GEM 533 User manual

GEMÜ 533 eSyStep
Positioner (Code S0)
Motorized globe valve
Operating instructions
EN
further information
webcode: GW-533

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
30.10.2023
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Positioner (Code S0)

Contents
1 General information ............................................. 4
1.1 Information .................................................... 4
1.2 Symbols used ................................................ 4
1.3 LED symbols .................................................. 4
1.4 Definition of terms ........................................ 4
1.5 Warning notes ............................................... 4
2 Safety information ............................................... 4
3 Product description ............................................. 5
3.1 Construction .................................................. 5
3.2 LED displays .................................................. 6
3.3 Description ..................................................... 6
3.4 Function ......................................................... 6
4 GEMÜ CONEXO .................................................... 6
5 Correct use .......................................................... 6
6 Order data ........................................................... 8
7 Technical data ..................................................... 10
8 Electrical connection ........................................... 16
9 Dimensions .......................................................... 21
10 Manufacturer's information .................................. 25
10.1 Delivery .......................................................... 25
10.2 Packaging ...................................................... 25
10.3 Transport ....................................................... 25
10.4 Storage ........................................................... 25
11 Installation in piping ............................................ 25
11.1 Preparing for installation .............................. 25
11.2 Installation position ....................................... 26
11.3 Installation with flanged connection ............ 26
12 Specific data IO-Link (pin 6) ................................. 27
12.1 Operation on IO-Link ..................................... 27
12.2 Process data .................................................. 30
12.3 Parameter overview ...................................... 31
12.4 Parameter ...................................................... 35
12.5 Events ............................................................ 52
13 Operation ............................................................. 54
13.1 Initialization ................................................... 54
13.2 Manual override ............................................. 54
14 Inspection and maintenance ................................ 55
14.1 Spare parts .................................................... 55
14.2 Removing the actuator .................................. 55
14.3 Replacing the seals ....................................... 56
14.4 Mounting the actuator .................................. 56
15 Troubleshooting .................................................. 57
16 Removal from piping ............................................ 59
17 Disposal .............................................................. 59
18 Returns ................................................................ 59
19 EU Declaration of Incorporation according to the
EC Machinery Directive 2006/42/EC, Annex II B ... 60
20 EU Declaration of Conformity in accordance with
2014/68/EU (Pressure Equipment Directive) ........ 61
21 EU Declaration of Conformity in accordance with
2014/30/EU (EMC Directive) ................................ 62
22 EU Declaration of Conformity In accordance with
2011/65/EU (RoHS Directive) ............................... 63
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Positioner (Code S0)
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www.gemu-group.com4 / 64GEMÜ 533 eSyStep
Positioner (Code S0)
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 LED symbols
The following LED symbols are used in the documentation:
Symbol LED conditions
Off
Lit (on)
Flashing
1.4 Definition of terms
Working medium
The medium that flows through the GEMÜ product.
Diaphragm size
Uniform seat size of GEMÜ diaphragm valves for different
nominal sizes.
1.5 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!
Incorrect combination of actuator and valve
body!
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:

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Positioner (Code S0)
- 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
substances.
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
1
6
5
3
2
4
7
Item Name Materials
1 Optical position indic-
ator
PA 12
2 Manual override
3 Actuator top with LED
display
Reinforced polyamide
4 Actuator base Reinforced polyamide
5 Distance piece with
leak detection hole
6 Valve body 1.4408, EN-GJS-400-18-
LT (GGG 40.3)
7 Electrical connections
3 Product description

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Positioner (Code S0)
4 GEMÜ CONEXO
3.2 LED displays
3.2.1 Status LEDs
LED Colour Function
Standard Inversed 1)
Power/fault green green Operating indica-
tion/
communication
status
red red
Open orange green Process valve in
OPEN position
Error red red Error
Closed green orange Process valve in
CLOSED position
1) Inversed representation of the OPEN and CLOSED LEDs, ad-
justable via IO-Link
3.2.2 LED conditions
Status
process
valve
Power/
fault
Open Error Closed
OPEN posi-
tion
CLOSED po-
sition
Position un-
known
Initialization
Open and Closed flash
alternately
LED conditions
lit (on) flashes off
3.3 Description
The GEMÜ 533 is a motorized 2/2-way globe valve. The
eSyStep electric actuator is available as On/Off actuator or
with integrated positioner. The valve spindle is sealed by a
self-adjusting 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. An integral optical and
electrical position indicator is standard. The self-locking actu-
ator holds its position in a stable manner when idle and in the
event of power supply failure.
3.4 Function
The product controls or regulates (depending on version) a
flowing medium by being closed or opened by a motorized ac-
tuator.
The product is equipped as standard with a mechanical posi-
tion indicator as well as an electrical position and status indic-
ator.
4 GEMÜ CONEXO
Order with CONEXO
GEMÜ CONEXO must be ordered separately with the ordering
option "CONEXO" (see order data).
For electronic identification purposes, each replaceable com-
ponent contained in the product is equipped with an RFID chip
(1). Where you can find the RFID chip differs from product to
product.
1
1
Actuator RFID chip Valve body RFID chip
The CONEXO pen helps read out information stored in these
RFID chips. The CONEXO app or CONEXO portal is required to
view this information.
5 Correct use
DANGER
Danger of explosion!
▶Risk of death or severe injury
●Do not use the product in potentially
explosive zones.
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.

