GEM 202 User manual

GEMÜ 202
Electrically operated solenoid valve
Operating instructions
EN
further information
webcode: GW-202

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
www.gemu-group.com2 / 20GEMÜ 202

Contents
1 General information ............................................. 4
1.1 Information .................................................... 4
1.2 Symbols used ................................................ 4
1.3 Definition of terms ........................................ 4
1.4 Warning notes ............................................... 4
2 Safety information ............................................... 5
3 Product description ............................................. 5
3.1 Construction .................................................. 5
3.2 Description ..................................................... 5
3.3 Function ......................................................... 6
3.4 Product label ................................................. 6
4 Correct use .......................................................... 7
5 Order data ........................................................... 8
6 Technical data ..................................................... 9
7 Dimensions .......................................................... 10
8 Manufacturer's information .................................. 12
8.1 Delivery .......................................................... 12
8.2 Transport ....................................................... 12
8.3 Storage ........................................................... 12
8.4 Scope of delivery ........................................... 12
9 Installation in piping ............................................ 12
9.1 Installation with solvent cement sockets .... 12
9.2 Installation with threaded sockets ............... 12
10 Electrical connection ........................................... 13
11 Commissioning .................................................... 13
12 Operation ............................................................. 13
13 Inspection and maintenance ................................ 14
14 Troubleshooting .................................................. 15
15 Removal from piping ............................................ 16
16 Disposal .............................................................. 16
17 Returns ................................................................ 16
18 Declaration of Incorporation according to
2006/42/EC (Machinery Directive) ....................... 17
19 Declaration of conformity according to 2014/68/
EU (Pressure Equipment Directive) ...................... 18
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www.gemu-group.com4 / 20GEMÜ 202
1 General information
1 General information
1.1 Information
- The descriptions and instructions apply to the standard ver-
sions. For special versions not described in this document
the basic information contained herein applies in combina-
tion with any additional special documentation.
- Correct installation, operation, maintenance and repair work
ensure faultless operation of the product.
- Should there be any doubts or misunderstandings, the Ger-
man version is the authoritative document.
- Contact us at the address on the last page for staff training
information.
1.2 Symbols used
The following symbols are used in this document:
Symbol Meaning
Tasks to be performed
Response(s) to tasks
– Lists
1.3 Definition of terms
Working medium
The medium that flows through the GEMÜ product.
1.4 Warning notes
Wherever possible, warning notes are organised according to
the following scheme:
SIGNAL WORD
Type and source of the danger
Possible
symbol for the
specific
danger
Possible consequences of non-observance.
Measures for avoiding danger.
Warning notes are always marked with a signal word and
sometimes also with a symbol for the specific danger.
The following signal words and danger levels are used:
DANGER
Imminent danger!
▶Non-observance can cause death or
severe injury.
WARNING
Potentially dangerous situation!
▶Non-observance can cause death or
severe injury.
CAUTION
Potentially dangerous situation!
▶Non-observance can cause moderate
to light injury.
NOTICE
Potentially dangerous situation!
▶Non-observance can cause damage to
property.
The following symbols for the specific dangers can be used
within a warning note:
Symbol Meaning
Danger of explosion
Hot plant components!
Risk of electric shock

