ba 768 gb - gemu-group.com

GEMÜ 768Motorized compact flanged ball valve

Operating instructionsEN

further informationwebcode: GW-768

All rights including copyrights or industrial property rights are expressly reserved.

Keep the document for future reference.

© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG11.12.2019

www.gemu-group.com2 / 40GEMÜ 768

Contents1 General information .................................................. 4

1.1 Information .......................................................... 41.2 Symbols used ...................................................... 41.3 Definition of terms .............................................. 41.4 Warning notes ..................................................... 4

2 Safety information .................................................... 53 Product description ................................................... 5

3.1 Construction ........................................................ 53.3 Function ............................................................... 6

4 GEMÜ CONEXO ......................................................... 65 Correct use ............................................................... 66 Order data ................................................................. 77 Technical data .......................................................... 98 Dimensions ............................................................... 139 Manufacturer's information ....................................... 17

9.1 Delivery ................................................................ 179.2 Packaging ............................................................ 179.3 Transport ............................................................. 179.4 Storage ................................................................. 17

10 Installation in piping .................................................. 1710.1 Preparing for installation .................................... 1710.2 Installation for flanged connection .................... 18

11 Electrical connection ................................................. 2011.1 Connection and wiring diagram – actuator ver-

sion 1015, 2015, 3035 ......................................... 2011.2 Connection and wiring diagram – actuator ver-

sion 2070, 4100, 4200 ......................................... 2212 Limit switches ........................................................... 27

12.1 Setting the limit switch for 1015, 2015 and3035 ..................................................................... 27

12.2 Setting the limit switch for 2070, 4100, 4200 .... 2813 Commissioning ......................................................... 2814 Operation .................................................................. 29

14.1 Normal operation ................................................ 2914.2 Optical position indicator .................................... 2914.3 Manual override ................................................... 29

15 Troubleshooting ........................................................ 3116 Inspection/maintenance ............................................ 32

16.1 Spare parts .......................................................... 3216.2 General information regarding actuator re-

placement ............................................................ 3316.3 Replacing the actuator ........................................ 3316.4 Replacing the seals ............................................. 34

17 Removal from piping ................................................. 3618 Disposal .................................................................... 3619 Returns ..................................................................... 3620 Declaration of Incorporation according to 2006/42/

EC (Machinery Directive) ........................................... 3721 Declaration of conformity according to 2014/30/EU

(EMC Directive) ......................................................... 3822 EU Declaration of conformity 2-way metal ball valve . 39

GEMÜ 768www.gemu-group.com 3 / 40


1 General information

1 General information

1.1 Information

– The descriptions and instructions apply to the stand-ard versions. For special versions not described in thisdocument the basic information contained herein ap-plies in combination with any additional special docu-mentation.

– Correct installation, operation, maintenance and repairwork ensure faultless operation of the product.

– Should there be any doubts or misunderstandings, theGerman version is the authoritative document.

– Contact us at the address on the last page for stafftraining information.

1.2 Symbols used

The following symbols are used in this document:

Symbol Meaning

Tasks to be performed

Response(s) to tasks

– Lists

1.3 Definition of terms

Working mediumThe medium that flows through the GEMÜ product.

1.4 Warning notes

Wherever possible, warning notes are organised according tothe following scheme:

SIGNAL WORDType and source of the danger

Possiblesymbol forthe specificdanger

Possible consequences of non-observance.Measures for avoiding danger.

Warning notes are always marked with a signal word andsometimes also with a symbol for the specific danger.The following signal words and danger levels are used:

DANGERImminent danger!▶ Non-observance can cause death or

severe injury.

WARNINGPotentially dangerous situation!▶ Non-observance can cause death or

severe injury.

CAUTIONPotentially dangerous situation!▶ Non-observance can cause moderate

to light injury.

NOTICEPotentially dangerous situation!▶ Non-observance can cause damage to

property.

The following symbols for the specific dangers can be usedwithin a warning note:

Symbol Meaning

Danger of explosion

Corrosive chemicals

Hot plant components!

Risk of electric shock

www.gemu-group.com 5 / 40 GEMÜ 768

2 Safety informationThe safety information in this document refers only to an indi-vidual product. Potentially dangerous conditions can arise incombination with other plant components, which need to beconsidered on the basis of a risk analysis. The operator is re-sponsible for the production of the risk analysis and for com-pliance with the resulting precautionary measures and re-gional safety regulations.The document contains fundamental safety information thatmust be observed during commissioning, operation and main-tenance. Non-compliance with these instructions may cause:– Personal hazard due to electrical, mechanical and

chemical effects.– Hazard to nearby equipment.– Failure of important functions.– Hazard to the environment due to the leakage of dan-

gerous materials.The safety information does not take into account:– Unexpected incidents and events, which may occur

during installation, operation and maintenance.– Local safety regulations which must be adhered to by

the operator and by any additional installation person-nel.

Prior to commissioning:1. Transport and store the product correctly.2. Do not paint the bolts and plastic parts of the product.3. Carry out installation and commissioning using trained

personnel.4. Provide adequate training for installation and operating

personnel.5. Ensure that the contents of the document have been fully

understood by the responsible personnel.6. Define the areas of responsibility.7. Observe the safety data sheets.8. Observe the safety regulations for the media used.

During operation:9. Keep this document available at the place of use.10. Observe the safety information.11. Operate the product in accordance with this document.12. Operate the product in accordance with the specifications.13. Maintain the product correctly.14. Do not carry out any maintenance work and repairs not de-

scribed in this document without consulting the manufac-turer first.

In cases of uncertainty:15. Consult the nearest GEMÜ sales office.

