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GEM 539 eSyDrive, Operating Instructions Manual

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GEMÜ 539

15.3.2 Replacing the seals DN 65 - DN 100

1. Remove the actuator.
2. Bend the locking plate 

h

 90°, so that it lies flat on the valve

plug 

c

.

g

c

h

3. Unscrew the entire valve plug 

c

 from the union nut 

g

.

4. Loosen cylindrical screws 

39 

from valve plug 

c

.

5. Remove retaining washer 

d

.

6. Remove seat seal 

14

.

7. Unscrew seat flange 

f

 from the union nut.

8. Remove sealing washer 

4

 from the valve body.

9. Clean all parts of contamination (do not damage parts dur-

ing cleaning).

10. Insert new sealing washer 

4

 in seat flange 

f

.

11. Screw the seat flange 

f

 into the union nut 

a

 and tighten it

until it is hand tight.

12. Screw union nut 

a

 tight with an appropriate open-end

wrench.

13. Insert new seat seal 

14

.

14. Insert retaining washer 

d 

and use cylindrical screws 

39 

to

fix it in place.

15. Place the locking plate 

h

 on the valve plug 

c

.

16. Screw the entire valve plug 

c

 onto the union nut 

g

.

17. Bend the locking plate 

h

 by 90°, so that it lies flat on the

union nut 

g

.

g

c

h

ð

The union nut 

g

 is secured against twisting.

18. Mount the actuator.

15.4 Mounting the actuator

 CAUTION

Incorrect combination of actuator and

valve body!

▶

Risk of damage to the actuator and

valve body.

●

For control valves with a reduced valve

seat, make sure that the combination

of actuator and valve body is correct.

●

Compare the product label of the actu-

ator with the valve body marking.

RXXX

Valve body marking

Actuator product label

Valve body marking

RAxxx

R002

RBxxx

R004

RCxxx

R006

RDxxx

R008

RExxx

R010

RFxxx

R012

RGxxx

R015

RHxxx

R020

RJxxx

R025

RKxxx

R032

RMxxx

R040

15 Inspection and maintenance

Summary of Contents for 539 eSyDrive

Page 1: ...GEMÜ 539 eSyDrive Motorized globe valve Operating instructions EN further information webcode GW 539 ...

Page 2: ... rights including copyrights or industrial property rights are expressly reserved Keep the document for future reference GEMÜ Gebr Müller Apparatebau GmbH Co KG 18 11 2019 www gemu group com 2 34 GEMÜ 539 ...

Page 3: ...n on the device 24 14 2 Operation via the web server 24 14 3 Manual override 25 15 Inspection and maintenance 25 15 1 Spare parts 26 15 2 Removing the actuator 26 15 2 1 Removing actuator DN 15 DN 50 26 15 2 2 Removing actuator DN 65 DN 100 26 15 3 Replacing the seals 26 15 3 1 Replacing the seals DN 15 DN 50 26 15 3 2 Replacing the seals DN 65 DN 100 27 15 4 Mounting the actuator 27 15 4 1 Mounti...

Page 4: ...terms Working medium The medium that flows through the GEMÜ product 1 5 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...

Page 5: ...ing 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 d...

Page 6: ...Software update alternating On site initialisation buttons Remote initialisation via DigIn Function LED MODE LED PWR Yellow Blue Green Red Operation via emergency power supply module 3 2 2 High visibility LEDs 11 11 11 11 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 p...

Page 7: ... 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 5 Correct use DANGER Danger of explosion Risk of death or severe injury Do not use the product in potentially explosive zones WARNING I...

Page 8: ...nsion FTF EN 558 series 1 ISO 5752 basic series 1 39 Flange JIS 20K face to face dimension FTF EN 558 series 10 ASME ANSI B16 10 table 1 column 16 DN 50 drilled to JIS 10K 48 5 Valve body material Code 1 4408 investment casting 37 EN GJS 400 18 LT GGG 40 3 90 6 Seat seal Code PTFE 5 PTFE glass fibre reinforced 5G 1 4404 10 7 Voltage frequency Code 24 V DC C1 8 Control module Code OPEN CLOSE positi...

