GEM Tugela R471 Bedienungsanleitung

GEMÜ R471 Tugela

Pneumatically operated butterfly valve

Operating instructions

further information

webcode: GW-R471

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

Keep the document for future reference.

23.08.2021

www.gemu-group.com2 / 33GEMÜ R471 Tugela

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 Additional design features ............................ 6

3.3 Description ..................................................... 6

3.4 Function ......................................................... 6

3.5 Product label ................................................. 7

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

5 Correct use .......................................................... 8

5.1 Product without special function X .............. 8

5.2 Product with special function X ................... 8

6 Order data ........................................................... 9

6.1 Order codes ................................................... 9

6.2 Order example ............................................... 10

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

7.1 Medium .......................................................... 12

7.2 Temperature .................................................. 12

7.3 Pressure ......................................................... 12

7.4 Product conformity ....................................... 13

7.5 Mechanical data ............................................ 14

8 Dimensions .......................................................... 16

8.1 Actuator flange .............................................. 16

8.2 Actuator ......................................................... 18

8.3 Body ............................................................... 19

9 Manufacturer's information .................................. 21

9.1 Delivery .......................................................... 21

9.2 Transport ....................................................... 21

9.3 Storage ........................................................... 21

10 Installation in piping ............................................ 21

10.1 Preparing for installation .............................. 21

10.2 Installation location ....................................... 22

10.3 Installation of the standard version ............. 23

10.4 Installation of the ATEX version ................... 23

11 Pneumatic connection ......................................... 24

11.1 Control functions ........................................... 24

11.2 Connecting the control medium ................... 24

11.3 Optical position indicator .............................. 24

12 Setting the end positions ..................................... 25

13 Commissioning .................................................... 25

14 Operation ............................................................. 25

15 Troubleshooting .................................................. 26

16 Inspection and maintenance ................................ 27

16.1 Cleaning the product ..................................... 27

16.2 ATEX version ................................................. 27

16.3 Removing the butterfly valve from the pip-

ing ................................................................... 27

17 Spare parts .......................................................... 28

17.1 Ordering spare parts ..................................... 28

17.2 Overview of spare parts ................................ 29

17.3 Replacement of spare parts ......................... 29

18 Removal from piping ............................................ 29

19 Disposal .............................................................. 29

20 Returns ................................................................ 30

21 Declaration of Incorporation according to

2006/42/EC (Machinery Directive) ....................... 31

22 Declaration of conformity according to 2014/68/

EU (Pressure Equipment Directive) ...................... 32

GEMÜ R471 Tugelawww.gemu-group.com 3 / 33

www.gemu-group.com4 / 33GEMÜ R471 Tugela

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.

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 of explosion!

Moving components.

Corrosive chemicals!

GEMÜ products without an operator!

Hot plant components!

Use as end-of-line valve!

Risk of crushing!

www.gemu-group.com 5 / 33 GEMÜ R471 Tugela

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

materials.

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 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 Designation Material

1 Shaft see order code (order

data)

2 Hexagon screw Stainless steel

3 Packing washer 1.4408

4 Upper packing PTFE

5 Medium packing PTFE

6 Lower packing PTFE

7 Packing washer PTFE

8 Carbon bushing Carbon

9 Body see order code (order

data)

10 Spring washer Stainless steel

11 Hexagon nut Stainless steel

12 Shaft bearing PTFE coated steel

13 Shaft bearing PTFE coated steel

14 Static spring Stainless steel

15 Sealing washer Stainless steel

16 Lower cap same as body

17 Hexagon screw Stainless steel

18 Disc pin Steel

3 Product description

www.gemu-group.com6 / 33GEMÜ R471 Tugela

3 Product description

Item Designation Material

19 Disc see order code (order

data)

20* Seat see order code (order

data)

21 Seat retainer

22 Hexagon screw Stainless steel

A Pneumatic actuator Aluminium

C CONEXO label with RFID

chip

* available as spare part

3.2 Additional design features

Double-eccentric design

Shaft axis

Flow central line

Trace of the disc

During operation, the disc directly disconnects from the seat,

thereby reducing friction between the seat and disc, as well as

the torque.

This design is particularly low-wear and this, together with the

temperature-resistant carbon bushing, increases the service

life.