3 Product description

3.1 Construction

1

2a

32b

Item Name Materials

1 Ball valve body 1.4408,investmentcasting (316)

2a Actuator housing coverActuator version 1015Actuator version 2015, 3035Actuator version 2070Actuator version 4100, 4200

PPO (10% glassfibre reinforced)PP (30% glassfibre reinforced)ABSAluminium

2b Actuator housing baseActuator version 1015, 2015, 3035Actuator version 2070Actuator version 4100, 4200

PP (30% glassfibre reinforced)ABSAluminium

3 Optical position indicator PP-R natural

Ball 1.4401,investmentcasting (316)

Seal material PTFE

Pressure-relief hole

3 Product description


4 GEMÜ CONEXO

3.2 Description

The GEMÜ 768 2/2-way metal ball valve is motorized. It has aplastic actuator housing. A manual override and an optical po-sition indicator are integrated as standard. The seat seal ismade of PTFE.

3.3 Function

The GEMÜ 768 2/2-way ball valve made of stainless steel hasa one-piece body with an actuator flange and a low mainten-ance electric actuator with a powerful DC motor.The reduction gear in the motor, consisting of a threadedspindle with a lever, provides the rotation through 90°.The actuator has an optical position indicator and a manualoverride as standard.

4 GEMÜ CONEXOInstalling the RFID chipIn the corresponding design with CONEXO, this product hasan RFID chip (1) for electronic recognition. The position of theRFID chip can be seen below.

1

Reading out the RFID chip

DANGERDanger of explosion▶ Death or severe injury● Install the product in such a way that

explosion protection is not impaired byexternal influences (e.g. mechanical,thermal or electrical influences, etc.)(see IEC/EN 60079-14).

The CONEXO pen helps read out information stored in theRFID chip. The CONEXO app or CONEXO portal is required toview this information.

For further information please read the operating instructionsfor CONEXO products or the CONEXO datasheet.Products such as the CONEXO app, the CONEXO portal andthe CONEXO pen are not included in the scope of delivery andneed to be ordered separately.

5 Correct use

WARNINGImproper use of the product!▶ Risk of severe injury or death.▶ Manufacturer liability and guarantee will be void.● Only use the product in accordance with the operating

conditions specified in the contract documentation andthis document.

The product is suitable for installation in piping and for con-trolling a media flow. The operating conditions according tothe technical data apply to the media to be controlled.The product is controlled via a motorized actuator.The product is not intended for use in potentially explosiveareas.

6 Order dataThe order data provide an overview of standard configurations.

Please check the availability before ordering. Other configurations available on request.

Order codes

1 Type Code

Ball valve, metal, electrically operated 768

2 DN Code

DN 15 15

DN 20 20

DN 25 25

DN 32 32

DN 40 40

DN 50 50

DN 65 65

DN 80 80

DN 100 100

3 Ball configur./port position Code

2/2-way body D

4 Connection type Code

Flange ANSI class 125/150 RF,up to DN 100 face-to-face dimension FTF EN 558series 3,ASME/ANSI B16.10 table 1, columns 8 and 9,from DN 125 face-to-face dimension FTF EN 558series 12,ASME/ANSI B16.10 table 1, column 3

46

Flange EN 1092, PN 16/PN40, form B DN 15 to DN80,flange EN 1092, PN 16, form B DN 100 only

68

5 Ball valve material Code

Body 1.4408 (CF8M),ball SS316 for DN 8 - DN 15,ball CF8M for DN 20 - DN 100

37

6 Seal material Code

PTFE 5

TFM 1600 (FDA compliant), maximum -20 °C -+220 °C

5T

7 Voltage/Frequency Code

12 VDC B1

12 V 50/60 Hz B4

24 VDC C1

24 V 50/60 Hz C4

120 V 50/60 Hz G4

230 V 50/60 Hz L4

100–250 V 50/60 Hz O4

8 Control module Code

On/Off actuator, relay, not reversible 00

On/Off actuator, two additional potential-free limitswitches,relay, not reversible

0E

On/Off actuator, potentiometer output, relay, notreversible

0P

On/Off actuator A0

On/Off actuator, two additional potential-free limitswitches, Class A (EN15714-2)

AE

On/Off actuator, potentiometer output, Class A(EN15714-2)

AP

Control actuator, external set value 0–10 VDC E1

Control actuator, external set value 0/4–20 mA E2

9 Actuator version Code

GEMÜ actuator, motorized, size 1, operating time11 s, torque 15 Nm,supply voltage B1, C1

1015

GEMÜ actuator, motorized, size 3, operating time15 s, torque 35 Nm,supply voltage C1, O4

3035

GEMÜ actuator, motorized, size 2, operating time15 s, torque 70 Nm,supply voltage C1

2070


4100


4200

10 CONEXO Code

without

Integrated RFID chip for electronic identificationand traceability

C

6 Order data


Order example

Order option Code Description

1 Type 768 Ball valve, metal, electrically operated

2 DN 25 DN 25

3 Ball configur./port position D 2/2-way body

4 Connection type 68 Flange EN 1092, PN 16/PN40, form B DN 15 to DN 80,flange EN 1092, PN 16, form B DN 100 only

5 Ball valve material 37 Body 1.4408 (CF8M),ball SS316 for DN 8 - DN 15,ball CF8M for DN 20 - DN 100

6 Seal material 5 PTFE

7 Voltage/Frequency C1 24 VDC

8 Control module A0 On/Off actuator

9 Actuator version 1015 GEMÜ actuator, motorized, size 1, operating time 11 s, torque 15 Nm,supply voltage B1, C1

10 CONEXO without

6 Order data


7 Technical data

7.1 Medium

Working medium: Corrosive, inert, gaseous and liquid media and steam which have no negative impact on the phys-ical and chemical properties of the body and seal material.

