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GEM R478 Tugela Operating Instructions Manual

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GEMÜ R478 Tugela
Motorized butterfly valve
Operating instructions
EN
further information
webcode: GW-R478

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Summary of Contents for GEM R478 Tugela

  • Page 1 GEMÜ R478 Tugela Motorized butterfly valve Operating instructions further information webcode: GW-R478...
  • 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 07.02.2024 GEMÜ R478 Tugela 2 / 56 www.gemu-group.com...

  • Page 3: Table Of Contents

    11.3 Installation of the standard version ..... 11.4 Installation of the ATEX version ....12 GEMÜ 9428 electrical connection ......13 GEMÜ 9468 electrical connection ......14 Electrical connection - Bernard, AUMA, J+J ..15 Commissioning ............ 16 Operation .............

  • Page 4: General Information

    – Lists 1.3 Definition of terms Moving components! Working medium The medium that flows through the GEMÜ product. Control function Corrosive chemicals! The possible actuation functions of the GEMÜ product. Control medium The medium whose increasing or decreasing pressure causes the GEMÜ...

  • Page 5: Safety Information

    Sealing washer Stainless steel turer first. Lower cap same as body In cases of uncertainty: Hexagon bolt Stainless steel 15. Consult the nearest GEMÜ sales office. Disc pin Steel Washer see order code (order data) Seat see order code (order...

  • Page 6: Additional Design Features

    • The smooth surface results in less abrasion of the shut-off seal and fewer abraded particles in the medium. 3.3 Description The GEMÜ R478 Tugela double-eccentric metal butterfly valve is operated by a motorized actuator. The butterfly valve is available in nominal sizes DN 50 to 300 and in standardized installation lengths API 609 category A (DIN 3202 K1).

  • Page 7: Product Label

    The month of manufacture is encoded in the traceability num- using the CONEXO pen RFID reader. The CONEXO app, which ber and can be obtained from GEMÜ. The product was manu- can be installed on mobile devices, not only facilitates and im- factured in Germany.

  • Page 8: Correct Use

    Index X is applied to the ATEX marking. The following special conditions must be complied with: - Temperature class depending on the temperature of the conveyed medium and the clock frequency - Not permissible as an end-of-line valve GEMÜ R478 Tugela 8 / 56 www.gemu-group.com...

  • Page 9: Order Data

    6 Order data 6 Order data 6.1 Butterfly valve with AUMA actuator Other configurations available on request. Please check the availability with GEMÜ before ordering. Order codes 1 Type Code 6 Body material Code Butterfly valve, double-eccentric, motorized, R478 1.0619 / ASTM A216 WCB, CDP coated 20 µm,...
  • Page 10 20 bar 5 Connection type PN 40 / flange EN 1092, face-to-face dimension FTF EN 558 series 6 Body material 1.4408 / ASTM A351 / CF8M 7 Disc material 1.4408 / ASTM A351 CF8M GEMÜ R478 Tugela 10 / 56 www.gemu-group.com...
  • Page 11 Class A (EN15714-2), Open/Close control, 75° to 105°, continuously adjustable, flasher unit for travel indication, heating, mechanical position indic- ator, KS, layer thickness 0, 140mm, RAL7037, manual override, IP68 14 Type of design Without 15 Special version Without 16 CONEXO Without www.gemu-group.com 11 / 56 GEMÜ R478 Tugela...

  • Page 12: Butterfly Valve With Bernard Actuator

    6 Order data 6.2 Butterfly valve with Bernard actuator Other configurations available on request. Please check the availability with GEMÜ before ordering. Order codes 1 Type Code 6 Body material Code Butterfly valve, double-eccentric, motorized, R478 1.0619 / ASTM A216 WCB, CDP coated 20 µm,...
  • Page 13 Actuator, motorized, operating time 35s, torque 500Nm, BERNARD, type AQ 2 additional limit switches, heating, manual override, aluminium housing, RAL1014, IP68 14 Type of design Without 15 Special version Without 16 CONEXO Without www.gemu-group.com 13 / 56 GEMÜ R478 Tugela...

  • Page 14: Technical Data

    These values apply to room temperature and air. The values may deviate for other media and other temperatures. Pressure/temperature diagram: PN25, PN40, Class 300 PN10, PN16, Class 150 -60 -40 -20 80 100 120 140 160 180 200 220 240 Temperature [°C] GEMÜ R478 Tugela 14 / 56 www.gemu-group.com...

