GEM ESyDrive 567 Bedienungsanleitung

GEMÜ 567 eSyDrive

Aseptic control valve with motorized eSyDrive actuator

Operating instructions

further information

webcode: GW-567

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

Keep the document for future reference.

23.11.2022

www.gemu-group.com2 / 60GEMÜ 567 eSyDrive

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

4 Correct use .......................................................... 9

5 GEMÜ CONEXO .................................................... 9

6 Order data - eSyDrive ........................................... 10

7 Technical data ..................................................... 12

8 Dimensions .......................................................... 18

9 Manufacturer's information .................................. 39

9.1 Delivery .......................................................... 39

9.2 Packaging ...................................................... 39

9.3 Transport ....................................................... 39

9.4 Storage ........................................................... 39

10 Installation in piping ............................................ 39

10.1 Installation location ....................................... 39

10.2 Preparing for installation .............................. 39

10.3 Installation with clamp connections ............ 40

10.4 Installation with butt weld spigots ............... 40

11 Mounting ............................................................. 41

12 Electrical connection ........................................... 42

13 Commissioning .................................................... 45

13.1 Commissioning on the device ...................... 45

13.2 Commissioning via the eSy-Web web inter-

face ................................................................ 45

13.3 Commissioning via digital input ................... 45

14 Troubleshooting .................................................. 46

15 Inspection and maintenance ................................ 47

16 Removal from piping ............................................ 56

17 Disposal .............................................................. 56

18 Returns ................................................................ 56

19 Declaration of Incorporation according to

2006/42/EC (Machinery Directive) ....................... 57

20 Declaration of conformity according to 2014/68/

EU (Pressure Equipment Directive) ...................... 58

21 Declaration of conformity according to 2014/30/

EU (EMC Directive) ............................................... 59

GEMÜ 567 eSyDrivewww.gemu-group.com 3 / 60

www.gemu-group.com4 / 60GEMÜ 567 eSyDrive

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 Definition of terms

Working medium

The medium that flows through the GEMÜ product.

PD = Plug Diaphragm

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!

Danger - high voltage!

www.gemu-group.com 5 / 60 GEMÜ 567 eSyDrive

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

3.1.1 Construction

Item Name Materials

1 O-rings EPDM

2 Electrical connections

3 Actuator base 1.4301

4 Distance piece 1.4408

5 Valve body with leak de-

tection hole

1.4435

6 CONEXO RFID chip

7 Optical position indicator PESU

8 Cover with high visibility

LED, manual override and

on-site control

PESU

3 Product description

www.gemu-group.com6 / 60GEMÜ 567 eSyDrive

3 Product description

3.1.2 Buttons for on-site control

Fig.1: Position of the buttons

Item Name Function

8 DIP switch, "ON-

site" control

Switches the on-site

control on the device

on or off

9 "OPEN" button Moves actuator to the

open position

Resets the network

settings

10 "INIT/CLOSE" but-

ton

Moves actuator to the

closed position

Starting initialisation

3.1.3 LED displays

3.1.3.1 On-site status LEDs

LED MODE LED PWR

Fig.2: Position of the status LEDs

The user checks the following conditions directly on-site at

the valve using LED MODE and LED PWR:

Function LED MODE LED PWR

Yellow Blue Green Red

Automatic oper-

ation

Manual opera-

tion

Actuator

switched off

(OFF mode)

Manual opera-

tion (on-site)

Software update

alternating

On-site initialisa-

tion (buttons)

Remote initial-

isation (via Di-

gIn)

www.gemu-group.com 7 / 60 GEMÜ 567 eSyDrive

Function LED MODE LED PWR

Yellow Blue Green Red

Operation via

emergency

power supply

module

3.1.3.2 High visibility LEDs

11 11

Fig.3: Position of the high visibility LEDs

Item Name

11 High visibility LEDs

Function High visibility LED

Green Orange

OPEN position Position indicator

LEDs,

standard

OPEN position Position indicator

LEDs,

inversed

CLOSED position Position indicator

LEDs,

standard

CLOSED position Position indicator

LEDs,

inversed

Position unknown (e.g. 50%)

Initialisation

Function High visibility LED

Green Orange

alternating

Location function

3.2 Description

The GEMÜ 567 eSyDrive 2/2-way diaphragm globe valve is a

precise motorized control valve for sterile applications. The

GEMÜ eSyDrive hollow shaft actuator can be operated as an

actuator with integrated positioner or process controller. Flow

rates range from 80 l/h to 63 m³/h, depending on the version.

