GEM 600 Montageanleitung

600, 630

Diaphragm Valve

Plastic, DN 12 - 50

INSTALLATION, OPERATING AND

MAINTENANCE INSTRUCTIONS

Actuator size Code 1

Actuator size Code 2-4

Membranventil

Kunststoﬀ, DN 12 - 50

DE ORIGINAL EINBAU- UND MONTAGEANLEITUNG

GEMÜ 600

Antriebsgröße Code 2-4

GEMÜ 630

Antriebsgröße Code 2-4

GEMÜ 630

Antriebsgröße Code 1

22 / 44

600, 630

Contents

1 General information 22

2 General safety information 22

2.1 Information for service

and operating personnel 23

2.2 Warning notes 23

2.3 Symbols used 24

3 Definition of terms 24

4 Intended area of use 24

5 Condition as supplied

to customer 24

6 Technical data 25

7 Order data 26

8 Manufacturer's information 27

8.1 Transport 27

8.2 Delivery and performance 27

8.3 Storage 27

8.4 Tools required 27

9 Functional description 27

10 Construction 28

11 Installation and connection 29

11.1 Installing the diaphragm valve 29

11.2 Control functions 31

11.3 Connecting the control medium 32

11.4 Optical position indicator 32

11.5 Setting the stroke limiter

GEMÜ 600 32

11.6 Manual override GEMÜ 600 32

12 Assembly / Disassembly

of spare parts 33

12.1 Valve disassembly

(removing actuator from body) 33

12.2 Removing the diaphragm 33

12.3 Mounting the diaphragm 33

12.3.1 General information 33

12.3.2 Mounting a concave diaphragm 34

12.3.3 Mounting a convex diaphragm 35

12.3.4 Actuator mounting

on the valve body 35

13 Commissioning 36

14 Inspection and servicing 36

15 Disassembly 36

16 Disposal 37

17 Returns 37

18 Information 37

19 Troubleshooting /

Fault clearance 38

20 Sectional drawings

and spare parts 39

21 Declaration of Incorporation 41

22 EC Declaration of conformity 42

1 General information

Prerequisites to ensure that the GEMÜ valve

functions correctly:

Correct transport and storage

Installation and commissioning by trained

personnel

Operation according to these installation,

operating and maintenance instructions

Recommended maintenance

Correct installation, operation, servicing and

repair work ensure faultless diaphragm valve

operation.

The descriptions and instructions

apply to the standard versions.

For special versions not described

in these installation, operating

and maintenance instructions the

basic information contained herein

applies in combination with any

additional special documentation.

All rights including copyright

and industrial property rights are

expressly reserved.

2 General safety information

The safety information does not take into

account:

Unexpected incidents and events, which

may occur during installation, operation

and servicing.

Local safety regulations which must be

adhered to by the operator and by any

additional installation personnel.

23 / 44 600, 630

2.1 Information for service

and operating personnel

The installation, operating and maintenance

instructions contain fundamental safety

information that must be observed during

commissioning, operation and servicing.

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 materials.

Prior to commissioning:

GRead the installation, operating and

maintenance instructions.

GProvide adequate training for the

installation and operating personnel.

GEnsure that the contents of the

installation, operating and maintenance

instructions have been fully understood

by the responsible personnel.

GDeﬁne the areas of responsibility.

During operation:

GKeep the installation, operating and

maintenance instructions available at the

place of use.

GObserve the safety information.

GUse only in accordance with the

speciﬁcations.

GAny servicing work and repairs not

described in the installation, operating

and maintenance instructions must not

be performed without consulting the

manufacturer ﬁrst.

DANGER

Strictly observe the safety data sheets

or the safety regulations that are valid

for the media used.

In cases of uncertainty:

Consult the nearest GEMÜ sales oﬃce.

2.2 Warning notes

Wherever possible, warning notes are

organised according to the following

scheme:

SIGNAL WORD

Type and source of the danger

®Possible consequences of

non-observance.

GMeasures 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 will lead to death or

severe injury.

WARNING

Potentially dangerous situation!

®Non-observance can cause death or

severe injury.

CAUTION

Potentially dangerous situation!

®Non-observance can cause medium to

light injury.

CAUTION (WITHOUT SYMBOL)

Potentially dangerous situation!

®Non-observance can cause damage to

property.

24 / 44

600, 630

2.3 Symbols used

Danger - hot surfaces!

Danger - corrosive materials!

Hand: indicates general information

and recommendations.

GBullet point: indicates the tasks to

be performed.

®Arrow: indicates the response(s) to

tasks.

Enumeration sign

3 Definition of terms

Working medium

The medium that ﬂows through the

diaphragm valve.

Control medium

The medium whose increasing or

decreasing pressure causes the valve to be

actuated and operated.

