GEM 710 Bedienungsanleitung

GEMÜ 710

Pneumatically operated ball valve

Operating instructions

further information

webcode: GW-710

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

Keep the document for future reference.

23.11.2020

www.gemu-group.com2 / 44GEMÜ 710

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 .................................................... 4

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

4 Correct use ............................................................... 6

5 Actuator assignment for 2/2-way valves ................... 7

6 Actuator assignment for multi-port valves ................. 7

7 Order data ................................................................. 8

8 Technical data .......................................................... 10

9 Dimensions ............................................................... 14

10 Manufacturer's information ....................................... 27

10.1 Delivery ................................................................ 27

10.2 Packaging ............................................................ 27

10.3 Transport ............................................................. 27

10.4 Storage ................................................................. 27

11 Installation in piping .................................................. 27

11.1 Preparing for installation .................................... 27

11.2 Installation with inserts for solvent cementing . 28

11.3 Installation with inserts for welding ................... 29

11.4 Installation with screw-type inserts ................... 29

11.5 Installation with flanged connection .................. 30

11.6 Fixing the mounting kit onto the actuator and

body ...................................................................... 30

12 Commissioning ......................................................... 31

13 Operation .................................................................. 31

14 Troubleshooting ........................................................ 33

15 Inspection and maintenance ...................................... 34

15.4 Cleaning the product ........................................... 39

16 Removal from piping ................................................. 39

17 Disposal .................................................................... 39

18 Returns ..................................................................... 39

19 Declaration of Incorporation according to 2006/42/

EC (Machinery Directive) ........................................... 40

20 Declaration of conformity according to 2014/68/EU

(Pressure Equipment Directive) ................................. 41

21 EU Declaration of conformity 2-way ball valve ........... 42

22 EU Declaration of conformity 3-way ball valve ........... 43

GEMÜ 710www.gemu-group.com 3 / 44

www.gemu-group.com4 / 44GEMÜ 710

1 General information

1.1 Information

– The descriptions and instructions apply to the stand-

ard versions. For special versions not described in this

document the basic information contained herein ap-

plies in combination with any additional special docu-

mentation.

– Correct installation, operation, maintenance and repair

work ensure faultless operation of the product.

– Should there be any doubts or misunderstandings, the

German 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 Definition of terms

Working medium

The medium that flows through the GEMÜ product.

Control medium

The medium whose increasing or decreasing pressure causes

the GEMÜ product to be actuated and operated.

Control function

The possible actuation functions of the GEMÜ product.

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 of explosion

Corrosive chemicals!

Hot plant components!

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 dan-

gerous materials.

The safety information does not take into account:

– Unexpected incidents and events, which may occur

during installation, operation and maintenance.

www.gemu-group.com 5 / 44 GEMÜ 710

– 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 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 Material

1 Ball valve body PVC-U, PVC-C, ABS, PP-H,

PVDF

2 Pipe connections PVC-U, PVC-C, ABS, PP-H,

PVDF

3 Anti-twist protection POM

4 Actuator housing Aluminium

5 Position indicator PP

Ball valve seals FPM, EPDM, FFKM

Ball valve seat seals PTFE

3.2 Description

The 2/2 and/or 3/2-way GEMÜ 710 plastic ball valve has a

pneumatic actuator, which can either be made from alu-

minium or plastic. The seat seal is made from PTFE and the

O-ring seals can be made from either EPDM or FKM.

3.3 Function

The product is a 2/2 or 3/2-way plastic ball valve. It has a low

maintenance pneumatic actuator. It has a low maintenance

pneumatic quarter turn actuator providing rotation through

90°. The actuator has an optical position indicator as stand-

ard.

The threaded connection locking device enables the unions to

be locked in place.

The ball valve body and the seal material are available in vari-

ous designs as shown in the datasheet.

3 Product description

www.gemu-group.com6 / 44GEMÜ 710

4 Correct use

3.4 Port positions

The port position can be variably adjusted by the customer.

The actuator must be removed in order to do this. The shaft

extension of the mounting kit can be turned in any number of

90° increments, allowing for a customized port position. A

tool with an appropriate wrench size is required to turn the

shaft extension. This tool is not included in the scope of deliv-

ery. Once the desired adjustment has been made to the port

position, the actuator can be refitted.

3.4.1 T-port

CLOSED end

position

OPEN end posi-

tion

Condition as

supplied to cus-

tomer OPEN

Delivery condition

Code T

1 2

Optional port positions, can be user adjusted

Code 2

Code 3

Code 4

1 2

3.4.2 L-port

CLOSED end

position

OPEN end posi-

tion

Condition as

supplied to cus-

tomer OPEN

Delivery condition

Code L

Optional port positions, can be user adjusted

Code 6

3.4.3 Control ball

Control ball Scale

Code R

For 0°- 90° control range, linear control characteristic

between port position and percentage flow rate.