  • Page 15: Product Conformity

    - Tightness or compliance with the specific leak rate within the sense of TA-Luft as well as VDI 2440 - Compliance with the requirements in accordance with DIN EN ISO 15848-1, Table C.2, Class BH www.gemu-group.com 15 / 56 GEMÜ R478 Tugela...

  • Page 16: Mechanical Data

    Code 6: PN 40 / flange EN 1092, face-to-face dimension FTF EN 558 series 109 Code D: ANSI B16.5, Class 150, face-to-face dimension FTF EN 558 series 108 Code M: ANSI B16.5, Class 300, face-to-face dimension FTF EN 558 series 109 GEMÜ R478 Tugela 16 / 56 www.gemu-group.com...

  • Page 17: Technical Data Of Actuator

    Code M: ANSI B16.5, Class 300, face-to-face dimension FTF EN 558 series 109 Flow direction: Indicated by an arrow on the product 8 Technical data of actuator Note: For technical data see manufacturer's original datasheets www.gemu-group.com 17 / 56 GEMÜ R478 Tugela...

  • Page 18: Dimensions

    4 x 22.0 4 x 18.0 20″ F14/F16 165.0 140.0 48.0 46.0 4 x 22.0 4 x 18.0 24″ F16/F25 254.0 165.0 48.0 46.0 8 x 19.0 4 x 22.0 Dimensions in mm GEMÜ R478 Tugela 18 / 56 www.gemu-group.com...
  • Page 19 8 x 19.0 4 x 22.0 20″ F16/F25 254.0 165.0 57.0 55.0 8 x 19.0 4 x 22.0 24″ F16/F25 254.0 165.0 57.0 55.0 8 x 19.0 4 x 22.0 Dimensions in mm www.gemu-group.com 19 / 56 GEMÜ R478 Tugela...

  • Page 20: Body

    337.5 480.0 17.0 101.5 347.0 363.5 18″ 502.0 353.5 533.0 17.0 114.0 394.0 414.0 20″ 524.0 376.5 584.0 17.0 127.0 434.0 458.0 24″ 625.0 453.5 692.0 22.0 154.0 524.0 550.0 Dimensions in mm GEMÜ R478 Tugela 20 / 56 www.gemu-group.com...
  • Page 21 365.5 470.0 17.0 133.5 347.0 363.5 18″ 531.0 382.5 560.0 17.0 149.0 394.0 414.0 20″ 593.0 426.5 585.0 22.0 162.0 434.0 456.5 24″ 645.0 498.0 692.0 22.0 181.0 524.0 550.0 Dimensions in mm www.gemu-group.com 21 / 56 GEMÜ R478 Tugela...
  • Page 22 525.0 11.25 30.0 550.0 11.25 M33 585.0 11.25 M36 18″ 565.0 585.0 600.0 610.0 20″ 620.0 650.0 660.0 670.0 24″ 725.0 770.0 770.0 795.0 Dimensions in mm n = number of bolt holes / bolts GEMÜ R478 Tugela 22 / 56 www.gemu-group.com...
  • Page 23 628.5 1¼” x 8UN 20″ 635.0 1⅛” x 8UN 685.5 1¼” x 8UN 24″ 749.5 1¼” x 8UN 812.8 1½” x 8UN Dimensions in mm n = number of bolt holes / bolts www.gemu-group.com 23 / 56 GEMÜ R478 Tugela...

  • Page 24: Gasket

    363.5 470.0 394.0 18″ 533.0 414.0 533.0 444.5 560.0 414.2 560.0 444.5 20″ 584.0 458.3 584.0 493.6 583.3 456.4 583.3 493.6 24″ 692.0 549.8 692.0 610.0 690.3 549.8 690.3 599.7 Dimensions in mm GEMÜ R478 Tugela 24 / 56 www.gemu-group.com...

  • Page 25: Manufacturer's Information

    When using the GEMÜ product as an ● 4. Do not store solvents, chemicals, acids, fuels or similar end-of-line valve, a mating flange must fluids in the same room as GEMÜ products and their spare be fitted. parts. CAUTION 11 Installation in piping Risk of crushing! ▶...

  • Page 26: Installation Location

    If media is contaminated and DN ≥ 300, install ▶ The product must be appropriate for the piping system GEMÜ R478 horizontally, so that the lower edge of the disc operating conditions (medium, medium concentration, opens in-line with flow direction.