7.2 Temperature

Media temperature: -20 to 180 °C

Ambient temperature: -20 to 60 °CHigher temperatures on request

Storage temperature: 0 to 40 °C

7.3 Pressure

Leakage rate: Leakage rate according to ANSI FCI70 – B16.104Leakage rate according to EN12266, 6 bar air, leakage rate A

Pressure/temperature diagram:

-20 204

28

21

1414

7

038 93-18

PN16

180°C

PN40

260

34

41

48-5 400100 200 3000 500

400

300

200

100

0

500

600

700

149Temperature [°C]

Ope

ratin

g pr

essu

re [b

ar]

Ope

ratin

g pr

essu

re [P

SIG

]

Temperature [°F]

Pressure rating: PN 16PN 40

Kv values: DN NPS Kv values

15 1/2” 12.8

20 3/4” 29.1

25 1” 47.8

32 1¼” 2.6

40 1½” 0.2

50 2” 213.7

65 2½” 273.3

80 3” 495.3

100 4” 871.1

Kv values in m³/h

7.4 Product compliance

Machinery Directive: 2006/42/EC

EMC Directive: 2014/30/EU


7 Technical data

Low VoltageDirective:

2014/35/EU

7.5 Mechanical data

Torques: DN NPS Torque

15 1/2” 5

20 3/4” 7

25 1” 29.1

32 1¼” 1.7

40 1½” 0.2

50 2” 36

65 2½” 60

80 3” 74

100 4” 90

Torques in Nm

Weight: Ball valve

DN NPS Weight

15 1/2” 1.1

20 3/4” 1.7

25 1” 72.6

32 1¼” 3.9

40 1½” 0.3

50 2” 6.0

65 2½” 10.8

80 3” 12.5

100 4” 18

Actuator

Actuator version 1015: 1.0

Actuator version 2015 (12/24V):

1.0

Actuator version 2015 (100–250 V):

2.4





Weights in kg


7 Technical data

7.6 Electrical data

Duty cycle: Supply voltage 12 V / 24 V: Continuous duty Supply voltage 100 - 250 V: 40 % duty

Electrical protection: Potential-free limit switches (change-over contact 250 V AC/6 A)Actual value potentiometer: 3 kΩ (± 20 %)

Electrical protectionclass:

I (DIN EN 61140)

Input signals: 24 V DC, 24 V AC, 120 V AC, 230 V ACdependent on rated voltage

Recommended motorprotection:

Voltage 12 V DC 24 V DC 120 V AC 230 V AC

Motor protectionswitch type

Siemens 3RV1011-1CA10

Siemens 3RV1011-1BA10

Siemens 3RV1011-OGA10

Siemens 3RV1011-OGA10

Set current 2.20 1.70 0.60 0.45

Current data in A

Cable diameter: Supply voltage 12 V / 24 V: 7.5 to 12.5 mmSupply voltage 100 - 250 V: 7.0 to 9.0 mm

Max. cross section of wire: 1.5 mm²

Power consumption: Actuator ver-sionCode

Control mod-ule

Code

12 V DC(Code B1)

12 V AC(Code B4)

24 V DC(Code C1)

24 V AC(Code C4)

100-250V AC

(Code O4)

1006 A0, AE 30 30 30 30 -

1015 A0, AE 30 - 30 - -

2006 A0, AE - - - - 60

2015 A0, AE - 30 - 30 50

3035 A0, AE - - 30 - 50

2070 00, 0E, 0P - - 63 - -

4100 00, 0E, 0P - - 105 - -

4200 00, 0E, 0P - - 90 - -

Power consumption in W

Max. current at start up: Actuator ver-sionCode

Control mod-ule

Code

12 V DC(Code B1)

12 V AC(Code B4)

24 V DC(Code C1)

24 V AC(Code C4)

100-250V AC

(Code O4)

1006 A0, AE 6.3 2.4 4.0 1.8 -

1015 A0, AE 9.2 - 3.8 - -

2006 A0, AE - - - - 0.3

2015 A0, AE - 2.3 - 1.8 0.4

3035 A0, AE - - 3.3 - 0.2

2070 00, 0E, 0P - - 14.0 -

4100 00, 0E, 0P - - 35.0 - -

4200 00, 0E, 0P - - 35.0 -

Current data in A


7 Technical data

Current consumption: Actuator ver-sionCode

Control mod-ule

Code

12 V DC(Code B1)

12 V AC(Code B4)

24 V DC(Code C1)

24 V AC(Code C4)

100-250V AC

(Code O4)

1006 A0, AE 2.2 2 1.2 1.5 -

1015 A0, AE 2.2 - 1.2 - -

2006 A0, AE - - - - 0.25

2015 A0, AE - 2 - 1.2 0.2

3035 A0, AE - - 1.3 - 0.2

2070 00, 0E, 0P - - 2.6 - -

4100 00, 0E, 0P - - 4.4 - -

4200 00, 0E, 0P - - 3.6 - -

Current data in A

Supply voltage 12 V / 24 V:Motor protective system by customerSupply voltage 100 - 250 V:Integrated stall and overload protectionplus excess current release T 1A 5x20 mm


