GEM 653 Montageanleitung

653, 654

Diaphragm Valve

Metal, Diaphragm sizes 8 - 100

GB INSTALLATION, OPERATING AND

MAINTENANCE INSTRUCTIONS

653, 654 2 / 28

20 Troubleshooting /

Fault clearance 25

21 Sectional drawing

and spare parts 26

22 EC Declaration of Conformity 27

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 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.

Contents

1 General information 2

2 General safety information 2

2.1 Information for service and

operating personnel 2

2.2 Warning notes 3

2.3 Symbols used 3

3 Deﬁnition of terms 4

4 Intended area of use 4

5 Condition as supplied

to customer 4

6 Technical data 4

7 Order data 6

8 Manufacturer’s information 9

8.1 Transport 9

8.2 Delivery and performance 9

8.3 Storage 9

8.4 Tools required 9

9 Functional description 9

10 Construction 9

11 Installation and operation 10

11.1 Installing the diaphragm valve 10

11.2 Operation 11

11.3 Setting the seal adjuster

and the stroke limiter 12

12 Assembly / disassembly

of spare parts 15

12.1 Valve disassembly

(removing bonnet from body) 15

12.2 Removing the diaphragm 15

12.3 Mounting the diaphragm 15

12.3.1 General information 15

12.3.2 Mounting a concave diaphragm 18

12.3.3 Mounting a convex diaphragm 19

12.4 Bonnet mounting

on the valve body 19

13 Special versions 20

13.1 Special version with

electrical locking device 20

13.2 Special version with

mechanical locking device 20

13.3 Special version for mounting

of proximity switches 21

14 Commissioning 23

15 Inspection and servicing 23

16 Disassembly 24

17 Disposal 24

18 Returns 24

19 Information 24

3 / 28 653, 654

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 moderate

to light injury.

CAUTION (WITHOUT SYMBOL)

Potentially dangerous situation!

®Non-observance can cause damage to

property.

2.3 Symbols used

Danger - hot surfaces!

Danger - corrosive materials!

Hand: indicates general information

and recommendations.

653, 654 4 / 28

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.

4 Intended area of use

The GEMÜ 653 or 654 diaphragm valve

is designed for installation in piping

systems. It controls a flowing medium by

manual operation.

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.

GThe diaphragm valve may only be used

in potentially explosive zones confirmed

in the declaration of conformity (ATEX).

5 Condition as supplied

to customer

The GEMÜ diaphragm valve is supplied as a

separately packed component.

6 Technical data

Bonnet material

Bonnet A4 stainless steel

Cap (DN 10 - DN 40) PEEK

Cap (DN 50 - DN 100) PES

653 handwheel PPS glass filled

654 handwheel A4 stainless steel

Ambient conditions

Max. ambient temperature Standard 60 °C

Max. ambient temperature Accessory MAG 35 °C

Temperature at mounting point for proximity switches see

ambient temperature diagram below

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.

Operating temperature max. 150 °C

(dependent on medium wetted materials)

The valve will seal in both flow directions up to full operating

pressure (all pressures are gauge pressures).

20 40 60 80 100 120 140 160

120

100

Medium temperature [°C]

Temperature at proximity switch [°C]

Values measured at 25 °C ambient temperature

Operating pressure [bar]

Diaphragm size EPDM/FPM PTFE

8 0 - 10 0 - 6

10 0 - 10 0 - 6

25 0 - 10 0 - 6

40 0 - 10 0 - 6

50 0 - 10 0 - 6

80 0 - 10 0 - 6

100 0 - 10 0 - 6

All pressures are gauge pressures. Operating pressure values were

determined with static operating pressure applied on one side of a

closed valve. Sealing at the valve seat and atmospheric sealing is

ensured for the given values. Information on operating pressures

applied on both sides and for high purity media on request.

Version with PTFE diaphragm up to 10 bar possible with bonnet

special function "H" and forged valve body.

5 / 28 653, 654

GEMÜ 654 - 0TN (MG 8)GEMÜ 654 - 0TH (MG 8)

GEMÜ 653 - T

(MG 10 - 100)

GEMÜ 654 - T

(MG 10 - 100)

GEMÜ 653 - D

(MG 10 - 50)

GEMÜ 654 - D

(MG 10 - 50)

Kv values [m³/h]

MG DN DIN

Code 0

DIN 11850

Series 1

Code 16

DIN 11850

Series 2

Code 17

DIN 11850

Series 3

Code 18

SMS 3008

Code 37

ASME BPE

Code 59

EN ISO

1127

Code 60

40.5------

6 1.1 - - - - - 1.2

8 1.3 - - - - 0.6 2.2

10 - 2.1 2.1 2.1 - 1.3 -

15 - - - - - 2.0 -

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 -

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

80 65 - - 77.0 - 68.5 68.5 96.0

80 - - 111.0 - 80.0 87.0 111.0

100 100 - - 194.0 - 173.0 188.0 214.0

Kv values determined acc. to IEC 534 standard, inlet pressure 6 bar, Δp 1 bar, stainless steel valve body and soft elastomer diaphragm.

