GEM 225 DN 10 User manual

GEMÜ 225
Electrically operated solenoid valve
Operating instructions
EN
further information
webcode: GW-225

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
18.02.2021
www.gemu-group.com2 / 24GEMÜ 225

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
4 Correct use ............................................................... 6
5 Order data ................................................................. 7
6 Technical data .......................................................... 8
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 solvent cement spigots .......... 12
9.3 Installation with threaded sockets .................... 12
9.4 Installation with union ends .............................. 12
10 Electrical connection ................................................. 13
11 Commissioning ......................................................... 14
12 Operation .................................................................. 15
13 Inspection and maintenance ...................................... 15
14 Troubleshooting ........................................................ 17
15 Removal from piping ................................................. 18
16 Disposal .................................................................... 18
17 Returns ..................................................................... 18
18 Declaration of Incorporation according to 2006/42/
EC (Machinery Directive) ........................................... 19
19 Declaration of conformity according to 2014/68/EU
(Pressure Equipment Directive) ................................. 20
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1 General information
1 General information
1.1 Information
•The descriptions and instructions apply to the standard
versions. For special versions not described in this docu-
ment the basic information contained herein applies in
combination 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 in-
dividual 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
responsible for the production of the risk analysis and for
compliance with the resulting precautionary measures and
regional safety regulations.
The document contains fundamental safety information that
must be observed during commissioning, operation and
maintenance. 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 specifica-
tions.
13. Maintain the product correctly.
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.
3 Product description
3.1 Construction
4
5
1
2
3
Item Name Materials
1 Plug PA
2 Optical position
indicator
PVC
3 Manual override PBT
4 Valve housing PBT
5 Valve body PVC-U, grey
Seal materials FPM or EPDM
3.2 Description
The GEMÜ 225 servo assisted 2/2-way plastic solenoid valve
has a high performance coil. The armature is sealed by a bel-
lows made of PTFE backed by an additional safety dia-
phragm. The plug has a rectifier for use with an AC supply. A
manual override and an optical position indicator are integ-
rated as standard.
3.3 Function
The GEMÜ 225 2/2-way servo assisted solenoid valve has a
plastic valve body. The flow direction is fixed and indicated
by an arrow on the valve body. A minimum pressure differen-
tial is required for the operation of the solenoid valve.
3 Product description

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4 Correct use
3.3.1 Valve closed
3
1
2
Fig.1: Valve closed
The compression spring closes the pilot seat 1. The dia-
phragm is pushed down onto the main valve seat 2. The me-
dium flows through the control aperture 3 into the control
chamber above the diaphragm and thus increases the clos-
ing force.
3.3.2 Valve open
45
Fig.2: Valve open
After applying a switching voltage the pilot spool 4 is ener-
gised. The pressure of the medium from the control chamber
reduces towards the valve outlet 5 through the open pilot
seat.
2
Fig.3: Valve open
More medium flows away from the control chamber through
the pilot seat than can flow in through the control aperture.
The differential pressure produced lifts the diaphragm thus
opening the main valve seat 2.
4 Correct use
DANGER
Danger of explosion
▶Risk of severe injury or death.
●Only versions that have been ap-
proved according to their technical
data may be used in potentially ex-
plosive environments.
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.

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, servo assisted 225
2 DN Code
DN 15 15
DN 20 20
DN 25 25
DN 32 32
DN 40 40
DN 50 50
3 Body configuration Code
2/2-way body D
4 Connection type Code
Spigot DIN 0
Union end with DIN insert (socket) 7
Spigot - inch 30
5 Valve body material Code
PVC-U, grey 1
6 Seal material Code
FPM 4
EPDM 14
7 Control function Code
Normally closed (NC) 1
8 Voltage Code
24 V 24
120 V 120
230 V 230
9 Frequency Code
DC DC
50 - 60 Hz 50/60
Order example
Ordering option Code Description
1 Type 225 Solenoid valve, servo assisted
2 DN 15 DN 15
3 Body configuration D 2/2-way body
4 Connection type 7 Union end with DIN insert (socket)
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
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: -4 — to 140 °F
Ambient temperature: 50 — 104 °F
Storage temperature: 32 — 104 °F
6.3 Product compliance
Machinery Directive: 2006/42/EC
Low Voltage
Directive:
2014/35/EU
EMC Directive: 2014/30/EU
Pressure Equipment Dir-
ective:
2014/68/EU
Technical standards used:
EN 55011:1991 (150 kHz to 30 MHz)
EN 55014:1993 (148.5 kHz to 30 MHz)
6.4 Mechanical data
Protection class: IP 65
Weight: DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50
0.85 0.9 0.9 2.8 2.8 3.6 3.6
Weights in kg
6.5 Pressure
Operating pressure: DN 15 DN 20 DN 25 DN 32 DN 40 DN 50
0.5 - 6.0 0.5 - 6.0 0 - 6.0 0 - 6.0 0 - 6.,0 0 - 6.0
The operating pressure applies to free discharge conditions. In closed systems Δp between the inlet and outlet
must be at least 0.1 bar.
Nominal size corresponds to valve seat diameter.
Kv values: DN 10 DN 15 DN 20 DN 25 DN 32 DN 40 DN 50
0.8 1.8 2.3 6.0 7.5 9.5 12.5
Kv values in m³/h
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6 Technical data

