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GEM 533 eSyStep Operating Instructions Manual

Motorized globe valve
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GEMÜ 533 eSyStep
Positioner (Code S0)
Motorized globe valve
Operating instructions
EN
further information
webcode: GW-533

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Summary of Contents for GEM 533 eSyStep

  • Page 1 GEMÜ 533 eSyStep Positioner (Code S0) Motorized globe valve Operating instructions further information webcode: GW-533...
  • 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 30.10.2023 GEMÜ 533 eSyStep 2 / 64 www.gemu-group.com Positioner (Code S0)

  • Page 3: Table Of Contents

    2 Safety information ..........3 Product description ..........Construction ..........LED displays ..........Description ............. Function ............4 GEMÜ CONEXO ............ 5 Correct use ............6 Order data ............7 Technical data ............. 8 Electrical connection ........... 9 Dimensions ............

  • 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 Incorrect combination of actuator and valve...

  • Page 5: Product Description

    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 / 64 GEMÜ 533 eSyStep...

  • Page 6: Led Displays

    ● explosive zones. 3.3 Description WARNING The GEMÜ 533 is a motorized 2/2-way globe valve. The eSyStep electric actuator is available as On/Off actuator or Improper use of the product! with integrated positioner. The valve spindle is sealed by a ▶...
  • Page 7 5 Correct use The product is not intended for use in potentially explosive areas. ● Use the product in accordance with the technical data. www.gemu-group.com 7 / 64 GEMÜ 533 eSyStep Positioner (Code S0)

  • Page 8: Order Data

    PTFE, glass fibre reinforced 1.4404 7 Voltage/frequency Code 24 V DC 8 Control module Code Positioner Positioner, configured for emergency power supply module (NC) Positioner, configured for emergency power supply module (NO) GEMÜ 533 eSyStep 8 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 9 Please find the number of the optional regulating cone (R-No.) for the linear or equal-percentage modified regulating cone in the Kv value table. 10 Actuator version Actuator size 0 11 Type of design Without 12 CONEXO Without www.gemu-group.com 9 / 64 GEMÜ 533 eSyStep Positioner (Code S0)

  • Page 10: Technical Data

    For max. operating pressures the pressure / temperature correlation must be observed. Higher operating pressures on request Leakage rate: Control valve Seat seal Standard Test procedure Leakage rate Test medium Metal DIN EN 60534-4 PTFE, FKM, EPDM DIN EN 60534-4 GEMÜ 533 eSyStep 10 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 11 RS481 RS501 10.0 RS482 RS502 15.0 RS483 RS503 10.0 RS484 RS504 10.0 RS485 RS505 16.0 RS486 RS506 25.0 RS488 RS508 40.0 RS490 RS510 Kv values in m³/h Pressures in bar www.gemu-group.com 11 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 12 Kv values determined in accordance with DIN EN 60534. The Kv value specifications refer to the largest actu- ator for the respective nominal size. The Kv values for other product configurations (e.g. other connections or body materials) may differ. GEMÜ 533 eSyStep 12 / 64 www.gemu-group.com...
  • Page 13 Valve body Weight Weights in kg Mechanical environ- Class 4M8 acc. to EN 60721-3-4:1998 mental conditions: Vibration: 5g acc. to IEC 60068-2-6 Test Fc Shock: 25g acc. to 60068-2-27 Test Ea www.gemu-group.com 13 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 14 ▶ 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 GEMÜ 533 eSyStep 14 / 64 www.gemu-group.com...
  • Page 15 0/4 - 20 mA; 0 - 10 V (function selectable via IO-Link) Output type: Active Accuracy: ≤ ±1% of full flow Temperature drift: ≤ ±0.1% / 10°K Load resistor: ≤ 750 kΩ Resolution: 12 bit Short-circuit proof: www.gemu-group.com 15 / 64 GEMÜ 533 eSyStep Positioner (Code S0)

  • Page 16: 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 17 8.2 Electrical connection 8.2.1 Connection X1 7-pin plug, Binder, type 693 Signal name Uv, 24 V DC supply voltage Digital input 1 Digital input 2 Digital input/output Digital output, IO-Link n.c. www.gemu-group.com 17 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 18 8.2.2 Connection X2 (only for positioner design) 5-pin M12 plug, A-coded Signal name I+/U+, set value input I-/U-, set value input I+/U+, actual value output I-/U-, actual value output n.c. GEMÜ 533 eSyStep 18 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 19 Safe/On tialization Digital input/output Open/Closed/Error/Error and Error Error warning/Initialization Digital output Open/Closed/Error/Error and Closed Closed warning Analogue input 4–20 mA/0–20 mA/0–10 V 4–20 mA 4–20 mA Analogue output 4–20 mA/0–20 mA/0–10 V 4–20 mA 4–20 mA www.gemu-group.com 19 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 20 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 GEMÜ 533 eSyStep 20 / 64 www.gemu-group.com Positioner (Code S0)

  • Page 21: Dimensions

    70.0 82.0 150.0 252.0 384.8 252.8 32.5 70.0 82.0 150.0 252.0 389.0 257.0 32.5 70.0 82.0 150.0 252.0 400.5 268.5 32.5 70.0 82.0 150.0 252.0 408.5 276.5 Dimensions in mm www.gemu-group.com 21 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 22 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 Code 37: 1.4408, investment casting Code 90: EN-GJS-400-18-LT (GGG 40.3) GEMÜ 533 eSyStep 22 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 23 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 www.gemu-group.com 23 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 24 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 37: 1.4408, investment casting Code 90: EN-GJS-400-18-LT (GGG 40.3) GEMÜ 533 eSyStep 24 / 64 www.gemu-group.com Positioner (Code S0)

  • Page 25: 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 26: Installation Position

    14. Please note the flow direction. 15. Please note the installation position (see chapter "Installa- tion position"). 11.2 Installation position GEMÜ recommend installing the actuator vertically upright or vertically down to optimise the service life. 11.3 Installation with flanged connection Fig. 1: Flanged connection...