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2 Safety information
The safety information in this document refers only to an indi-
vidual product. Potentially dangerous conditions can arise in
combination with other plant components, which need to be
considered on the basis of a risk analysis. The operator is re-
sponsible for the production of the risk analysis and for com-
pliance with the resulting precautionary measures and re-
gional safety regulations.
The document contains fundamental safety information that
must be observed during commissioning, operation and main-
tenance. Non-compliance with these instructions may cause:
- Personal hazard due to electrical, mechanical and chemical
effects.
- Hazard to nearby equipment.
- Failure of important functions.
- Hazard to the environment due to the leakage of dangerous
materials.
The safety information does not take into account:
- Unexpected incidents and events, which may occur during
installation, operation and maintenance.
- Local safety regulations which must be adhered to by the
operator and by any additional installation personnel.
Prior to commissioning:
1. Transport and store the product correctly.
2. Do not paint the bolts and plastic parts of the product.
3. Carry out installation and commissioning using trained
personnel.
4. Provide adequate training for installation and operating
personnel.
5. Ensure that the contents of the document have been fully
understood by the responsible personnel.
6. Define the areas of responsibility.
7. Observe the safety data sheets.
8. Observe the safety regulations for the media used.
During operation:
9. Keep this document available at the place of use.
10. Observe the safety information.
11. Operate the product in accordance with this document.
12. Operate the product in accordance with the specifications.
13. Maintain the product correctly.
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.
3 Product description
3.1 Construction
2
4
1
3
Item Name Materials
1 Plug PA
2 Coil housing PP
3 Union of valve housing PVC-U, grey or PVDF
4 Valve body PVC-U, grey or PVDF
Seal materials FPM, PTFE or EPDM
3.2 Description
The GEMÜ 202 directly controlled 2/2-way solenoid valve has
a completely plastic encapsulated coil. The armature is
sealed by a bellows made of PTFE backed by an additional
safety diaphragm. The valve body is available in various ma-
terials and with a straight through or angle valve body design.
3 Product description

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3 Product description
3.3 Function
The GEMÜ 202 directly controlled 2/2-way plastic solenoid
valve is designed for controlling media.
When the valve is closed the medium flows into the valve
body and presses onto the piston. The valve remains closed.
Observe the permissible operating pressure.
Fig.1: Valve CLOSED
CAUTION
Operating pressure too high
▶Damage to the solenoid / destruction of the solenoid.
NOTICE
Operating pressure too high
▶The valve cannot be opened electromagnetically if the op-
erating pressure is too high.
When voltage is applied the solenoid in the valve actuator is
activated and lifts the armature. This opens the valve outlet.
Fig.2: Valve OPEN
3.4 Product label
The product label is located on the actuator. Product label
data (example):
- XXXXXXXX|YYYY
Design in accordance with order data
Device-specific data
Year of manufacture
Item number Traceability number Consecutive number
The month of manufacture is encoded in the traceability num-
ber and can be obtained from GEMÜ. The product was manu-
factured in Germany.
The operating pressure stated on the product label applies to
a media temperature of 20 °C. The product can be used up to
the maximum stated media temperature. You can find the
pressure/temperature correlation in the technical data.

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4 Correct use
DANGER
Danger of explosion
▶Risk of severe injury or death.
●Only versions that have been approved
according to their technical data may
be used in potentially explosive envir-
onments.
WARNING
Improper use of the product
▶Risk of severe injury or death.
▶Manufacturer liability and guarantee will be void.
●Only use the product in accordance with the operating
conditions specified in the contract documentation and in
this document.
The product is designed for installation in piping systems and
for controlling a working medium.
1. Use the product in accordance with the technical data.
2. Protect the product from direct weathering.
4 Correct use

