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GEM R639 eSyStep Operating Instructions Manual

Motorized diaphragm valve
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GEMÜ R639 eSyStep
OPEN / CLOSE (Code AE)
Motorized diaphragm valve
Operating instructions
EN
further information
webcode: GW-R639

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Summary of Contents for GEM R639 eSyStep

  • Page 1 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE) Motorized diaphragm valve Operating instructions further information webcode: GW-R639...
  • Page 2 All rights including copyrights or industrial property rights are expressly reserved. Keep the document for future reference. © GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG 25.09.2023 GEMÜ R639 eSyStep 2 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 3: Table Of Contents

    2014/68/EU (Pressure Equipment Directive) ..20 EU Declaration of Conformity in accordance with 2014/30/EU (EMC Directive) ........ 21 EU Declaration of Conformity in accordance with 2011/65/EU (RoHS Directive) ....... www.gemu-group.com 3 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)

  • Page 4: General Information

    1.4 Definition of terms Corrosive chemicals! Working medium The medium that flows through the GEMÜ product. Diaphragm size Uniform seat size of GEMÜ diaphragm valves for different Hot plant components! nominal sizes. 1.5 Warning notes Wherever possible, warning notes are organised according to...

  • Page 5: Safety Information

    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. www.gemu-group.com 5 / 71 GEMÜ R639 eSyStep...

  • Page 6: Led Displays

    (on) flashes 3.3 Description The GEMÜ R639 eSyStep 2/2-way diaphragm valve is electric- ally operated. The eSyStep electric actuator is available as On/Off actuator or with integrated positioner. An integral op- tical and electrical position indicator is standard. The self- locking actuator holds its position in a stable manner when idle and in the event of power supply failure.

  • Page 7: Order Data

    FTF EN 558 series 1, ISO 5752, basic series 1, length only for body configuration D Flare Flare connection with PVDF union nut 5 Valve body material Code PVC-U, grey PP, reinforced www.gemu-group.com 7 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 8 6 Diaphragm material EPDM 7 Voltage/Frequency 24 V DC 8 Control module On/Off actuator, additional end position indicators 9 Actuator version Actuator size 0 diaphragm size 10 10 Mounting plate Without GEMÜ R639 eSyStep 8 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 9: Technical Data

    Information on operating pressures applied on both sides and for high purity media on request. The operating pressures apply at room temperature. In case of deviating temperatures, observe the pressure / temperature correlation. Pressure rating: PN 10 www.gemu-group.com 9 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 10 Therefore the Kv values may exceed the tolerance limits of the standard. The Kv value curve (Kv value dependent on valve stroke) can vary depending on the diaphragm material and dur- ation of use. GEMÜ R639 eSyStep 10 / 71 www.gemu-group.com...
  • Page 11 FDA* * depending on version and / or operating parameters EMC Directive: 2014/30/EU RoHS Directive: 2011/65/EU 6.5 Materials Materials: Diaphragm material O-ring material PTFE EPDM EPDM EPDM www.gemu-group.com 11 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 12 1.89 0.50 0.40 0.73 0.83 0.93 1.13 2.36 0.57 0.47 1.00 1.40 1.50 1.60 3.08 MG = diaphragm size, weight in kg Installation position: Optional Flow direction: Optional GEMÜ R639 eSyStep 12 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 13 ▶ With reduced forces, higher duty cycles and/or higher ambient temperatures are possible. At higher force settings the duty cycle and/or ambient temperature is reduced. ▶ IO-Link: Index 0x90 - Subindex 2 - Force www.gemu-group.com 13 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 14 1906701 (eSyStep ON/OFF, code AE, A5, A6) Product-ID: eSyStep On/Off (code AE, A5, A6) ISDU support: SIO operation: IO-Link specification: V1.1 IODD files can be downloaded via https://ioddfinder.io-link.com/ or www.gemu-group.com. GEMÜ R639 eSyStep 14 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 15: Electrical Connection

    Notes: Moving to the error position is only possible with full power supply. This behaviour is not a safety position. The valve must be operated with a GEMÜ 1571 emergency power supply module (see accessories) to ensure the function in case of voltage loss.
  • Page 16 Digital input 1 Off/Open/Closed/Safe/On/ Open Open Initialization Digital input 2 Off/Open/Closed/Safe/On/ Closed Safe/On Initialization Digital input/output Open/Closed/Error/Error and Open Open warning/Initialization Digital output Open/Closed/Error/Error and Closed Closed warning GEMÜ R639 eSyStep 16 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 17 Adjustable 0-20mA / 0-10V Analogue input 5-pin M12 plug Actual value (Y)+ A-coded Default setting 4 -20mA Actual value (Y)- Adjustable 0-20mA / 0-10V Switch Consumer Signal direction Power supply www.gemu-group.com 17 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)

