gemÜ 649 esydrive - gemu-group.com · gemÜ 649 4 / 41 1 general information 1 general information...

GEMÜ 649 eSyDriveMotorized diaphragm valve

Operating instructionsEN

further informationwebcode: GW-649

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

Keep the document for future reference.

© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG08.07.2020

www.gemu-group.com2 / 41GEMÜ 649

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

1.1 Information ......................................................... 41.2 Symbols used ..................................................... 41.3 LED symbols ....................................................... 41.4 Definition of terms ............................................. 41.5 Warning notes .................................................... 4

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

3.1 Construction ....................................................... 53.3 Function .............................................................. 73.4 Correct use ......................................................... 7

4 Correct use ............................................................... 75 GEMÜ CONEXO ......................................................... 86 Reading out the RFID transponder ............................. 97 Order data ................................................................. 10

7.1 Order codes ........................................................ 107.2 Order example .................................................... 12

8 Technical data .......................................................... 138.1 Medium ............................................................... 138.2 Temperature ....................................................... 138.3 Pressure .............................................................. 148.4 Product compliance ........................................... 158.5 Mechanical data ................................................. 158.6 Electrical data ..................................................... 16

9 Dimensions ............................................................... 189.1 Actuator dimensions .......................................... 189.2 Body dimensions ................................................ 19

10 Delivery ..................................................................... 2811 Transport .................................................................. 2812 Storage ..................................................................... 2813 Installation in piping .................................................. 28

13.1 Preparing for installation ................................... 2813.2 Installation position ........................................... 2913.3 Installation with clamp connections ................. 2913.4 Installation with butt weld spigots .................... 2913.5 Installation with threaded sockets .................... 2913.6 Installation with threaded spigots .................... 2913.7 Installation with flanged connection ................. 30

14 Electrical connection ................................................. 3015 Network connection .................................................. 31

15.1 Network settings ................................................ 3115.2 Connecting the network ..................................... 3115.3 Resetting the network settings ......................... 31

16 Commissioning ......................................................... 3117 Operation .................................................................. 32

17.1 Operation on the device ..................................... 3217.2 Operation via the web server ............................. 3217.3 Manual override .................................................. 32

18 Inspection and maintenance ...................................... 3318.1 Spare parts ......................................................... 3318.4 Mounting the compressor ................................. 3418.5 Mounting the diaphragm ................................... 34

19 Troubleshooting ........................................................ 3620 Removal from piping ................................................. 3721 Disposal .................................................................... 3722 Returns ..................................................................... 37

23 Declaration of Incorporation according to 2006/42/EC (Machinery Directive) ........................................... 38

24 Declaration of conformity according to 2014/68/EU(Pressure Equipment Directive) ................................. 39

25 Declaration of conformity according to 2014/30/EU(EMC Directive) ......................................................... 40

GEMÜ 649www.gemu-group.com 3 / 41


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 MeaningTasks to be performedResponse(s) to tasks

– Lists

1.3 LED symbols

The following LED symbols are used in the documentation:

Symbol LED conditionsOff

Lit (on)

Flashing

1.4 Definition of terms

Working mediumThe medium that flows through the GEMÜ product.Diaphragm sizeUniform seat size of GEMÜ diaphragm valves for differentnominal sizes.

1.5 Warning notes

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

SIGNAL WORD

Type and source of the dangerPossiblesymbol for thespecificdanger

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 MeaningDanger of explosion

Danger of explosion!

Corrosive chemicals!

Hot plant components!

Rotating cover!

www.gemu-group.com 5 / 41 GEMÜ 649

2 Safety informationThe safety information in this document refers only to an in-dividual product. Potentially dangerous conditions can arisein combination with other plant components, which need tobe considered on the basis of a risk analysis. The operator isresponsible for the production of the risk analysis and forcompliance with the resulting precautionary measures andregional safety regulations.The document contains fundamental safety information thatmust be observed during commissioning, operation andmaintenance. Non-compliance with these instructions maycause:– 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 specifica-

tions.13. Maintain the product correctly.14. Do not carry out any maintenance work and repairs not

described in this document without consulting the manu-facturer first.

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

3 Product description

3.1 Construction

3.1.1 Construction

7

81

2

3

4

5

6

9

Item Name Materials1 O-rings NBR2 Electrical connections3 Actuator base 1.43014 Distance piece with

leak detection hole1.4408

5 Diaphragm CR, EPDM, FPM, NBR,PTFE,

6 Valve body 1.4408, 1.4435, 1.4439,cast iron, SG ironDepending on version,also with elastomer orplastic lining

7 Optical positionindicator

PESU

8 Cover with highvisibility LED, manualoverride and on-sitecontrol

PESU

9 CONEXO RFID chip




3.1.2 Buttons for on-site control

89

10

Fig. 1: Position of the buttons

Item Name Function8 DIP switch, "ON-

site" controlSwitches the on-sitecontrol on the deviceon or off

9 "OPEN" button Moves actuator tothe open positionResets the networksettings

10 "INIT/CLOSE"button

Moves actuator tothe closed positionStarting initialisation

3.1.3 LED displays

3.1.3.1 On-site status LEDs

LED MODE LED PWR

Fig. 2: Position of the status LEDsThe user checks the following conditions directly on-site atthe valve using LED MODE and LED PWR:

Function LED MODE LED PWR

Yellow Blue Green RedAutomaticoperation

Manualoperation

Actuatorswitched off(OFF mode)

Manualoperation (on-site)

Software update

alternatingOn-siteinitialisation(buttons)

Remoteinitialisation (viaDigIn)


Function LED MODE LED PWR

Yellow Blue Green RedOperation viaemergencypower supplymodule

3.1.3.2 High visibility LEDs

11

11 11

11 11

11Fig. 3: Position of the high visibility LEDs

Item Name11 High visibility LEDs

Function High visibility LED

Green OrangeOPEN position Position indicator

LEDs,standard

OPEN position Position indicatorLEDs,inversed

CLOSED position Position indicatorLEDs,standard

CLOSED position Position indicatorLEDs,inversed

Position unknown (e.g. 50%)

Initialisation

alternating

Function High visibility LED

Green OrangeLocation function

3.2 Description

The GEMÜ 649 diaphragm valve is actuated by a motorizedhollow shaft actuator. It is based on technology that does notuse brushes or sensors and therefore guarantees high per-formance and a long service life. In addition to OPEN/CLOSEapplications, the valve is ideal for variable and complex con-trol applications. The actuator has an integrated web serverfor parameterization and diagnosis purposes.

3.3 Function

The product controls or regulates (depending on version) aflowing medium by being closed or opened by a motorizedactuator.The product has an optical position indicator as standard.The optical position indicator indicates the OPEN andCLOSED positions.

3.4 Correct use

DANGERDanger of explosion▶ Risk of death or severe injury.● Do not use the product in potentially

explosive zones.

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 andin this document.

The product is designed for installation in piping systemsand for controlling a working medium.The product is not intended for use in potentially explosiveareas.

● Use the product in accordance with the technical data.

4 Correct use

DANGERDanger of explosion!▶ Risk of severe injury or death.● Do not use the product in potentially

explosive zones.● Only use the product in potentially ex-

plosive zones confirmed in the declar-ation of conformity.

4 Correct use


5 GEMÜ CONEXO

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 andin this document.

The product is designed for installation in piping systemsand for controlling a working medium.1. Use the product in accordance with the technical data.2. Note the supplement acc. to ATEX3. Please note the flow direction on the valve body.

