GEM 652 User manual

GEMÜ 652

Pulsation damper

Operating instructions

further information

webcode: GW-652

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

Keep the document for future reference.

16.12.2022

www.gemu-group.com2 / 26GEMÜ 652

Contents

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

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

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

1.3 Definition of terms ........................................ 4

1.4 Warning notes ............................................... 4

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

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

3.1 Construction .................................................. 5

3.2 Description ..................................................... 6

3.3 Function ......................................................... 6

3.4 Product label ................................................. 6

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

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

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

6.1 Order codes ................................................... 8

6.2 Order example ............................................... 9

7 Technical data ..................................................... 10

7.1 Medium .......................................................... 10

7.2 Temperature .................................................. 10

7.3 Pressure ......................................................... 11

7.4 Product conformity ....................................... 12

7.5 Mechanical data ............................................ 12

8 Dimensions .......................................................... 13

8.1 Actuator dimensions ..................................... 13

8.2 Body dimensions ........................................... 14

9 Manufacturer's information .................................. 16

9.1 Delivery .......................................................... 16

9.2 Packaging ...................................................... 16

9.3 Transport ....................................................... 16

9.4 Storage ........................................................... 16

10 Installation in piping ............................................ 16

10.1 Preparing for installation .............................. 16

10.2 Installation position ....................................... 17

10.3 Installation with butt weld spigots ............... 17

10.4 After the installation ...................................... 17

10.5 Optical position indicator .............................. 17

10.6 Optimized draining of valves ........................ 17

11 Pneumatic connections ....................................... 18

11.1 Control function ............................................. 18

11.1.1 Zero and working positions ............. 19

11.2 Connecting the control medium ................... 19

12 Commissioning .................................................... 19

13 Troubleshooting .................................................. 20

14 Inspection and maintenance ................................ 21

14.1 Spare parts .................................................... 21

14.1.1 Spare parts MG 25, MG 40, MG 50 .. 21

14.1.1 Spare parts MG 80 ........................... 21

14.2 Cleaning the product ..................................... 21

14.3 Assembly/disassembly of spare parts ........ 22

15 Removal from piping ............................................ 23

16 Disposal .............................................................. 23

17 Returns ................................................................ 23

18 EU Declaration of Incorporation according to the

EC Machinery Directive 2006/42/EC ..................... 24

19 EU Declaration of Conformity in accordance with

2014/68/EU (Pressure Equipment Directive) ........ 25

GEMÜ 652www.gemu-group.com 3 / 26

www.gemu-group.com4 / 26GEMÜ 652

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.

- A supplement to Directive 2014/34/EU (ATEX Directive) is

included with the product, provided that it was ordered in

accordance with ATEX.

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 medium

The medium that flows through the GEMÜ product.

Diaphragm size

Uniform seat size of GEMÜ diaphragm valves for different

nominal sizes.

Control function

The possible actuation functions of the GEMÜ product.

Control medium

The medium whose increasing or decreasing pressure causes

the GEMÜ product to be actuated and operated.

1.4 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 - corrosive materials

Danger - hot surfaces

www.gemu-group.com 5 / 26 GEMÜ 652

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 screws 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

2 Actuator Stainless steel

3 CONEXO actuator RFID

chip (see “GEMÜ CON-

EXO“, page7)

4 Diaphragm EPDM, PTFE/EPDM

5 Valve body 1.4435 (F316L), forged body

1.4435 (BN2), forged body, Δ

Fe < 0.5%

1.4539, forged body

6 CONEXO body RFID

chip (see “GEMÜ CON-

EXO“, page7)

7 CONEXO diaphragm

RFID chip (see “GEMÜ

CONEXO“, page7)