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Positioner (Code S0)
The product is not intended for use in potentially explosive
areas.
●Use the product in accordance with the technical data.
5 Correct use

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, electrically operated,
eSyStep
533
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 125/150 RF,
face-to-face dimension FTF EN 558 series 1, ISO 5752,
basic series 1,
length only for body configuration D
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
Investment casting material
1.4408, investment casting 37
SG iron material
EN-GJS-400-18-LT (GGG 40.3) 90
6 Seat seal Code
PTFE 5
PTFE, glass fibre reinforced 5G
1.4404 10
7 Voltage/frequency Code
24V DC C1
8 Control module Code
Positioner S0
Positioner, configured for emergency power supply
module (NC)
S5
Positioner, configured for emergency power supply
module (NO)
S6
9 Regulating cone Code
Without
Please find the number of the optional regulating cone
(R-No.) for the linear or equal-percentage modified
regulating cone in the Kv value table.
R….
10 Actuator version Code
Actuator size 0 0A
Actuator size 1 1A
11 Type of design Code
Without
Spindle seal PTFE-PTFE 2013
12 CONEXO Code
Without
Integrated RFID chip for electronic identification and
traceability
C
6 Order data
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Positioner (Code S0)

Order example
Ordering option Code Description
1 Type 533 Globe valve, electrically operated,
eSyStep
2 DN 20 DN 20
3 Body configuration D 2/2-way body
4 Connection type 10 Flange EN 1092, PN 25, form B,
face-to-face dimension FTF EN 558 series 1, ISO 5752, basic series 1
5 Valve body material 37 1.4408, investment casting
6 Seat seal 5 PTFE
7 Voltage/frequency C1 24V DC
8 Control module S0 Positioner
9 Regulating cone R…. Please find the number of the optional regulating cone (R-No.) for the
linear or equal-percentage modified regulating cone in the Kv value
table.
10 Actuator version 0A Actuator size 0
11 Type of design Without
12 CONEXO Without
6 Order data
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Positioner (Code S0)

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.
Max. permissible viscos-
ity:
600 mm²/s
Other versions for lower / higher temperatures and higher viscosities on request.
7.2 Temperature
Media temperature: -10 — 180 °C
Ambient temperature: 0 — 60 °C
* depending on version and/or operating parameters (see chapter Duty cycle and service life)
7.3 Pressure
Operating pressure: DN Actuator size 0 (code
0A)
Actuator size 1 (code
1A),
Open/Close valve (code
A0)
Actuator size 1 (code
1A),
control valve (code S0)
15 15 40 25
20 10 32 15
25 6 23 10
32 - 15 6.5
40 - 9 4
50 - 6 1
All pressures are gauge pressures.
For max. operating pressures the pressure / temperature correlation must be observed.
Higher operating pressures on request
Leakage rate: Control valve
Seat seal Standard Test procedure Leakage rate Test medium
Metal DIN EN 60534-4 1 IV Air
PTFE, FKM, EPDM DIN EN 60534-4 1 VI Air
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Positioner (Code S0)
7 Technical data

Pressure/temperature
correlation:
Connection
type
code 1)
Material
code 2)
Max. allowable operating pressures in bar at temperature in °C
RT 100 150 200
8 37 16.0 16.0 14.5 13.4
10 37 25.0 25.0 22.7 21.0
11 37 40.0 40.0 36.3 33.7
39 37 19.0 16.0 14.8 13.6
8 90 16.0 16.0 15.5 14.7
39 90 17.0 16.0 14.8 13.9
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 125/150 RF, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic
series 1, length only for body configuration D
2) Valve body material
Code 37: 1.4408, investment casting
Code 90: EN-GJS-400-18-LT (GGG 40.3)
Kv values: Standard regulating cone
DN Kv values Operating
pressure
Actuator ver-
sion
linear equal
percentage
15 4.0 15.0 0A RS480 RS500
25.0 1A RS481 RS501
20 6.3 10.0 0A RS482 RS502
15.0 1A RS483 RS503
25 10.0 6.0 0A RS484 RS504
10.0 1A RS485 RS505
32 16.0 6.5 1A RS486 RS506
40 25.0 4.0 1A RS488 RS508
50 40.0 1.0 1A RS490 RS510
Kv values in m³/h
Pressures in bar
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Positioner (Code S0)
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7 Technical data

