Rethinking valve platform architecture?

Addresses growing demand for higher airflow in automation.

Across factory automation, packaging, water treatment, and automotive manufacturing, machine builders are facing a familiar challenge: higher airflow demands in increasingly compact machine designs. Moving to a larger valve platform can solve the airflow problem but introduces new complexity — different interfaces, different configurations, and disruption to established machine architectures. Emerson has developed the AVENTICS™ XV05 High Flow Valve System to address this gap directly.

Their XV05 High Flow variant delivers up to 1,200 L/min — enabling OEMs and machine builders to achieve greater airflow capacity without moving to a larger valve system.

Now available globally, the XV05 High Flow is an extension of the established AVENTICS XV platform — the same architecture, the same electrical connection options, the same communication protocols, and the same modularity that machine builders already rely on. The difference is flow capacity: up to 1,200 L/min, compared to 1,000 L/min for the standard XV05. Larger ports and dedicated high-flow fittings deliver the increased airflow where applications demand it, while compatibility with the standard XV05 means High Flow and standard modules can be combined within a single valve system.

The XV05 High Flow is available in front-, top-, and bottom-ported configurations, giving design engineers the flexibility to integrate higher airflow capacity into new and existing machine layouts without redesigning the broader pneumatic architecture. Applications well suited to the new variant include pilot valve systems for process valves in water treatment, package molding equipment, slicing and cutting units requiring high actuator force, cleaning systems, pneumatically driven winches in oil and gas operations, and automotive manufacturing equipment with high airflow requirements.

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• See also Next Generation Pneumatic Valves.(24/2/2025) 

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Next-generation pneumatic valves.

Greater range with new flow rates, configurations, functionality, certifications and more.

The latest stage of Emerson's next-generation AVENTICS™ Series XV pneumatic valve systems with new flow rates, configurations, accessories, UL certifications and more. These updates give original equipment manufacturers (OEMs) greater design flexibility and scalability to precisely configure valves when engineering handling systems and automation solutions.

After successfully launching the AVENTICS Series XV03 in most world regions in July, Emerson has now released the popular XV03 valve for U.S. markets, as well as globally released the larger Series XV05 and a bottom-ported version of the XV03. The XV03 provides flow volumes up to 350 liters per minute in normal conditions (NL/min), and the XV05 provides up to 1000 NL/min.

In addition to new flow rates and configurations, Series XV valves are also available with UL certifications and more accessories. Both the XV03 and XV05 are designed for compliance with UL429 and UL61010 for quality and safety. New and existing accessories provide greater functionality and include separators, blank stations, pressure supply plates, sandwich pressure supply, and sandwich pressure exhaust. There is also a custom toolbox that contains the most important tools to assemble XV systems.

The next phase of the staged XV release will see the continued launch of new accessories as they become available, as well as greater connectivity. Additional fieldbus protocols will be launched throughout 2025, including Powerlink, CanOpen in mid-2025 and AS-I in late 2025. The valve systems currently support Profinet, Ethernet/IP, EtherCAT, Modbus TCP, Profibus DP and IO-Link.

Next-generation Series XV valves use proven core valve AVENTICS technology and include metal threads, aluminum base plates and compact dimensions to make integration easier. Complete valve systems are easy to commission with the AVENTICS online configurator that streamlines design and layout. To reduce lead times for every global region, three Emerson plants are equipped to manufacture orders.

Providing higher flow rates in a compact valve package, Series XV valves enable more efficient and flexible pneumatic system performance while offering products customized for specific markets, including factory automation, automotive and tire, food and packaging applications. Part of a Floor to CloudTM approach, Series XV valves power machinery and processes at a component level, helping manufacturers boost productivity in applications.

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Dewpoint monitoring in gas processes.

Unique industrial sensor that monitors dew point, temperature, humidity and air quality values.

The new AVENTICSTM DS1 dew point sensor, the only industrial sensor to monitor dew point, temperature, humidity levels and quality of compressed air and other non-corrosive gases in real time from one device has been launched by Emerson. The DS1 can help operators detect and mitigate excess moisture in its early stages and prevent moisture-related equipment damage. By optimizing air quality in this way, operators can better control processes, extend pneumatic component life, ensure regulatory compliance, and reduce maintenance and unplanned downtime.