8 Leak detection hole

9 Vent hole

3 Product description

www.gemu-group.com6 / 26GEMÜ 652

3 Product description

3.2 Description

The GEMÜ 652 pulsation damper is designed for use with li-

quid and gaseous media in sterile areas of application. In

many production plants, unwanted pressure surges arise

which are generated by switching on pumps or quickly switch-

ing valves, for example. In addition, pressure surges may

cause unwanted momentary opening of shut-off valves, thus

contaminating media. Likewise, an increased pressure may

arise in the medium pipe due to thermal expansion of the me-

dium. This can cause damage to plant components such as

filters, sensors or piping. As a solution to this GEMÜ has de-

veloped the pulsation damper GEMÜ 652 , which is based on

the proven diaphragm valve technology and is designed so

that it releases a volume in a particular pre-defined pressure

surge area, and consequently catches and compensates for

the pressure surge. The valve body is open in-line with flow

direction, and not intended to shut off the medium.

3.3 Function

The GEMÜ 652 pulsation damper is usually installed in piping

in order to compensate for pressure surges or else thermal

expansions of the medium. The product has a piston actuator

and an optical position indicator as standard.

All actuator parts including closing springs (except seals) are

made from stainless steel. In diaphragm size 80, the com-

pression springs consist of epoxy coated spring steel. The

product is pushed by the spring force in the direction of the

pipe, and releases the corresponding compensation volume,

depending on version, pressure surge or thermal expansion.

The product body and the diaphragm are available in various

designs in accordance with the datasheet. The product can be

cleaned (CIP) and sterilized (SIP) without disassembly, and is

autoclavable (depending on version).

Electrical position indicators are available as accessories.

3.4 Product label

The product label is located on the actuator. Product label

data (example):

Item number Traceability number Consecutive number

Design in accordance with order data

Device-specific data

Year of manufacture

The month of manufacture is encoded in the traceability num-

ber and can be obtained from GEMÜ. The product was manu-

factured in Germany.

www.gemu-group.com 7 / 26 GEMÜ 652

4 GEMÜ CONEXO

Processing industry 4.0 – Traceability and service

Fig.1: Product with RFID transponders

Description

You can use the GEMÜ CONEXO pen to read and process

identification data from devices and components. In conjunc-

tion with the GEMÜ CONEXO app for maintenance techni-

cians, field data can be collected, processed, and managed

and archived centrally via the GEMÜ CONEXO portal.

Features

- Captive electronic identification of the valve body, actuator

and diaphragm

- Simplified identification and inventory of devices in the field

- Traceability of the components by providing the serial num-

ber

- Electronic supply of product and project-specific document-

ation

- Optimized maintenance processes thanks to a maintenance

log book and photo documentation

Technical specifications – CONEXO PEN:

- Mobile RFID reading device in the form of a pen

- Bluetooth coupling to mobile end devices

- Stylus for touchscreens (smartphone and tablet)

- UHF signal processing

Technical specifications – CONEXO APP:

- Service software for more efficient maintenance

- Available for tablets and smartphones that have the An-

droid or iOS operating system

- High security standards implemented in portal-reader com-

munication

- Workflow template for customizing the maintenance pro-

cess

- Electronically supported diaphragm assessment and photo

documentation

Technical specifications – CONEXO PORTAL:

- Integrated service functions and remote support

- Portable server application with database for Industry 4.0

- Interfaces to maintenance and ERP systems

- High level of IT security thanks to access rights and encryp-

ted data

- Open system (option to integrate third-party devices)

5 Correct use

DANGER

Danger 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 declara-

tion of conformity.

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. In the event

of pressure surges or medium expansion, it releases a certain

volume range so as to enable pressure compensation.