  • Page 18: Dimensions

    8.1.1 Actuator version code 0C Actuator version 12 - 20 203.5 39.0 33.2 59.4 81.0 133.5 Dimensions in mm, MG = diaphragm size * CT = A + H1 (see body dimensions) GEMÜ R639 eSyStep 18 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 19 70.0 82.0 150.0 40 - 50 304.0 122.0 32.5 70.0 82.0 150.0 Dimensions in mm, MG = diaphragm size * CT = A + H1 (see body dimensions) www.gemu-group.com 19 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 20 Code 30: Spigot – inch, for welding or bonding, depending on the body material 2) Valve body material Code 1: PVC-U, grey Code 4: ABS Code 71: Inliner PP-H, grey, outliner PP, reinforced Code 75: Inliner PVDF/outliner PP, reinforced GEMÜ R639 eSyStep 20 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 21 1) Connection type Code 20: Spigot for IR butt welding 2) Valve body material Code 71: Inliner PP-H, grey, outliner PP, reinforced Code 75: Inliner PVDF/outliner PP, reinforced www.gemu-group.com 21 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 22 41.0 16.0 134.0 Dimensions in mm MG = diaphragm size 1) Connection type Code 28: Spigot for IR butt welding, BCF 2) Valve body material Code 20: PVDF GEMÜ R639 eSyStep 22 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 23 Code 4: ABS Code 5: PP, reinforced Code 20: PVDF Code 71: Inliner PP-H, grey, outliner PP, reinforced Code 75: Inliner PVDF/outliner PP, reinforced Code N5: PP-H, natural www.gemu-group.com 23 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 24 Code 3M: Union end with inch insert – ASTM (socket) Code 3T: Union end with insert – JIS (socket) 2) Valve body material Code 1: PVC-U, grey Code 4: ABS GEMÜ R639 eSyStep 24 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 25 2) Valve body material Code 5: PP, reinforced Code 20: PVDF Code 71: Inliner PP-H, grey, outliner PP, reinforced Code 75: Inliner PVDF/outliner PP, reinforced Code N5: PP-H, natural www.gemu-group.com 25 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 26 266.0 G 2¾ Dimensions in mm 1) Connection type Code 7R: Union end with insert (Rp threaded socket) – DIN 2) Valve body material Code 1: PVC-U, grey GEMÜ R639 eSyStep 26 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 27 27.5 12.5 55.0 13.0 Dimensions in mm MG = diaphragm size 1) Connection type Code 2: Solvent cement socket DIN 2) Valve body material Code 1: PVC-U, grey www.gemu-group.com 27 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 28 Code 4: Flange EN 1092, PN 10, form B, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic series 1 2) Valve body material Code 1: PVC-U, grey Code 71: Inliner PP-H, grey, outliner PP, reinforced Code 75: Inliner PVDF/outliner PP, reinforced GEMÜ R639 eSyStep 28 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 29 Code 39: Flange ANSI Class 125/150 RF, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic series 1, length only for body config- uration D 2) Valve body material Code 1: PVC-U, grey Code 71: Inliner PP-H, grey, outliner PP, reinforced Code 75: Inliner PVDF/outliner PP, reinforced www.gemu-group.com 29 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 30 DN 10 - 20 35.0 MG 20 DN 15 - 25 25.0 MG 25 DN 32 25.0 MG 40 DN 40, DN 50 44.5 Dimensions in mm MG = diaphragm size GEMÜ R639 eSyStep 30 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 31 8 Dimensions 8.4 Mounting plate ø5,5 Dimensions in mm, MG = diaphragm size www.gemu-group.com 31 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)

  • Page 32: Manufacturer's Information

    Provide precautionary measures against exceeding the ● 4. Do not store solvents, chemicals, acids, fuels or similar maximum permitted pressures caused by pressure fluids in the same room as GEMÜ products and their spare surges (water hammer). parts. CAUTION Use as step.

  • Page 33: Installation Position

    9. Connect the other side of the body of the product with the 8. Flush the system. piping in the same way. 10. Reactivate all safety and protective devices. www.gemu-group.com 33 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)

  • Page 34: Installation With Solvent Cement Sockets

    4. Reactivate all safety and protective devices. 10.7 Installation with flare connection NOTICE Fittings! ▶ For preparation and connection of the flare connections, please refer to the GEMÜ FlareStar ® brochure and the GEMÜ flare and assembly instructions. Depending on the ambient conditions, use resistant and ●...