  • Page 27: Installation Of The Standard Version

    3. Test the resistance between the earthing cable and actu- 12. Insert bolts 4 in all holes in the flange. ator shaft (value <106 Ω, typical value <5 Ω). www.gemu-group.com 27 / 56 GEMÜ R478 Tugela...

  • Page 28: Gemü 9428 Electrical Connection

    12 GEMÜ 9428 electrical connection 12 GEMÜ 9428 electrical connection DANGER Risk of electric shock! ▶ Risk of injury or death (if operating voltage is higher than safe extra low voltage). ▶ Adjustments are made with the actu- ator cover removed.
  • Page 29 12 GEMÜ 9428 electrical connection 12.1 Connection/wiring diagram 12.1.1 ON/OFF actuator (code A0) 12 V AC (code B4) / 24 V AC (code C4) Assignment of the terminal strips Item Description L1, supply voltage N, supply voltage L1, change-over (OPEN/CLOSED)
  • Page 30 12 GEMÜ 9428 electrical connection Electrical connection Plug assignment UV Description Uv+, direction of travel CLOSED Uv-, direction of travel CLOSED Uv+, direction of travel OPEN Uv-, direction of travel OPEN n.c. n.c. PE, protective earth conductor Connection diagram External...
  • Page 31 12 GEMÜ 9428 electrical connection Plug assignment X1 Description Uv+, direction of travel CLOSED Uv-, direction of travel CLOSED Uv+, direction of travel OPEN Uv-, direction of travel OPEN n.c. n.c. PE, protective earth conductor Connection diagram External wiring CLOSED-0-OPEN...
  • Page 32 12 GEMÜ 9428 electrical connection Description n.c. PE, protective earth conductor Preferred direction -OPEN- when all signals are present Connection diagram External wiring L1 N Actuator Direction of travel CLOSED OPEN 12 V DC (code B1) / 24 V DC (code C1) / K-no. 6410...
  • Page 33 12 GEMÜ 9428 electrical connection Connection diagram (Actuator) Motor Actuator Motor Actuator (Actuator) Actuator CLOSED Direction of travel CLOSED OPEN Direction of travel OPEN 12 V DC (code B1) / 24 V DC (code C1) Assignment of the terminal strips...
  • Page 34 12 GEMÜ 9428 electrical connection 12 V DC (code B1) / 24 V DC (code C1) / K-no. 6410 NOTICE Parallel operation ▶ Parallel operation only possible with K-no. 6410. Assignment of the terminal strips Item Description Uv+, direction of travel CLOSED...
  • Page 35 12 GEMÜ 9428 electrical connection 12.1.2 ON/OFF actuator with 2 potential-free limit switches (code AE) 12 V DC (code B1) / 24 V DC (code C1) Position of the connectors Actuator version 3006, 3015 S1/S2 Electrical connection Plug assignment UV...
  • Page 36 12 GEMÜ 9428 electrical connection 12 V DC (code B1) / 24 V DC (code C1) Position of the connectors Actuator version Actuator version 3035, 3055 1006, 1015 S1/S2 UV Electrical connection Plug assignment X1, UV Plug assignment X2, S1/S2...
  • Page 37 12 GEMÜ 9428 electrical connection 12 V AC (code B4) / 24 V AC (code C4) Position of the connectors Actuator version 2015 Actuator version 1006 S1/S2 UV S1/S2 Electrical connection Plug assignment UV Plug assignment S1/S2 Description Description L1, supply voltage...
  • Page 38 12 GEMÜ 9428 electrical connection 12 V DC (code B1) / 24 V DC (code C1) / K-no. 6722 Position of the connectors Electrical connection Plug assignment X1 Plug assignment X2 Description Description Uv+, direction of travel CLOSED Change-over contact limit switch CLOSED...
  • Page 39 12 GEMÜ 9428 electrical connection 12 V AC (code B4) / 24 V AC (code C4) / K-no. 6722 Position of the connectors Electrical connection Plug assignment X1 Plug assignment X2 Description Description L1, supply voltage Change-over contact limit switch CLOSED...

