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GEM 543 eSyStep Operating Instructions Manual

Motorized angle seat globe valve
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GEMÜ 543 eSyStep
Positioner (Code S0)
Motorized angle seat globe valve
Operating instructions
EN
further information
webcode: GW-543

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Summary of Contents for GEM 543 eSyStep

  • Page 1 GEMÜ 543 eSyStep Positioner (Code S0) Motorized angle seat globe valve Operating instructions further information webcode: GW-543...
  • 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 01.03.2021 GEMÜ 543 eSyStep 2 / 69 www.gemu-group.com Positioner (Code S0)

  • Page 3: Table Of Contents

    LED symbols ............Definition of terms ..........Warning notes ............ 2 Safety information ............ 3 Product description ........... 4 GEMÜ CONEXO ............5 Correct use ............... 6 Order data ..............7 Technical data ............8 Dimensions ............... 16 9 Manufacturer's information ........28 Delivery ...............

  • Page 4: General Information

    1.4 Definition of terms Working medium The medium that flows through the GEMÜ product. Diaphragm size Uniform seat size of GEMÜ diaphragm valves for different nominal sizes. 1.5 Warning notes Wherever possible, warning notes are organised according to the following scheme:...

  • Page 5: Safety Information

    14. Do not carry out any maintenance work and repairs not described in this document without consulting the manu- facturer first. In cases of uncertainty: 15. Consult the nearest GEMÜ sales office. www.gemu-group.com 5 / 69 GEMÜ 543 eSyStep Positioner (Code S0)

  • Page 6: Gemü Conexo

    3.3 Description WARNING The GEMÜ 543 eSyStep is a motorized 2/2-way angle seat Improper use of the product globe valve. The eSyStep electric actuator is available as ON/ OFF or with integrated positioner. The valve spindle is sealed ▶...

  • Page 7: Order Data

    Actuator size 0 Actuator size 1 Clamp ASME BPE, face-to-face dimension FTF ASME BPE 12 CONEXO Code Clamp DIN 32676 series B, Without face-to-face dimension FTF EN 558 series 1 www.gemu-group.com 7 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 8 Kv value table. 10 Type of design Without 11 Actuator version Actuator size 0 12 CONEXO Integrated RFID chip for electronic identification and traceability GEMÜ 543 eSyStep 8 / 69 www.gemu-group.com Positioner (Code S0)

  • Page 9: 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 www.gemu-group.com 9 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 10 Code 88: Clamp ASME BPE, face-to-face dimension FTF EN 558 series 1 2) Valve body material Code 34: 1.4435, investment casting Code 37: 1.4408, investment casting Code 40: 1.4435 (F316L), forged body Code C2: 1.4435, investment casting GEMÜ 543 eSyStep 10 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 11 RS460 25.0 RS441 RS461 10.0 RS442 RS462 15.0 RS443 RS463 13.3 RS444 RS464 13.3 10.0 RS445 RS465 35.6 RS446 RS466 50.0 RS448 RS468 Pressures in bar Kv values in m³/h www.gemu-group.com 11 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 12 Regulation (EC) No. 1935/2004* Regulation (EC) No. 10/2011* FDA* * depending on version and/or operating parameters Pressure Equipment Dir- 2014/68/EU ective: Machinery Directive: 2006/42/EU EMC Directive: 2014/30/EU Interference resistance: DIN EN 61000-6-2 GEMÜ 543 eSyStep 12 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 13 7.20 2.07 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 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 14 Yes (up to ± 24 V DC) tion: 7.7.2 Digital input signals Inputs: Function selectable via IO-Link (see table Overview of available functions – Input and output sig- nals) Input voltage: 24 V DC GEMÜ 543 eSyStep 14 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 15 1906801 (eSyStep positioner, code S0, S5, S6), Product-ID: eSyStep Positioner (code S0, S5, S6) 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. www.gemu-group.com 15 / 69 GEMÜ 543 eSyStep Positioner (Code S0)