NOTE: Ball configuration (R) cannot be retrofitted to standard

2/2-way bodies at a later date.

4 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.

The product is controlled via a pneumatic actuator.

●Use the product in accordance with the technical data.

5 Actuator assignment for 2/2-way valves

5.1 Metal actuator

Actuator assignment ADA / ASR

DN Double acting ADA Code Single acting ASR Code

10 ADA0020UF03F05YS09A BU02AN0 ASR0020US08 F04YS14/S11A 1 AU02FN0

20 ADA0020UF03F05YS09A BU02AN0 ASR0020US08 F04YS14/S11A 1 AU02FN0

25 ADA0020UF03F05YS09A BU02AN0 ASR0020US08 F04YS14/S11A 1 AU02FN0

32 ADA0020UF03F05YS09A BU02AN0 ASR0040US14 F05YS14/S11A 1 AU04KB0

40 ADA0020UF03F05YS09A BU02AN0 ASR0040US14 F05YS14/S11A 1 AU04KB0

50 ADA0040UF05YS14/S11A BU04AB0 ASR0080US14 F05F07YS17/S14A 1 AU08KC0

65 ADA0040UF05YS14/S11A BU04AB0 ASR0130US14 F05F07YS17/S14A 1 AU13KC0

80 ADA0080UF05F07YS17/S14A BU08AC0 ASR0130US14 F05F07YS17/S14A 1 AU13KC0

100 ADA0080UF05F07YS17/S14A BU08AC0 ASR0200US14F07F10YS17/S14A 1 AU20KE0

Actuator assignment DR / SC

DN Double acting DR Code Single acting SC Code

10 DR0015U F03F05NS11A 2 DU01AW0 SC0015U 8F03F05NS11A 1 SU01KW0

15 DR0015U F03F05NS11A 2 DU01AW0 SC0015U 8F03F05NS11A 1 SU01KW0

20 DR0015U F03F05NS11A 2 DU01AW0 SC0015U 8F03F05NS11A 1 SU01KW0

25 DR0015U F03F05NS11A 2 DU01AW0 SC0015U 8F03F05NS11A 1 SU01KW0

32 DR0015U F03F05NS11A 2 DU01AW0 SC0030U 6F05F07NS14A 1 SU03KP0

40 DR0015U F03F05NS11A 2 DU01AW0 SC0060U 6F05F07NS14A 1 SU06KP0

50 DR0030U F05F07NS14A 2 DU03AP0 SC0060U 6F05F07NS14A 1 SU06KP0

65 DR0030U F05F07NS14A 2 DU03AP0 SC0100U 6F05F07NS17A 1 SU10KC0

80 DR0060U F05F07NS14A 2 DU06AP0 SC0100U 6F05F07NS17A 1 SU10KC0

100 DR0060U F05F07NS17A 2 DU06AC0 SC0220U 6F07F10NS22A 1 SU22KD0

5.2 Plastic actuator

Normally closed Double acting

Actuator size code 1)

DN 15 0 0

DN 20 0 0

DN 25 1 1

DN 32 1 1

DN 40 1 1

DN 50 1 1

DN 65 - 1

1) Actuator version

Code 0: GEMÜ actuator, pneumatic, size 0, piston diameter 50 mm

Code 1: GEMÜ actuator, pneumatic, size 1, piston diameter 70 mm

6 Actuator assignment for multi-port valves

Please contact GEMÜ for the actuator assignment of multi-port valves.