MG = diaphragm size

Diaphragm temperature range [°C]

Diaphragm Liquid Media Steam

(Sterilisation)Code

Min. Max.

EPDM -10 90 150 °C, max. 60 min 13/3A

EPDM -10 90 150 °C, max. 60 min 16/6A

EPDM -10 90 150 °C, max. 180 min 17

PTFE -10 90 Constant temperature* 150 °C 52/5A

PTFE -10 90 Constant temperature* 150 °C 5E

FPM -10 90 not applicable 4/4A

PTFE -10 90 150 °C, max. 40 min 5F

* The valves concerned must be serviced regulary if steam is applied continuously

6 / 28

653, 654

7 Order data

GEMÜ 653 - LOC GEMÜ 654 - MAG GEMÜ 653 - proximity switches

Body configuration Code

Tank valve body B**

2/2-way body D

Multi-port design M**

T body T*

* For dimensions see T Valves brochure

** Dimensions and versions on request

Bonnet size Code

Diaphragm size 8 0

Diaphragm size 10 1

Diaphragm size 25 2

Diaphragm size 40 3

Diaphragm size 50 4

Diaphragm size 80 5

Diaphragm size 100 6

Valve body material Code

1.4435 - BN2 (CF3M), investment casting Fe<0.5% 32

1.4435 (ASTM A 351 CF3M

≙316L

), investment casting 34

1.4408, investment casting 37

1.4408, PFA lined 39

1.4435 (316L), forged body 40

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

Control function Code

Manually operated 0

Bonnet version Code

For body configuration D

(diaphragm size 10 - 50) D

For body configurations B, D, M and T

(diaphragm size 8- 100) T

Bonnet for special function

for body configurations B, D, M and T

(diaphragm size 10 - 100) X

Flanges

Flanges EN 1092 / PN16 / form B,

length EN 558, series 1,

ISO 5752, basic series 1 8

Flanges ANSI CLASS 125/150 RF,

length MSS SP-88 38

Flanges ANSI CLASS 125/150 RF,

length EN 558, series 1,

ISO 5752, basic series 1 39

Clamp connections

Clamps ASME BPE for pipe ASME BPE,

length ASME BPE 80

Clamps DIN 32676 series B for pipe EN ISO 1127,

length EN 558, series 7 82

Clamps ASME BPE for pipe ASME BPE,

length EN 558, series 7 88

Clamps DIN 32676 series A for pipe DIN 11850,

length EN 558, series 7 8A

Clamps SMS 3017 for pipe SMS 3008,

length EN 558, series 7 8E

Aseptic clamps on request

For overview of available valve bodies see data sheet page 13

Connection Code

Butt weld spigots

Spigots DIN 0

Spigots DIN 11850, series 1 16

Spigots DIN 11850, series 2 17

Spigots DIN 11850, series 3 18

Spigots DIN 11866, series A 1A

Spigots DIN 11866, series B 1B

Spigots JIS-G 3447 35

Spigots JIS-G 3459 36

Spigots SMS 3008 37

Spigots BS 4825, part 1 55

Spigots ASME BPE 59

Spigots EN ISO 1127 60

Spigots ANSI/ASME B36.19M, Schedule 10s 63

Spigots ANSI/ASME B36.19M, Schedule 40s 65

Threaded connections

Threaded sockets DIN ISO 228 1

Threaded spigots DIN 11851 6

One side threaded spigot, other side

cone spigot and union nut, DIN 11851 62

Aseptic unions on request

Diaphragm material Code

FPM 4 4A*

EPDM 13 3A*

EPDM 16 6A*

EPDM 17 17*

PTFE/EPDM convex PTFE loose 5E**

PTFE/FPM convex PTFE loose 5F

PTFE/EPDM PTFE laminated 52 5A*

* for diaphragm size 8

** for use with valve bodies see data sheet page 13

Material complies with FDA requirements, except code 4 and 4A

7 / 28 653, 654

Bonnet function Code

With seal adjuster and stroke limiter (GEMÜ 653 diaphragm size 10 - 50) H

(GEMÜ 654 diaphragm size 8- 100)

Without seal adjuster and without stroke limiter (GEMÜ 653 diaphragm size 10 - 100) N

(GEMÜ 654 diaphragm size 8- 100)

With seal adjuster (diaphragm size 80 - 100) S

Special versions

With seal adjuster, stroke limiter and mounting for proximity switches M 8x1 (diaphragm size 10 - 50) A*

With seal adjuster and mounting for proximity switches M 12x1 (diaphragm size 80 - 100)

