GEM 639 eSyStep User manual

GEMÜ 639 eSyStep

Positioner (Code S0)

Motorized diaphragm valve

Operating instructions

TYPE EL

CLASS I

AUGUST 2021

further information

webcode: GW-639

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

Keep the document for future reference.

03.07.2023

www.gemu-group.com2 / 75GEMÜ 639 eSyStep

Positioner (Code S0)

Contents

1 General information ............................................. 4

1.1 Information .................................................... 4

1.2 Symbols used ................................................ 4

1.3 LED symbols .................................................. 4

1.4 Definition of terms ........................................ 4

1.5 Warning notes ............................................... 4

2 Safety information ............................................... 5

3 Product description ............................................. 5

3.2 LED displays .................................................. 6

4 GEMÜ CONEXO .................................................... 7

5 Correct use .......................................................... 7

6 Order data ........................................................... 8

7 Technical data ..................................................... 11

7.2 Temperature .................................................. 11

8 Electrical connection ........................................... 17

9 Dimensions .......................................................... 22

10 Manufacturer's information .................................. 35

10.1 Delivery .......................................................... 35

10.2 Packaging ...................................................... 35

10.3 Transport ....................................................... 35

10.4 Storage ........................................................... 35

11 Installation in piping ............................................ 35

11.1 Preparing for installation .............................. 35

11.2 Installation position ....................................... 35

11.3 Installation with clamp connections ............ 36

11.4 Installation with butt weld spigots ............... 36

11.5 Installation with threaded sockets ............... 36

11.6 Installation with threaded spigots ................ 36

12 Specific data IO-Link (pin 6) ................................. 37

12.1 Operation on IO-Link ..................................... 37

12.2 Process data .................................................. 40

12.3 Parameter overview ...................................... 41

12.4 Parameter ...................................................... 45

12.5 Events ............................................................ 62

13 Operation ............................................................. 64

13.1 Initialization ................................................... 64

13.2 Manual override ............................................. 64

14 Inspection and maintenance ................................ 65

14.2 Removing the actuator .................................. 65

14.3 Removing the diaphragm .............................. 65

14.6 Mounting the actuator .................................. 67

15 Troubleshooting .................................................. 68

16 Removal from piping ............................................ 70

17 Disposal .............................................................. 70

18 Returns ................................................................ 70

19 EU Declaration of Incorporation according to the

EC Machinery Directive 2006/42/EC, Annex II B ... 71

20 EU Declaration of Conformity in accordance with

2014/68/EU (Pressure Equipment Directive) ........ 72

21 EU Declaration of Conformity in accordance with

2014/30/EU (EMC Directive) ................................ 73

22 EU Declaration of Conformity In accordance with

2011/65/EU (RoHS Directive) ............................... 74

GEMÜ 639 eSyStep

Positioner (Code S0)

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www.gemu-group.com4 / 75GEMÜ 639 eSyStep

Positioner (Code S0)

1 General information

1.1 Information

- The descriptions and instructions apply to the standard ver-

sions. For special versions not described in this document

the basic information contained herein applies in combina-

tion with any additional special documentation.

- Correct installation, operation, maintenance and repair work

ensure faultless operation of the product.

- Should there be any doubts or misunderstandings, the Ger-

man version is the authoritative document.

- Contact us at the address on the last page for staff training

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 LED symbols

The following LED symbols are used in the documentation:

Symbol LED conditions

Off

Lit (on)

Flashing

1.4 Definition of terms

Working medium

The medium that flows through the GEMÜ product.

Diaphragm size

Uniform seat size of GEMÜ diaphragm valves for different

nominal sizes.

1.5 Warning notes

Wherever possible, warning notes are organised according to

the following scheme:

SIGNAL WORD

Type and source of the danger

Possible

symbol for the

specific

danger

Possible consequences of non-observance.

Measures for avoiding danger.

Warning notes are always marked with a signal word and

sometimes also with a symbol for the specific danger.

The following signal words and danger levels are used:

DANGER

Imminent danger!

▶Non-observance can cause death or

severe injury.

WARNING

Potentially dangerous situation!

▶Non-observance can cause death or

severe injury.

CAUTION

Potentially dangerous situation!

▶Non-observance can cause moderate

to light injury.

NOTICE

Potentially dangerous situation!

▶Non-observance can cause damage to

property.

The following symbols for the specific dangers can be used

within a warning note:

Symbol Meaning

Danger of explosion!

Corrosive chemicals!

Hot plant components!

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Positioner (Code S0)

2 Safety information

The safety information in this document refers only to an indi-

vidual product. Potentially dangerous conditions can arise in

combination with other plant components, which need to be

considered 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 that

must 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 dangerous

substances.

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 personnel.