5 GEMÜ CONEXOFor electronic identification purposes, each replaceable com-ponent contained in the product you have purchased isequipped with an RFID transponder (1). Where you can findthe RFID transponder differs from product to product.

1

Fig. 4: Actuator RFID transponder

1Fig. 5: Diaphragm RFID transponder

1

Fig. 6: Valve body RFID transponderThe CONEXO pen helps read out information stored in theRFID transponder. The CONEXO app or CONEXO portal is re-quired to view this information.


6 Reading out the RFID transponder

1. Press the On/Off key 4 on the CONEXO pen.

ð The CONEXO pen has been switched on.

ð LED 1 flashes.2. Connect the CONEXO pen to the tablet.

ü The user finds themselves in a menu within the CONEXOapp where a scanning operation is requested.

3. Hold the CONEXO pen directly against the RFID chip of acomponent or functional location and press the scan key8.

ð If an RFID chip has been scanned correctly, the LED 7turns green.

ð If an RFID chip has not been scanned correctly, the LED 5turns red.

ð An audible signal is emitted during a correct scan pro-cess.

ð The data that is read out is transferred to the CONEXOapp.

4. Scan as many components as required.5. Hold down the On/Off key 4 for at least three seconds.

ð The CONEXO pen has been switched off.

6 Reading out the RFID transponder

7 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 CodeDiaphragm valve, electrically operated,electro-mechanical hollow shaft actuator,eSyDrive

649

2 DN CodeDN 10 10DN 12 12DN 15 15DN 20 20DN 25 25

2 Continuation of DN CodeDN 32 32DN 40 40DN 50 50DN 65 65

3 Body configuration CodeTank bottom valve body B2/2-way body DT body T

Body configuration code B: Dimensions and designs on request

Body configuration code T: For dimensions, see T Valves brochure

4 Connection type Code

SpigotSpigot DIN 0Spigot EN 10357 series B,formerly DIN 11850 series 1

16

Spigot EN 10357 series A (formerly DIN 11850series 2)/DIN 11866 series A

17

Spigot DIN 11850 series 3 18Spigot JIS-G 3447 35Spigot JIS-G 3459 schedule 10s 36Spigot SMS 3008 37Spigot ASME BPE / DIN 11866 series C 59Spigot ISO 1127/EN 10357 series C/DIN 11866series B

60

Spigot ANSI/ASME B36.19M schedule 10s 63Spigot ANSI/ASME B36.19M schedule 40s 65Threaded connectionThreaded socket DIN ISO 228 1Threaded spigot DIN 11851 6Threaded spigot on one side, DIN 11851,cone spigot and union nut, DIN 11851 on the otherside

62

FlangeFlange EN 1092, PN 16, form B,face-to-face dimension FTF EN 558 series 1, ISO5752, basic series 1,length only for body configuration D

8

Flange ANSI Class 150 RF,face-to-face dimension FTF MSS SP-88,length only for body configuration D

38

Flange ANSI Class 125/150 RF,face-to-face dimension FTF EN 558 series 1, ISO5752, basic series 1,length only for body configuration D

39

4 Continuation of Connection type Code

ClampClamp ASME BPE,face-to-face dimension FTF ASME BPE,length only for body configuration D

80

Clamp DIN 32676 series B,face-to-face dimension FTF EN 558 series 7,length only for body configuration D

82

Clamp ASME BPE,face-to-face dimension FTF EN 558 series 7,length only for body configuration D

88

Clamp DIN 32676 series A,face-to-face dimension FTF acc. to EN 558 series7,length only for body configuration D

8A

Clamp ISO 2852/SMS 3017,face-to-face dimension FTF EN 558 series 7,length only for body configuration D

8E

5 Valve body material CodeEN-GJL-250 (GG 25) 8EN-GJS-400-18-LT (GGG 40.3),PFA lined

17

EN-GJS-400-18-LT (GGG 40.3),PP lined

18

1.4408, investment casting 371.4408, PFA lined 391.4435 (F316L), forged body 401.4435 (BN2), forged body, Δ Fe < 0.5% 42EN-GJS-400-18-LT (GGG 40.3),hard rubber lined

83

1.4435, investment casting C31.4539, forged body F4

7 Order data


6 Diaphragm material CodeNBR 2FPM 4CR 8EPDM 13EPDM 17EPDM 36

7 Voltage/Frequency Code24 V DC C1

8 Control module CodeON/OFF, positioner and process controller L0

9 Surface CodeRa ≤ 6.3 μm (250 μin.) for media wetted surfaces,mechanically polished internal

1500

Ra ≤ 0.8 µm (30 µin.) for media wetted surfaces,in accordance with DIN 11866 H3,mechanically polished internal

1502

Ra ≤ 0.8 µm (30 µin.) for media wetted surfaces,in accordance with DIN 11866 HE3,electropolished internal/external

1503

Ra ≤ 0.6 μm (25 μin.) for media wetted surfaces,mechanically polished internal

1507

Ra ≤ 0.6 µm (25 µin.) for media wetted surfaces,electropolished internal/external

1508

Ra ≤ 0.4 µm (15 µin.) for media wetted surfaces,in accordance with DIN 11866 H4,mechanically polished internal

1536

Ra ≤ 0.4 µm (15 µin.) for media wetted surfaces,in accordance with DIN 11866 HE4,electropolished internal/external

1537

Ra ≤ 0.25 μm (10 µin.) for media wetted surfaces*),in accordance with DIN 11866 HE5,electropolished internal/external,*) for inner pipe diameters < 6 mm, in the spigotRa ≤ 0.38 μm

1516

Ra ≤ 0.25 μm (10 µin.) for media wetted surfaces*),in accordance with DIN 11866 H5,mechanically polished internal,*) for inner pipe diameters < 6 mm, in the spigotRa ≤ 0.38 μm

1527

Ra max. 0.51 µm (20 µin.) for media wettedsurfaces,in accordance with ASME BPE SF1,mechanically polished internal

SF1


SF2


SF3

9 Continuation of Surface CodeRa max. 0.38 µm (15 µin.) for media wettedsurfaces,in accordance with ASME BPE SF4,electropolished internal/external

SF4

Ra max. 0.51 µm (20 µin.) for media wettedsurfaces,in accordance with ASME BPE SF5,electropolished internal/external

SF5

Ra max. 0.64 µm (25 µin.) for media-wettedsurfaces,in accordance with ASME BPE SF6,electropolished internal/external

SF6

10 Actuator version CodeActuator size 0 0AActuator size 1 1AActuator size 2 2 A

11 Special version CodeSpecial version for oxygen,maximum medium temperature: 60 °C

S

12 CONEXO CodewithoutIntegrated RFID chip for electronic identificationand traceability

C

7 Order data


Order example

Order option Code Description1 Type 649 Diaphragm valve, electrically operated,

electro-mechanical hollow shaft actuator,eSyDrive

2 DN 50 DN 503 Body configuration D 2/2-way body4 Connection type 60 Spigot ISO 1127/EN 10357 series C/DIN 11866 series B5 Valve body material 40 1.4435 (F316L), forged body6 Diaphragm material7 Voltage/Frequency C1 24 V DC8 Control module L0 ON/OFF, positioner and process controller9 Surface 1503 Ra ≤ 0.8 µm (30 µin.) for media wetted surfaces,

in accordance with DIN 11866 HE3,electropolished internal/external

10 Actuator version 2 A Actuator size 211 Special version S Special version for oxygen,

maximum medium temperature: 60 °C12 CONEXO without

7 Order data


8 Technical data

8.1 Medium

Working medium: Corrosive, inert, gaseous and liquid media which have no negative impact on the physical andchemical properties of the body and diaphragm material.For special oxygen version (code S):only gaseous oxygen

