) provides local switching electronics, internal protection, and status displays for its assigned valve slots.

• Rated Voltage: 24 V DC (±10%, max residual ripple 2.4 Vss).
• Power Consumption: 2 x 0.8 W per station with integrated power reduction (nominal coil current 40 mA, reducing to a holding current of 28 mA after 120 ms).
• Module Protection: Resettable short-circuit fuses on each output channel; blow fuse on left supply unit and electronic base modules.
• Diagnostics: Channel-specific wire break and short-circuit monitoring, supply voltage monitoring (L+), and dual switching cycle counters per channel (separate counters for pilot valve and external actuator).
• Visual Indicators: Left connection unit features "PWR OK" LED. Each electronic module includes a green PWR LED, a red/green DIAG LED, and a graphical LC display indicating channel status, process values, and error text.

Pneumatic and Mechanical Installation

Port Allocation for Dual 3/2-Way Valves

On Type 6524 dual 3/2-way valve modules, both working connections are active:

• Upper connection: Working port 2 (A)
• Lower connection: Working port 4 (B)

Installation Requirements and Torques

• Tightening Torques: Threaded G 1/4 pneumatic ports (P, R, S) require 4 Nm to 7 Nm (maximum 20 Nm). Standard rail fastening screws require approximately 1.8 Nm.
• Cabinet Clearances: Maintain a minimum vertical clearance of 5 cm above the upper edge of the valve block (8 cm if EVS shutdown connections are present) for tool access and heat dissipation.
• Cabinet Protection: Valve block AirLINE SP Type 8647 carries an IP20 rating and must be housed in an industrial control cabinet or enclosure meeting at least IP54 per EN 60529 (IP65 inside closed cabinets).

Tubing Preparation Guidelines (ISO 14743:2020)

Cut pneumatic tubing precisely at a 90° angle without burrs. Outer diameter tolerance for 6 mm tubing must not exceed ±0.08 mm for polyamide (PA) or ±0.10 mm for polyurethane (PU). Insert tubing firmly until the internal grip ring engages. Minimum pull-off retention force is 120 N for PA and 100 N for PU.

Replacement Valves and Common Spare Parts

Replacement Components for 8647 REV.2 11 mm Valve Islands

Component Description	Package Content	Article Number
Replacement Valve Type 6524 2x3/2-way NC (2.5 to 10 bar, 24 V DC, REV.2)	1 piece	204710
Replacement Valve Type 6524 2x3/2-way NC without manual override	1 piece	300818
Valve Seal Set FM20 for Type 6524 2x3/2-way	12 seals	20016305
Module Seal Set MP16 for REV.2 base modules	4 seals	20024339
Intermediate Feed Unit G 1/4 (PSU-M, 11 mm)	1 piece	20030063
Left Connection Unit G 1/4 (PSU-L, 11 mm)	1 piece	20030062
Right Connection Unit G 1/4 (PSU-R, 11 mm)	1 piece	20030064
Pneumatic Base Module 4-slot, D6, FM20, HotSwap, RSV	1 piece	20040335
Electronic Base Module PQ8VS4 (4-slot, double valve)	1 piece	20040550
Electronic Base Module PQ16VS8 (8-slot, double valve)	1 piece	20040556
Cover Plate for Type 6524 2x3/2-way unused slots (REV.2)	1 piece	661092
Electrical Connection Cover (all valve types)	1 piece	653670
Push-in Connector ∅6 mm Brass	8 pieces	20024340
Push-in Connector ∅6 mm Stainless Steel (VA)	8 pieces	20024341