5 Order data
The order data provide an overview of standard configurations.
Please check the availability before ordering. Other configurations available on request.
Order codes
1 Type Code
Solenoid valve, directly controlled 202
2 DN Code
DN 10 10
DN 15 15
3 Body configuration Code
2/2-way body D
Angle valve body E
4 Connection type Code
Threaded socket DIN ISO 228 1
Solvent cement socket DIN 2
5 Valve body material Code
PVC-U, grey 1
PVDF 20
6 Seal material Code
FPM 4
PTFE 5
6 Seal material Code
EPDM 14
7 Control function Code
Normally closed (NC) 1
8 Voltage Code
12 V 12
24 V 24
120 V 120
230 V 230
9 Frequency Code
DC DC
50 - 60 Hz 50/60
10 Special specification Code
UL approval U
Without
11 CONEXO Code
Integrated RFID chip for electronic identification and
traceability
C
Order example
Ordering option Code Description
1 Type 202 Solenoid valve, directly controlled
2 DN 10 DN 10
3 Body configuration D 2/2-way body
4 Connection type 1 Threaded socket DIN ISO 228
5 Valve body material 1 PVC-U, grey
6 Seal material 4 FPM
7 Control function 1 Normally closed (NC)
8 Voltage 230 230 V
9 Frequency 50/60 50 - 60 Hz
10 Special specification Without
11 CONEXO C Integrated RFID chip for electronic identification and traceability
5 Order data
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6 Technical data
6.1 Medium
Working medium: Corrosive, inert, gaseous and liquid media which have no negative impact on the physical and
chemical properties of the body and seal material.
6.2 Temperature
Media temperature: PVC-U, grey (code 1): 10 to 60 °C
PVDF (code 20): -20 to 100 °C
Ambient temperature: 10 — 40 °C
Storage temperature: 0 — 40 °C
6.3 Pressure
Operating pressure: DN 10: 0 to 2.0 bar
DN 15: 0 to 1.0 bar
Kv values: DN 10: 1.70 m³/h
DN 15: 2.30 m³/h
Leakage rate: Seat seal Standard Test procedure Leakage rate Test medium
EPDM, FKM, PTFE DIN EN 12266-1 P12 A Air
6.4 Product compliance
Approvals: UL approval, UR (recognized) Y10Z2
Only for 24 V 50/60 Hz, 230 V 50/60 Hz, 12 V DC and 24 V DC
Pressure Equipment Dir-
ective:
2014/68/EU
Low Voltage
Directive:
2014/35/EU
EMC Directive: 2014/30/EU
Technical standards used:
EN 55011:1991 (150 kHz to 30 MHz)
EN 55014:1993 (148.5 kHz to 30 MHz)
6.5 Mechanical data
Protection class: IP 65
Weight: 0.21 kg
Cable gland: PG 11
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6 Technical data

6.6 Electrical data
Power consumption: Pull in / Hold in AC and DC voltage: 14.0 W / 15.25 W (with UL approval)
Permissible voltage toler-
ance:
±10 % to VDE 0580
Duty cycle: Continuous duty
Wiring note: Special wiring on request. When using electronic switches and additional wiring, carefully design
out any potential residual currents upon installation.
Installation note: Please note: A plug with an integrated bridge rectifier must be used for the AC design (provided in
the scope of delivery).
7 Dimensions
7.1 Actuator dimensions
ø 68
A = 60 (DC) / 67 (AC)
123
A
Dimensions in mm
7.2 Body dimensions
7.2.1 Threaded socket (code 1)
ø 68 16
16
ø 68
G
16
G
G
15
15
DN 10: G = G3/8
DN 15: G = G1/2
Dimensions in mm
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7 Dimensions

7.2.2 Solvent cement socket (code 2)
ø68 16
16
ø68
ød
16
ød
15
15
ød
DN 10: ød = 16
DN 15: ød = 20
Dimensions in mm
7.3 Mounting dimensions
M5 (9 mm depth)
40
Dimensions in mm
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7 Dimensions

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8 Manufacturer's information
8 Manufacturer's information
8.1 Delivery
●Check that all parts are present and check for any damage
immediately upon receipt.
The product's performance is tested at the factory. The scope
of delivery is apparent from the dispatch documents and the
design from the order number.
8.2 Transport
1. Only transport the product by suitable means. Do not drop.
Handle carefully.
2. After the installation dispose of transport packaging ma-
terial according to relevant local or national disposal regu-
lations / environmental protection laws.
8.3 Storage
1. Store the product free from dust and moisture in its ori-
ginal packaging.
2. Avoid UV rays and direct sunlight.
3. Do not exceed the maximum storage temperature (see
chapter "Technical data").
4. Do not store solvents, chemicals, acids, fuels or similar
fluids in the same room as GEMÜ products and their spare
parts.
8.4 Scope of delivery
The following is included in the scope of delivery:
- Solenoid valve with solenoid coil
- Plug
- Installation, operating and maintenance instructions
9 Installation in piping
WARNING
The equipment is subject to pressure!
▶Risk of severe injury or death.
●Depressurize the plant.
●Completely drain the plant.
CAUTION
Hot plant components!
▶Risk of burns.
●Only work on plant that has cooled
down.
CAUTION
Operating pressure too high or working medium temperat-
ure too high
▶Damage to the valve body
●Only install the solenoid valve in aligned pipes in order to
avoid stresses in the valve body.
●Do not exceed the permissible operating pressure.
●Do not exceed the permissible temperature of the work-
ing medium.
9.1 Installation with solvent cement sockets
CAUTION
Wrong solvent cement
▶Valve body will be damaged.
●Only use solvent cement suitable for the valve body.
NOTICE
▶The solvent cement is not included in the scope of deliv-
ery.
●Only use suitable solvent cement!
1. Apply solvent cement inside the valve body socket con-
nections and on the piping as specified by the solvent ce-
ment manufacturer.
2. Solvent cement the valve body to the piping.
9.2 Installation with threaded sockets
NOTICE
Thread sealant
▶The thread sealant is not included in the scope of deliv-
ery.
●Only use appropriate thread sealant.
●Screw the threaded connections into the piping in accord-
ance with valid standards.