1. Use the product in accordance with the technical data.

2. Note the supplement acc. to ATEX

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

Pulsation damper,

stainless steel piston actuator, electropolished,

optical position indicator

652

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

3 Body configuration Code

2/2-way body D

4 Connection type Code

Spigot

Spigot EN 10357 series A (formerly DIN 11850 series

2)/DIN 11866 series A

Spigot ASME BPE/DIN 11866 series C 59

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

5 Valve body material Code

Forged material

1.4435 (F316L), forged body 40

1.4435 (BN2), forged body, Δ Fe < 0.5% 42

1.4539, forged body F4

6 Diaphragm material Code

EPDM 17

EPDM 19

PTFE/EPDM one-piece 54

7 Actuator version Code

Actuator size 2T1 2T1

Actuator size 2T2 2T2

Actuator size 2T3 2T3

Actuator size 3T1 3T1

Actuator size 3T2 3T2

Actuator size 3T3 3T3

Actuator size 3T4 3T4

Actuator size 3T5 3T5

Actuator size 4T1 4T1

Actuator size 4T2 4T2

Actuator size 4T3 4T3

Actuator size 4T4 4T4

Actuator size 4T5 4T5

7 Actuator version Code

Actuator size 5T1 5T1

Actuator size 5T2 5T2

Actuator size 5T3 5T3

Actuator size 5T4 5T4

Actuator size 5T5 5T5

Actuator size 5T6 5T6

8 Surface Code

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 H5,

mechanically polished internal,

*) for inner pipe diameters < 6 mm, in the spigot Ra ≤

0.38 μm

1527

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 spigot Ra ≤

0.38 µm

1516

Ra max. 0.51 µm (20 µin.) for media wetted surfaces,

in accordance with ASME BPE SF1,

mechanically polished internal

SF1

Ra max. 0.64 µm (25 µin.) for media wetted surfaces,

in accordance with ASME BPE SF2,

mechanically polished internal

SF2

Ra max. 0.76 µm (30 µin.) for media wetted surfaces,

in accordance with ASME BPE SF3,

mechanically polished internal

SF3

Ra max. 0.38 µm (15 µin.) for media wetted surfaces,

in accordance with ASME BPE SF4,

electropolished internal/external

SF4

Ra max. 0.51 µm (20 µin.) for media wetted surfaces,

in accordance with ASME BPE SF5,

electropolished internal/external

SF5

Ra max. 0.64 µm (25 µin.) for media wetted surfaces,

in accordance with ASME BPE SF6,

electropolished internal/external

SF6

6 Order data

www.gemu-group.com8 / 26GEMÜ 652

9 CONEXO Code

Without

9 CONEXO Code

Integrated RFID chip for electronic identification and

traceability

Order example

Ordering option Code Description

1 Type 652 Pulsation damper,

stainless steel piston actuator, electropolished,

optical position indicator

2 DN 50 DN 50

3 Body configuration D 2/2-way body

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

5 Valve body material 40 1.4435 (F316L), forged body

6 Diaphragm material 17 EPDM

7 Actuator version 4T1 Actuator size 4T1

8 Surface 1508 Ra ≤ 0.6 µm (25 µin.) for media wetted surfaces,

electropolished internal/external

9 CONEXO Without

6 Order data

www.gemu-group.com 9 / 26 GEMÜ 652

7 Technical data

7.1 Medium

Working medium: Corrosive, inert, gaseous and liquid media which have no negative impact on the physical and

chemical properties of the body and diaphragm material.

Control medium: Inert gases

Connection of the control medium is only required for diaphragm replacement. Under normal work-

ing conditions, control air is not required.

7.2 Temperature

Media temperature: -10 — 100 °C

Sterilization temperature: EPDM (Code 17) max. 150 °C, max. 180 min per cycle

EPDM (Code 19) max. 150 °C, max. 180 min per cycle

PTFE/EPDM (Code 54) max. 150 °C, permanent temperature per cycle

The sterilization temperature is only valid for steam (saturated steam) or superheated water.

If the sterilization 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 accord-

ingly.

This also applies to PTFE diaphragms exposed to high temperature fluctuations. The maintenance cycles must

be adapted accordingly.

Control medium temper-

ature:

0 — 60 °C

Ambient temperature: 0 — 60 °C

Autoclavability: Actuator version Autoclavability

2T1, 2T2, 2T3 Autoclavable

3T1, 3T2, 3T3, 3T4, 3T5 with special version

4T1, 4T2, 4T3, 4T4, 4T5

5T1, 5T2, 5T3, 5T4, 5T5, 5T6

www.gemu-group.com10 / 26GEMÜ 652

7 Technical data

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