8.2 Temperature

Media temperature: Diaphragm material Standard Special versionoxygen

NBR (Code 2) -10 to 100 °C -FKM (Code 4) -10 to 90 °C -CR (Code 8) -10 to 100 °C -EPDM (Code 13) -10 to 100 °C 0 to 60 °CEPDM (Code 17) -10 to 100 °C -EPDM (Code 29) -10 to 90 °C -EPDM (Code 36) -10 to 100 °C -PTFE (Code 54) -10 to 100 °C -

Sterilisation temperature: EPDM (Code 13) max. 150 °C, max. 60 min per cycleEPDM (Code 17) max. 150 °C, max. 180 min per cycleEPDM (Code 36) max. 150 °C, max. 60 min per cyclePTFE (Code 54) max. 150 °C, permanent temperature per cycle

The sterilisation temperature is only valid for steam (saturated steam) or superheated water.If the sterilisation temperatures listed above are applied to the EPDM diaphragms for longer periods of time,the service life of the diaphragms will be reduced. In these cases, maintenance cycles must be adapted ac-cordingly.PTFE diaphragms can also be used as moisture barriers; however, this will reduce their service life. This alsoapplies to PTFE diaphragms exposed to high temperature fluctuations. The maintenance cycles must be adap-ted accordingly. GEMÜ 555 and 505 globe valves are particularly suitable for use in the area of steam genera-tion and distribution. The following valve arrangement for interfaces between steam pipes and process pipeshas proven itself over time: A globe valve for shutting off steam pipes and a diaphragm valve as an interface tothe process pipes.

Steam input

Process pipe

Steam distribution Sterile process

Ambient temperature: -10 to 60 °C14 °F to 140 °F


8 Technical data

8.3 Pressure

Operating pressure: MG DN Actuatorversion

Elastomer PTFE

Diaphragmmaterial

all valvebody mater-

ials

Diaphragmmaterial

Forgedbody

Investmentcastbody

10 10 to 20 0A 2, 4, 8, 13,14, 17, 36

0 - 10 52 0 - 10 0 - 6

25 15 to 25 1A 2, 4, 8, 13,14, 17, 36

0 - 10 5E 0 - 10 0 - 6

40 32 to 40 1A 2, 4, 8, 13,14, 17, 36

0 - 5 5E 0 - 2 0 - 2

2A 2, 4, 8, 13,14, 17, 36

0 - 10 5E 0 - 10 0 - 6

50 50 to 65 2A 2, 4, 8, 13,14, 17, 36

0 - 10 5E 0 - 10 0 - 6

MG = diaphragm size

All pressures are gauge pressures. Operating pressure values were determined with static operat-ing pressure applied on one side of a closed valve. Sealing at the valve seat and atmospheric seal-ing is ensured for the given values.Information on operating pressures applied on both sides and for high purity media on request.

Leakage rate: Leakage rate A to P11/P12 EN 12266-1

Kv values: Connection typescode 1)

0 16 17 18 37 59 60

MG DN

10 10 - 2.4 2.4 2.4 - 2.2 3.3

15 3.3 3.8 3.8 3.8 - 2.2 4.0

20 - - - - - 3.8 -

25 15 4.1 4.7 4.7 4.7 - - 7.4

20 6.3 7.0 7.0 7.0 - 4.4 13.2

25 13.9 15.0 15.0 15.0 12.6 12.2 16.2

40 32 25.3 27.0 27.0 27.0 26.2 - 30.0

40 29.3 30.9 30.9 30.9 30.2 29.5 32.8

50 50 46.5 48.4 48.4 48.4 51.7 50.6 55.2

65 - - - - 62.2 61.8 -

MG = diaphragm sizeKv values in m³/hKv values determined in accordance with DIN EN 60534 standard, inlet pressure 5 bar, Δp 1 bar, stainless steelvalve body and soft elastomer diaphragm. The Kv values for other product configurations (e.g. other dia-phragm or body materials) may differ. In general, all diaphragms are subject to the influences of pressure,temperature, the process and their tightening torques. Therefore the Kv values may exceed the tolerance limitsof the standard.The Kv value curve (Kv value dependent on valve stroke) can vary depending on the diaphragm material andduration of use.1) Connection type

Code 0: Spigot DINCode 16: Spigot EN 10357 series B, formerly DIN 11850 series 1Code 17: Spigot EN 10357 series A (formerly DIN 11850 series 2)/DIN 11866 series ACode 18: Spigot DIN 11850 series 3Code 37: Spigot SMS 3008Code 59: Spigot ASME BPE / DIN 11866 series CCode 60: Spigot ISO 1127/EN 10357 series C/DIN 11866 series B


8 Technical data

8.4 Product compliance

Pressure EquipmentDirective:

2014/68/EU

Machinery Directive: 2006/42/EU

EMC Directive: 2014/30/EU

Food: Regulation (EC) No. 1935/2004*Regulation (EC) No. 10/2011*FDA*USP* Class VI* depending on version and/or operating parameters

8.5 Mechanical data

Protection class: IP 65 acc. to EN 60529 Actuator version 0A, 2AIP 61 acc. to EN 60529 Actuator version 1A

Weight: ActuatorActuator version 0A 1.8 kgActuator version 1A 3.0 kgActuator version 2A 9.0 kg

Body

Connection types code 0, 16, 17,18, 35, 36,37, 55, 59,60, 63, 65

1 31 6, 62 8, 38, 39,51, 56

80, 82, 88,8A , 8E

Valve body Spigot Threadedsocket

Threadedsocket

Threadedspigot

Flange Clamp

MG DN

10 10 0.30 - - 0.33 - 0.30

12 - - 0.17 - - -

15 0.30 - 0.26 0.35 - 0.43

20 0.30 - - - - 0.43

25 15 0.62 0.50 0.32 0.71 1.85 0.75

20 0.58 0.60 0.34 0.78 2.35 0.71

25 0.55 0.90 0.39 0.79 2.85 0.63

40 32 1.45 1.20 0.88 1.66 4.90 1.62

40 1.32 1.80 0.93 1.62 5.65 1.50

50 50 2.25 2.60 1.56 2.70 7.45 2.50

65 2.20 - - - - 2.30

Weights in kgWeight in lb

Operating time: adjustable, max. 6 mm/s


8 Technical data

8.6 Electrical data

Supply voltage: Actuator size 0 Actuator size 1 Actuator size 2Voltage Uv = 24 V DC ± 10%Rating Max. 28 W Max. 65 W Max. 120 WOperating mode(OPEN/CLOSEoperation)

Continuous duty

Operating mode(control operation)

Class C acc. to EN 15714-2

Reverse batteryprotection

Yes

8.6.1 Analogue input signals

8.6.1.1 Set value

Input signals: 0/4 - 20 mA; 0 – 10 V DC (selectable using software)

Input type: passive

Input resistance: 250 Ω

Accuracy/linearity: ≤ ±0.3% of full flow

Temperature drift: ≤ ±0.1% / 10°K

Resolution: 12 bit

Reverse batteryprotection:

No

Overload proof: Yes (up to ± 24 V DC)

8.6.1.2 Process actual value

Input signals: 0/4 - 20 mA; 0 – 10 V DC (selectable using software)

Input type: passive

Input resistance: 250 Ω

Accuracy/linearity: ≤ ±0.3% of full flow


Resolution: 12 bit

Reverse batteryprotection:

No



8 Technical data

8.6.2 Digital input signals

Digital inputs: 3

Function: selectable using software

Voltage: 24 V DC

Logic level "1": >14 V DC

Logic level "0": < 8 V DC

Input current: typ. 2.5 mA (at 24 V DC)

8.6.3 Analogue output signals

8.6.3.1 Actual value

Output signal: 0/4 - 20 mA; 0 – 10 V DC (selectable using software)

Output type: Active (AD5412)

Accuracy: ≤ ±1% of full flow


Load resistor: ≤ 750 kΩ

Resolution: 10 bit


Short-circuit proof: Yes

8.6.4 Digital output signals

8.6.4.1 Switching outputs 1 and 2

Design: 2x change-over contact, potential-free

Switch rating: 125 V AC / 2 A48 V DC / 2 A

Switch points: Adjustable 0 - 100 %

8.6.4.2 Switching output 3

Function: Signal fault

Type of contact: Push-Pull

Switching voltage: Supply voltage

Switching current: ≤ 0.1 A

Drop voltage: Max. 2.5 V DC at 0.1 A


Short-circuit proof: Yes

Pull-Down resistance: 120 kΩ

8.6.5 Communication

Interface: Ethernet


8 Technical data

Function: Parameterisation via web browser

IP address: 192.168.2.1 alterable via web browser

Subnet screen: 255.255.252.0 alterable via web browser

The actuator and the PC must be in the same network to use the web server. The IP address of the actuator is entered in theweb browser and the actuator can then be parametrised. In order to use more than one actuator, a definitive IP address mustbe assigned to each actuator in the same network.

9 Dimensions

9.1 Actuator dimensions

B2

ØBB1

B3

A1

CT*

A

MG DN Actu-ator

version

A A1 B B1 B2 B3

10 10 to 20 0A 230.0 44.0 68.0 126.0 160.0 190.0

25 15 to 25 1A 305.0 83.0 82.0 132.0 172.0 250.0

40 32, 40 1A 303.0 75.0 82.0 132.0 172.0 243.02A 303.0 75.0 82.0 132.0 172.0 243.0

50 50, 65 2A 360.0 124.0 134.0 157.0 224.0 296.0

Dimensions in mm, MG = diaphragm sizeDimensions in inch, MG = diaphragm size* CT = A + H1 (see body dimensions)


9 Dimensions

9.2 Body dimensions

9.2.1 Spigot DIN/EN ISO

L

c

øds

H1

Connection types code 1) 0 16 17 18 60

Material code C3 40,42, F4

40, 42, C3, F4

MG DN NPS L c(min)

H1 H1 ød s ød s ød s ød s ød s

10 10 3/8" 108.0 25.0 12.5 12.5 - - 12.0 1.0 13.0 1.5 14.0 2.0 17.2 1.6

15 1/2" 108.0 25.0 12.5 12.5 18.0 1.5 18.0 1.0 19.0 1.5 20.0 2.0 21.3 1.6

25 15 1/2" 120.0 25.0 13.0 19.0 18.0 1.5 18.0 1.0 19.0 1.5 20.0 2.0 21.3 1.6

20 3/4" 120.0 25.0 16.0 19.0 22.0 1.5 22.0 1.0 23.0 1.5 24.0 2.0 26.9 1.6

25 1" 120.0 25.0 19.0 19.0 28.0 1.5 28.0 1.0 29.0 1.5 30.0 2.0 33.7 2.0

40 32 1¼" 153.0 25.0 24.0 26.0 34.0 1.5 34.0 1.0 35.0 1.5 36.0 2.0 42.4 2.0

40 1½" 153.0 25.0 26.0 26.0 40.0 1.5 40.0 1.0 41.0 1.5 42.0 2.0 48.3 2.0

50 50 2" 173.0 30.0 32.0 32.0 52.0 1.5 52.0 1.0 53.0 1.5 54.0 2.0 60.3 2.0

Dimensions in mm, MG = diaphragm sizeDimensions in inch, MG = diaphragm size1) Connection type

Code 0: Spigot DINCode 16: Spigot EN 10357 series B, formerly DIN 11850 series 1Code 17: Spigot EN 10357 series A (formerly DIN 11850 series 2)/DIN 11866 series ACode 18: Spigot DIN 11850 series 3Code 60: Spigot ISO 1127/EN 10357 series C/DIN 11866 series B


9 Dimensions

9.2.2 Spigot ASME/BS

L

c

øds

H1

Connectiontypes code 1)

55 59 63 65

Materialcode

C3 40, 42,F4

40, 42,F4

40, 42,F4

40, 42,C3, F4

40, 42,C3, F4

40, 42,F4

40, 42,F4

40, 42,F4

40, 42,F4

MG DN NPS L c (min) H1 H1 ød s ød s ød s ød s

10 10 3/8" 108.0 25.0 - 12.5 9.53 1.2 9.53 0.89 17.1 1.65 17.1 2.31

15 1/2" 108.0 25.0 - 12.5 12.70 1.2 12.70 1.65 21.3 2.11 21.3 2.77

20 3/4" 108.0 25.0 12.5 12.5 19.05 1.2 19.05 1.65 - - - -

25 15 1/2" 120.0 25.0 - 19.0 - - - - 21.3 2.11 21.3 2.77

20 3/4" 120.0 25.0 16.0 19.0 19.05 1.2 19.05 1.65 26.7 2.11 26.7 2.87

25 1" 120.0 25.0 19.0 19.0 - - 25.40 1.65 33.4 2.77 33.4 3.38

40 32 1¼" 153.0 25.0 - 26.0 - - - - 42.2 2.77 42.2 3.56

40 1½" 153.0 25.0 26.0 26.0 - - 38.10 1.65 48.3 2.77 48.3 3.68

50 50 2" 173.0 30.0 32.0 32.0 - - 50.80 1.65 60.3 2.77 60.3 3.91

65 2½" 173.0 30.0 - 34.0 - - 63.50 1.65 - - - -


Code 55: Spigot BS 4825, part 1Code 59: Spigot ASME BPE / DIN 11866 series CCode 63: Spigot ANSI/ASME B36.19M schedule 10sCode 65: Spigot ANSI/ASME B36.19M schedule 40s


9 Dimensions

9.2.3 Spigot JIS/SMS

L

c

øds

H1

Connection types code 1) 35 36 37

Material code C3 40, 42,F4

40, 42, F4 40, 42, F4 40, 42, C3, F4

MG DN NPS L c (min) H1 H1 ød s ød s ød s

10 10 3/8" 108.0 25.0 - 12.5 - - 17.3 1.65 - -

15 1/2" 108.0 25.0 - 12.5 - - 21.7 2.10 - -

25 15 1/2" 120.0 25.0 - 19.0 - - 21.7 2.10 - -

20 3/4" 120.0 25.0 - 19.0 - - 27.2 2.10 - -

25 1" 120.0 25.0 19.0 19.0 25.4 1.2 34.0 2.80 25.0 1.2

40 32 1¼" 153.0 25.0 - 26.0 31.8 1.2 42.7 2.80 33.7 1.2

40 1½" 153.0 25.0 26.0 26.0 38.1 1.2 48.6 2.80 38.0 1.2

50 50 2" 173.0 30.0 32.0 32.0 50.8 1.5 60.5 2.80 51.0 1.2

65 2½" 173.0 30.0 - 34.0 63.5 2.0 - - 63.5 1.6


Code 35: Spigot JIS-G 3447Code 36: Spigot JIS-G 3459 schedule 10sCode 37: Spigot SMS 3008