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10 Electrical connection
DANGER
Risk of electric shock
▶Risk of injury or death (if operating
voltage is higher than safe extra low
voltage).
▶Electric shock can cause severe burns
and fatal injury.
●Work on electrical connections only by
qualified trained personnel.
●Disconnect the cable from the power
supply before making the electrical
connection.
●Connect the protective earth con-
ductor.
CAUTION
AC voltage
▶Solenoid valve will be destroyed by wrong plug.
●Solenoid valves used with AC voltage may only be oper-
ated with a plug with a built-in rectifier.
1
2
3
4
1. Insert the cable through the locking screw 1, the pressure
ring 2, the seal 3 and the housing of the plug 4.
12
Supply voltage
Item Name
1 Supply voltage
2 Supply voltage
Protective earth conductor (PE)
2. Connect the cable to the relevant terminals on the terminal
block.
3. Push the terminal block into the housing of the plug (acc.
to DIN EN 175301-803, previously DIN 43650) until it aud-
ibly clicks in position.
4. Ensure that the cable is not caught.
5. Tighten the locking screw on the plug.
1234
6. Push the plug 2 and the gasket 3 onto the valve actuator
4.
7. Tighten the fixing screw 1 with a torque of approx. 0.6 Nm.
NOTICE
▶If the torque is too high the thread may be stripped.
11 Commissioning
CAUTION
Medium flowing out
▶Danger from medium flowing out.
●Before commissioning make sure that there is no danger
from medium flowing out.
●Before commissioning check the tightness of the media
connections.
NOTICE
Operating pressure too high
▶The valve cannot be opened electromagnetically if the op-
erating pressure is too high.
CAUTION
Foreign matter
▶Damage to the valves.
●If the plant is new and after repairs, rinse the piping sys-
tem with the valves fully open.
ðThe plant operator is responsible for selecting the clean-
ing material and performing the procedure.
1. Make sure that the operating voltage corresponds with the
permissible valve voltage.
2. Make sure that the unit is installed properly.
3. Check the function of the solenoid valve.
4. Check the tightness of the media connections and the
solenoid valve itself.
12 Operation
During normal operation there is no need for adjustments at
the valve.
12 Operation

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13 Inspection and maintenance
13 Inspection and maintenance
WARNING
The equipment is subject to pressure!
▶Risk of severe injury or death.
●Depressurize the plant.
●Completely drain the plant.
CAUTION
Use of incorrect spare parts!
▶Damage to the GEMÜ product.
▶Manufacturer liability and guarantee will be void.
●Use only genuine parts from GEMÜ.
CAUTION
Hot plant components!
▶Risk of burns.
●Only work on plant that has cooled
down.
NOTICE
Exceptional maintenance work!
▶Damage to the GEMÜ product.
●Any maintenance work and repairs not described in these
operating instructions must not be performed without
consulting the manufacturer first.
The operator must carry out regular visual examination of the
GEMÜ products depending on the operating conditions and
the potential danger in order to prevent leakage and damage.
The product also must be disassembled and checked for
wear in the corresponding intervals.
1. Have servicing and maintenance work performed by
trained personnel.
2. Wear appropriate protective gear as specified in plant op-
erator's guidelines.
3. Shut off plant or plant component.
4. Secure plant or plant component against recommission-
ing.
5. Depressurize the plant or plant component.
6. Actuate GEMÜ products which are always in the same po-
sition four times a year.
13.1 Cleaning the product
CAUTION
Foreign matter
▶Damage to the valves.
●If the plant is new and after repairs, rinse the piping sys-
tem with the valves fully open.
ðThe plant operator is responsible for selecting the clean-
ing material and performing the procedure.
- Clean the product with a damp cloth.
- Do not clean the product with a high pressure cleaning
device.
13.2 Spare parts
Spare parts
Plugs GEMÜ 1220
GEMÜ 1221
Order number on request
1
2
546
3
Item Name
1 Screw
2 Plug
3 Terminal block
4 Pressure ring
5 Gasket
6 Cable entry

