GEM eSyStep 639 AE Series Operating Instructions Manual
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GEM eSyStep 639 AE Series Operating Instructions Manual

Motorized diaphragm valve
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GEMÜ 639 eSyStep
OPEN / CLOSE (Code AE)
Motorized diaphragm valve
Operating instructions
EN
TYPE EL
CLASS I
AUGUST 2021
further information
webcode: GW-639

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Summary of Contents for GEM eSyStep 639 AE Series

  • Page 1 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE) Motorized diaphragm valve Operating instructions TYPE EL CLASS I AUGUST 2021 further information webcode: GW-639...
  • 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 09.05.2022 GEMÜ 639 eSyStep 2 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • 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 ............. Behaviour in the event of an error ....

  • 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 639 eSyStep...

  • Page 6: Gemü Conexo

    Colour Function the RFID chip is used for traceability in the production process and quality assurance. Expansion to include the CONEXO Standard Inversed functionality at a later date must be coordinated with GEMÜ. Power/fault green green Operating indica- tion/ Order with CONEXO communication GEMÜ...
  • Page 7 The product is designed for installation in piping systems and for controlling a working medium. 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 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)

  • Page 8: Order Data

    1.4408, investment casting Threaded socket NPT 1.4408, PFA lined Threaded spigot DIN 11851 1.4435, investment casting Cone spigot and union nut DIN 11851 Forged material 1.4435 (F316L), forged body GEMÜ 639 eSyStep 8 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 9 Ra ≤ 0.25 μm (10 µin.) for media wetted surfaces *), 1516 in accordance with DIN 11866 HE5, electropolished internal/external, *) for inner pipe diameters < 6 mm, in the spigot Ra ≤ 0.38 μm www.gemu-group.com 9 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 10 DIN 11866 HE3, electropolished internal/external 10 Actuator version Actuator size 0 11 Special version Without 12 CONEXO Integrated RFID chip for electronic identification and traceability GEMÜ 639 eSyStep 10 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 11: Technical Data

    PTFE diaphragms exposed to high temperature fluctuations. The maintenance cycles must be adapted accordingly. GEMÜ 555 and 505 globe valves are particularly suitable for use in the area of steam generation and distribution. The following valve arrangement for interfaces between steam pipes and process pipes has proven itself over time: A globe valve for shutting off steam pipes and a diaphragm valve as an interface to the process pipes.
  • Page 12 Therefore the Kv values may exceed the tolerance limits of the stand- ard. The Kv value curve (Kv value dependent on valve stroke) can vary depending on the diaphragm material and dur- ation of use. GEMÜ 639 eSyStep 12 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 13 DIN EN 61000-6-4 (07/2011) DIN EN 61326-1 (industry) (07/2013) Interference emission class: Class A Interference emission group: Group 1 Interference resistance DIN EN 61000-6-2 (03/2006) DIN EN 61326-1 (industry) (07/2013) www.gemu-group.com 13 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 14 MG = diaphragm size, weight 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 GEMÜ 639 eSyStep 14 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 15 ▶ 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 15 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 16 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 639 eSyStep 16 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 17: Behaviour In The Event Of An Error

    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 18: Dimensions

    70.0 82.0 150.0 32 - 40 304.0 122.0 32.5 70.0 82.0 150.0 Dimensions in mm MG = diaphragm size * CT = A + H1 (see body dimensions) GEMÜ 639 eSyStep 18 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 19 19.0 21.3 12.5 108.0 1/2" 25.0 19.0 21.3 13.0 120.0 3/4" 25.0 23.0 26.9 16.0 120.0 1" 25.0 29.0 33.7 19.0 120.0 1¼" 25.0 35.0 42.4 24.0 153.0 www.gemu-group.com 19 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 20 Code 60: Spigot ISO 1127/EN 10357 series C/DIN 11866 series B 2) Valve body material Code 40: 1.4435 (F316L), forged body Code 42: 1.4435 (BN2), forged body, Δ Fe < 0.5% Code F4: 1.4539, forged body GEMÜ 639 eSyStep 20 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 21 2) Valve body material Code 40: 1.4435 (F316L), forged body Code 42: 1.4435 (BN2), forged body, Δ Fe < 0.5% Code C3: 1.4435, investment casting Code F4: 1.4539, forged body www.gemu-group.com 21 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 22 2) Valve body material Code 40: 1.4435 (F316L), forged body Code 42: 1.4435 (BN2), forged body, Δ Fe < 0.5% Code C3: 1.4435, investment casting Code F4: 1.4539, forged body GEMÜ 639 eSyStep 22 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 23 1) Connection type Code 1: Threaded socket DIN ISO 228 2) Valve body material Code 12: CW614N, CW617N (brass) Code 37: 1.4408, investment casting Code 90: EN-GJS-400-18-LT (GGG 40.3) www.gemu-group.com 23 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 24 MG = diaphragm size n = number of flats 1) Connection type Code 31: Threaded socket NPT 2) Valve body material Code 37: 1.4408, investment casting Code 90: EN-GJS-400-18-LT (GGG 40.3) GEMÜ 639 eSyStep 24 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 25 1) Connection type Code 6: Threaded spigot DIN 11851 2) Valve body material Code 40: 1.4435 (F316L), forged body Code 42: 1.4435 (BN2), forged body, Δ Fe < 0.5% www.gemu-group.com 25 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 26 Code 6K: Cone spigot and union nut DIN 11851 2) Valve body material Code 40: 1.4435 (F316L), forged body Code 42: 1.4435 (BN2), forged body, Δ Fe < 0.5% GEMÜ 639 eSyStep 26 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 27 Code 40: 1.4435 (F316L), forged body Code 42: 1.4435 (BN2), forged body, Δ Fe < 0.5% Code 83: EN-GJS-400-18-LT (GGG 40.3), hard rubber lined Code C3: 1.4435, investment casting www.gemu-group.com 27 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 28 Code 40: 1.4435 (F316L), forged body Code 42: 1.4435 (BN2), forged body, Δ Fe < 0.5% Code 83: EN-GJS-400-18-LT (GGG 40.3), hard rubber lined Code C3: 1.4435, investment casting GEMÜ 639 eSyStep 28 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 29 Code 8T: Clamp DIN 32676 series C, face-to-face dimension FTF EN 558 series 7, length only for body configuration D 2) Valve body material Code 40: 1.4435 (F316L), forged body Code 42: 1.4435 (BN2), forged body, Δ Fe < 0.5% Code F4: 1.4539, forged body www.gemu-group.com 29 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)