9 Dimensions

9.2.4 Threaded socket

R

Lt

SW2

HH

1

Connectiontypes code 1)

1

Materialcode 2)

8 37

MG DN R H H1 t L SW 2 n R H H1 t L SW 2 n

10 12 - - - - - - - G3/8 25.0 13.0 12.0 55.0 22.0 2

15 - - - - - - - G1/2 30.0 15.0 15.0 68.0 27.0 2

25 15 G 1/2 35.0 19.0 12.0 85.0 32 6 G 1/2 29.0 16.0 15.0 85.0 27.0 6

20 G 3/4 40.0 19.0 13.0 85.0 41 6 G 3/4 32.0 16.0 16.0 85.0 32.0 6

25 G 1 42.0 19.0 16.0 110.0 46 6 G 1 37.0 16.0 13.0 110.0 41.0 6

40 32 G 1¼ 56.0 28.0 16.0 120.0 55 6 G 1¼ 49.0 24.0 20.0 120.0 50.0 8

40 G 1½ 61.0 28.0 18.0 140.0 65 6 G 1½ 52.0 24.0 18.0 140.0 55.0 8

50 50 G 2 73.0 35.0 18.0 165.0 75 6 G 2 68.0 33.0 26.0 165.0 70.0 8

Dimensions in mm, MG = diaphragm sizeDimensions in inch, MG = diaphragm sizen = number of flats1) Connection type

Code 1: Threaded socket DIN ISO 228

2) Valve body materialCode 8: EN-GJL-250 (GG 25)Code 37: 1.4408, investment casting


9 Dimensions

9.2.5 Threaded spigot

L

Rød1

R

H1

H1

Rød1

L

Connection types code 1) Code 6 Code 62

Material code 2) 40, 42

MG DN H1 ød1 R L L

10 10 12.5 10.0 Rd 28 x 1/8 118.0 116.0

15 12.5 16.0 Rd 34 x 1/8 118.0 116.0

25 15 19.0 16.0 Rd 34 x 1/8 118.0 116.0

20 19.0 20.0 Rd 44 x 1/6 118.0 114.0

25 19.0 26.0 Rd 52 x 1/6 128.0 127.0

40 32 26.0 32.0 Rd 58 x 1/6 147.0 147.0

40 26.0 38.0 Rd 65 x 1/6 160.0 160.0

50 50 32.0 50.0 Rd 78 x 1/6 191.0 191.0


Code 6: Threaded spigot DIN 11851Code 62: Threaded spigot on one side, DIN 11851, cone spigot and union nut, DIN 11851 on the other side

2) Valve body materialCode 40: 1.4435 (F316L), forged bodyCode 42: 1.4435 (BN2), forged body, Δ Fe < 0.5%


9 Dimensions

9.2.6 Flange connection EN 1092

ØL

ØDøk

H1

FTF

Connection typescode 1)

8

Materialcode 2)

8 17, 18,39, 83

C3 40, 42 8, 17, 18,39, 40,42, 83

C3

MG DN øD øk øL n H1 H1 H1 H1 FTF FTF

25 15 95.0 65.0 14.0 4 19.0 18.0 13.0 19.0 130.0 150.0

20 105.0 75.0 14.0 4 19.0 20.5 16.0 19.0 150.0 150.0

25 115.0 85.0 14.0 4 19.0 23.0 19.0 19.0 160.0 160.0

40 32 140.0 100.0 19.0 4 28.0 28.7 24.0 26.0 180.0 180.0

40 150.0 110.0 19.0 4 28.0 33.0 26.0 26.0 200.0 200.0

50 50 165.0 125.0 19.0 4 35.0 39.0 32.0 32.0 230.0 230.0

Dimensions in mm, MG = diaphragm sizeDimensions in inch, MG = diaphragm sizen = number of bolts1) Connection type

Code 8: Flange EN 1092, PN 16, form B, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic series 1, length only for body config-uration D

2) Valve body materialCode 8: EN-GJL-250 (GG 25)Code 17: EN-GJS-400-18-LT (GGG 40.3), PFA linedCode 18: EN-GJS-400-18-LT (GGG 40.3), PP linedCode 39: 1.4408, PFA linedCode 40: 1.4435 (F316L), forged bodyCode 42: 1.4435 (BN2), forged body, Δ Fe < 0.5%Code 83: EN-GJS-400-18-LT (GGG 40.3), hard rubber linedCode C3: 1.4435, investment casting


9 Dimensions

9.2.7 Flange connection ANSI Class

ØL

ØDøk

H1

FTF

Connection typescode 1)

38, 39 39 38, 39 39 39 38 38 39

Materialcode 2)

8 17, 18,39, 83

C3 40, 42 17, 18,39

83 8, 17,18, 39,40, 42,83, C3

MG DN øD øk øL n H1 H1 H1 H1 FTF FTF FTF

25 15 90.0 60.3 15.9 4 19.0 18.0 13.0 19.0 - - 130.0

20 100.0 69.9 15.9 4 19.0 20.5 16.0 19.0 146.0 146.4 150.0

25 110.0 79.4 15.9 4 19.0 23.0 19.0 19.0 146.0 146.4 160.0

40 32 115.0 88.9 15.9 4 28.0 28.7 24.0 26.0 - - 180.0

40 125.0 98.4 15.9 4 28.0 33.0 26.0 26.0 175.0 171.4 200.0

50 50 150.0 120.7 19.0 4 35.0 39.0 32.0 32.0 200.0 197.4 230.0

Dimensions in mm, MG = diaphragm sizeDimensions in inch, MG = diaphragm sizen = number of bolts1) Connection type

Code 38: Flange ANSI Class 150 RF, face-to-face dimension FTF MSS SP-88, length only for body configuration DCode 39: Flange ANSI Class 125/150 RF, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic series 1, length only for body con-figuration D

2) Valve body materialCode 8: EN-GJL-250 (GG 25)Code 17: EN-GJS-400-18-LT (GGG 40.3), PFA linedCode 18: EN-GJS-400-18-LT (GGG 40.3), PP linedCode 39: 1.4408, PFA linedCode 40: 1.4435 (F316L), forged bodyCode 42: 1.4435 (BN2), forged body, Δ Fe < 0.5%Code 83: EN-GJS-400-18-LT (GGG 40.3), hard rubber linedCode C3: 1.4435, investment casting


9 Dimensions

9.2.8 Clamp DIN/ISO

L

H1

ød3

ød1

Connection types code 1) 82 8A 8E

Material code 2) 40, 42, F4

MG DN NPS H1* H1 ød1 ød3 L ød1 ød3 L ød1 ød3 L

10 10 3/8" 12.5 12.5 14.0 25.0 108.0 10.0 34.0 108.0 - - -

15 1/2" 12.5 12.5 18.1 50.5 108.0 16.0 34.0 108.0 - - -

20 3/4" 12.5 12.5 - - - - - - - - -

25 15 1/2" 13.0 19.0 18.1 50.5 108.0 16.0 34.0 108.0 - - -

20 3/4" 16.0 19.0 23.7 50.5 117.0 20.0 34.0 117.0 - - -

25 1" 19.0 19.0 29.7 50.5 1270 26.0 50.5 127.0 22.6 50.5 127.0

40 32 1¼" 24.0 26.0 38.4 64.0 146.0 32.0 50.5 146.0 31.3 50.5 146.0

40 1½" 26.0 26.0 44.3 64.0 159.0 38.0 50.5 159.0 35.6 50.5 159.0

50 50 2" 32.0 32.0 56.3 77.5 190.0 50.0 64.0 190.0 48.6 64.0 190.0

65 2½" - 34.0 - - - - - - 60.3 77.5 216.0


Code 82: Clamp DIN 32676 series B, face-to-face dimension FTF EN 558 series 7, length only for body configuration DCode 8A: Clamp DIN 32676 series A, face-to-face dimension FTF acc. to EN 558 series 7, length only for body configuration DCode 8E: Clamp ISO 2852/SMS 3017, face-to-face dimension FTF EN 558 series 7, length only for body configuration D