“By having greater certainty about compressed air quality and control over moisture levels in compressed air lines, manufacturers of all kinds can prevent a number of common condensate-related issues and their associated costs,” said Manuel Goerbert, product marketing manager of discrete sensors at Emerson. “The new AVENTICS DS1 dew point sensor allows operators to detect changes in air quality in real time with a single device, so they can quickly make necessary adjustments to optimize production and increase overall process reliability.”

Pneumatic systems power manufacturing processes across the plant floor in most industries, from pharmaceuticals and food and beverage to semiconductor and automotive. Excess moisture in pneumatic systems can cause multiple issues, including corroded components, product inconsistency and erratic processes.

While most industrial sensors only monitor humidity, the DS1 provides precise dew point monitoring that makes it possible for manufacturers to continuously track critical values, address excess moisture and prevent its negative effects. For instance, moisture can affect process reliability by corroding components, washing the lubrication out of moving parts, and extending switching and reaction times.

Ideal air quality is also critical in instances where compressed air may come in contact with consumer products such as pharmaceuticals or food. Condensate in compressed air can cause discoloration, texture inconsistency and bacterial growth. The DS1 provides essential data that facilities need to maintain a stable dew point and protect product quality. And if there are regulations around air quality, the DS1 can help companies meet requirements and maintain compliance.

To support industrial digital transformation strategies, the DS1 dew point sensor easily integrates into existing systems, including the AVENTICS Series AS3 and AVENTICS Series 652 air preparation units, and connects to networks via Modbus TCP (PoE). One of the key advantages of an integrated dew point sensor is the ability to place the sensor – and track conditions – close to the process rather than where the compressed air is generated, which can be far from the process itself and have much different conditions. The sensor element is condensation-resistant and provides long-term, drift-proof performance. With fast response time, DS1 measurement values include pressure dewpoint, temperature, relative humidity, absolute humidity, moisture content, moisture content V/V, water vapor partial pressure and atmospheric dew point. The DS1 is also suitable for other non-corrosive gases, including nitrogen, oxygen, argon, helium and sulfur hexafluoride.

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Feeding and handling solutions.

Afag is now officially part of Emerson*. As a result, Afag's feeding and handling solutions will be integrated into Emerson’s extensive automation portfolio. All content on Afag.com, including product documentation, data, and certificates, has been migrated to Emerson.com under the AVENTICS™ brand. This migration will streamline Emerson’s comprehensive automation offerings, making it easier for original equipment manufacturers (OEMs) to access the solutions they need in a single location.

The AVENTICS brand is globally recognized for its innovation and proven performance. By bringing Afag’s feeding and handling products under the AVENTICS umbrella, OEMs will benefit from single-source access to a broader range of machine automation experts, as well as pneumatic and electric solutions that optimize the performance of new equipment designs.

In the months following the migration, Emerson will gradually rebrand Afag’s products under the AVENTICS line. While the brand name will change, the Afag product portfolio will remain consistent, ensuring OEMs continue to receive the high quality and support they trust. Customers will still be able to contact their existing representatives for ongoing assistance.

The legacy AVENTICS portfolio includes cylinders, valves, air preparation, and pressure technology. The newly incorporated Afag portfolio adds vibratory feeders, refilling devices, control units, linear and rotary axes, rotary modules, grippers, and more, further strengthening Emerson’s machine automation offering.

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* See also Accelerating factory automation capabilities. (19/9/2023)

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Interoperable valv pneumatic valves.

Multiple interoperable valve sizes and higher flow rates in a compact design.

Emerson has just launched its AVENTICS™ Series XV pneumatic valves. Series XV valves are designed with interoperability in mind to provide machine builders across multiple industries and factory automation applications with a flexible and cost-effective valve platform. The new valves are ideal for machine builders and end users that operate across the globe, with universal threads and other features that support regional standards and global availability.