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

Item Name Materials

1 Optical position indic-

ator

PA 12

2 Manual override

3 Actuator top with LED

display

Reinforced polyamide

4 Actuator base Reinforced polyamide

5 Valve body EN-GJS-400-18-LT (GGG 40.3)

EN-GJS-400-18-LT (GGG

40.3), PFA lined

EN-GJS-400-18-LT (GGG

40.3), PP lined

EN-GJS-400-18-LT (GGG

40.3), hard rubber lined

1.4408, investment casting

1.4408, PFA lined

1.4435 (F316L), forged body

1.4435 (BN2), forged body, Δ

Fe < 0.5 %

1.4435, investment casting

1.4539, forged body

CW614N, CW617N (brass)

6 Diaphragm CR, EPDM, FKM, NBR,

PTFE/EPDM (one-piece),

PTFE/EPDM (two-piece)

7 CONEXO diaphragm

RFID chip

(see Conexo informa-

tion)

3 Product description

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Positioner (Code S0)

3 Product description

Item Name Materials

8 CONEXO body RFID

chip

(see Conexo informa-

tion)

9 Electrical connections

10 CONEXO actuator RFID

chip

(see Conexo informa-

tion)

3.2 LED displays

3.2.1 Status LEDs

LED Colour Function

Standard Inversed 1)

Power/fault green green Operating indica-

tion/

communication

status

red red

Open orange green Process valve in

OPEN position

Error red red Error

Closed green orange Process valve in

CLOSED position

1) Inversed representation of the OPEN and CLOSED LEDs, ad-

justable via IO-Link

3.2.2 LED conditions

Status

process

valve

Power/

fault

Open Error Closed

OPEN posi-

tion

CLOSED po-

sition

Position un-

known

Initialization

Open and Closed flash

alternately

LED conditions

lit (on) flashes off

3.3 Description

The GEMÜ 639 eSyStep 2/2-way diaphragm valve is electric-

ally operated. The eSyStep electric actuator is available as

On/Off actuator or with integrated positioner. An integral op-

tical and electrical position indicator is standard. The self-

locking actuator holds its position in a stable manner when

idle and in the event of power supply failure.

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Positioner (Code S0)

3.4 Function

The product controls or regulates (depending on version) a

flowing medium by being closed or opened by a motorized ac-

tuator.

The product is equipped as standard with a mechanical posi-

tion indicator as well as an electrical position and status indic-

ator.

4 GEMÜ CONEXO

Order without CONEXO

If you have ordered the product without CONEXO functionality,

the RFID chip is used for traceability in the production process

and quality assurance. Expansion to include the CONEXO

functionality at a later date must be coordinated with GEMÜ.

Order with CONEXO

GEMÜ CONEXO must be ordered separately with the ordering

option "CONEXO" (see order data).

For electronic identification purposes, each replaceable com-

ponent contained in the product is equipped with an RFID chip

(1). Where you can find the RFID chip differs from product to

product.

Actuator RFID chip Diaphragm RFID

chip

Valve body RFID

chip

The CONEXO pen helps read out information stored in these

RFID chips. The CONEXO app or CONEXO portal is required to

view this information.

5 Correct use

DANGER

Danger of explosion!

▶Risk of death or severe injury

●Do not use the product in potentially

explosive zones.

WARNING

Improper 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 and in

this document.

The product is designed for installation in piping systems and

for controlling a working medium.

The product is not intended for use in potentially explosive

areas.

●Use the product in accordance with the technical data.

5 Correct use

6 Order data

The order data provide an overview of standard configurations.

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

Order codes

1 Type Code

Diaphragm valve, electrically operated,

eSyStep

639

2 DN Code

DN 4 4

DN 6 6

DN 8 8

DN 10 10

DN 12 12

DN 15 15

DN 20 20

DN 25 25

DN 32 32

DN 40 40

3 Body configuration Code

Tank bottom valve body B

Body configuration code B: Dimensions and designs on

request

2/2-way body D

T body T

Body configuration code T: For dimensions, see T

Valves brochure

4 Connection type Code

Spigot

Spigot DIN 0

Spigot EN 10357 series B,

formerly DIN 11850 series 1

Spigot EN 10357 series A/DIN 11866 series A

formerly DIN 11850 series 2

Spigot DIN 11850 series 3 18

Spigot JIS-G 3447 35

Spigot JIS-G 3459 schedule 10s 36

Spigot SMS 3008 37

Spigot BS 4825, part 1 55

Spigot ASME BPE/DIN 11866 series C 59

Spigot ISO 1127/EN 10357 series C/DIN 11866 series B 60

Spigot ANSI/ASME B36.19M schedule 10s 63

Spigot ANSI/ASME B36.19M schedule 5s 64

Spigot ANSI/ASME B36.19M schedule 40s 65

Threaded connection

Threaded socket DIN ISO 228 1

NPT female thread 31

Threaded spigot DIN 11851 6

Cone spigot and union nut DIN 11851 6K

4 Connection type Code

Flange

Flange EN 1092, PN 16, form B,

face-to-face dimension FTF EN 558 series 1, ISO 5752,

basic series 1,