  • Page 35: Specific Data Io-Link (Pin 6)

    11.1 Operation on IO-Link 11.1.1 Operation on PLC as a 24 V device The motorized actuator GEMÜ eSyStep can be operated directly in a PLC control unit without limitations. Technical data of the product and of PLC must be complied with.
  • Page 36 During IO-Link operation, pin 6 cannot be evaluated by the PLC control unit as an output signal. Item Name eSyStep PLC with supply voltage USB IO-Link Master USB interface Mains plug – laptop GEMÜ R639 eSyStep 36 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 37 ● Connect pin 4 (CQ) IO-Link master with pin 6 of the product. Do not connect (pin 3) L- IO-Link master. (L-) Item Name eSyStep B1 and B2 Supply voltages USB IO-Link Master www.gemu-group.com 37 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)

  • Page 38: Process Data

    Valve position Close 0 → Process valve not in Closed position 1 → Process valve in Closed position Operating mode 0 → Normal operation 1 → Initialization mode GEMÜ R639 eSyStep 38 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 39: Parameter Overview

    "eSyStep On/Off" 0x15 Serial number Read out serial "XXXXXXXX/YYYY" number 0x16 Hardware revision Read out hardware "Rev. XX/XX" version 0x17 Firmware revision Read out software "V X.X.X.X." version www.gemu-group.com 39 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 40 Configure logical di- 0 → Active high gital input/output 1 → Active low Output 2 Configure logical di- 0 → Active high gital output 1 → Active low GEMÜ R639 eSyStep 40 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 41 Motor unable to move Motor fault / motor 0 … 65.535 blocked Internal error Internal error of the 0 … 65.535 actuator www.gemu-group.com 41 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 42 0 to 255 CLOSE (0 to 25.5s) 0x90 Drive sets Speed Speed – average 1 … 3 traversing range Force Force, dependent on 1 … 6 valve used GEMÜ R639 eSyStep 42 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 43: Parameter

    Data storage index Data Storage Cmd UIntegerT8 1 byte State Property UIntegerT8 4 bytes Data Storage Size UIntegerT32 4 bytes Parameter Check- UIntegerT32 41 bytes Index List OctetStringT www.gemu-group.com 43 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 44 Characteristics 0x8002 0x8003 0x8100 Description of parameter values Index name Parameter Values Description Profile Characteristics 0x8000 Device identification objects 0x8002 Process data mapping 0x8003 Diagnostics 0x8100 External identification GEMÜ R639 eSyStep 44 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 45 The device name can be read out in ASCII format with the Product name parameter. Index Sub- Off- Access Length Index name Parameter Type Values Index Rights 0x12 14 bytes Product name StringT "eSyStep On/Off" www.gemu-group.com 45 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 46 For example, installation location, function, installation date, etc. Index Sub- Off- Access Length Index name Parameter Type Values Index Rights 0x18 32 bytes Application StringT „**************** " specific tag GEMÜ R639 eSyStep 46 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 47 Rights 0x25 39 byte Detailed Device ArrayT See chapter 12.5 Events Status Description of parameter values Index name Parameter Values Description Detailed Device Status See chapter 12.5 Events www.gemu-group.com 47 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 48 The functions of the digital inputs can be configured with the Function digital inputs parameter. Index Sub- Off- Access Length Index name Parameter Type Default Values Rights 0x4B 3 bits Function digital in- Input 1 uint:8 puts 3 bits Input 2 uint:8 GEMÜ R639 eSyStep 48 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 49 The safety position is defined by the parameter Error Action (index 0x4F (see "Error Action'"). (Init) Input can be used as an initialization input. www.gemu-group.com 49 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 50 (Output Error & Warning) Output error and warnings. (Input Init) Configure input/output as initialization input. Type in- / output (Push-Pull) Configure output as Push-Pull. (NPN) Configure output as NPN. (PNP) Configure output as PNP. GEMÜ R639 eSyStep 50 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 51 (Active low) Input 2 inversed. Input / output 1 (Active high) Input/output not inversed. (Active low) Input/output inversed. Output 2 (Active high) Output not inversed. (Active low) Output inversed. www.gemu-group.com 51 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 52 (Hold) Actuator remains in the current position in case of an error. (Open) Actuator moves to the OPEN position in case of an error. (Close) Actuator moves to the CLOSED position in case of an error. GEMÜ R639 eSyStep 52 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 53 Manual initialization mode activated. IO-Link process data (Disabled) Use of IO-Link process data (see “Process data“, page 38) is deactivated. (Enabled) Use of IO-Link process data (see “Process data“, page 38) is activated. www.gemu-group.com 53 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 54 0 … 4092 Analog value valve position OPEN Close 0 … 4092 Analog value valve position CLOSED Stroke 0 … 4092 Analog value stroke (difference between OPEN and CLOSED). GEMÜ R639 eSyStep 54 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 55 16 bits Potifail close uint: 16 0 … 65.535 16 bits Overcurrent out 1 uint: 16 0 … 65.535 16 bits Overcurrent out 2 uint: 16 0 … 65.535 www.gemu-group.com 55 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 56 Read out current analog value of the potentiometer. Supply voltage 0 … 4095 Read out current analog value of the supply voltage. Temperature 0 … 4095 Read out current analog value of the temperature sensor. GEMÜ R639 eSyStep 56 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 57: Events