2) Valve body materialCode 40: 1.4435 (F316L), forged bodyCode 42: 1.4435 (BN2), forged body, Δ Fe < 0.5%Code F4: 1.4539, forged body


9 Dimensions

9.2.9 Clamp ASME

L

H1

ød3

ød1

Connection types code 1) 80 88

Material code 2) 40, 42, F4

MG DN NPS H1* H1 ød1 ød3 L ød1 ød3 L

10 10 3/8" 12.5 12.5 - - - - - -

15 1/2" 12.5 12.5 9.40 25.0 88.9 940 25.0 108.0

20 3/4" 12.5 12.5 15.75 25.0 101.6 15.75 25.0 117.0

25 15 1/2" 13.0 19.0 9.40 25.0 101.6 9.40 25.0 108.0

20 3/4" 16.0 19.0 15.75 25.0 101.6 15.75 250 117.0

25 1" 19.0 19.0 22.10 50.5 114.3 22.10 50.5 127.0

40 40 1½" 26.0 26.0 34.80 50.5 139.7 34.80 50.5 159.0

50 50 2" 32.0 32.0 47.50 64.0 158.8 47.50 64.0 190.0

65 2½" - 34.0 60.20 77.5 193.8 60.20 77.5 216.0


Code 80: Clamp ASME BPE, face-to-face dimension FTF ASME BPE, length only for body configuration DCode 88: Clamp ASME BPE, face-to-face dimension FTF EN 558 series 7, length only for body configuration D

2) Valve body materialCode 40: 1.4435 (F316L), forged bodyCode 42: 1.4435 (BN2), forged body, Δ Fe < 0.5%Code F4: 1.4539, forged body


9 Dimensions


10 Delivery

10 Delivery● Check that all parts are present and check for any dam-

age immediately upon receipt.The product's performance is tested at the factory. Thescope of delivery is apparent from the dispatch documentsand the design from the order number.

11 Transport1. Only transport the product by suitable means. Do not

drop. Handle carefully.2. After the installation dispose of transport packaging ma-

terial according to relevant local or national disposal reg-ulations / environmental protection laws.

12 Storage1. 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 theirspare parts.

13 Installation in piping

13.1 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 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 va-porization temperature and cannot cause scalding.

11. Correctly decontaminate, rinse and ventilate the plant orplant component.

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

13. Only install the product between matching aligned pipes(see chapters below).

14. Please note the flow direction (see chapter "Flow direc-tion").

15. Please note the installation position (see chapter "Install-ation position").

13.2 Installation position

The installation position of the product is optional.

13.3 Installation with clamp connections

Fig. 7: Clamp connection

NOTICEGasket and clamp▶ The gasket and clamps for clamp connections are not in-

cluded in the scope of delivery.

1. Keep ready gasket and clamp.2. Carry out preparation for installation (see chapter "Pre-

paring for installation").3. Insert the corresponding gasket between the body of the

product and the pipe connection.4. Connect the gasket between the body of the product and

the pipe connection using clamps.5. Re-attach or reactivate all safety and protective devices.

13.4 Installation with butt weld spigots

Fig. 8: Butt weld spigots1. Carry out preparations for installation (see chapter "Pre-

paring for installation").2. Adhere to good welding practices!3. Remove actuator A (see chapter "Removing the actu-

ator").4. Weld the body of the product in the piping.5. Allow butt weld spigots to cool down.6. Mount actuator A (see chapter "Mounting the actuator").7. Re-attach or reactivate all safety and protective devices.8. Flush the system.

13.5 Installation with threaded sockets

Fig. 9: Threaded socket

NOTICESealing material▶ The sealing material is not included in the scope of deliv-

ery.● Only use appropriate sealing material.

1. Keep thread sealant ready.2. Carry out preparations for installation (see chapter "Pre-

paring for installation").3. Screw the threaded connections into the pipe in accord-

ance with valid standards.4. Screw the body of the product onto the piping using ap-

propriate thread sealant.5. Re-attach or reactivate all safety and protective devices.

13.6 Installation with threaded spigots

Fig. 10: Threaded spigots

13 Installation in piping


14 Electrical connection

NOTICEThread sealant▶ The thread sealant is not included in the scope of deliv-

ery.● Only use appropriate thread sealant.

1. Keep thread sealant ready.2. Carry out preparations for installation (see chapter "Pre-

paring for installation").3. Screw the pipe into the threaded connection of the valve

body in accordance with valid standards.

ð Use appropriate thread sealant.4. Re-attach or reactivate all safety and protective devices.

13.7 Installation with flanged connection

Fig. 11: Flanged connection

NOTICESealing material▶ The sealing material is not included in the scope of deliv-

ery.● Only use appropriate sealing material.

NOTICEConnector elements▶ The connector elements are not included in the scope of

delivery.● Only use connector elements made of approved materi-

als.● Observe permissible tightening torque of the bolts.

1. Keep sealing material ready.2. Carry out preparations for installation (see chapter "Pre-

paring for installation").3. Ensure clean, undamaged sealing surfaces on the con-

nection flanges.4. Align flanges carefully before installing them.5. Clamp the product centrally between the piping with

flanges.6. Centre the gaskets.7. Connect the valve flange and the piping flange using ap-

propriate sealing materials and matching bolting.8. Use all flange holes.9. Tighten the bolts diagonally.10. Re-attach or reactivate all safety and protective devices.

14 Electrical connection

NOTICEAppropriate cable socket/appropriate mating connector!▶ The appropriate cable socket and/or appropriate mating

connector is included for X1, X3 and X4.▶ The appropriate cable socket and/or appropriate mating

connector is not included for X2.

X3X2 X4

X1

Fig. 12: Overview of electrical connections

14.1 Connection X1

13 2

654

7-pin plug, Binder, type 693

Pin Signal namePin 1 Uv, 24 V DC supply voltagePin 2 Uv GNDPin 3 Relay output K1, commonPin 4 Relay output K1, make contactPin 5 Relay output K2, commonPin 6 Relay output K2, make contactPin PE Function earth

14.2 Connection X2

1 5

4

3

2

5-pin M12 built-in socket, D-coded

Pin Signal namePin 1 Tx + (Ethernet)Pin 2 Rx + (Ethernet)Pin 3 Tx - (Ethernet)


Pin Signal namePin 4 Rx - (Ethernet)Pin 5 Shield

14.3 Connection X3

65

32

4 78

1

8-pin M12 plug, A-coded

Pin Signal namePin 1 I + set value inputPin 2 I – set value inputPin 3 I + actual value outputPin 4 GND (actual value output, digital input 1 – 3,

error message output)Pin 5 Error message output 24 V DCPin 6 Digital input 3Pin 7 Digital input 1Pin 8 Digital input 2

14.4 Connection X4

14

32

4-pin M12 built-in socket, A-coded

Pin Signal namePin 1 UV, 24 V DC actual value supplyPin 2 n. c.Pin 3 X -, process actual value inputPin 4 X+, process actual value inputPin 5 n. c.