6.6 Electrical data
Power consumption: AC operation
Pull in DN 15 - 20 125 VA
DN 25 - 50 400 VA
Hold in DN 15 - 20 12 VA
DN 25 - 50 30 VA
DC operation
Pull in DN 15 - 20 35 W
DN 25 - 50 70 W
Hold in DN 15 - 20 7 W
DN 25 - 50 18 W
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: The DC solenoid is designed for unsmoothed voltages, e.g. as obtained from a bridge
rectifier.
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6 Technical data

7 Dimensions
7.1 Actuator
C
B
F
A
Plug rotatable 90°
DN 15 DN 20 DN 25 DN 32 DN 40 DN 50
A134 134 167 167 196 196
B100 100 128 128 157 157
C110 110 144 144 158 158
F52 52 88 88 110 110
Dimensions in inch
7.2 Body dimensions
7.2.1 Solvent cement spigot (code 0, 30)
H1
H
L
C
ød
Connection
Code 1)
DN 20 DN 25 DN 32 DN 40 DN 50
C19 22 26 31 39
ød 0 25 32 40 50 63
30 26.7 33.4 - - -
H50 72 72 85 85
H1 17 24 24 34 34
L144 154 174 194 224
Dimensions in inch
1) Connection type
Code 0: Spigot DIN
Code 30: Spigot - inch
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7 Dimensions

7.2.2 Union end with insert (code 7)
H
H1
G
LB LA
ød
øD
DN 15 DN 20
ø d 20 25
ø d G 1 G 1 1/4
H63 63
H1 30 30
øD 43 53
LA 108 108
LB 146 152
Dimensions in inch
7.3 Mounting dimensions
G
E
DN 15 DN 20 DN 25 DN 32 DN 40 DN 50
E40 40 44.5 44.5 44.5 44.5
GM5 M5 M8 M8 M8 M8
10 - 32 UNF 10 - 32 UNF 5/16” - 32 UNF - - -
Dimensions in inch
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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 dam-
age 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 reg-
ulations / 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 to high or working medium temperature
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 solvent cement spigots
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!
1 212
1. Apply solvent cement on the outside of the valve body
spigots 1 and on the inside of the piping connector 2 as
specified by the solvent cement manufacturer.
2. Connect the valve body to the piping.
9.3 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.
9.4 Installation with union ends
CAUTION
Do not use the solenoid coil as a lever
▶If the solenoid coil is used as a lever, the solenoid coil
and bush could be destroyed.
●Use only the spanner flats provided to screw the solen-
oid valve to the piping.

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CAUTION
Welding!
▶Damage to the valve actuator or valve body.
●Observe welding standards.
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. Push the union nut 1 over the piping 4. Connect the insert
5 with the piping 4 by cementing / welding.
12
2. Unscrew union nut 1 from valve body 2.
3
3. Reinsert O-ring 3 if necessary.
4. Screw the union nut 1 to the valve body 2 again.
5. Connect the other side of the valve body 2 to the piping 4,
too.
5 1 4
23
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 ter-
minal 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.
10 Electrical connection

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11 Commissioning
1
2
3
4
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
operating 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.
11.1 Optical position indicator
Valve closed Valve open

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12 Operation
12.1 Normal operation
During normal operation there is no need for adjustments at
the valve.
12.2 Emergency operation via manual override
NOTICE
Manual override
▶Only actuate the manual override in case of malfunction
(currentless)!
1
2
The solenoid valve is equipped with a manual override 1 and
an optical position indicator 2.
Open the valve via manual override (currentless)
1. Turn the lever upwards.
ðThe indicator of the optical position indicator moves away
from the valve actuator.
Close the valve via manual override (currentless)
2. Turn the lever downwards.
ðThe indicator of the optical position indicator moves to-
wards the valve actuator.
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
position four times a year.
13 Inspection and maintenance

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13 Inspection and maintenance
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
PTFE bush leaking Replace solenoid valve
Armature blocked Replace solenoid valve
Solenoid valve leaking Valve seat leaking Replace solenoid valve
Solenoid valve does not close Manual override engaged/actuated Check the position of the manual over-
ride and close if necessary
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
Serial number: from 29.12.2009
Project number: Type 225
Commercial name: GEMÜ 225
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
authorities, 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.
2018-03-28
Joachim Brien
Head of Technical Department
GEMÜ 225www.gemu-group.com 19 / 24
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: GEMU 225
Notified body: TÜV Rheinland Industrie Service GmbH
Number: 0035
Certificate no.: 01 202 926/Q-02 0036
Conformity assessment procedure: Module H
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.
2020-10-23
Joachim Brien
Head of Technical Department
www.gemu-group.com20 / 24GEMÜ 225
19 Declaration of conformity according to 2014/68/EU (Pressure Equipment Directive)