Series XV valves provide higher flow rates in a compact valve package that enables more efficient and flexible pneumatic system performance for factory automation, automotive and tire, and food and packaging applications. This helps manufacturers boost productivity and allows them to offer products customized for specific markets and customer preferences.

“In all industries, manufacturers need high-performance technology that gives them the agility and flexibility to stay ahead of rapidly changing market demands,” said Wolf Gerecke, director of product marketing for Emerson’s machine automation business. “The new AVENTICS Series XV pneumatic valves deliver that performance with optimized flow, a wide range of valves and an extensive portfolio of accessories.”

Series XV valves include the XV03, providing flow volumes up to 350 liters per minute in normal conditions (NL/min), and the XV05, scheduled for release in October 2024, providing up to 880 NL/min.

All valves in the Series XV line use proven AVENTICS core technology and include metal threads, parallel wiring, aluminum base plates and compact dimensions to make it easier to integrate into production system designs.

Series XV valves use consistent interfaces and have wide connectivity from single wiring over parallel connections such as D-SUB connectors. They also support leading fieldbus protocols, including PROFINET®, Ethernet/IP, EtherCAT, Powerlink, Modbus TCP, IO-Link, AS-I, to simplify integration into machine control networks.

Series XV valves are also easy to commission. The AVENTICS online configurator supports system layout, providing useful information, while easy-to-understand system documentation in the design phase helps speed up machine development.

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Pressure valves for high-precision manufacturing.

Enables quick startup, monitoring and control directly on a PC.

The AVENTICSTM Series 625 Sentronic Proportional Pressure Control Valves has been announced by Emerson. With a control deviation of less than 0.5%, the new valves are designed to deliver highly accurate, electronic proportional pressure control and provide the flexibility needed to support sophisticated pneumatic control engineering applications. Data acquisition software (DaS) software included with Series 625 Sentronic valves also make it possible to quickly startup, monitor and control valves directly on a PC.

“In high-precision equipment, such as that used for flame cutting and laser eye surgery, accuracy and control are critical,” said Nicolas Jacquet, director of product management for Emerson’s discrete automation business. “Series 625 Sentronic valves are engineered to precisely control pressure, flow rate, power, speed, distance and angular positions. As part of the extensive AVENTICS portfolio of cylinders, valves, air preparation and pressure regulators, the Series 625 Sentronic is a core technology for factory automation.”

Four valve sizes from 1 millimeter up to 20 mm support a comprehensive range of flow rates, from 55 liters per minute to 4,700 l/min. Pressure capabilities range from vacuum levels up to 50 bar, which can reduce the overall number of valves required for a machine design. Housing material is available in brass, aluminum or stainless steel and sealing material in nitrile (NBR) or fluoroelastomer (FKM) options. There are also three sets of connectors, M12 5-pin, M12 8-pin and M16 7-pin.

As development and manufacturing phases continue to get shorter, fast startup procedures and reliable, controllable manufacturing processes are more important than ever. Using the DaS software, operators can diagnose, control, repair or individually configure valves. They can also perform cascade controls when applications require exceptional precision and other complex control loops. The expanded range of diagnostic and monitoring functions include input pressure, commanded pressure, internal temperature and ethernet communication.

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New IO-Link Master.

Customers can reduce costs by including multiple IO-Link masters on one G3 Fieldbus platform.

Emerson has introduced a new Class A, IO-Link master that provides customers with a cost-effective solution for smart and analog sensor connectivity on the AVENTICSTM Series G3 Fieldbus platform. The G3 IO-Link Master is suitable for machine architectures with many sensors and pneumatic valves, and where it’s important to have reliable digital data communication between field devices, such as sensors and the machine controller. Application areas include automotive, tire manufacturing, food and beverage, packaging and metalworking.

IO-Link is an internationally standardized I/O technology (IEC 61131-9) for communication at the sensor/actuator level in machine control. During replacement, IO-Link devices can identify and configure themselves automatically, saving maintenance time. The IO-Link master provides pneumatic valve control through direct digital data communication with the machine controller. It offers event-based and I/O mapped diagnostics – both important predictive maintenance requirements for Industry 4.0 and Industrial Internet of Things (IIoT) applications.