GEMÜ 710www.gemu-group.com 7 / 44

6 Actuator assignment for multi-port valves

7 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

Ball valve, plastic, pneumatically operated 710

2 DN Code

DN 10 10

DN 15 15

DN 20 20

DN 25 25

DN 32 32

DN 40 40

DN 50 50

DN 65 65

DN 80 80

DN 100 100

3 Body configuration Code

2/2-way body D

Multi-port version M

4 Connection type Code

Union end with insert (solvent cement or weld

socket) - DIN

Union end with flange EN 1092, PN 10, form B,

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

5752, basic series 1

Union end with inch insert - BS (socket) 33

Union end with flange ANSI Class 125/150 RF 39

Union end with inch insert – ASTM (socket) 3M

Union end with JIS insert (socket) 3T

Union end with insert (for IR butt welding) - DIN 78

Union end with insert (Rp threaded socket) - DIN 7R

5 Ball valve material Code

PVC-U, grey 1

PVC-C 2

PVDF 20

ABS 4

PP-H, grey 5

6 Seal material Code

FKM 4

EPDM 14

FFKM F5

7 Control function Code

Normally closed (NC) 1

Normally open (NO) 2

7 Continuation of Control function Code

Double acting (DA) 3

8 Actuator version Code

Actuator GEMÜ ADA and ASR

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR0020US08F03/05 S09

AU02FN

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR0040US14F05 S14S11

AU04KB

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR0130US14F05/07S17S14

AU13KC

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR0200US14F07/10S17S14

AU20KE

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA0020U F03/05 S09

BU02AN

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA0040U F05 S14S11

BU04AB

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA0080U F05/07S17S14

BU08AC

Actuator GEMÜ DR and SC

Actuator, pneumatic, double acting, clockwise rota-

tion,

DR0015U F03/05 S11

DU01AW

Actuator, pneumatic, double acting, clockwise rota-

tion,

DR0030U F05/07 S14

DU03AP

Actuator, pneumatic, double acting, clockwise rota-

tion,

DR0060U F05/07 S14

DU06AP

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

SC0015U 6F03/05 S11

SU01KW

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

SC0030U 6F04 S11

SU03KO

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

SC0060U 6F05/07 S14

SU06KP

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

SC0100U 6F05/07S17D11

SU10KC

7 Order data

www.gemu-group.com8 / 44GEMÜ 710

8 Continuation of Actuator version Code

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

SC0220U 6F07/10 S22

SU22KD

Actuator GEMÜ 9415

GEMÜ actuator, pneumatic, size 0, piston diameter

50 mm

GEMÜ actuator, pneumatic, size 1, piston diameter

70 mm

9 Actuator particulars Code

Gen. industrial version,

body alu, anodising layer 25-35µm, end caps alu,

powder coated,

shaft C steel + ENP, bolts A2

10 Ball config./port position Code

2/2-way body

R ball (control ball)

for 0°- 90° control range

linear control characteristic between port position

and percentage flow rate

Multi-port version

L-port, standard end position "Open", connection 2

and 3 open,

L-port, standard end position "Closed", connection

1 and 3 open

10 Continuation of Ball config./port position Code

T-port, standard end position "Open", connection 1,

2 and 3 open,

T-port, standard end position "Closed", connection

1 and 3 open

T-port, end position "Open", connection 1 and 3

open,

T-port, end position "Closed", connection 1 and 2

open

T-port, end position "Open", connection 1 and 2

open,

T-port, end position "Closed", connection 2 and 3

open

T-port, end position "Open", connection 2 and 3

open,

T-port, end position "Closed", connection 1, 2 and 3

open

L-port, end position "Open", connection 1 and 3

open,

L-port, end position "Closed", connection 1 open

11 Type of design Code

Without

Insert in PE 1187

12 CONEXO Code

without

Integrated RFID chip for electronic identification

and traceability

Order example

Order option Code Description

1 Type 710 Ball valve, plastic, pneumatically operated

2 DN 15 DN 15

3 Body configuration M Multi-port version

4 Connection type 33 Union end with inch insert - BS (socket)

5 Ball valve material 1 PVC-U, grey

6 Seal material 14 EPDM

7 Control function 3 Double acting (DA)

8 Actuator version BU02AN Actuator, pneumatic, double acting, clockwise rotation,

ADA0020U F03/05 S09

9 Actuator particulars 0 Gen. industrial version,

body alu, anodising layer 25-35µm, end caps alu, powder coated,

shaft C steel + ENP, bolts A2

10 Ball config./port position L L-port, standard end position "Open", connection 2 and 3 open,

L-port, standard end position "Closed", connection 1 and 3 open

11 Type of design Without

12 CONEXO without

7 Order data

www.gemu-group.com 9 / 44 GEMÜ 710

8 Technical data

8.1 Medium

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

ical and chemical properties of the body and seal material.

Control medium: Inert gases

8.2 Temperature

Medientemperatur: see Pressure / temperature diagram

Seal material: FPM: -15 – 210 °C

EPDM: -20 – 95 °C

Umgebungstemperatur: Valve body ABS: -20 to 60 °C

Valve body PP-H: 5 to 60 °C

Valve body PVC-U, PVC-C: 10 to 50 °C

Valve body PVDF: -5 to 50 °C

8.3 Pressure

Operating pressure: Pressure / temperature diagram

-40 -20 020 40 60 80 100 120 140

PVDF

PVC-C

PVC-U

PP-H

ABS

Operating pressure [bar]

Temperature [°C]

Data for extended temperature ranges on request. Please note that the ambient temperature and media temper-

ature generate a combined temperature at the valve body which must not exceed the above values.

Control pressure: 2 to 8 bar(depending on version and/or control function)

www.gemu-group.com10 / 44GEMÜ 710

8 Technical data

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