14.5 Connecting the valve electrically

1. Protect the electrical connections from direct contactwith rain water.

2. Lay the cables and pipework so that neither condensatenor rain water can get into the plug unions.

3. Check that all plug cable glands and fittings are mechan-ically secured.

ð The cable must be held firmly on all sides.4. Check whether the actuator cover/manual override is

closed and undamaged.5. Correctly close the actuator cover/manual override again

immediately after use (see chapter "Manual override" (see“Manual override“, page 32)).

6. Correctly close the product again after replacing the dia-phragm (see chapter "Diaphragm replacement" (see“Mounting the diaphragm“, page 34)).

15 Network connection

15.1 Network settings

The network interface has the following default settings:IP address: 192.168.2.1Subnet screen: 255.255.252.0The default settings can be changed. See the eSy-Web oper-ating instructions.

15.2 Connecting the network

1. Connect the network plug and cables with the electricalconnection X2 of the product.

2. Change the IP address using the web server.

15.3 Resetting the network settings

1. Ensure that the "ON-Site" DIP switch 8 is not in the "ON"position.

2. Press and hold down the "OPEN" button 9 for at least 8 s.

ð LED 1 flashes fast in blue.3. Press the "INIT/CLOSE" button 10.

ð Network settings are reset in the default settings.

16 Commissioning

16.1 Commissioning on the device

1. Ensure that the "ON-Site" DIP switch 8 is not in the "ON"position.

2. Press and hold down the "INIT/CLOSE" button 10 for atleast 8 s.

ð Initialisation of the actuator begins.3. Green and orange LEDs flash alternately.

ð Initialisation is completed.

ð Commissioning is completed.

16.2 Commissioning via the eSy-Web web interface

● See separate eSy-Web operating instructions.

16 Commissioning


17 Operation

16.3 Commissioning via digital input

ü The function of input 3 is set to init.1. Connect 24 V signal briefly (max. 2 s) to connection X3 on

pins 7 and 4.

ð Initialisation of the actuator begins.2. Green and orange LEDs flash alternately.

ð Initialisation is completed.

ð Commissioning is completed.

17 Operation

17.1 Operation on the device

17.1.1 Moving the valve to the open position

1. Move the "ON-Site" DIP switch 8 to the "ON" position.

ð Control on the device is activated.2. Press the "OPEN" button 9.

ð The valve moves slowly to the open position.3. Also press the "INIT/CLOSE" button 10.

ð The valve moves quickly to the open position.

ð If the valve is fully opened, the high visibility LEDs arelit in green.

4. Move the "ON-Site" DIP switch 8 to the "OFF" position.

ð Control on the device is deactivated.

ð The valve is in the open position.

17.1.2 Moving the valve to the closed position

1. Move the "ON-Site" DIP switch 8 to the "ON" position.

ð Control on the device is activated.2. Press the "INIT/CLOSE" button 10.

ð The valve moves slowly to the closed position.3. Also press the "OPEN" button 9.

ð The valve moves quickly to the closed position.

ð If the valve is fully closed, the high visibility LEDs arelit in orange.

4. Move the "ON-Site" DIP switch 8 to the "OFF" position.

ð Control on the device is deactivated.

ð The valve is in the closed position.

17.2 Operation via the web server

See separate "eSy-Web" operating instructions.

17.3 Manual override

WARNINGRotating cover!▶ Risk of crushing.● Disconnect the power supply before

using the manual override.

1. Disconnect the power supply.2. Turn housing cover 3 clockwise.3. Remove housing cover 3.

3

4. Place the actuator of housing cover 12 in the startingpoint for manual override.

312

Item Name3 Housing cover12 Housing cover actuator

Starting point for manual override

Groove for actuator

5. Turn housing cover 3 anticlockwise.

ð The product opens.6. Turn housing cover 3 clockwise.


ð The product closes.7. Pull manual override off the starting point.8. Ensure correct positioning of the O-ring.9. Push actuator 12 into the groove provided for this pur-

pose.10. Turn housing cover 3 anticlockwise until it stops.

ð The actuator cover is closed.11. Reconnect the power supply.

18 Inspection and maintenance

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

CAUTIONUse of incorrect spare parts!▶ Damage to the GEMÜ product.▶ Manufacturer liability and guarantee will be void.● Use only genuine parts from GEMÜ.

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

down.

NOTICEExceptional maintenance work!▶ Damage to the GEMÜ product.● Any maintenance work and repairs not described in

these operating instructions must not be performedwithout consulting the manufacturer first.

The operator must carry out regular visual examination of theGEMÜ products depending on the operating conditions andthe potential danger in order to prevent leakage and damage.The product also must be disassembled and checked forwear in the corresponding intervals.1. Have servicing and maintenance work performed by

trained personnel.2. Wear appropriate protective gear as specified in plant op-

erator's guidelines.3. Shut off plant or plant component.4. Secure plant or plant component against recommission-

ing.5. Depressurize the plant or plant component.6. Actuate GEMÜ products which are always in the same

position four times a year.

18.1 Spare parts

A

118

19

20

2

Fig. 13: Spare parts

Item Name Order descriptionA Actuator 96491 Valve body K6002 Diaphragm 600…M18 Bolt 649…S30…19 Washer20 Nut

18.2 Removing the actuator

1. Move the actuator A to the open position.2. Loosen the fastening elements between actuator A and

body 1 diagonally and remove them.3. Lift actuator A off valve body 1.4. Move the actuator A to the closed position.5. Clean all parts of contamination (do not damage parts

during cleaning).6. Check parts for potential damage, replace if necessary

(only use genuine parts from GEMÜ).

18.3 Removing the diaphragm

1. Remove actuator A (see chapter "Removing the actu-ator").

2. Unscrew the diaphragm.

ð Please note: Depending on the version, the com-pressor may fall out.

3. Clean all parts of contamination (do not damage partsduring cleaning).

4. Check parts for potential damage, replace if necessary(only use genuine parts from GEMÜ).




18.4 Mounting the compressor

D

D

C

C

1. Place the compressor loosely on the actuator spindle.2. Fit recesses D into guides C.

ð The compressor must be able to be moved freely betweenthe guides.

18.5 Mounting the diaphragm

18.5.1 Mounting the convex diaphragm

NOTICE▶ Fit the diaphragms suitable for the product (suitable for

medium, medium concentration, temperature and pres-sure). The diaphragm is a wearing part. Check the tech-nical condition and function of the product before com-missioning and during the whole term of use. Carry outchecks regularly and determine the check intervals in ac-cordance with the conditions of use and/or the regulat-ory codes and provisions applicable for this application.

NOTICE▶ If the diaphragm is not screwed into the adapter far

enough, the closing force is transmitted directly onto thediaphragm pin and not via the compressor. This willcause damage and early failure of the diaphragm andleakage of the product. If the diaphragm is screwed intoo far, perfect sealing at the valve seat will not beachieved. The function of the product is no longer en-sured.

NOTICE▶ Incorrectly mounted diaphragms cause the product leak-

age and emission of medium. In this case, remove thediaphragms, check the complete valve and diaphragmsand reassemble again proceeding as described above.

NOTICE▶ The compressor is loose and can fall out.