Control function

The possible actuation functions of the

diaphragm valve.

4 Intended area of use

The GEMÜ 600, 630 diaphragm valve

is designed for installation in piping

systems. It controls a ﬂowing medium

by being closed or opened by a control

medium.

The valve may only be used providing

the product technical criteria are

complied with (see chapter 6

"Technical data").

Do not paint the bolts and plastic parts of

the diaphragm valve!

WARNING

Use the diaphragm valve only for the

intended purpose!

®Otherwise the manufacturer liability and

guarantee will be void.

GUse the diaphragm valve only in

accordance with the operating

conditions speciﬁed in the contract

documentation and in the installation,

operating and maintenance

instructions.

5 Condition as supplied

to customer

The GEMÜ diaphragm valve is supplied as a

separately packed component.

25 / 44 600, 630

6 Technical data

Ambient temperature

Valve body PVC-U 10 to 50 °C

Valve body PP / PP-H 5 to 50 °C

Valve body ABS / PVDF -10 to 50 °C

Control medium

Inert gases

Min. required control pressure see table below

Max. permiss. control pressure 6 bar

Max. perm. temperature of control medium 40 °C

Filling volume:

Actuator size 1 0.02 dm³

Actuator size 2 0.25 dm³

Actuator size 3 0.50 dm³

Actuator size 4 0.80 dm³

Working medium temperature

Valve body PVC-U 10 to 60 °C

Valve body ABS -20 to 60 °C

Valve body PP, PP-H 5 to 80 °C

Valve body PVDF -20 to 80 °C

The permissible operating pressure depends on the working

medium temperature.

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.

Pressure / temperature correlation for PN 10 (valve bodies diaphragm size 25-50)

Temperature in °C

(plastic body)-20 -10 ±0 5 10 20 25 30 40 50 60 70 80

Valve body material Permissible operating pressure in bar

PVC-U Code 1 - - - - 10.0 10.0 10.0 8.0 6.0 3.5 1.5 - -

ABS Code 4 10.0 10.0 10.0 10.0 10.0 10.0 10.0 8.0 6.0 4.0 2.0 - -

PP-H Code 71 - - - 10.0 10.0 10.0 10.0 8.5 7.0 5.5 4.0 2.7 1.5

PVDF Code 20 10.0 10.0 10.0 10.0 10.0 10.0 10.0 9.0 8.0 7.1 6.3 5.4 4.7

Data for extended temperature ranges on request.

Please note that the ambient temperature and medium temperature generate a combined temperature at the valve body which must not

exceed the above values.

O-ring material for valve bodies

with union ends

Diaphragm material O-ring material

NBR EPDM

FPM FPM

EPDM EPDM

PTFE FPM

Other combinations on request

Control function 1 [bar] Control function 2+3 [bar] Kv value

Type Diaphragm

size DN Operating pressure Control

pressure

Operating pressure Control

pressure [m³/h]

EPDM/FPM PTFE EPDM/FPM PTFE

GEMÜ

630 10

0 - 6 0 - 6 3.2 - 6.0 - - -

2.8

15 3.5

20 3.5

GEMÜ

600

0 - 10 0 - 6 4.0 - 6.0 0 - 10 0 - 6

max. 6.0

5.6

20 8.2

25 10.5

40 32 0 - 10 0 - 6 4.0 - 6.0 0 - 10 0 - 6 18.0

40 25.0

50 50 0 - 10 0 - 6 4.0 - 6.0 0 - 10 0 - 6 46.0

All pressures are gauge pressures.

Kv values determined acc. to IEC 534 standard, inlet pressure 6 bar, ∆p 1 bar, PVC-U valve body and soft elastomer diaphragm.

Pressure / temperature correlation for PN 6 (valve bodies diaphragm size 10)

Temperature in °C

(plastic body)-20 -10 ±0 5 10 20 25 30 40 50 60 70 80

Valve body material Permissible operating pressure [bar]