  • Page 16: Dimensions

    202.0 265.0 271.1 70.0 32.5 70.0 82.0 150.0 202.0 271.5 277.6 70.0 32.5 70.0 82.0 150.0 202.0 278.5 284.6 70.0 32.5 70.0 82.0 150.0 202.0 288.4 294.5 Dimensions in mm GEMÜ 543 eSyStep 16 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 17 202.0 358.3 226.3 M52x1.5 32.5 70.0 82.0 150.0 202.0 360.1 228.1 M60x2.0 32.5 70.0 82.0 150.0 202.0 365.5 233.5 M72x2.0 32.5 70.0 82.0 150.0 202.0 370.5 238.5 Dimensions in mm www.gemu-group.com 17 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 18 Code 37: Spigot SMS 3008 Code 59: Spigot ASME BPE Code 60: Spigot ISO 1127/EN 10357 series C/DIN 11866 series B 2) Valve body material Code 34: 1.4435, investment casting GEMÜ 543 eSyStep 18 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 19 Code 17: Spigot EN 10357 series A (formerly DIN 11850 series 2)/DIN 11866 series A Code 60: Spigot ISO 1127/EN 10357 series C/DIN 11866 series B 2) Valve body material Code 37: 1.4408, investment casting www.gemu-group.com 19 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 20 Code 17: Spigot EN 10357 series A (formerly DIN 11850 series 2)/DIN 11866 series A Code 59: Spigot ASME BPE Code 60: Spigot ISO 1127/EN 10357 series C/DIN 11866 series B 2) Valve body material Code C2: 1.4435, investment casting GEMÜ 543 eSyStep 20 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 21 Code 3C: Threaded socket Rc ISO 7-1, EN 10226-1, JIS B 0203, BS 21, end-to-end dimension ETE DIN 3202-4 series M8 Code 3D: Threaded socket NPT, end-to-end dimension ETE DIN 3202-4 series M8 2) Valve body material Code 37: 1.4408, investment casting www.gemu-group.com 21 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 22 1) Connection type Code 1: Threaded socket DIN ISO 228 Code 3D: Threaded socket NPT, end-to-end dimension ETE DIN 3202-4 series M8 2) Valve body material Code 37: 1.4408, investment casting GEMÜ 543 eSyStep 22 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 23 G 1¾ 13.0 175.0 50.0 G 2⅜ 15.0 Dimensions in mm 1) Connection type Code 9: Threaded spigot DIN ISO 228 2) Valve body material Code 37: 1.4408, investment casting www.gemu-group.com 23 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 24 Code 10: Flange EN 1092, PN 25, 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 GEMÜ 543 eSyStep 24 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 25 = number of bolts 1) Connection type Code 13: Flange EN 1092, PN 25, form B Code 47: Flange ANSI Class 150 RF 2) Valve body material Code 34: 1.4435, investment casting www.gemu-group.com 25 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 26 Code 86: Clamp DIN 32676 series A, face-to-face dimension FTF EN 558 series 1 Code 88: Clamp ASME BPE, face-to-face dimension FTF EN 558 series 1 2) Valve body material Code 34: 1.4435, investment casting GEMÜ 543 eSyStep 26 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 27 Code 86: Clamp DIN 32676 series A, face-to-face dimension FTF EN 558 series 1 Code 88: Clamp ASME BPE, face-to-face dimension FTF EN 558 series 1 2) Valve body material Code C2: 1.4435, investment casting www.gemu-group.com 27 / 69 GEMÜ 543 eSyStep Positioner (Code S0)

  • Page 28: Manufacturer's Information

    4. Do not store solvents, chemicals, acids, fuels or similar Use appropriate, functional and safe tools. ● fluids in the same room as GEMÜ products and their 1. Ensure the product is suitable for the relevant application. spare parts. 2. Check the technical data of the product and the materials.

  • Page 29: Installation With Butt Weld Spigots

    7. Connect the valve flange and the piping flange using ap- propriate sealing materials and matching bolting. 8. Use all flange holes. 9. Tighten the bolts diagonally. 10. Re-attach or reactivate all safety and protective devices. Fig. 3: Threaded spigots www.gemu-group.com 29 / 69 GEMÜ 543 eSyStep Positioner (Code S0)

  • Page 30: Installation With Clamp Connections

    4. Connect the gasket between the body of the product and the pipe connection using clamps. 5. Re-attach or reactivate all safety and protective devices. GEMÜ 543 eSyStep 30 / 69 www.gemu-group.com Positioner (Code S0)

  • Page 31: Electrical Connection

    Digital output, IO-Link n. c. Connection X2 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. www.gemu-group.com 31 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 32 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 GEMÜ 543 eSyStep 32 / 69 www.gemu-group.com Positioner (Code S0)

  • Page 33: 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 34 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 543 eSyStep 34 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 35 ● 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 35 / 69 GEMÜ 543 eSyStep Positioner (Code S0)

  • Page 36: 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 543 eSyStep 36 / 69 www.gemu-group.com Positioner (Code S0)

  • Page 37: Parameter Overview

    0x16 Hardware revision Read out hardware "Rev. XX/XX" version 0x17 Firmware revision Read out software "V X.X.X.X." version 0x18 Application specific Text with 32 char- „****************“ acters can be entered www.gemu-group.com 37 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 38 Output 2 Configure logical 0 → Active high digital output 1 → Active low 0x4F Error action Error action Set safety position 0 → Hold 1 → Open 2 → Close GEMÜ 543 eSyStep 38 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 39 0xB0 Control parameters P amplification P component – po- 1 … 200 sitioner (0.1 … 20.0) D amplification D component – po- 1 … 200 sitioner (0.1 … 20.0) www.gemu-group.com 39 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 40 2 → 0 to 10 V Min. Determine min- 0 to Max imum signal output (0.0% to Max) Determine max- 1000 Min to 1000 imum signal output (Min to 100%) GEMÜ 543 eSyStep 40 / 69 www.gemu-group.com Positioner (Code S0)