  • Page 27: Specific Data Io-Link (Pin 6)

    12.1 Operation on IO-Link 12.1.1 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 28 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 533 eSyStep 28 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 29 ● 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 29 / 64 GEMÜ 533 eSyStep Positioner (Code S0)

  • Page 30: Process Data

    1 → Process valve in Closed position Operating mode 0 → Normal operation 1 → Initialization mode Valve position analog 8 … 23 Position of the valve in the range 0 … 1000 GEMÜ 533 eSyStep 30 / 64 www.gemu-group.com Positioner (Code S0)

  • Page 31: Parameter Overview

    Read out product ID "eSyStep Posi- tioner" 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 31 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 32 Input / output 1 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 533 eSyStep 32 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 33 Operating time 0 to 255 OPEN (0 to 25.5s) Close Operating time 0 to 255 CLOSE (0 to 25.5s) 0x90 Drive sets Force Force, dependent on 1 … 6 valve used www.gemu-group.com 33 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 34 1 → 4 to 20 mA 2 → 0 to 10 V Min. Determine minimum 0 to Max signal output (0.0% to Max) Determine max- 1000 Min to 1000 imum signal output (Min to 100%) GEMÜ 533 eSyStep 34 / 64 www.gemu-group.com Positioner (Code S0)

  • Page 35: Parameter

    1 byte 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 35 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 36 ArrayT 0x8000 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 533 eSyStep 36 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 37 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 18 byte Product name StringT "eSyStep Positioner" www.gemu-group.com 37 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 38 A text with 32 characters can be stored in the device with the Application specific tag parameter. 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 533 eSyStep 38 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 39 Values Index 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 39 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 40 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 533 eSyStep 40 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 41 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 41 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 42 (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 533 eSyStep 42 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 43 (Active high) Input 2 not inversed. (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 43 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 44 (Open) Actuator moves to the OPEN position in case of an error. (Close) Actuator moves to the CLOSED position in case of an error. Error time 1 … 1000 Determine delay time between error detection and error mes- sage. GEMÜ 533 eSyStep 44 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 45 Operating mode for OPEN/CLOSE control activated. IO-Link process data (Disabled) Use of IO-Link process data (see “Process data“, page 30) is deactivated. (Enabled) Use of IO-Link process data (see “Process data“, page 30) is activated. www.gemu-group.com 45 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 46 Open 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 533 eSyStep 46 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 47 Read out current analog value of the supply voltage. Temperature 0 … 4095 Read out current analog value of the temperature sensor. Set value (W) 0 … 4095 Read out current analog value of the set value. www.gemu-group.com 47 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 48 1 … 6 Set the force during initialization. Preset at the factory de- pending on the valve type. Force settings Actuator size Setting parameter Force AG0 and AG1 Minimum force Maximum force GEMÜ 533 eSyStep 48 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 49 800 … 1000 Set the sealing function valve position OPEN. (80.0 … 100.0 %) Close tight 0 … 200 Set the sealing function valve position CLOSED. (0 … 20.0 %) www.gemu-group.com 49 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 50 Set the stroke limiter of the control range in valve position (Min Pos to OPEN. 100.0%) Min pos 0 to Max Pos Set the stroke limiter of the control range in valve position (0.0% to Max CLOSED. Pos) GEMÜ 533 eSyStep 50 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 51 U max 100 to 110 Determine maximum value of the voltage input. If the set (10.0 to 11.0 V) value is exceeded, the message "Set value too high" is is- sued. www.gemu-group.com 51 / 64 GEMÜ 533 eSyStep Positioner (Code S0)

  • Page 52: Events

    The event occurs when the Valve is blocked (for example, Check valve 0x8CE0 motor is blocked. solid stuck in valve). Carry out initialization if valve Valve corroded (rusted in is OK place). GEMÜ 533 eSyStep 52 / 64 www.gemu-group.com Positioner (Code S0)
  • Page 53 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). www.gemu-group.com 53 / 64 GEMÜ 533 eSyStep Positioner (Code S0)

  • Page 54: Operation

    ð OPEN and CLOSED LEDs flash alternately. 2. Valve automatically moves into the OPEN position. 3. Valve automatically moves into the CLOSED position. 4. Initialization mode is automatically ended. 5. The end positions are set. GEMÜ 533 eSyStep 54 / 64 www.gemu-group.com Positioner (Code S0)

  • Page 55: Inspection And Maintenance

    5. Clean all parts of contamination (do not damage parts dur- 5. Depressurize the plant or plant component. ing cleaning). 6. Actuate GEMÜ products which are always in the same po- 6. Check parts for potential damage, replace if necessary sition four times a year.

  • Page 56: Replacing The Seals

    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 GEMÜ 533 eSyStep 56 / 64 www.gemu-group.com Positioner (Code S0)

  • Page 57: Troubleshooting

    Emergency power operation, CLOSED position Emergency power operation, position unknown Set value too small Set value too high Abort IO-Link communication Maintenance required, OPEN position Maintenance required, CLOSED position Maintenance required, position unknown www.gemu-group.com 57 / 64 GEMÜ 533 eSyStep Positioner (Code S0)
  • Page 58 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 59: 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 17 Disposal goods at the operator's expense.

  • Page 60: 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 61: 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 62: 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 63: 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 64 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 10.2023 | 88668387...

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