7 Technical data

8 Dimensions

8.1 Actuators

8.1.1 Actuator version 1006, 1015, 2006, 2015

AB

14540

8055C62*

* Standard with supply voltage code O4

Actuator ver-sion

A B C

1006, 1015 69 94 49

2006, 2015 96 122 53

Dimensions in mm

8.1.2 Actuator version 3035

66 76172 208

94

B

Voltages B

24 V 100.5

100 V - 250 V 124.5

Dimensions in mm


8 Dimensions

8.1.3 Actuator version 2070

83,5 121,5

40

51235

167

155

Dimensions in mm

8.1.4 Actuator version 4100, 4200

277,5

131

207

105

145

Dimensions in mm


8 Dimensions

8.1.5 Connection dimensions actuator

8.1.5.1 Connection dimensions

LK ØA

G1 G2

SW 2

T

LK ØB

SW 1

DIN ISO 5211

Actuator versioncode

Connectionsize code

With flange type LK øA LK øB G1 G2 SW1 SW2* SW3* T

2070 F07 F05 / F07 70 50 M8 M6 17 14 11 19.5

4100 F10 F07 / F10 102 70 M10 M8 17 14 - 23.0

4200 F10 F07 / F10 102 70 M10 M8 22 17 - 23.0

Dimensions in mm

8.1.5.2 Connection dimensions actuator version (10XX, 20XX, 3035)

LK

G

SW

T

DIN ISO 5211

Actuator version(code)

Connection size(code)

Location spigot(code)

SW G LK T

10XX / 20XX G05 Y S08 Ø5.5 48 15

10XX / 20XX F03 N S09 M5 36 16

10XX / 20XX F04 N S09 M5 42 16

10XX / 20XX F05 N S09 M6 50 16

10XX / 20XX F05 N S11 M6 50 16

3035 F05 Y S14 M6 50 22

Dimensions in mm


8 Dimensions

8.2 Ball valve body

fb

L

øgøe

h

økØD

45°22,5°

Ø d x Y

F2F1

h1

B

Actuator flange

DN Actuator flange ØD L Z b d Øe f Øg h h1 Øk

F1 F2 B

15 F03 36 ø6x4 F04 ø6x4 9 81 41 4 16 M12 15 2 45 49 7 65

20 F03 36 ø6x4 F04 ø6x4 9 99 44 4 18 M12 20 2 58 54 8 75

25 F04 42 ø6x4 F05 ø7x4 11 115 50 4 18 M12 25 2 68 65 12 85

32 F04 42 ø6x4 F05 ø7x4 11 140 60 4 18 M16 32 2 78 77 11.3 100

40 F05 50 ø7x4 F07 ø9x4 14 150 65 4 18 M16 38 3 88 88.5 15.5 110

50 F05 50 ø7x4 F07 ø9x4 14 165 80 4 20 M16 50 3 102 93 16 125

65 F07 70 ø9x4 F10 ø11x4 17 185 110 4 22 M16 65 3 122 109.7 15.8 145

80 F07 70 ø9x4 F10 ø11x4 17 200 120 8 24 M16 80 3 138 119.5 16 160

100 F07 70 ø9 x 4 F10 ø11x4 17 220 150 8 24 M16 100 3 158 132.7 17.8 180


8 Dimensions


9 Manufacturer's information

9.1 Delivery

● Check that all parts are present and check for any damageimmediately upon receipt.

The product's performance is tested at the factory. The scopeof delivery is apparent from the dispatch documents and thedesign from the order number.

9.2 Packaging

The product is packed in a cardboard box which can be re-cycled as paper.

9.3 Transport

1. Only transport the product by suitable means. Do not drop.Handle carefully.

2. After the installation dispose of transport packing materialaccording to relevant local or national disposal regula-tions / environmental protection laws.

9.4 Storage

1. Store the product free from dust and moisture in its ori-ginal packaging.

2. Avoid UV rays and direct sunlight.3. Do not exceed the maximum storage temperature (see

chapter "Technical data").4. Do not store solvents, chemicals, acids, fuels or similar

fluids in the same room as GEMÜ products and their spareparts.

10 Installation in piping

10.1 Preparing for installation

WARNINGThe equipment is subject to pressure!▶ Risk of severe injury or death.● Depressurize the plant.● Completely drain the plant.

WARNINGCorrosive chemicals▶ Risk of caustic burns● Wear suitable protective gear.● Completely drain the plant.

CAUTIONHot plant components!▶ Risk of burns!● Only work on plant that has cooled

down.

CAUTIONExceeding the maximum permissible pressure.▶ Damage to the GEMÜ product.● Provide precautionary measures against exceeding the

maximum permitted pressures caused by pressuresurges (water hammer).

CAUTIONUse as step.▶ Damage to the product.▶ Risk of slipping-off.● Choose the installation location so that the product can-

not be used as a foothold.● Do not use the product as a step or a foothold.

NOTICESuitability of the product!▶ The product must be appropriate for the piping system

operating conditions (medium, medium concentration,temperature and pressure) and the prevailing ambientconditions.




NOTICETools▶ The tools required for installation and assembly are not

included in the scope of delivery.● Use appropriate, functional and safe tools.

1. Ensure the product is suitable for the relevant application.2. Check the technical data of the product and the materials.3. Keep appropriate tools ready.4. Wear appropriate protective gear, as specified in the plant

operator's guidelines.5. Observe appropriate regulations for connections.6. Have installation work carried out by trained personnel.7. Shut off plant or plant component.8. Secure plant or plant component against recommission-

ing.9. Depressurize the plant or plant component.10. Completely drain the plant (or plant component) and let it

cool down until the temperature is below the media vapor-ization temperature and cannot cause scalding.

11. Decontaminate, rinse and ventilate the plant or plant com-ponent properly.

12. Lay piping so that the product is protected against trans-verse and bending forces, and also from vibrations andtension.