Page 9: ...1 ISO 5752 basic series 1 5 Valve body material 37 1 4408 investment casting 6 Seat seal 5 PTFE 7 Voltage frequency C1 24 V DC 8 Control module L0 OPEN CLOSE positioner and process controller 9 Regulating cone RS916 60 m h mod EQ 10 Actuator version 2A Actuator size 2 11 Special version S Special version for oxygen maximum medium temperature 60 C media wetted seal materials and auxiliary materials...

Page 10: ...Actuator version 0A 1A 2A 15 32 20 20 40 25 12 32 32 20 40 12 25 50 8 16 65 5 10 80 4 6 100 4 Pressures in bar All pressures are gauge pressures For max operating pressures the pressure temperature correlation must be observed Higher operating pressures on request Leakage rate Open closed valve Seat seal Standard Test procedure Leakage rate Test medium Metal DIN EN 12266 1 P12 F Air EPDM FPM PTFE ...

Page 11: ...on FTF EN 558 series 1 ISO 5752 basic series 1 Code 39 Flange ANSI Class 125 150 RF face to face dimension FTF EN 558 series 1 ISO 5752 basic series 1 Code 48 Flange JIS 20K face to face dimension FTF EN 558 series 10 ASME ANSI B16 10 table 1 column 16 DN 50 drilled to JIS 10K 2 Valve body material Code 37 1 4408 investment casting Code 90 EN GJS 400 18 LT GGG 40 3 Kv values Open closed valve DN 1...

Page 12: ...at DN Kv values Operating pressure Actuator version linear equal percentage 15 0 10 40 0A RA104 RA307 0 16 40 0A RB110 RA309 0 25 40 0A RB111 RB307 0 40 40 0A RB112 RB308 0 63 40 0A RC107 RC307 1 00 40 0A RC108 RC308 1 60 40 0A RD107 RD307 2 50 40 0A RE110 RE310 20 1 60 40 0A RD108 RD308 2 50 40 0A RE111 RE311 4 00 40 0A RF113 RF313 25 2 50 40 0A RE112 RE312 4 00 40 0A RF114 RF314 6 30 32 0A RG115...

Page 13: ... 60529 Actuator version 1A Weight Actuator Actuator version 0A 1 8 kg Actuator version 1A 3 0 kg Actuator version 2A 9 0 kg Body Connection types 8 11 39 40 8 10 13 47 8 10 39 Valve body Flange K512 Flange K514 Flange K534 DN 15 3 4 1 8 2 2 20 4 6 2 5 3 0 25 6 8 3 1 3 7 32 8 8 4 6 5 3 40 10 9 5 1 6 3 50 14 5 7 2 8 4 65 21 7 80 29 2 100 37 1 Weights in kg Operating time Actuator version 0A 6 mm s A...

Page 14: ... mA 0 10 V DC selectable using software Input type passive Input resistance 250 Ω Accuracy linearity 0 3 of full flow Temperature drift 0 1 10 K Resolution 12 bit Reverse battery protection No Overload proof Yes up to 24 V DC 5 6 1 2 Process actual value Input signals 0 4 20 mA 0 10 V DC selectable using software Input type passive Input resistance 250 Ω Accuracy linearity 0 3 of full flow Tempera...

Page 15: ...esistor 750 kΩ Resolution 10 bit Overload proof Yes up to 24 V DC Short circuit proof Yes 5 6 4 Digital output signals 5 6 4 1 Switching outputs 1 and 2 Design 2x change over contact potential free Switch rating 125 V AC 2 A 48 V DC 2 A Switch points Adjustable 0 100 5 6 4 2 Switching output 3 Function Signal fault Type of contact Push Pull Switching voltage Supply voltage Switching current 0 1 A ...

Page 16: ...f the actuator is entered in the web browser and the actuator can then be parametrised In order to use more than one actuator a definitive IP address must be assigned to each actuator in the same network 6 Dimensions 6 1 Installation dimensions SW 1 CT Actuator version 0A Actuator version 1A Actuator version 2A DN SW1 CT CT CT 15 36 311 20 41 318 375 25 46 328 386 32 55 391 40 60 402 471 50 55 410...