PVC-U Code 1 - - - - 6.0 6.0 6.0 4.8 3.6 2.1 0.9 - -

PP Code 5 - - - 6.0 6.0 6.0 6.0 5.1 4.2 3.3 2.4 1.6 0.9

PP-H Code N5 - - - 6.0 6.0 6.0 6.0 5.1 4.2 3.3 2.4 1.6 0.9

PVDF Code 20 6.0 6.0 6.0 6.0 6.0 6.0 6.0 5.4 4.8 4.3 3.8 3.2 2.8

26 / 44

600, 630

7 Order data

Diaphragm material Code

NBR 2

FPM 4

EPDM 14

PTFE / EPDM PTFE laminated MG 10 52

PTFE / EPDM convex PTFE loose MG 25 - 50 5E

MG = diaphragm size

Body conﬁguration Code

2/2-way body D

Connection Code

Spigots DIN for socket solvent cementing / welding 0

Threaded sockets DIN ISO 228 1

Solvent cement sockets DIN 2

Flanges EN 1092 / PN10 / form B

length EN 558, series 1,

ISO 5752, basic series 1 4

Union ends with DIN insert (socket) 7

Spigots for IR butt welding 20

Spigots for IR butt welding, BCF 28

Spigots - inch 30

Union ends with inch insert - BS (socket) 33

Flanges ANSI CLASS 125/150 RF

length EN 558, series 1,

ISO 5752, basic series 1 39

Flare connection with PVDF union nut 75

Union ends with

DIN insert (for IR butt welding) 78

Valve body material Code

PVC-U, grey 1

ABS 4

PP, reinforced 5

PVDF 20

Inliner PP-H grey / outliner PP reinforced 71

PP-H natural N5*

* only with integrated mounting plate (code M)

Control function Code

Normally closed NC 1

diaphragm size 10 - 50

Normally open NO 2

diaphragm size 25 - 50

Double acting DA 3

diaphragm size 50

Actuator version Code

Piston ø 54 diaphragm size 10 (GEMÜ 630) 1/N

Piston ø 85 diaphragm size 25 (GEMÜ 600) 2/N

Piston ø 105 diaphragm size 40 (GEMÜ 600) 3/N

Piston ø 125 diaphragm size 50 (GEMÜ 600) 4/N

Valve type Code

GEMÜ 630 diaphragm size 10 630

GEMÜ 600 diaphragm size 25 - 50 600

Note: Standard connection to NAMUR (diaphragm size 25). For diaphragm sizes 40 and 50 please use the control air adapter

GEMÜ 1470. Please order separately.

Order example 600 15 D 7 1 14 1 2/N -

Type 600

Nominal size 15

Body configuration (code) D

Connection (code) 7

Valve body material (code) 1

Diaphragm material (code) 14

Control function (code) 1

Actuator version (code) 2/N

Integrated mounting plate (code) -

Integrated mounting plate Code

With integrated mounting plate (MG 10 / GEMÜ 630) M

Material code 20, N5

Without mounting plate (MG 10 / GEMÜ 630) O

Material code 20

Without mounting plate -

MG = diaphragm size

27 / 44 600, 630

8 Manufacturer's information

8.1 Transport

GOnly transport the diaphragm valve by

suitable means. Do not drop. Handle

carefully.

GDispose of packing material according

to relevant local or national disposal

regulations / environmental protection

laws.

8.2 Delivery and performance

GCheck that all parts are present and

check for any damage immediately upon

receipt.

GThe scope of delivery is apparent from

the dispatch documents and the design

from the order number.

GThe valve's delivery condition:

Control function:Condition:

1Normally closed (NC) closed

2Normally open (NO) open

3Double acting (DA) undeﬁned

GThe performance of the diaphragm valve

is checked at the factory.

8.3 Storage

GStore the diaphragm valve free from dust

and moisture in its original packaging.

GAvoid UV rays and direct sunlight.

GMaximum storage temperature: 40 °C.

GSolvents, chemicals, acids, fuels or

similar ﬂuids must not be stored in the

same room as valves and their spare

parts.

8.4 Tools required

GThe tools required for installation and

assembly are not included in the scope

of delivery.

GUse appropriate, functional and safe

tools.

9 Functional description

GEMÜ 600 / 630 is a plastic diaphragm

valve with a 2/2-way body.The valve has

a piston actuator and an optical position

indicator as standard. "Normally closed

(NC)", "Normally open (NO)" and "Double

acting (DA)" control functions are available.

The valve body and the diaphragm are

available in various designs as shown in

the data sheet. Diverse accessories are

available, such as pilot valves, electrical

position indicator with microswitches or

proximity switches, pneumatic or electro-

pneumatic positioner and a NAMUR plate.

10 Construction

Optical position

indicator

Connector 4

Connector 2

Stroke limiter

Manual

override

Construction - GEMÜ 600

Actuator size Code 2-4

A Actuator

1 Valve body

2 Diaphragm

28 / 44

600, 630

Optical position

indicator

Vent hole

Connector 2

Construction - GEMÜ 630

Actuator size Code 1

A Actuator

1 Valve body

2 Diaphragm

Optical position

indicator

Connector 4

Connector 2

Construction - GEMÜ 630

Actuator size Code 2-4

A Actuator

1 Valve body

2 Diaphragm

11 Installation and connection

Prior to installation:

GEnsure that valve body and diaphragm

material are appropriate and compatible

to handle the working medium.

GCheck the suitability prior to the

installation.

See chapter 6 "Technical data".

11.1 Installing the diaphragm valve

WARNING

The equipment is subject to pressure!

