GEM 532Z User manual

GEMÜ 532Z
Pneumatically operated globe valve with two-stage actuator
Operating instructions
EN
further information
webcode: GW-532Z

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
23.11.2020
www.gemu-group.com2 / 28GEMÜ 532Z

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
3.3 Functional description ....................................... 6
3.4 Flow direction ..................................................... 6
4 GEMÜ CONEXO ......................................................... 6
5 Correct use ................................................................ 6
6 Order data ................................................................. 7
6.1 Order codes ........................................................ 7
6.2 Order example .................................................... 8
7 Technical data ........................................................... 9
7.1 Medium ............................................................... 9
7.2 Temperature ....................................................... 9
7.3 Pressure .............................................................. 9
7.4 Product compliance ........................................... 12
7.5 Mechanical data ................................................. 12
8 Dimensions ............................................................... 13
8.1 Actuator/Installation dimensions ..................... 13
8.2 Body dimensions ................................................ 14
9 Manufacturer's information ....................................... 17
9.1 Delivery ............................................................... 17
9.2 Packaging ........................................................... 17
9.3 Transport ............................................................ 17
9.4 Storage ............................................................... 17
10 Installation in piping .................................................. 17
10.1 Preparing for installation ................................... 17
10.2 Installation position ........................................... 18
10.3 Installation with butt weld spigots .................... 18
10.4 Installation with threaded sockets .................... 18
10.5 Installation with threaded spigots .................... 18
10.6 Installation with flanged connections ............... 18
11 Pneumatic connections ............................................. 19
11.1 Control function .................................................. 19
11.2 Connecting the control medium ........................ 19
12 Commissioning ......................................................... 20
13 Operation .................................................................. 20
13.1 Control function 1 ............................................... 20
14 Troubleshooting ........................................................ 21
15 Inspection and maintenance ...................................... 22
15.1 Spare parts ......................................................... 22
15.2 Removing the actuator ...................................... 22
15.3 Replacing the seals ............................................ 23
15.4 Mounting the actuator ....................................... 23
16 Removal from piping ................................................. 24
17 Disposal .................................................................... 24
18 Returns ..................................................................... 24
19 Declaration of Incorporation according to 2006/42/
EC (Machinery Directive) ........................................... 25
20 Declaration of conformity according to 2014/68/EU
(Pressure Equipment Directive) ................................. 26
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1 General information
1 General information
1.1 Information
– The descriptions and instructions apply to the stand-
ard versions. For special versions not described in this
document the basic information contained herein ap-
plies in combination with any additional special docu-
mentation.
– Correct installation, operation, maintenance and repair
work ensure faultless operation of the product.
– Should there be any doubts or misunderstandings, the
German 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!
Corrosive chemicals!
Hot plant components!
The actuator cover is under spring pressure!
Incorrect combination of actuator and valve
body!

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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 dan-
gerous 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 person-
nel.
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
2
3
4
1
A
B
5
Ite
m
Name Materials
A Actuator -
B Valve body 1.4408 investment casting, EN-
GJS-400-18-LT (GGG 40.3)
1 Stroke limiter 1.4305
2 Lock nut 1.4305
3 Piston Aluminium
4 Spindle 1.4305
5 Seat seal PTFE
3.2 Description
The GEMÜ 532Z 2/2-way globe valve has a low maintenance
aluminium two-stage double piston actuator and is pneu-
matically operated. The valve spindle is sealed by a self-ad-
justing gland packing providing low maintenance and reliable
valve spindle sealing even after a long service life. A wiper
ring fitted in front of the gland packing protects the seal
against contamination and damage.
3 Product description

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4 GEMÜ CONEXO
3.3 Functional description
1
2
3
4
1
2
3
4
R
V
R
V
When control pressure (connection V) is applied, the lower
actuator piston strokes 100%. The stroke of the upper part of
the actuator (connection R), however, can be steplessly lim-
ited from 0% to 100% by means of the stroke limiter (item 1)
and secured by the lock nut (item 2).
When a stroke limiter is used, the piston (item 3) moves
against the stroke limiter (item 1) and flow restriction is pos-
sible (connection R).
If the lower part of the actuator (connection V) is under con-
trol pressure, the valve fully opens, pushing the spindle (item
4) upwards through the upper piston.
3.4 Flow direction
The flow direction is indicated by an arrow on the valve body.
2/2-way body
under the seat
4 GEMÜ CONEXO
In the corresponding design with CONEXO, this product has
an RFID transponder for electronic recognition. The position
of the RFID transponder can be seen below. The CONEXO pen
helps read out information stored in the RFID transponders.
The CONEXO app or CONEXO portal is required to view this
information.
Installing the RFID transponder
RFID transponder
5 Correct use
DANGER
Danger of explosion!
▶Risk of severe injury or death.
●Do not use the product in potentially
explosive zones.
●Only use the product in potentially ex-
plosive zones confirmed in the declar-
ation of conformity.
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. Note the supplement acc. to ATEX
3. Please note the flow direction on the valve body.