Page 17: ...1 CT CT CT 100 75 543 Dimensions in mm 6 2 Actuator dimensions ØB B2 B1 B3 A1 Actuator version A1 B B1 B2 B3 0A 45 0 68 0 126 0 160 0 193 0 1A 86 0 82 0 132 0 172 0 252 0 2A 121 0 129 0 157 0 224 0 304 0 Dimensions in mm GEMÜ 539 www gemu group com 17 34 6 Dimensions ...

Page 18: ...10 0 4 50 230 0 165 0 18 0 125 0 4 230 0 165 0 18 0 125 0 4 65 290 0 185 0 18 0 145 0 4 290 0 185 0 18 0 145 0 4 80 310 0 200 0 18 0 160 0 8 310 0 200 0 18 0 160 0 8 100 350 0 220 0 18 0 180 0 8 350 0 220 0 18 0 180 0 8 Dimensions in mm n number of bolts 1 Connection type Code 8 Flange EN 1092 PN 16 form B face to face dimension FTF EN 558 series 1 ISO 5752 basic series 1 2 Valve body material Cod...

Page 19: ... 4 180 0 140 0 18 0 100 0 4 40 200 0 150 0 18 0 110 0 4 200 0 150 0 18 0 110 0 4 16 0 140 0 19 0 105 0 4 50 230 0 165 0 18 0 125 0 4 203 0 155 0 19 0 120 0 4 Dimensions in mm n number of bolts 1 Connection type Code 10 Flange EN 1092 PN 25 form B face to face dimension FTF EN 558 series 1 ISO 5752 basic series 1 Code 11 Flange EN 1092 PN 40 form B face to face dimension FTF EN 558 series 1 ISO 575...

Page 20: ... 9 88 9 4 40 200 0 125 0 15 9 98 4 4 50 230 0 150 0 19 0 120 7 4 65 290 0 180 0 19 0 139 7 4 80 310 0 190 0 19 0 152 4 4 100 350 0 230 0 19 0 190 5 8 Dimensions in mm n number of bolts 1 Connection type Code 39 Flange ANSI Class 125 150 RF face to face dimension FTF EN 558 series 1 ISO 5752 basic series 1 2 Valve body material Code 37 1 4408 investment casting Code 90 EN GJS 400 18 LT GGG 40 3 www...

Page 21: ...s and their spare parts 10 Installation in piping 10 1 Preparing for installation WARNING The equipment is subject to pressure Risk of severe injury or death Depressurize the plant Completely drain the plant WARNING Corrosive chemicals Risk of caustic burns Wear suitable protective gear Completely drain the plant CAUTION Hot plant components Risk of burns Only work on plant that has cooled down CA...

Page 22: ...ion 13 Only install the product between matching aligned pipes see chapters below 14 Please note the flow direction 15 Please note the installation position see chapter Installa tion position 10 2 Installation position GEMÜ recommend installing the actuator vertically upright or vertically down to optimise the service life 10 3 Installation with flanged connection Fig 4 Flanged connection NOTICE S...

Page 23: ...Pin 1 Tx Ethernet Pin 2 Rx Ethernet Pin Signal name Pin 3 Tx Ethernet Pin 4 Rx Ethernet Pin 5 Shield 11 3 Connection X3 6 5 3 2 4 7 8 1 8 pin M12 plug A coded Pin Signal name Pin 1 I set value input Pin 2 I set value input Pin 3 I actual value output Pin 4 GND actual value output digital input 1 3 error message output Pin 5 Error message output 24 V DC Pin 6 Digital input 3 Pin 7 Digital input 1 P...

Page 24: ...ð Initialisation of the actuator is started 3 Green and orange LEDs flash alternately ð Initialisation is completed ð Commissioning is completed 13 2 Commissioning via the eSy Web web interface See separate eSy Web operating instructions 13 3 Commissioning via digital input ü The function of input 3 is set to init 1 Connect 24 V signal briefly max 2 s to connection X3 on pins 7 and 4 ð Initialisat...