13. Only mount the product between matching aligned pipes(see following chapters).

14. Flow direction and installation position are optional.

10.2 Installation for flanged connection

NOTICE▶ Observe valid standards for mounting flanges!

SW3

Attention!

Onlyactuate when power is switched off

Manual override

F1 D 1 D F21. Ensure sealing surfaces on the mating flanges are clean

and undamaged.2. Only use connector elements made of approved materials!3. Install the ball valve in the state it is delivered.4. Carefully align the ball valve body 1 centrally between the

pipes with flanges (F1 and F2).5. Centre the seals D accurately. Seals are not included in the

scope of delivery.6. Connect the ball valve flange and the piping flange using

appropriate sealing material and matching bolting. Sealingmaterial and bolts are not included in the scope of deliv-ery.


SW3

Attention!


Manual override

SN M

7. Insert bolts SN in all holes in the flange.8. Slightly tighten the bolts SN and nuts M diagonally.

9. Check the alignment of the piping.10. Tighten nuts M diagonally.Comply with appropriate regulations for the connections!After the installation:11. Re-attach or reactivate all safety and protective devices.


11 Electrical connection

11.1 Connection and wiring diagram – actuator version 1015, 2015, 3035

11.1.1 Control module A0/AE

12 V DC (code B1) / 24 V DC (code C1)

Assignment of the terminal strips

12345

Item Description

1 Uv+, direction of travel CLOSED

2 Uv-, direction of travel CLOSED

3 Uv+, direction of travel OPEN

4 Uv-, direction of travel OPEN

5 PE, protective earth conductor

Connection diagram

+ − PE

12345

0

S3

Limit switch OPEN

Limit switch CLOSED

Term

inal

stri

p

CLO

SED

OPE

N

Motor

Externalwiring

S3 Actuator

CLOSED Direction of travel CLOSED

0 OFF

OPEN Direction of travel OPEN



100 - 250 V AC (code 04)

Position of the connectors

X1

Electrical connection

21

34

65

Plug assignment X1

Pin Description

1 L1, supply voltage

2 N, supply voltage

3 L1, direction of travel CLOSED

4 N, direction of travel CLOSED

5 L1, direction of travel OPEN

6 N, direction of travel OPEN

PE, protective earth conductor

The potential must be assigned by the user.

Connection diagram

1 26

53

4

L1

PEN

External wiring

OPENCLOSED



11.2 Connection and wiring diagram – actuator version 2070, 4100, 4200

11.2.1 Control module A0

24 V DC (code C1), 120 V AC (code G4) and 230 V AC (code L4)


X2X1 X2 X1 X2

X1

Actuator version 2070 Actuator version 4100, 4200


13 2

654

Plug assignment X1

Pin Description

1 L1 / Uv+, supply voltage

2 N / Uv-, supply voltage

3 L1 / Uv+, direction of travel CLOSED

4 N / Uv-, direction of travel CLOSED

5 L1 / Uv+, direction of travel OPEN

6 N / Uv-, direction of travel OPEN


N/L- signals in the unit are separated.The potential must be assigned by the user.When the OPEN and CLOSED switches are operated simultaneously the actuator moves in the "CLOSED" direction.Pins 2, 4 and 6 can be connected in the connector plug, so you can also use a 5-wire cable.

Connection diagram

13 2

654

L1/ Uv+N / Uv-

PEOPEN CLOSED

External wiring



11.2.2 Control module AE



X2X1 X2 X1 X2

X1



13 2

654 1

3 2

654

Plug assignment X1 Plug assignment X2

Pin Description Pin Description

1 L1 / Uv+, supply voltage 1 Change-over contact limit switch CLOSED

2 N / Uv-, supply voltage 2 Make contact limit switch CLOSED

3 L1 / Uv+, direction of travel CLOSED 3 Break contact limit switch CLOSED

4 N / Uv-, direction of travel CLOSED 4 Break contact limit switch OPEN

5 L1 / Uv+, direction of travel OPEN 5 Make contact limit switch OPEN

6 N / Uv-, direction of travel OPEN 6 Change-over contact limit switch OPENPE, protective earth conductor PE, protective earth conductor


Connection diagram

13 2

654

L1/ Uv+N / Uv-

PEOPEN CLOSED

External wiring

13 2

654

1 4 2 142

OPEN CLOSED

Additional limit switches

Connection assignment X1 Connection assignment X2



11.2.3 Control module AP



X2X1 X2 X1 X2

X1



13 2

654 1

3 2

654



1 L1 / Uv+, supply voltage 1 n. c.

2 N / Uv-, supply voltage 2 n. c.

3 L1 / Uv+, direction of travel CLOSED 3 n. c.

4 N / Uv-, direction of travel CLOSED 4 Us-, actual value potentiometer signal voltage minus

5 L1 / Uv+, direction of travel OPEN 5 Us -⌐, actual value potentiometer signal output

6 N / Uv-, direction of travel OPEN 6 Us+, actual value potentiometer signal voltage plusPE, protective earth conductor PE, protective earth conductor


Connection diagram

13 2

654

L1/ Uv+N / Uv-

PEOPEN CLOSED

External wiring

13 2

654

0

Actual value potentiometer




11.2.4 Control module E1



X2X1 X2 X1 X2

X1



132

13 2

654



1 L1 / L+, supply voltage 1 n.a. (do not use)

2 N / L-, supply voltage 2 n.a. (do not use)

3 n. c. 3 U-, external set value 0-10VPE, protective earth conductor 4 U+, external set value 0-10V

5 n. c.

6 n. c.