By adding the IO-Link capabilities to our valve systems, our customers can include multiple IO-Link masters on only one G3 Fieldbus platform, saving hardware costs, thus enabling our customers to be future-proof and positioned for Industry 4.0/IIoT application requirements.

Customers can cut costs by reducing the number of communication nodes. G3 IO-Link master is optimized for sensor-rich applications with eight Class A ports per module to support multiple IO-Link smart and standard analog sensors. The IO-Link master can be distributed up to 30 meters away from G3. Together with the 20-meter IO-Link cable length maximum, the sensors can be located up to 50 total meters in total from the G3 Fieldbus platform. As a result, material cost is reduced, and machines are more streamlined because fewer cables are required.

The IO-Link Master offers a complete Emerson solution. Customers can experience the benefits of integrating IIoT into their systems by connecting to the IO-Link-capable Series AV03/AV05 and 500 valve systems, Series EV12 and EV18 electropneumatic pressure regulators, Series 617 Sentronic LP and Series 614 Sentronic PLUS proportional valves, Series ECD-IV and ECD-LV intelligent compact vacuum ejectors, Series SM6-AL distance measuring sensors, Series ST4-2P magnetic proximity sensors, Series PE5 and PE7 pressure sensors, and Series AF2 flow sensors. In addition, Class B IO-Link solutions can be supported with an optional T-adapter.

The G3 is the only fieldbus electronics platform for pneumatic valve systems that contains a graphical display used for configuration, commissioning, and diagnostics. It offers improvements in performance and reduces maintenance for original equipment manufacturers (OEMs) and end-users alike. The G3 IO-Link Master can also be configurable with the G3 web server. With easy access to connections, the electronic platform is simple to assemble, install, commission, and maintain. G3's functionality allows programmable logic controllers to efficiently turn valves on and off, and to channel I/O data from sensors, lights, relays, individual valves, or other I/O devices via various industrial networks.

Further benefits include compatibility with the full G3 range of valve interfaces, including Series 501, 502, 503 (ISO15407-2), 2035, 2002, 2005, 2012 and 511, 512, 513 (ISO 5599-2). The G3 IO-Link Master supports the widely used protocols EtherNet/IPTM DLR and PROFINETTM. Additional protocols are also available.

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Versatile electric actuators.

Featuring three different screw technologies, these rod-style electric actuators offer unmatched versatility that can better meet exacting application requirements

The new AVENTICS™ Series Servo Profile Advanced (SPRA) Electric Actuators have been launched by Emerson. This is aline of precise and highly repeatable rod-style cylinders. While only one electric actuator screw type is typically available in the market, the SPRA actuators offer three screw technologies. These include a precision ball screw, which provides exceptional durability and accuracy for applications that need optimal quality or throughput, a cost-effective lead screw option and roller screws for precision, speed and heavy loads.

“With four sizes and multiple mounting options, the AVENTICS Series SPRA Electric Actuators are cost-effective, high-performance solutions that cover most machine automation applications,” said Linda Schwartzen, product marketing manager with Emerson’s AVENTICS actuator business. “Compliance with the ISO-15552 standard offers a wide range of accessories and our online calculation tool and configurator ensures the appropriate implementation and can meet exacting application requirements.”

This versatile range of rod-style cylinders lets users in the automotive, food and beverage, packaging and life sciences industries configure electric actuators to meet exacting application requirements, such as improved sustainability or efficiency, rather than settle for standard approximation.

Interconnected online tools allow users to instantly size and customize electric actuators, with no software installation or registration necessary. The configuration includes a direct download of CAD files, which comprises all elements of the configured solution, such as electric cylinder, accessories, mounting options and motor adapter.

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Valve system with OPC UA.

Emerson's AVENTICS™ Series Advanced Valve (AV) valve system with Advanced Electronic System (AES) Profinet and Ethernet/IP is now available with preinstalled Open Platform Communications Unified Architecture (OPC UA)* functionality, making it the first and only valve system to offer this directly integrated capability. The AES helps users solve interoperability challenges and access data more easily while the integration of the digital twin can improve productivity and efficiency.