®Risk of severe injury or death!

GOnly work on depressurized plant.

WARNING

Corrosive chemicals!

®Risk of caustic burns!

GWear appropriate protective

gear when installing.

CAUTION

Hot plant components!

®Risk of burns!

GOnly work on plant that has

cooled down.

CAUTION

Never use the valve as a step or an aid

for climbing!

®This entails the risk of slipping-oﬀor

damaging the valve.

CAUTION

Do not exceed the maximum

permissible pressure!

®Take precautionary measures to

avoid possible pressure surges

(water hammer).

GInstallation work must only be performed

by trained personnel.

GUse appropriate protective gear as

speciﬁed in plant operator's guidelines.

29 / 44 600, 630

Installation location:

CAUTION

GDo not apply external force to the valve.

GChoose the installation location so that

the valve cannot be used as a foothold

(climbing aid).

GLay the pipeline so that the valve body

is protected against transverse and

bending forces, and also vibrations and

tension.

GOnly mount the valve between

matching aligned pipes.

Direction of the working medium:

optional.

Mounting position of the diaphragm valve:

optional.

Installation:

1. Ensure the suitability of the valve for

each respective use.The valve must

be appropriate for the piping system

operating conditions (medium, medium

concentration, temperature and

pressure) and the prevailing ambient

conditions. Check the technical data of

the valve and the materials.

2. Shut oﬀplant or plant component.

3. Secure against recommissioning.

4. Depressurize the plant or plant

component.

5. Completely drain the plant (or plant

component) and let it cool down until

the temperature is below the media

vaporization temperature and scalding

can be ruled out.

6. Correctly decontaminate, rinse and

ventilate the plant or plant component.

Installation - Butt weld spigots:

1. Adhere to good welding practices!

2. Disassemble the actuator with the

diaphragm before welding the valve body

into the pipeline (see chapter 12.1).

3. Allow butt weld spigots to cool down.

4. Reassemble the valve body and the

actuator with diaphragm (see chapter

12.4).

Installation - Union ends with insert:

CAUTION

Damage to the valve actuator or valve

body!

®Adhere to good welding practices!

CAUTION

Damage to the valve body!

®Only use solvent cement suitable for

the valve body.

The solvent cement is not included

in the scope of delivery!

1. Screw the threaded connections into

the piping in accordance with valid

standards.

2. Unscrew union nut 1from valve body 2.

3. Reinsert O-ring 3if necessary.

5 1 4

4. Push the union nut 1over the piping 4.

Connect the insert 5with the piping 4by

cementing / welding.

5. Screw the union nut 1to the valve body 2

again.

6. Connect the other side of the valve

body 2to the piping 4, too.

30 / 44

600, 630

Installation - Threaded connections:

1. Screw the threaded connections into

the piping in accordance with valid

standards.

2. Screw the diaphragm valve body into the

piping, use appropriate thread sealant.

The thread sealant is not included in the

scope of delivery.

Installation - Flange connection:

1. Pay attention to clean, undamaged

sealing surfaces on the mating ﬂanges.

2. Align ﬂanges carefully before installing

them.

3. Centre the seals accurately.

4. Connect the valve ﬂange and the piping

ﬂange using appropriate sealing material

and matching bolting. Sealing material

and bolts are not included in the scope

of delivery. Use all ﬂange holes.

5. Only use connector elements made of

approved materials!

6. Tighten the bolts diagonally!

Installation - Solvent cement sockets:

CAUTION

Damage to the valve body!

®Only use solvent cement suitable for

the valve body.

The solvent cement is not included

in the scope of delivery!

1. Apply solvent cement on the inside of

the valve body and on the outside of

the piping as speciﬁed by the solvent

cement manufacturer.

2. Connect the valve body to the piping.

Installation - Solvent cement spigots:

CAUTION

Damage to the valve body!

®Only use solvent cement suitable for

the valve body.

The solvent cement is not included

in the scope of delivery!

1 212

1. Apply solvent cement on the outside

of the valve body spigots 1and on

the inside of the piping connector 2

as speciﬁed by the solvent cement

manufacturer.

2. Connect the valve body to the piping.

Installation - Flare connection:

1. Also refer to GEMÜ FlareStar®brochure

and GEMÜ ﬂare and assembly

instructions for preparation and

connection of ﬂare connections!

2. Push the ﬂared PFA tube onto the ﬂare

connection.

3. Screw on union nut.

4. Use connection ﬁttings resistant to and

suitable for the ambient conditions.

Observe appropriate regulations for

connections!

After the installation:

Important:

Diaphragms degrade in the course

of time. After valve installation

and commissioning you must

retighten the bolts 18 (see chapter

20 "Sectional drawings and spare

parts").

GReactivate all safety and protective

devices.

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