Page 25: ...ver 3 clockwise ð The product closes 7 Pull manual override off the starting point 8 Ensure correct positioning of the O ring 9 Push actuator 12 into the groove provided for this pur pose 10 Turn housing cover 3 anticlockwise until it stops ð The actuator cover is closed 11 Reconnect the power supply 15 Inspection and maintenance WARNING The equipment is subject to pressure Risk of severe injury o...

Page 26: ...t h Locking plate 15 2 Removing the actuator 15 2 1 Removing actuator DN 15 DN 50 1 Move the actuator A to the open position 2 Undo union nut a 3 Lift actuator A off valve body 1 4 Move the actuator A to the closed position 5 Clean all parts of contamination do not damage parts dur ing cleaning 6 Check parts for potential damage replace if necessary only use genuine parts from GEMÜ 15 2 2 Removing...

Page 27: ...13 Insert new seat seal 14 14 Insert retaining washer d and use cylindrical screws 39 to fix it in place 15 Place the locking plate h on the valve plug c 16 Screw the entire valve plug c onto the union nut g 17 Bend the locking plate h by 90 so that it lies flat on the union nut g g c h ð The union nut g is secured against twisting 18 Mount the actuator 15 4 Mounting the actuator CAUTION Incorrect...

Page 28: ...or clockwise approx 90 to the desired position Nominal size Torque DN 15 90 Nm DN 20 100 Nm DN 25 120 Nm DN 32 120 Nm DN 40 150 Nm DN 50 200 Nm 5 Move the actuator A to the closed position 6 With the valve fully assembled check the function and tightness 15 4 2 Mounting actuator DN 65 DN 100 1 Move the actuator A to the open position 2 Insert new sealing washer 30 in valve body flange 3 Place actu...

Page 29: ...ends incorrectly wired Wire cable ends correctly The product leaks between actuator and valve body Bolting between valve body and actuator loose Retighten bolting between valve body and actuator Actuator valve body damaged Replace actuator valve body The product leaks between actuator flange and valve body Mounting parts loose Retighten mounting parts Valve body actuator damaged Replace valve body...

Page 30: ...nvironmental protection laws 19 Returns Legal regulations for the protection of the environment and personnel require that the completed and signed return deliv ery note is included with the dispatch documents Returned goods can be processed only when this note is completed If no return delivery note is included with the product GEMÜ cannot process credits or repair work but will dispose of the go...

Page 31: ... 1 4 4 2 5 2 5 3 5 4 6 1 1 6 3 1 6 4 3 We also declare that the specific technical documentation has been compiled in accordance with part B of Annex VII The manufacturer or his authorised representative undertake to transmit in response to a reasoned request by the national au thorities relevant information on the partly completed machinery This transmission takes place Electronically Authorised ...

Page 32: ...ndustrie Service GmbH Number 0035 Certificate no 01 202 926 Q 02 0036 Conformity assessment procedure Module H Technical standard used AD 2000 Note for products with a nominal size DN 25 The products are developed and produced according to GEMÜ process instructions and quality standards which comply with the requirements of ISO 9001 and ISO 14001 According to Article 4 Paragraph 3 of the Pressure ...

Page 33: ...hat the product listed below complies with the safety requirements of the EMC Directive 2014 30 EU Description of the product GEMÜ 539 Technical standards used Interference resistance DIN EN 61326 1 industrial processes DIN EN 61800 3 Interference emission DIN EN 61800 3 Ingelfingen Criesbach 2019 09 25 Joachim Brien Head of Technical Department GEMÜ 539 www gemu group com 33 34 22 Declaration of ...

Page 34: ...GEMÜ Gebr Müller Apparatebau GmbH Co KG Fritz Müller Straße 6 8 74653 Ingelfingen Criesbach Germany Phone 49 0 7940 123 0 info gemue de www gemu group com Subject to alteration 11 2019 88614468 88614468 ...

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