6 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
Globe valve, pneumatically operated,
aluminium piston actuator
532
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
Flange EN 1092, PN 16, form B,
face-to-face dimension FTF EN 558 series 1, ISO
5752, basic series 1
8
Flange EN 1092, PN 25, form B,
face-to-face dimension FTF EN 558 series 1, ISO
5752, basic series 1
10
Flange EN 1092, PN 40, form B,
face-to-face dimension FTF EN 558 series 1, ISO
5752, basic series 1
11
Flange ANSI Class 150 RF,
face-to-face dimension FTF EN 558 series 1, ISO
5752, basic series 1
39
Flange JIS 20K,
face-to-face dimension FTF EN 558 series 10,
ASME/ANSI B16.10 table 1, column 16,
DN 50 drilled to JIS 10K
48
5 Valve body material Code
1.4408, investment casting 37
EN-GJS-400-18-LT (GGG 40.3) 90
6 Seat seal Code
PTFE 5
PTFE, glass fibre reinforced 5G
1.4404 10
7 Control function Code
Normally Closed (NC) 1
8 Actuator version Code
Two-stage actuator, actuator size 1 1Z
Two-stage actuator, actuator size 2 2Z
9 Type of design Code
For higher operating temperatures 2023
Spindle seal FPM-PTFE,
actuator components suitable for high ambient
temperatures
2017
Spindle seal PTFE-PTFE 2013
without
10 Special version Code
Rigid plug fixing,
special version for oxygen,
maximum medium temperature: 60°C,
media-wetted seal materials and auxiliary materi-
als with BAM testing
B
Rigid plug fixing C
without
11 CONEXO Code
without
Integrated RFID chip for electronic identification
and traceability
C
6 Order data
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Order example
Order option Code Description
1 Type 532 Globe valve, pneumatically operated,
aluminium piston actuator
2 DN 25 DN 25
3 Body configuration D 2/2-way body
4 Connection type 8 Flange EN 1092, PN 16, form B,
face-to-face dimension FTF EN 558 series 1, ISO 5752, basic series 1
5 Valve body material 90 EN-GJS-400-18-LT (GGG 40.3)
6 Seat seal 5 PTFE
7 Control function 1 Normally Closed (NC)
8 Actuator version 1Z Two-stage actuator, actuator size 1
9 Type of design without
10 Special version without
11 CONEXO without
6 Order data
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7 Technical data
7.1 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.
Control medium: Inert gases
Max. permissible viscos-
ity:
600 mm²/s (cSt)
Other versions for lower/higher temperatures and higher viscosities on request.
7.2 Temperature
Media temperature: Standard: -10 to 180 °C
Special version: -10* to 210 °C
only with ordering option Seat seal code 5G or 10 and
Design 2023
Control medium temper-
ature:
max. 60 °C
Ambient temperature: Standard: 0 to 60 °C
Special version: 0 to 130 °C
only with ordering option Type of design 2017
Storage temperature: 0 to 40 °C
7.3 Pressure
Operating pressure: DN Actuator version 1Z Actuator version 2Z
piston ø 70 mm piston ø 120 mm
15 25.0 -
20 20.0 25.0
25 10.0 25.0
32 7.0 16.0
40 4.5 15.0
50 - 10.0
Pressures in bar
Pressure rating: PN 16
PN 25
PN 40
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7 Technical data

Pressure/temperature
correlation: Connection
types
Code 1)
Materials
Code 2)
Max. allowable operating pressures in bar at temperature in °C
RT 100 150 200 250 300
8 37 16.0 16.0 14.5 13.4 12.7 11.8
10 25.0 25.0 22.7 21.0 19.8 18.5
11 40.0 40.0 36.3 33.7 31.8 29.7
39 19.0 16.0 14.8 13.6 12.0 10.2
8 90 16.0 16.0 15.5 14.7 13.9 11.2
39 17.2 16.0 14.8 13.9 12.1 10.2
All pressures are gauge pressures.
The valves may be used to -10 °C
RT = room temperature
1) Connection type
Code 8: Flange EN 1092, PN 16, form B, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic series
1
Code 10: Flange EN 1092, PN 25, form B, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic
series 1
Code 11: Flange EN 1092, PN 40, form B, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic
series 1
Code 39: Flange ANSI Class 150 RF, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic series 1
2) Valve body material
Code 37: 1.4408, investment casting
Code 90: EN-GJS-400-18-LT (GGG 40.3)
Control pressure: DN Actuator version 1Z Actuator version 2Z
piston ø 70 mm pistonø 120 mm
15 5.5 - 10.0 -
20 5.5 - 10.0 4.5 - 8.0
25 5.5 - 10.0 4.5 - 8.0
32 5.5 - 10.0 4.5 - 8.0
40 5.5 - 10.0 4.5 - 8.0
50 - 5.5 - 8.0
Pressures in bar
Kv values: DN Kv values
15 4.6
20 8.0
25 13.0
32 22.0
40 35.0
50 50.0
Kv values in m³/h
Filling volume: Actuator version Piston Filling volume
1Z Top 0.07 dm³
Bottom 0.10 dm³
2Z Top 0.51 dm³
Bottom 0.60 dm³
Leakage rate: Seat seal Standard Test procedure Leakage rate Test medium
Metal DIN EN 12266-1 P12 F Air
PTFE DIN EN 12266-1 P12 A Air
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7 Technical data