Set value and supply voltage must be galvanically isolated.The potential must be assigned by the user.

Connection diagram

L1 / L+N / L-

PE

132

External wiring

13 2

654

PositionerValve position

Motor

Exte

rnal

set

val

ue




11.2.5 Control module E2

24 V DC (code C1), 24 V AC (code C4), 120 V AC (code G4) and 230 V AC (code L4)


X2X1 X2 X1 X2

X1



132

13 2

654



1 L1 / L+, supply voltage 1 n.a. (do not use)

2 N / L-, supply voltage 2 n.a. (do not use)

3 n. c. 3 I-, external set value 4-20mAPE, protective earth conductor 4 I+, external set value 4-20mA

5 n. c.

6 n. c.


Set value and supply voltage must be galvanically isolated.The potential must be assigned by the user.

Connection diagram

L1 / L+N / L-

PE

132

External wiring

13 2

654

PositionerValve position

Motor

Exte

rnal

set

val

ue





12 Limit switches

DANGERRisk of electric shock▶ Risk of injury or death (if operating

voltage is higher than safe extra lowvoltage).

▶ Adjustments are made with the actu-ator cover removed.

▶ Electric shock can cause severe burnsand fatal injury.

● Always disconnect the product frompower supply!

● Therefore, have all work performedonly by qualified electricians.

CAUTIONIncorrectly adjusted limit switch!▶ Actuator continues running.▶ Damage to the actuator.● Do not move the limit switch too far outwards.

NOTICETools required for setting the limit switches:● Allen key SW3● Small Philips head screw driver

NOTICE● Always switch the limit switch for signal so that the mo-

tor switch is actuated first.ð Limit switches for signal and motor are already preset.

12.1 Setting the limit switch for 1015, 2015 and 3035

The motorized actuator versions 1015, 2015 and 3035 aresupplied in the open position.The "OPEN" and "CLOSED" end positions are set using limitswitches. These are actuated using the levers and can be ad-justed by loosening the 2 screws.The following drawings differ depending on the actuator ver-sion!1. Disconnect the plant from power supply and secure

against recommissioning.

2. Remove the protective caps 1.3. Undo screws 2.4. Remove the cover of the actuator 3.

5. Undo the screws on the corresponding limit switch(4 = "CLOSED", 5 = "OPEN").

6. Move limit switches to the desired position.7. Tighten limit switch screws.

12 Limit switches


13 Commissioning

1

2

3

8. Put on cover of actuator 3.9. Tighten cover 3.10. Put on protective caps 1.

ð Limit switches are set.

12.2 Setting the limit switch for 2070, 4100, 4200

The motorized actuator versions 2070, 4100 and 4200 aresupplied in the open position.The "OPEN" and "CLOSED" end positions are set using limitswitches. These are actuated using the levers and can be ad-justed by loosening the 2 screws.

CAUTIONIncorrectly adjusted limit switch!▶ Actuator continues running.▶ Damage to the actuator.● Do not move the limit switch too far outwards.

Versions 00, 0E, 0P: – The actuator is not reversible, i.e. it must be held

briefly when switching over from "OPEN" to "CLOSED"or "CLOSED" to "OPEN".

– For the above actuator types, overall height 1 applies.Versions A0, AE, AP, E1, E2: – The actuator is reversible, i.e. it can be switched dir-

ectly from "OPEN" to "CLOSED". To this end, a deadzone of 200 ms is integrated into the electronic sys-tem, i.e. when switching over, the actuator does notrun for this time.

– Independent of the supply voltage, the OPEN/CLOSEcontrol is freely selectable via a mains supply of 24 VDC, 24 V AC up to 250 V AC or operated directly via aPLC.

– An electronic current limitation limits the torque.– For the above actuator types (except for code 2070),

overall height 2 applies.







13 Commissioningü The product is installed in piping.

ü The product is connected electrically.

ü Limit switches on the product are set.1. Check the tightness and the function of the product (close

and reopen the product).2. Flush the piping system of new plant and following repair

work (the product must be fully open).

ð Harmful foreign matter has been removed.

ð The product is ready for use.3. Commission the product.


14 Operation

14.1 Normal operation

For opening or closing, the product must be activated in ac-cordance with the electrical connection.

14.2 Optical position indicator

The actuator has an optical position indicator which indicatesthe position of the actuator.

Actuator versions 1015, 2015, 3035

CLOSED OPEN

Actuator version 2070

openoffen

closed zu

CLOSED OPEN

Actuator versions 4100, 4200

OPEN CLOSED

14.3 Manual override

CAUTIONOnly actuate the manual override when the power isswitched off.▶ Damage to the actuator!

CAUTIONSet the actuator position to "centred" after using the manualoverride!▶ Trip cams may be outside the limit switches as the limit

switch position was manually exceeded by the manualoverride.

▶ Damage to the actuator.● Set the actuator position to "centred" before electrical op-

eration.

14.3.1 Manual overrides 1015, 2015, 3035

Actuator version 1015 and 2015

2 = OPEN

1 = CLOSED

Attention! Manual override


operationemergency

CLOSED

OPEN


2 = CLOSED

1 = OPEN

1. Disconnect the plant from power supply and secureagainst recommissioning.

2. Remove red protective cap.

3. To open the valve, turn the Allen key (SW3) clockwise 1until the position indicator shows "open".

4. To close the valve turn the Allen key (SW3) anti-clock-wise 2 until the position indicator shows "closed".

5. Reinsert red protective cap.

14 Operation


14 Operation

14.3.2 Manual overrides 2070, 4100, 4200

On the side of the actuator there is a blanking cover for themanual override. The crank handle for manual override is loc-ated on the base of the actuator. Actuation of the manualoverride additionally actuates a switch that shuts off power tothe actuator.