    App/Disapp Error 0x5000 Motor Unable To Move App/Disapp Error 0x8CE0 Device Temperature Over-Run App/Disapp Warning/Error 0x4210 Emergency Power App/Disapp Warning 0x5100 Primary Supply Voltage Under-Run App/Disapp Error 0x5111 www.gemu-group.com 57 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)
  • Page 58 Error when replacing a dia- ection. phragm (stroke of the valve in incorrect area). Actuator has been fitted on the valve incorrectly (stroke of the valve in the incorrect area). GEMÜ R639 eSyStep 58 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 59 The configuration data that has been changed has been re- set to its default values. The event serves to signal the changes in the configuration data. www.gemu-group.com 59 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)

  • Page 60: Operation

    4. Valve automatically moves into the CLOSED position. ð Turn clockwise to close the valve. 5. Initialization mode is automatically ended. ð Turn anticlockwise to open the valve. 6. The end positions are set. GEMÜ R639 eSyStep 60 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 61: Inspection And Maintenance

    5. Depressurize the plant or plant component. 13.3 Removing the diaphragm 6. Actuate GEMÜ products which are always in the same po- 1. Remove actuator A (see chapter "Removing the actuator"). sition four times a year. 2. Unscrew the diaphragm.
  • Page 62 ▶ Incorrectly mounted diaphragms cause the product leak- age and emission of medium. In this case, remove the diaphragms, check the complete valve and diaphragms and reassemble again proceeding as described above. GEMÜ R639 eSyStep 62 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 63: Mounting The Actuator

    1. Move the actuator A to the open position. 2. Position actuator A with the mounted diaphragm on the valve body 1. 3. Screw in bolts, washers and nuts hand tight. www.gemu-group.com 63 / 71 GEMÜ R639 eSyStep OPEN / CLOSE (Code AE)

  • Page 64: Troubleshooting

    Emergency power operation, position unknown Mechanical stop, OPEN position Mechanical stop, CLOSED position Abort IO-Link communication Maintenance required, OPEN position Maintenance required, CLOSED position Maintenance required, position unknown GEMÜ R639 eSyStep 64 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 65 Retighten mounting parts flange and valve body Valve body / actuator damaged Replace valve body/actuator Valve body of the GEMÜ product is leak- Valve body of the GEMÜ product is faulty Check valve body of the GEMÜ product or corroded...

  • Page 66: Removal From Piping

    3. Disassemble the product. Observe warning notes and goods can be processed only when this note is completed. If safety information. no return delivery note is included with the product, GEMÜ cannot process credits or repair work but will dispose of the 16 Disposal goods at the operator's expense.

  • Page 67: Eu Declaration Of Incorporation According To The Ec Machinery Directive 2006/42/Ec, Annex Ii B

    EC Machinery Directive 2006/42/EC, Annex II B Machinery Directive introductory text We, the company GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Strasse 6–8 74653 Ingelfingen-Criesbach, Germany hereby declare under our sole responsibility that the below-mentioned product complies with the relevant essential health and safety requirements in accordance with Annex I of the above-mentioned Directive.

  • Page 68: Eu Declaration Of Conformity In Accordance With 2014/68/Eu (Pressure Equipment Directive)

    Information for products with a nominal size ≤ DN 25: The products are developed and produced according to GEMÜ's in-house process instructions and standards of quality which comply with the requirements of ISO 9001 and ISO 14001. According to Article 4, Paragraph 3 of the Pressure Equipment Direct- ive 2014/68/EU, these products must not be identified by a CE-marking.

  • Page 69: Eu Declaration Of Conformity In Accordance With 2014/30/Eu (Emc Directive)

    2014/30/EU (EMC Directive) EMC introductory text We, the company GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Strasse 6–8 74653 Ingelfingen-Criesbach, Germany hereby declare under our sole responsibility that the below-mentioned product complies with the regulations of the above-men- tioned Directive.

  • Page 70: Eu Declaration Of Conformity In Accordance With 2011/65/Eu (Rohs Directive)

    In accordance with 2011/65/EU (RoHS Directive) EMC introductory text We, the company GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Strasse 6–8 74653 Ingelfingen-Criesbach, Germany hereby declare under our sole responsibility that the below-mentioned product complies with the regulations of the above-men- tioned Directive.
  • Page 71 GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Straße 6-8, 74653 Ingelfingen-Criesbach, Germany Subject to alteration Phone +49 (0) 7940 1230 · info@gemue.de www.gemu-group.com 09.2023 | 88668343...

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