  • Page 41: Parameter

    Data storage index 0x03 1 byte 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 41 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 42 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 543 eSyStep 42 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 43 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 Product name 0x12 18 byte StringT "eSyStep Positioner" www.gemu-group.com 43 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 44 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 Application 0x18 32 bytes StringT „**************** " specific tag GEMÜ 543 eSyStep 44 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 45 Values Index Rights Detailed Device 0x25 39 byte 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 45 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 46 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 3 bits Function digital in- 0x4B Input 1 uint:8 puts 3 bits Input 2 uint:8 GEMÜ 543 eSyStep 46 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 47 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 47 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 48 (Output Error & Warning) Output error and warnings. (Input Init) Configure input/output as initialization input. (Push-Pull) Configure output as Push-Pull. Type in- / output (NPN) Configure output as NPN. (PNP) Configure output as PNP. GEMÜ 543 eSyStep 48 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 49 Input 2 (Active low) Input 2 inversed. (Active high) Input/output not inversed. Input / output 1 (Active low) Input/output inversed. (Active high) Output not inversed. Output 2 (Active low) Output inversed. www.gemu-group.com 49 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 50 (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 message. GEMÜ 543 eSyStep 50 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 51 Operating mode for OPEN/CLOSE control activated. (Disabled) Use of IO-Link process data (see “Process data“, IO-Link process data page 36) is deactivated. (Enabled) Use of IO-Link process data (see “Process data“, page 36) is activated. www.gemu-group.com 51 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 52 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 543 eSyStep 52 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 53 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 53 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 54 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 543 eSyStep 54 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 55 800 … 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 55 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 56 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 543 eSyStep 56 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 57 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 57 / 69 GEMÜ 543 eSyStep Positioner (Code S0)

  • Page 58: Events

    Carry out initialization if valve Valve corroded (rusted in is OK place). End position can no longer be reached (after replacing the diaphragm). GEMÜ 543 eSyStep 58 / 69 www.gemu-group.com Positioner (Code S0)
  • Page 59 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 59 / 69 GEMÜ 543 eSyStep Positioner (Code S0)

  • Page 60: Operation

    ð Turn anticlockwise to open the valve. 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 543 eSyStep 60 / 69 www.gemu-group.com Positioner (Code S0)

  • Page 61: Inspection And Maintenance

    3. Lift actuator A off valve body 1. 5. Depressurize the plant or plant component. 4. Clean all parts of contamination (do not damage parts 6. Actuate GEMÜ products which are always in the same during cleaning). position four times a year.
  • Page 62 150 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. 7. Carry out initialisation. GEMÜ 543 eSyStep 62 / 69 www.gemu-group.com Positioner (Code S0)

  • Page 63: Troubleshooting

    Emergency power operation, CLOSED position Emergency power operation, position unknown Set value too small Set value too high Maintenance required, OPEN position Maintenance required, CLOSED position Maintenance required, position unknown www.gemu-group.com 63 / 69 GEMÜ 543 eSyStep Positioner (Code S0)
  • Page 64 Valve body / actuator damaged Replace valve body/actuator Body of the GEMÜ product is leaking Body of the GEMÜ product is faulty or Check the body of the GEMÜ product for corroded potential damage, replace body if neces-...

  • Page 65: 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 66: Declaration Of Incorporation According To 2006/42/Ec (Machinery Directive)

    19 Declaration of Incorporation according to 2006/42/EC (Machinery Directive) Declaration of Incorporation according to the EC Machinery Directive 2006/42/EC, Annex II, 1.B for partly completed machinery GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Straße 6-8 74653 Ingelfingen-Criesbach, Germany declare that the following product Make: GEMÜ...

  • Page 67: Declaration Of Conformity According To 2014/68/Eu (Pressure Equipment Directive)

    EN 1983, 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 Equipment Directive 2014/68/EU these products must not be identified by a CE-label.

  • Page 68: Declaration Of Conformity According To 2014/30/Eu (Emc Directive)

    21 Declaration of conformity according to 2014/30/EU (EMC Directive) EU Declaration of Conformity in accordance with 2014/30/EU (EMC Directive) GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Straße 6-8 74653 Ingelfingen-Criesbach, Germany declare that the product listed below complies with the safety requirements of the EMC Directive 2014/30/EU.
  • Page 69 GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Subject to alteration Fritz-Müller-Straße 6–8, 74653 Ingelfingen-Criesbach, Ger- *88668392* many 03.2021 | 88668392 Phone +49 (0) 7940 1230 · info@gemue.de www.gemu-group.com...

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Esystep 543

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