Spherical surface

The disc is designed with a spherical surface for improved

mechanical behaviour under pressure and temperature fluctu-

ations.

Shaft blow-out protection

There is a chamfer at the upper end of the shaft which acts as

an additional safety measure in case the shaft breaks.

Flow direction

Flow direction*

* Indicated by an arrow on the product

Shut-off seal material

TFM™ is made from conventional PTFE and a 1% proportion

of perfluoropropyl vinyl ether (PPVE). While the properties of

conventional PTFE (excellent chemical resistance, application

in a wide temperature range and resistance to embrittlement

or ageing, etc.) are maintained, the PPVE additive leads to a

better distribution of the PTFE particles and thus to a higher

density of the polymer structure.

This leads to the following additional advantages:

• Significantly improved cold flow properties (measured as de-

formation under load):

The same cold flow properties as PTFE with 25% glass fibres.

• Reduced gas permeability and increased blocking properties

• The smooth surface results in less abrasion of the shut-off

seal and fewer abraded particles in the medium.

3.3 Description

The GEMÜ R471 Tugela double eccentric metal butterfly valve

is operated by a pneumatic actuator. The butterfly valve is

available in nominal sizes DN50 to 400 and in standardized

installation lengths API 609 category A (DIN 3202 K1).

3.4 Function

The product controls a flowing medium by being closed or

opened by a control medium.

www.gemu-group.com 7 / 33 GEMÜ R471 Tugela

3.5 Product label

The product label is located on the valve body. Product label

data (example):

Design in accordance with order data

Device-specific data

Year of manufacture

Item number

The month of manufacture is encoded in the traceability num-

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

factured in Germany.

The operating pressure stated on the product label applies to

a media temperature of 20 °C. The product can be used up to

the maximum stated media temperature. You can find the

pressure/temperature correlation in the technical data.

4 GEMÜ CONEXO

The interaction of valve components that are equipped with

RFID chips and an associated IT infrastructure actively in-

crease process reliability.

Thanks to serialization, every valve and every relevant valve

component such as the body, actuator or diaphragm, and

even automation components, can be clearly traced and read

using the CONEXO pen RFID reader. The CONEXO app, which

can be installed on mobile devices, not only facilitates and im-

proves the "installation qualification" process, but also makes

the maintenance process much more transparent and easier

to document. The app actively guides the maintenance techni-

cian through the maintenance schedule and directly provides

him with all the information assigned to the valve, such as

test reports, testing documentation and maintenance histor-

ies. The CONEXO portal acts as a central element, helping to

collect, manage and process all data.

For further information on GEMÜ CONEXO please visit:

www.gemu-group.com/conexo

4 GEMÜ CONEXO

www.gemu-group.com8 / 33GEMÜ R471 Tugela

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 systems and

for controlling a working medium.

●Use the product in accordance with the technical data.

5.1 Product without special function X

The product is not intended for use in potentially explosive

areas.

5.2 Product with special function X

With the special version X order option, the product is inten-

ded for use in potentially explosive areas in zone 1 with gases,

mists or vapours and zone 21 with combustible dusts in ac-

cordance with EU Directive 2014/34/EU (ATEX).

The product has the following explosion protection marking:

Gas: II -/2 G Ex h -/IIB T6 …T3 -/Gb X

Dust: II -/2 D Ex h -/IIIC T150°C -/Db X

The product has been developed in compliance with the fol-

lowing harmonized standards:

•EN 1127-1:2011

•ISO 80079-36:2016

•ISO 80079-37:2016

The product can be used in the following ambient temperat-

ure ranges: -20 °C…+70 °C

For use in potentially explosive areas, the following special

conditions or operation limits must be observed:

Index X is applied to the ATEX marking.

The following special conditions must be complied with:

•Temperature class depending on the temperature of the

conveyed medium and the clock frequency

•Not permissible as an end-of-line valve

6 Order data

Other configurations available on request. Please check the availability with GEMÜ before ordering.