  • Page 30: Manufacturer's Information

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

  • Page 31: Installation With Clamp Connections

    4. Re-attach or reactivate all safety and protective devices. 7. Re-attach or reactivate all safety and protective devices. 8. Flush the system. 10.5 Installation with threaded sockets Fig. 3: Threaded socket www.gemu-group.com 31 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)

  • Page 32: Electrical Connection

    11 Electrical connection 11 Electrical connection NOTICE Appropriate cable socket/appropriate mating connector ▶ The appropriate connector is included for X1. 11.1 Position of the connectors 11.2 Electrical connection GEMÜ 639 eSyStep 32 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 33 11.2.1 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 33 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 34 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 639 eSyStep 34 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 35 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 35 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)

  • Page 36: 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 37 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 www.gemu-group.com 37 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 38 ● 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 GEMÜ 639 eSyStep 38 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 39: 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 www.gemu-group.com 39 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)

  • Page 40: 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 GEMÜ 639 eSyStep 40 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 41 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 www.gemu-group.com 41 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 42 Motor unable to Motor fault / motor 0 … 65.535 move blocked Internal error Internal error of the 0 … 65.535 actuator GEMÜ 639 eSyStep 42 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 43 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 www.gemu-group.com 43 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)

  • Page 44: 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 GEMÜ 639 eSyStep 44 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 45 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 www.gemu-group.com 45 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 46 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" GEMÜ 639 eSyStep 46 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 47 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 www.gemu-group.com 47 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 48 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 GEMÜ 639 eSyStep 48 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 49 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 www.gemu-group.com 49 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 50 The safety position is defined by the parameter Error Action (index 0x4F (see "Error Action'"). (Init) Input can be used as an initialization input. GEMÜ 639 eSyStep 50 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 51 (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. www.gemu-group.com 51 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 52 (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. GEMÜ 639 eSyStep 52 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 53 (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. www.gemu-group.com 53 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 54 Manual initialization mode activated. IO-Link process data (Disabled) Use of IO-Link process data (see “Process data“, page 39) is deactivated. (Enabled) Use of IO-Link process data (see “Process data“, page 39) is activated. GEMÜ 639 eSyStep 54 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 55 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). www.gemu-group.com 55 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 56 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 GEMÜ 639 eSyStep 56 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 57 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. www.gemu-group.com 57 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)

  • Page 58: 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 GEMÜ 639 eSyStep 58 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)
  • Page 59 Event Description Possible cause Troubleshooting Device Hardware Fault The event occurs when a hard- Fault in valve position detec- Contact GEMÜ Support 0x5000 ware fault is detected. tion. Parameter can no longer be read when switching the device on. Motor Unable To Move...
  • Page 60 (spindle, diaphragm or valve body incorrectly mounted, for example). Not Calibrated The event occurs if the actu- Contact GEMÜ Support 0x8CA9 ator does not have a valid cal- ibration. The actuator is calib- rated in the factory. Over Current Output 1...

  • Page 61: 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. www.gemu-group.com 61 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)

  • Page 62: Inspection And Maintenance

    5. Depressurize the plant or plant component. 14.3 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 63 7. When definitive resistance is felt, turn back the diaphragm until its bolt holes are in correct alignment with the bolt the guides. holes of the actuator. 8. Align the weir of compressor and diaphragm in parallel. www.gemu-group.com 63 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 64 7. Ensure even compression of the diaphragm (approx. 10 to 15%). ð Even compression is detected by an even outer bulge. 8. With the valve fully assembled, check the function and tightness. 9. Carry out initialisation. GEMÜ 639 eSyStep 64 / 71 www.gemu-group.com OPEN / CLOSE (Code AE)

  • Page 65: 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 65 / 71 GEMÜ 639 eSyStep OPEN / CLOSE (Code AE)
  • Page 66 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 67: 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 68: 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 69: 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 70: 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 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 05.2022 | 88668313...

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