3.3 Function

The product controls or regulates (depending on version) a

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

tuator.

The product has an optical position indicator as standard. The

optical position indicator indicates the OPEN and CLOSED po-

sitions.

3 Product description

3.4 PD seal system without bypass

Seal material code 4 Seal material code 5

1234 5

Item Name Materials

1 Plug diaphragm PTFE

2 Support ring 1.4435 (316L)

3 O-ring FKM

4 Regulating cone 1.4435 (316L)

5 PTFE plug diaphragm with regulating cone

3.5 PD seal system with bypass

only for actuator size 2

Item Name Materials

1 Plug diaphragm FKM, PTFE PTFE

2 Support ring 1.4435 (316L)

3 O-ring FKM

4 Regulating cone 1.4435 (316L)

5 Bypass valve diaphragm

www.gemu-group.com8 / 60GEMÜ 567 eSyDrive

3 Product description

www.gemu-group.com 9 / 60 GEMÜ 567 eSyDrive

3.6 Installation position for optimized draining

in closed and open position in open position

Actuator horizontal Actuator horizontal or vertical

Control range

We recommend designing the valves in such a way that the

control range is within an opening stroke of 20% to 90% of the

control valve.

3.7 Product label

The product label is located on the actuator. Product label

data (example):

Design in accordance with order

data

Item number

Device-specific data

Year of manufacture

Traceability number Counting number

12103529 I0001

The month of manufacture is encoded in the traceability num-

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

factured in Germany.

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.

●Use the product in accordance with the technical data.

5 GEMÜ CONEXO

For electronic identification purposes, each replaceable com-

ponent contained in the product you have purchased is

equipped with an RFID chip (1). Where you can find the RFID

chip differs from product to product.

Fig.4: Actuator RFID chip

Fig.5: Diaphragm RFID chip

Fig.6: 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 GEMÜ CONEXO

6 Order data - eSyDrive

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

Control valve 567

2 DN Code

DN 8 8

DN 10 10

DN 15 15

DN 20 20

DN 25 25

DN 32 32

DN 40 40

DN 50 50

DN 65 65

3 Body configuration Code

2-way angle body E

2-way angle body with bypass M

4 Connection type Code

Spigot

Spigot DIN 0

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

Clamp

Clamp DIN 32676 series B 82

Clamp DIN 32676 series A 86

Clamp ASME BPE 88

5 Valve body material Code

1.4435 (316L), block material 41

1.4435 (BN2), block material, Δ Fe < 0.5% 43

6 Seal material Code

Actuator seal PTFE / seat seal FKM 4

Actuator seal PTFE / seat seal PTFE 5

Actuator seal PTFE / seat seal FKM / bypass seal EPDM

bypass diaphragm code 13

Actuator seal PTFE / seat seal FKM / bypass seal PTFE

bypass diaphragm code 54

Actuator seal PTFE / seat seal FKM / bypass seal EPDM

bypass diaphragm code 17

Actuator seal PTFE / seat seal PTFE / bypass seal PTFE

bypass diaphragm code 54

Actuator seal PTFE / seat seal FFKM F

Actuator seal PTFE / seat seal FFKM / bypass seal

PTFE

bypass diaphragm code 54

7 Voltage/Frequency Code

24 V DC C1

8 Control module Code

OPEN/CLOSE, positioner and process controller L0

9 Control characteristic Code

Modified equal-percentage G

Linear L

10 Kv value Code

80l/h AA

100 l/h AB

160 l/h BC

250 l/h BD

400 l/h BE

630 l/h CF

1.0 m³/h CG

1.6 m³/h DH

2.6 m³/h EJ

4.1 m³/h G1

8.0 m³/h H2

12.5 m³/h J3

14.0 m³/h K4

18.0 m³/h K5

25.0 m³/h K6

32.0 m³/h M7

40.0 m³/h M8

50.0 m³/h N9

63.0 m³/h NK

11 Bypass actuator version Code

Pneumatically operated, normally closed, diaphragm

size 8,

Pneumatically operated, normally open, diaphragm size

Manually operated, with seal adjuster, diaphragm size 8, S0

12 Surface Code

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 ≤ 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 ≤ 0.4 µm (15 µin.) for media wetted surfaces,

in accordance with DIN 11866 H4,

mechanically polished internal

1536

6 Order data - eSyDrive

www.gemu-group.com10 / 60GEMÜ 567 eSyDrive

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