Order codes

1 Type Code

Butterfly valve, pneumatically operated

(double-eccentric), Tugela

R471

2 DN Code

DN 50 50

DN 65 65

DN 80 80

DN 100 100

DN 125 125

DN 150 150

DN 200 200

DN 250 250

DN 300 300

DN 350 350

DN 400 400

DN 450 450

DN 500 500

DN 600 600

3 Body configuration Code

Wafer design,

face-to-face dimension FTF API609 table 3, EN 558

series 108, EN 558 series 109

4 Operating pressure Code

10 bar 2

16 bar 3

20 bar 4

25 bar 5

40 bar 6

5 Connection type Code

PN 10 / flange EN 1092, face-to-face dimension

FTF EN 558 series 108

PN 16 / flange EN 1092, face-to-face dimension

FTF EN 558 series 108

PN 25 / flange EN 1092, face-to-face dimension

FTF EN 558 series 20

PN 40 / flange EN 1092, face-to-face dimension

FTF EN 558 series 109

ANSI B16.5, Class 150, face-to-face dimension FTF

EN 558 series 108

ANSI B16.5, Class 300, dimension FTF EN 558

series 109

6 Body material Code

1.4408 / ASTM A351 / CF8M 4

6 Continuation of Body material Code

1.0619 / ASTM A216 WCB, CDP coated 20 µm,

for non-European countries,

1.0619 is not a material for pressure equipment

according to 2014/68/EU

7 Disc material Code

1.4408 / ASTM A351 / CF8M A

8 Shaft material Code

1.4542, ASTM 564 630 6

9 Shut-off seal material Code

TFM 1600 (FDA certification) T

10 Liner fixing Code

Loose liner L

11 Control function Code

Normally closed (NC) 1

Normally open (NO) 2

Double acting (DA) 3

Normally closed (NC), actuator mounted across

the piping

Double acting (DA), actuator mounted across the

piping

Normally open (NO), actuator mounted across the

piping

12 Actuator version Code

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, single acting, clockwise rota-

tion, spring closing,

ASR0300US14F07/10 S22

AU30KD

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR0500US14F07/10 S22

AU50KD

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA0080U F05/07S17S14

BU08AC

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA0130U F05/07S17S14

BU13AC

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA0200U F07/10S17S14

BU20AE

6 Order data

www.gemu-group.com 9 / 33 GEMÜ R471 Tugela

12 Continuation of Actuator version Code

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL0130US14F05/07S17S14

LU13KC

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL0200US14F07/10S17S14

LU20KE

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL0300US14F07/10 S22

LU30KD

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL0500US14F07/10 S22

LU50KD

Actuator, pneumatic, single acting, spring closing,

clockwise rotation,

ASR1200U S14 F10F12YS27A

A12UKG

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR1750US14F14 S36

A17UKK

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR2100US14F16 S46

A21UKL

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR2500US14F16 S46

A25UKL

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR4000US14F16/25 S55

A40UKM

Actuator, pneumatic, single acting, clockwise rota-

tion, spring closing,

ASR0850US14F10/12 S27

AU85KG

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA1200U F10/12 S27

B12UAG

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA1750U F14 S36

B17UAK

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA2100U F16 S46

B21UAL

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA0300U F07/10 S22

BU30AD

12 Continuation of Actuator version Code

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA0500U F10 S22

BU50AF

Actuator, pneumatic, double acting, clockwise rota-

tion,

ADA0850U F10/12 S27

BU85AG

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL1200US14F10/12 S27

L12UKG

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL1750US14F14 S36

L17UKK

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL2100US14F14 S36

L21UKK

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL2500US14F14 S36

L25UKK

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL4000US14F16/25 S55

L40UKM

Actuator, pneumatic, single acting, anticlockwise

rotation, spring opening,

ASL0850US14F10/12 S27

LU85KG

13 Type of design Code

Without

Valve free of oil and grease, media wetted area

cleaned and packed in PE bag

0107

Thermal separation between actuator and valve

body via mounting kit,

mounting parts made from stainless steel

5227

14 Special version Code

Without

ATEX certification X

15 CONEXO Code

Without

Integrated RFID chip for electronic identification

and traceability

Order example

Ordering option Code Description

1 Type R471 Butterfly valve, pneumatically operated

(double-eccentric), Tugela

2 DN 300 DN 300

3 Body configuration W Wafer design,

face-to-face dimension FTF API609 table 3, EN 558 series 108, EN 558

series 109

4 Operating pressure 4 20 bar

6 Order data

www.gemu-group.com10 / 33GEMÜ R471 Tugela

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