Example: Actuator version 2070

Blanking cover for manual override

Crank handle for manual override

If manual override is required, take the following steps:1. Unscrew the blanking cover using a screw driver.2. Insert crank handle and actuate the actuator by hand.Crank into the desired valve position (in the direction indic-ated on label):


Clockwise: OPEN

Anticlockwise: CLOSED

Actuator versions 4100, 4200

Clockwise: CLOSED

Anticlockwise: OPEN

15 Troubleshooting

Error Possible cause Troubleshooting

Valve doesn't open/close or doesn'topen/close fully

Operating pressure too high Operate the product with operatingpressure specified in datasheet

The actuator design is not suitable for theoperating conditions

Use an actuator that is designed for theoperating conditions

Seat and flange seals incorrectlymounted

Replace seat and flange seals or mountthem correctly (see chapter "Replacingseals")

Actuator defective Replace the actuator

Voltage is not connected Connect voltage

Cable ends incorrectly wired Wire cable ends correctly

End positions incorrectly set Correctly set the end positions

Foreign matter in the product Remove and clean the product

The product leaks between actuator andvalve body

Actuator/valve body damaged Replace actuator/valve body

Bolting between valve body and actuatorloose

Retighten bolting between valve body andactuator

Seals faulty Replace seals

Valve body connection to piping leaks Incorrect installation Check installation of valve body in piping

Flange bolting loose/thread leaking Retighten flange bolting / reseal threads

Flange seals faulty Replace flange seals

Valve body leaks Incorrect installation Check installation of valve body in piping

Seat and flange seals incorrectlymounted

Mount seat and flange seals correctly(see chapter "Replacing seat seals")

Wrong seat and flange seals mounted Replace seat and flange seals (seechapter "Replacing seat seals")

Seat and flange seals faulty Replace seat and flange seals (seechapter "Replacing seat seals")

Valve body leaks or is corroded Check valve body for damage, replacevalve body if necessary

15 Troubleshooting



16 Inspection/maintenance


WARNINGThe equipment is subject to pressure!▶ Risk of severe injury or death.● Depressurize the plant.● Completely drain the plant.

CAUTIONHot plant components!▶ Risk of burns!● Only work on plant that has cooled

down.

CAUTION● Servicing and maintenance work must only be performed

by trained personnel.● Do not extend hand lever. GEMÜ shall assume no liability

whatsoever for damages caused by improper handling orthird-party actions.

● In case of doubt, contact GEMÜ prior to commissioning.

1. Use appropriate protective gear as specified in plant oper-ator's guidelines.

2. Shut off plant or plant component.3. Secure against recommissioning.4. Depressurize the plant or plant component.The operator must carry out regular visual examinations ofthe ball valves, dependent on the operating conditions and thepotential danger in order to prevent leakage and damage. Theball valve also has to be disassembled in corresponding inter-vals and checked for wear (see chapter "Removal from pip-ing").

16.1 Spare parts

A

1

109

2175644

44

Item Name Order description

1 Ball valve body assembly K762..

4 Seat and flange seals

SP.761/762DN…

5 Seal

6 Seal

7 Conical spindle seal

9 V-ring spindle packing

10 V-ring

21 O-ring

A Actuator dependent on theversion

Description Order number

Spare parts kit for DN 15 88297188










16.2 General information regarding actuatorreplacement

NOTICEThe following tools are required for actuator replacement:● Open-end wrench● Ring wrench

SZ

● Check the position of the ball indicated by the groove SZand compare with position indicator, rotate ball valve tocorrect position if necessary.

ð Groove transverse to piping direction: Ball valve closed.

ð Groove in piping direction: Ball valve open.

NOTICE▶ For flanged bodies, the actuator is fitted offset by 90°.

16.3 Replacing the actuator







16.3.1 Removing the actuator

SW3

A

31

32

Attention! Manual override


1. Disconnect the actuator from the power supply.2. Remove the protective caps 30.3. Unscrew the hexagon screws 32.4. Do not lose the washers 31.5. The actuator A can be removed from the ball valve body.




16.3.2 Mounting the actuator

SW3

A

3132

Attention!


Manual override

1. Push the new actuator A onto the ball valve body.2. Turn the actuator until the hexagon screws 32 can be in-

serted.3. Tighten the hexagon screws 32 with their washers 31 until

hand tight.4. Diagonally tighten the hexagon screws 32 evenly until

they are hand tight.5. Put the protective caps 30 back on.6. Reconnect the actuator to the power supply.

16.4 Replacing the seals

NOTICE● Only use genuine GEMÜ spare parts.● When ordering spare parts, specify the complete order

number of the ball valve.

1. Remove actuator (see chapter "Removing the actuator").

13

2. Bend the tab 13 of the screw locking device downwards.

14

13

1212

11

3. Loosen spindle nut 14 and remove.4. Remove screw locking device 13.5. Remove upper spring washer 12.6. Remove lower spring washer 12.7. Remove stainless steel sleeve 11.


SN M D M SN

8. Loosen bolts SN with nuts M and remove with seals D.9. Remove the ball valve from the piping.

Side view

4 6 5 2 2 2a

10. Remove screwed in side piece 2 of the ball valve:- Insert a suitable tool into the holes 2a.- Unscrew the side piece 2.

NOTICE▶ DN 100: Seal 4 non existent.