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14 Troubleshooting
Error Error cause Troubleshooting
No function No power supply Check power supply and connection with
product label
Solenoid coil faulty Replace solenoid valve
Plug wrongly connected Check connection of plug and correct if
necessary
Operating pressure too high Check operating pressure, reduce if ne-
cessary
Armature blocked Replace solenoid valve
Solenoid valve leaking Valve seat leaking Replace solenoid valve
PTFE bellows leaking Replace solenoid valve
14 Troubleshooting

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15 Removal from piping
15 Removal from piping
WARNING
The equipment is subject to pressure!
▶Risk of severe injury or death.
●Depressurize the plant.
●Completely drain the plant.
CAUTION
Hot plant components!
▶Risk of burns.
●Only work on plant that has cooled
down.
1. Allow the plant to cool down.
2. Allow the plant to run empty.
3. Unscrew the electrical wiring.
4. Remove the product from the piping with appropriate
measures
16 Disposal
1. Pay attention to adhered residual material and gas diffu-
sion from penetrated media.
2. Dispose of all parts in accordance with the disposal regu-
lations/environmental protection laws.
17 Returns
Legal regulations for the protection of the environment and
personnel require that the completed and signed return deliv-
ery note is included with the dispatch documents. Returned
goods can be processed only when this note is completed. 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.
1. Clean the product.
2. Request a return delivery note from GEMÜ.
3. Complete the return delivery note.
4. Send the product with a completed return delivery note to
GEMÜ.

18 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, GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8
74653 Ingelfingen-Criesbach, Germany
declare that the following product
Make: GEMÜ Pneumatically operated filling valve
Serial number: from 29.12.2009
Project number: Types 52, 102, 202
Commercial name: GEMÜ 202
meets the following essential requirements of the Machinery Directive 2006/42/EC:
1.1.5., 1.2.1., 1.3., 1.3.2., 1.3.9., 1.5.1., 1.5.2., 1.5.5., 1.5.6., 1.5.7., 1.5.16., 1.6.3.
We also declare that the specific technical documentation has been compiled in accordance with part B of Annex VII.
The manufacturer or his authorised representative undertake to transmit, in response to a reasoned request by the national au-
thorities, relevant information on the partly completed machinery. This transmission takes place:
Electronically
Authorised documentation officer GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8
74653 Ingelfingen, Germany
This does not affect the industrial property rights!
Important note! The partly completed machinery may be put into service only if it was determined, where appropriate, that the
machinery into which the partly completed machinery is to be installed meets the provisions of this Directive.
2022-01-18
Joachim Brien
Head of Technical Department
GEMÜ 202www.gemu-group.com 17 / 20
18 Declaration of Incorporation according to 2006/42/EC (Machinery Directive)

19 Declaration of conformity according to 2014/68/EU (Pressure Equipment Directive)
EU Declaration of Conformity
in accordance with 2014/68/EU (Pressure Equipment Directive)
We, 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 Pressure Equipment Directive 2014/68/EU.
Description of the pressure equipment: GEMÜ 202
Notified body: TÜV Rheinland Industrie Service GmbH
Number: 0035
Certificate no.: 01 202 926/Q-02 0036
Conformity assessment procedure: Module H1
Technical standard used: 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.
2021-08-11
Joachim Brien
Head of Technical Department
www.gemu-group.com18 / 20GEMÜ 202
19 Declaration of conformity according to 2014/68/EU (Pressure Equipment Directive)

www.gemu-group.com19 / 20GEMÜ 202

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8, 74653 Ingelfingen-Criesbach, Germany
Phone [phone] · [email protected]
www.gemu-group.com
Subject to alteration
05.2022 | 88593450