With seal adjuster, stroke limiter and locking device (both directions) and (diaphragm size 10 - 50) B*

mounting for proximity switches M 8x1

With seal adjuster, locking device (both directions) and (diaphragm size 80 - 100)

mounting for proximity switches M 12x1

With seal adjuster, stroke limiter and safety gland packing (diaphragm size 10 - 50) E*

With seal adjuster and safety gland packing (diaphragm size 80 - 100)

With seal adjuster, stroke limiter, locking device to prevent closing and (diaphragm size 10 - 50) F*

mounting for proximity switches M 8x1

With seal adjuster, locking device to prevent closing and (diaphragm size 80 - 100)

mounting for proximity switches M 12x1

With seal adjuster, stroke limiter, locking device to prevent opening and (diaphragm size 10 - 50) K*

mounting for proximity switches M 8x1

With seal adjuster, locking device to prevent opening and (diaphragm size 80 - 100)

mounting for proximity switches M 12x1

* only in connection with bonnet version X

* only in T-valve version

Order example 653 50 D 60 40 13 0 4 D H 1503

Type 653

Nominal size 50

Body configuration (code) D

Connection (code) 60

Valve body material (code) 40

Diaphragm material (code) 13

Control function (code) 0

Bonnet size (code) 4

Bonnet version (code) D

Bonnet function (code) H

Nominal size (mm)*

Connection (code)*

Surface finish (code) 1503

Valve body surface finish, internal contour

Forged body

Code 40, 42 Investment casting

Code 32, 34 Code

Ra ≤6.3 μm blasted internal/external - X 1500

-- electropolished - X 1509

Ra ≤0.8 μm mechanically polished internal, blasted external X X 1502

Ra ≤0.8 μm electropolished internal/external X - 1503

Ra ≤0.6 μm mechanically polished internal, blasted external X X 1507

Ra ≤0.6 μm electropolished internal/external X - 1508

Ra ≤0.4 μm mechanically polished internal, blasted external X - 1536

Ra ≤0.4 μm electropolished internal/external X - 1537

Ra ≤0.25 μm mechanically polished internal, blasted external X - 1527

Ra ≤0.25 μm electropolished internal/external X - 1516

Ra acc. to DIN 4768; at defined reference points

Surface finish data refer to medium wetted surfaces

653, 654 8 / 28

Special versions

See chapter 13 for a detailed description of special versions.

The solenoids, padlocks etc. for the "locking device" must be ordered separately as accessories.

Available only in connection with the bonnet additional functions B, K, F!

Type of accessory MAG - Electrical locking device

Control function 1 - Normally closed (locking device active)

Control function 2 - Normally open (locking device inactive)

Voltage / Frequency C1 - 24 V DC

Type of accessory LOC - Mechanical locking device

Control function B - without padlock

L - with padlock

EDP No. Designation Description

88264576 653MAGSV1 C1 AT

Electromagnetic locking device

24 V DC, normally closed, M22x1

ATEX

88232776 653MAGSV1 C1

Electromagnetic locking device

24 V DC, normally closed, M22x1

IP 54, connector socket design A DIN EN 175301-803

88279388 653MAGSV2 C1

Electromagnetic locking device

24 V DC, normally open, M22x1

IP 54, connector socket design A DIN EN 175301-803

88239348 653LOCSVL Locking device M22x1 with padlock

88239405 653LOCSVB Locking device M22x1 without padlock

Order example 653 MAG SV 1 C1

Type 653

Type of accessory MAG

Kit SV

Control function (code) 1

Voltage / Frequency (code) C1

9 / 28 653, 654

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 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.

GStore the diaphragm valve in "open"

position.

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. Only the setting tool for the

stroke limiter of GEMÜ 654 diaphragm

size 80 + 100 is included (see page 14).

GUse appropriate, functional and safe

tools.

9 Functional description

The metal diaphragm valve is equipped

with a stainless steel bonnet. GEMÜ 653

has a handwheel in high temperature and

chemically resistant plastic, GEMÜ 654 a

stainless steel handwheel.The handwheels

for diaphragm size 8 are rising, those for

diaphragm sizes 10-100 are non-rising. An

optical position indicator is standard.Two

bonnet versions are available: for 2/2-way

bodies and for T bodies or multi-port bodies.

The valve body and the diaphragm are

available in various designs as shown in

the data sheet.The diaphragm valve can

be continuously opened or closed.Various

special versions are described in these

installation, operating and maintenance

instructions.

10 Construction

Optical position

indicator

Handwheel

Diaphragm size 8

Optical position

indicator

Handwheel

Diaphragm size 10-100

Construction

1 Valve body

2 Diaphragm

A Bonnet

653, 654 10 / 28

11 Installation and operation

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-off or

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.

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 off plant 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 bonnet 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

bonnet with diaphragm (see chapter

12.4).

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