11. Remove seals 4, 5 and front seat seal 6 from main part ofball valve.

6 3

12. Move the ball to the closed position.13. Remove the ball 3 and the rear seat seal 6.

14. Press shaft carefully into the body and remove it.

9

7 21

15. Remove seals 9 upwards from the ball valve.



17 Removal from piping

NOTICE▶ Seals 9:▶ DN 15-80: 2 pieces▶ DN 100: 3 pieces

16. Take off O-ring 7 from shaft.17. Take off seal 21 from shaft.18. Mount the seals and the ball valve in reverse order.

17 Removal from piping1. Remove the clamp or screw connections in reverse order

to installation.2. Remove welded or solvent cemented connections using a

suitable cutting tool.3. Observe the safety information and accident prevention

regulations.

18 Disposal1. Pay attention to adhered residual material and gas diffu-

sion from penetrated media.2. Dispose of all parts in accordance with the disposal regu-

lations/environmental protection laws.

19 ReturnsLegal regulations for the protection of the environment andpersonnel require that the completed and signed return deliv-ery note is included with the dispatch documents. Returnedgoods can be processed only when this note is completed. Ifno return delivery note is included with the product, GEMÜcannot process credits or repair work but will dispose of thegoods at the operator's expense.1. Clean the product.2. Request a return delivery note from GEMÜ.3. Complete the return delivery note.4. Send the product with a completed return delivery note to

GEMÜ.

20 Declaration of Incorporation according to 2006/42/EC (Machinery Directive)

Declaration of Incorporationaccording to the EC Machinery Directive 2006/42/EC, Annex II, 1.B for partly

completed machinery

We, GEMÜ Gebr. Müller Apparatebau GmbH & Co. KGFritz-Müller-Straße 6-874653 Ingelfingen-Criesbach, Germany

declare that the following product

Make: GEMÜ

Commercial name: GEMÜ 768

meets the following essential requirements of the Machinery Directive 2006/42/EC:We also declare that the specific technical documentation has been compiled in accordance with part B of Annex VII. The manufacturer or his authorised representative undertake to transmit, in response to a reasoned request by the national au-thorities, relevant information on the partly completed machinery. This transmission takes place:Electronically

Authorised documentation officer GEMÜ Gebr. Müller Apparatebau GmbH & Co. KGFritz-Müller-Straße 6-874653 Ingelfingen, Germany

This does not affect the industrial property rights!Important note! The partly completed machinery may be put into service only if it was determined, where appropriate, that themachinery into which the partly completed machinery is to be installed meets the provisions of this Directive.

Ingelfingen-Criesbach 2018-06-07

Joachim BrienHead of Technical Department


20 Declaration of Incorporation according to 2006/42/EC (Machinery Directive)

21 Declaration of conformity according to 2014/30/EU (EMC Directive)

EU Declaration of Conformityaccording to 2014/30/EU (EMC Directive)

We, GEMÜ Gebr. Müller Apparatebau GmbH & Co. KGFritz-Müller-Straße 6-874653 Ingelfingen-Criesbach, Germany

declare that the product listed below complies with the safety requirements of the EMC Directive 2014/30/EU.

Description of the product: GEMÜ 768

Technical standards used:

Interference emission: DIN EN 61800-3Interference resistance: DIN EN 61326-1 (industrial processes)

DIN EN 61800-3

Ingelfingen-Criesbach 2018-07-03

Joachim BrienHead of Technical Department


21 Declaration of conformity according to 2014/30/EU (EMC Directive)

22 EU Declaration of conformity 2-way metal ball valveThe type TW-1F16 corresponds to the ball valve GEMÜ 768.

EU DECLARATION OF CONFORMITY According to Annex IV of Directive 2014/68/EU – Pressure Equipment

EU DOC No.：DC-TW-1F16(Series 99-10)

Manufacturer:

Transworld Steel Enterprise Co.,Ltd.

Manufacturing Plant: No. 34, 14th Road, Da-Li Industrial Park, Da-Li City, Taichung Hsien, 412, Taiwan, R.O.C.

Characteristics of pressure Equipment : Description of pressure equipment/assembly:

One-Piece Wafer Type Flange PN16 Ball Valve

For gases, group 1 NPS PN

Type / model: TW-1F16 DN 15~100 PN 16

Category: DN 15 ~ DN 25 S.E.P DN 32 ~ DN 50 Category I DN 65 ~ DN 100 Category II

Conformity assessment procedure: Module H (Full Quality Assurance) Module H Certificate NO: 01 202 TWN/Q-3 0075 Respective EC Design-Examination Certificate: Notified Body : TÜV Rheinland industries Service GmbH Am Grauen Stein D-51101 Cologne, Germany

Identification No.: 0035 Harmonized Standards other techn. Standards & Specifications

applied EN 12516-1，EN12266-1 ASME B16.34，API 598，ISO 5211

DIN 2543 PN16 EN 10213，ASTM A276

Other European Directives applied: None I,the undersigned, on behalf of, Transworld Steel Enterprise Co., Ltd. declare that the design, manufacturing and inspection of the pressure equipment described above are in conformity with the provisions of the Directive Annex I of 2014/68/EU referred to as the EC Pressure Equipment Directive and Technical standards and Specification aforementioned. _______2016.12.15_______ _________________________

Taichung , Taiwan Name, President

22 EU Declaration of conformity 2-way metal ball valve


GEMÜ Gebr. Müller Apparatebau GmbH & Co. KGFritz-Müller-Straße 6-8, 74653 Ingelfingen-Criesbach, GermanyPhone +49 (0)7940 123-0 · [email protected]

Subject to alteration

12.2019 | 88601495

*88601495*

mailto:[email protected]

http://www.gemu-group.com

ba 768 gb - gemu-group.com

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