Diaphragm pinDiaphragm face

Fig. 14: Inverting the diaphragm face

Compressor

Backing diaphragmDiaphragm face Diaphragm boss

Diaphragm pin

Adapter Recess of compressor

Fig. 15: Screwing in the diaphragm face1. Move the actuator A to the closed position.2. Mount the compressor (see "Mounting the compressor").3. Check if the compressor is fitted in the guides.4. Invert the new diaphragm face manually (use a clean,

padded mat with larger nominal sizes).5. Position the new backing diaphragm onto the com-

pressor.6. Position the diaphragm face onto the backing diaphragm.7. Screw diaphragm face tightly into the compressor manu-

ally.


ð The diaphragm boss must fit closely in the recess ofthe compressor.

8. If it is difficult to screw it in, check the thread and replacedamaged parts.

9. When definitive resistance is felt, turn back the diaphragmuntil its bolt holes are in correct alignment with the boltholes of the actuator.

10. Press the diaphragm face tightly onto the backing dia-phragm manually so that it returns to its original shapeand fits closely on the backing diaphragm.

11. Align the weir of compressor and diaphragm in parallel.

18.5.2 Mounting the concave diaphragm

Diaphragm boss

Diaphragm pin

Recess of compressor

1. Move the actuator A to the closed position.2. Mount the compressor (see "Mounting the compressor").3. Check if the compressor is fitted in the guides.4. Manually screw new diaphragm tightly into the com-

pressor.5. Check if the diaphragm boss fits closely in the recess of

the compressor.6. If it is difficult to screw it in, check the thread and replace

damaged parts.7. When definitive resistance is felt, turn back the diaphragm

until its bolt holes are in correct alignment with the boltholes of the actuator.

8. Align the weir of compressor and diaphragm in parallel.

18.6 Mounting the actuator

NOTICEDiaphragms set in the course of time▶ Leakage.● After disassembly/assembly of the product, check that

the bolts and nuts on the body are tight and retighten ifrequired.

● Retighten the bolts and nuts at the very latest after thefirst sterilisation process.

1. Move the actuator A to the open position.2. Position actuator A with the mounted diaphragm on the

valve body.3. Screw in bolts, washers and nuts hand tight.

ð Fastening elements may vary depending on the dia-phragm size and/or valve body version.

4. Move the actuator A to the closed position.5. Open actuator A approx. 20%.6. Fully tighten the bolts with nuts diagonally.7. Ensure even compression of the diaphragm (approx. 10 to

15%).

ð Even compression is detected by an even outer bulge.8. With the valve fully assembled, check the function and

tightness.9. Carry out initialisation.



19 Troubleshooting

19 Troubleshooting

Error Possible cause TroubleshootingThe product leaks downstream (doesn'tclose or doesn't close fully)

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

Foreign matter between shut offdiaphragm and valve body weir

Remove the actuator, remove foreignmatter, check diaphragm and valve bodyweir for potential damage, replaceactuator if necessary

Valve body leaks or is damaged Check valve body for potential damage,replace valve body if necessary

Shut off diaphragm faulty Check shut off diaphragm for potentialdamage, replace diaphragm if necessary

The product doesn't close or doesn'tclose fully

The actuator design is not suitable forthe operating conditions

Use an actuator that is designed for theoperating conditions

Foreign matter in the product Remove and clean the productVoltage is not connected Connect voltage

The product doesn't open or doesn'topen fully

Actuator defective Replace the actuatorShut off diaphragm incorrectly mounted Remove actuator, check diaphragm

mounting, replace if necessaryOperating pressure too high Operate the product with operating

pressure specified in datasheetForeign matter in the product Remove and clean the productThe actuator design is not suitable forthe operating conditions

Use an actuator that is designed for theoperating conditions

Voltage is not connected Connect voltageCable ends incorrectly wired Wire cable ends correctly

The product leaks between actuator andvalve body

Shut off diaphragm incorrectly mounted Remove actuator, check diaphragmmounting, replace if necessary

Bolting between valve body and actuatorloose

Retighten bolting between valve bodyand actuator

Shut off diaphragm faulty Check shut off diaphragm for damage,replace diaphragm if necessary

Actuator/valve body damaged Replace actuator/valve bodyThe product leaks between actuatorflange and valve body

Mounting parts loose Retighten mounting partsValve body / actuator damaged Replace valve body/actuator

Body of the GEMÜ product is leaking Body of the GEMÜ product is faulty orcorroded

Check the body of the GEMÜ product forpotential damage, replace body ifnecessary

Incorrect installation Check installation of valve body in pipingValve body connection to piping leaks Incorrect installation Check installation of valve body in pipingLED 1 is not lit No initialisation Initialise valve

Supply voltage too low Check supply voltageLED 1 lights up yellow Set value signal outside of the area Check set value signal

Temperature error Check temperatureLED 1 flashes yellow Actual value signal outside of the area Check actual value signalLED 1 and 2 are flashing yellow and redsimultaneously

No calibration Contact GEMÜInternal error Contact GEMÜ


20 Removal from piping1. Remove in reverse order to installation.2. Unscrew the electrical wiring.3. Disassemble the product. Observe warning notes and

safety information.

21 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.

22 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.

22 Returns

23 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 Motorized diaphragm valve

Serial number: from 01.02.2017Project number: MV-Elektromot-2017-02

Commercial name: GEMÜ 649

meets the following essential requirements of the Machinery Directive 2006/42/EC:1.1.2. a), 1.1.2. d), 1.1.3., 1.1.4., 1.1.5., 1.1.6., 1.1.7., 1.1.8., 1.2.1., 1.3., 1.3.2., 1.3.4., 1.3.5., 1.3.6., 1.3.7., 1.3.8., 1.3.9., 1.5.1.,1.5.3., 1.5.5., 1.5.6., 1.5.7., 1.6.1., 1.6.3., 1.6.5., 2.1.1., 2.3., 3.2.1., 3.2.2., 3.3.2., 3.3.4., 4.1.2.1., 4.1.2.3., 4.1.2.4., 4.1.2.5., 4.1.2.6.a), 4.1.2.6. c), 4.1.2.6. d), 4.1.2.6. e), 4.1.3., 4.2.1.4., 4.2.2., 4.2.3., 4.3.1., 4.3.2., 4.3.3., 4.4.1., 4.4.2., 5.2., 5.3., 5.4., 6.1.1., 6.3.1.,6.4.3.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 nationalauthorities, 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.

2019-01-31

Joachim BrienHead of Technical Department


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

24 Declaration of conformity according to 2014/68/EU (Pressure Equipment Directive)

EU Declaration of Conformityin accordance with 2014/68/EU (Pressure Equipment Directive)


declare that the product listed below complies with the safety requirements of the Pressure Equipment Directive 2014/68/EU.

Description of the pressure equipment: GEMU 649Notified body: TÜV Rheinland Industrie Service GmbHNumber: 0035Certificate no.: 01 202 926/Q-02 0036Conformity assessment procedure: Module HTechnical standard used: EN 1983, AD 2000

Note for products with a nominal size ≤ DN 25: The products are developed and produced according to GEMÜ process instructions and quality standards which comply withthe requirements of ISO 9001 and ISO 14001.According to Article 4, Paragraph 3 of the Pressure Equipment Directive 2014/68/EU these products must not be identified bya CE-label.

2020-06-22



24 Declaration of conformity according to 2014/68/EU (Pressure Equipment Directive)

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

EU Declaration of Conformityin accordance with 2014/30/EU (EMC Directive)


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

Description of the product: GEMÜ 649

Technical standards used:Interference resistance:– DIN EN 61326-1 (industrial processes)– DIN EN 61800-3

Interference emission:– DIN EN 61800-3

2020-05-27



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

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

07.2020 | 88614490

*88614490*

mailto:[email protected]

http://www.gemu-group.com

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