“The AVENTICS Series AV System with OPC UA is a notable leap forward in the flexibility and integration of valve systems because it makes the transition to IIoT significantly simpler for engineers,” said Nils Beckmann, senior manager of product marketing, IIoT at Emerson. “With OPC UA, engineers don’t need to change a whole system or architecture to access valve data. They now have the flexibility to continue using their own cloud systems and software to gain easy access to data and analytics without disrupting or modifying the PLC.”
 

A valve system with integrated OPC UA functionality simplifies communication with upper systems since data and analytics are received via the valve system and communicated directly to upper systems, no gateway necessary unless deeper analysis or local dashboards are required. This can result in costs savings for users since it’s more complex and expensive to receive analytics from a valve system without OPC UA.

OPC UA functionality also expands the connected capabilities of the valve system itself, making it easier for users in industries such as automotive, food and beverage, packaging, pulp and paper industries and more to digitally transform. When organizations undergo digital transformation, key protocols such as OPC UA embedded in technologies enable device monitoring and machine connectivity when sending data from a valve system to an upper system. The AES is simple to integrate and connect to new or existing applications and machines and provides easy access to data and analytics without changing the programmable logic controller (PLC).

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*Developed by the OPC Foundation, OPC UA is a platform independent, information technology standard for sensor-to-cloud data exchange that features integrated security.

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Pneumatic Valve System with Embedded Wireless Connectivity.

Emerson has introduced a wireless automatic recovery module (ARM) for its AVENTICS™ G3 electronic fieldbus platform that makes it easy for technicians to perform pneumatic valve system commissioning and diagnostics from a mobile phone, tablet or laptop computer.

“The AVENTICS G3 fieldbus platform is the first in the industry to offer wireless technology that puts valve system configuration and diagnostics at the control engineer’s fingertips,” said Enrico De Carolis, vice president of global technology, fluid control and pneumatics, at Emerson. “This offering furthers our quest to help manufacturers reduce production downtime and simplify valve system commissioning, while creating a path for using diagnostics/prognostics for analytics and advancing our offering of intelligent devices with IIoT capability.”

The new wireless ARM module and AVENTICS G3 fieldbus platform are ideal for pneumatic valve system applications in the automotive, food and beverage, tire, packaging and metalworking industries.

The wireless ARM module provides easy access to the AVENTICS G3 fieldbus platform’s diagnostic and commissioning capabilities via an internal Wi-Fi access point and mobile website — even when the valve system is located inside a machine or on a ceiling. It offers the visual benefits of a hard-wired human machine interface (HMI) at lower cost and with higher flexibility. The wireless ARM module generates error notification for alarms, voltage levels, short circuits, module errors, open load errors and distribution errors to reduce system downtime.

The device has a small footprint that connects easily to the AVENTICS G3 fieldbus platform in the space of a jumper clip. It features three power settings for low-, medium-, or high-distance signals to ensure safe and secure access to data — regardless of where the valve system is mounted. Additional security benefits include wireless signal that can be turned off during configuration, multiple password options, and diagnostic and commissioning information provided with no control capability.

The wireless ARM module is compatible with Ethernet/IP DLR, and PROFINET protocols. Additional protocols are targeted for future release.

The  module also protects the AVENTICS G3 fieldbus platform’s configuration information from a critical failure, including all settable node and attached I/O module parameters.

Emerson also has introduced an upgraded ARM clip for the AVENTICS G3 fieldbus platform that is backwardly compatible to existing ARMs and G3 fieldbus platforms. The ARM clip improves system reliability by protecting configuration information from critical valve system failure.

The AVENTICS G3 fieldbus platform’s electronic parameters and settings are automatically stored in the ARM’s nonvolatile memory and then the ARM is automatically disconnected from power, to ensure stored information is not erased during a power spike or critical failure. “A replacement G3 fieldbus communication node can automatically download the required parameters from the ARM module,” said De Carolis. “This enables the valve system and production line to quickly resume operation without the need for re-commissioning by a controls engineer, offering true ‘plug and play’ capability.”

The compact ARM module is easy to install in the space of an AVENTICS G3 fieldbus platform’s jumper clip without having to change the mounting.

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