  • Page 40: Gemü 9468 Electrical Connection

    13 GEMÜ 9468 electrical connection 13 GEMÜ 9468 electrical connection DANGER Risk of electric shock! ▶ Risk of injury or death (if operating voltage is higher than safe extra low voltage). ▶ Adjustments are made with the actu- ator cover removed.
  • Page 41 13 GEMÜ 9468 electrical connection 13.1 Connection/wiring diagram 13.1.1 ON/OFF actuator with relay (code 00), 24 V DC (code C1) 13.1.1.1 Position of the connectors Actuator version 2070 Actuator version 4100, 4200 13.1.1.2 Electrical connection Plug assignment X1 Description L1 / Uv+, direction of travel CLOSED...
  • Page 42 13 GEMÜ 9468 electrical connection 13.1.2 ON/OFF actuator with 2 additional potential-free limit switches, with relay (code 0E), 24 V DC (code C1) 13.1.2.1 Position of the connectors Actuator version 2070 Actuator version 4100, 4200 13.1.2.2 Electrical connection Plug assignment X1...
  • Page 43 13 GEMÜ 9468 electrical connection 13.1.3 ON/OFF actuator with potentiometer output, with relay (code 0P), 24 V DC (code C1) 13.1.3.1 Position of the connectors Actuator version 2070 Actuator version 4100, 4200 13.1.3.2 Electrical connection Plug assignment X1 Plug assignment X2...

  • Page 44: Electrical Connection - Bernard, Auma, J+J

    ● maximum permitted pressures caused by pressure surges (water hammer). CAUTION Use as end-of-line valve! ▶ Damage to the GEMÜ product. When using the GEMÜ product as an ● end-of-line valve, a mating flange must be fitted. CLOSED OPEN CAUTION Cleaning agent! ▶...
  • Page 45 ð Limit switches for signal and motor are already preset. 1 = CLOSED Actuator versions 1006, 1015, 2006, 2015 2 = CLOSED emergency OPEN operation CLOSED 1 = OPEN Actuator version 3035 www.gemu-group.com 45 / 56 GEMÜ R478 Tugela...
  • Page 46 16 Operation The GEMÜ 9428 motorized actuator is delivered in open posi- tion. The following drawings differ depending on the actuator ver- sion! 1. Disconnect the plant from power supply and secure against recommissioning. 8. Put on cover of actuator 3.

  • Page 47: Operation - Gemü 9468

    Anticlockwise: Open 16.2.3 Setting the end positions The GEMÜ 9468 motorized actuator is delivered in its open position. The "OPEN" and "CLOSED" end positions are set using the limit switch 4. These are actuated using the lever 9 and can be adjusted by undoing the two screws (see chapter "Product...

  • Page 48: Operation - Third-Party Actuators

    Always disconnect the product from ● power supply! Therefore, have all work performed ● only by qualified electricians. 16.3 Operation - Third-party actuators For more detailed information on third-party actuators, refer to the manufacturers' documentation GEMÜ R478 Tugela 48 / 56 www.gemu-group.com...

  • Page 49: Troubleshooting

    Check the actuator for potential damage, replace the actuator if necessary Valve body damaged Check valve body for potential damage, replace valve body if necessary Unions loose Tighten unions Incorrect assembly Check actuator mounting on the valve body www.gemu-group.com 49 / 56 GEMÜ R478 Tugela...

  • Page 50: Inspection And Maintenance

    WARNING CAUTION Corrosive chemicals! Use of incorrect spare parts! ▶ Risk of caustic burns ▶ Damage to the GEMÜ product Wear appropriate protective gear. ▶ Manufacturer liability and guarantee will be void ● Completely drain the plant. Use only genuine parts from GEMÜ.
  • Page 51 19 Spare parts 19.1 Ordering spare parts CAUTION Use of incorrect spare parts! ▶ Damage to the GEMÜ product ▶ Manufacturer liability and guarantee will be void Use only genuine parts from GEMÜ. ● When ordering spare parts, please provide the following information: 1.
  • Page 52 PN10, 16, Item 20, 6 5T part liner 25, 40, TFM 1600 R470 CL150, CL300 88728139 R470200SLN Wearing PN10, 16, Item 20, 6 5T part liner 25, 40, TFM 1600 R470 CL150, CL300 GEMÜ R478 Tugela 52 / 56 www.gemu-group.com...
  • Page 53 If no return delivery note is included with the product, GEMÜ cannot process credits or repair work but will dispose of the goods at the operator's expense.
  • Page 54 23 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 We, the company GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Strasse 6–8 74653 Ingelfingen-Criesbach, Germany declare that the following product Make:...
  • Page 55 DN250–DN600 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 56 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 02.2024 | 88742761...

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