Kv values: Standard regulating cone with reduced seat
DN Operating pressure [bar] Kv value [m³/
h]
Seat seal
code
R-Number
0A 1A Linear Equal-per-
centage
15 40.0 - 0.1 1) 10 RA105 RA310
40.0 - 0.16 1) 10 RB113 RA311
40.0 - 0.25 1) 10 RB114 RB309
40.0 - 0.4 1) 10 RB115 RB310
40.0 - 0.63 1) 10 RC109 RC309
40.0 - 1.0 1) 10 RC110 RC310
40.0 - 1.6 5, 5G RD109 RD309
30.0 - 2.5 5, 5G RE113 RE313
20 40.0 - 1.6 5, 5G RD110 RD310
40.0 - 2.5 5, 5G RE114 RE314
25.0 - 4.0 5, 5G RF116 RF316
25 35.0 - 2.5 5, 5G RE115 RE315
25.0 - 4.0 5, 5G RF117 RF317
15.0 - 6.3 5, 5G RG118 RG318
32 25.0 - 4.0 5, 5G RF118 RF318
15.0 - 6.3 5, 5G RG119 RG319
10.0 - 10.0 5, 5G RH113 RH313
40 15.0 - 6.3 5, 5G RG120 RG320
10.0 - 10.0 5, 5G RH114 RH314
6.0 - 16.0 5, 5G RJ109 RJ309
50
2)
10.0 - 10.0 5, 5G RH115 RH315
6.0 - 16.0 5, 5G RJ110 RJ310
- 6.5 25.0 5, 5G RK105 RK305
1) metal seated
2) only for connection type code 8, 39, 48
Kv values determined in accordance with DIN EN 60534. The Kv value specifications refer to the largest actu-
ator for the respective nominal size. The Kv values for other product configurations (e.g. other connections or
body materials) may differ.
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Positioner (Code S0)
7 Technical data

7.4 Product compliance
Machinery Directive: 2006/42/EC
Pressure Equipment Dir-
ective:
2014/68/EU
Food: Regulation (EC) No. 1935/2004*
Regulation (EC) No. 10/2011*
FDA*
* depending on version and / or operating parameters
EMC Directive: 2014/30/EU
RoHS Directive: 2011/65/EU
7.5 Mechanical data
Protection class: IP 65 acc. to EN 60529
Actuating speed: Max. 3 mm/s
Weight: Actuator
Actuator size 0 (code 0A) 0.95 kg
Actuator size 1 (code 1A) 1.88 kg
Valve body
DN Weight
15 2.2
20 3.0
25 3.7
32 5.3
40 6.3
50 8.4
Weights in kg
Mechanical environ-
mental conditions:
Class 4M8 acc. to EN 60721-3-4:1998
Vibration: 5g acc. to IEC 60068-2-6 Test Fc
Shock: 25g acc. to 60068-2-27 Test Ea
GEMÜ 533 eSyStep
Positioner (Code S0)
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7 Technical data

7.6 Actuator duty cycle and service life
Service life: Control operation - Class C according to EN 15714-2 (1,800,000 starts and 1200 starts per hour).
Open/Close duty - At least 500,000 switching cycles at room temperature and permissible duty
cycle.
Duty cycle: Control module Positioner (code S0, S5, S6), Open/Close duty
0 10 20 30 40 50 60 70
0
10
20
30
40
50
60
70
80
90
100
Duty cycle [%]
Ambient temperature [°C]
Globe valve DN 15 - 25 (code 0A)
Globe valve DN 15 - 50 (code 1A)
Control module positioner (code S0, S5, S6), control operation - class C acc. to EN 15714-2
- DN 15 - 25 (code 0A) up to 50 °C ambient temperature
- DN 15 - 50 (code 1A) up to 60 °C ambient temperature
NOTICE
▶The specified characteristics and values apply to the default setting.
▶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
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Positioner (Code S0)
7 Technical data

7.7 Electrical data
Supply voltage Uv: 24 V DC ± 10%
Rating: Actuator size 0 (code 0A) 20 W
Actuator size 1 (code 1A) 60 W
Operation: Stepper motor, self-locking
Reverse battery protec-
tion:
Yes
7.7.1 Analogue input signals – Control module Positioner (code S0, S5, S6)
7.7.1.1 Set value
Input signal: 0/4 - 20 mA; 0 - 10 V (function selectable via IO-Link)
Input type: passive
Input resistance: 250 Ω
Accuracy/linearity: ≤ ±0.3% of full flow
Temperature drift: ≤ ±0.1% / 10°K
Resolution: 12 bit
Reverse battery protec-
tion:
Yes (up to ± 24 V DC)
7.7.2 Digital input signals
Inputs: Function selectable via IO-Link (see table Overview of available functions – Input and output sig-
nals)
Input voltage: 24 V DC
Logic level "1": > 15.3 V DC
Logic level "0": < 5.8 V DC
Input current: typically < 0.5 mA
7.7.3 Analogue output signals – Control module Positioner (code S0, S5, S6)
7.7.3.1 Actual value
Output signal: 0/4 - 20 mA; 0 - 10 V (function selectable via IO-Link)
Output type: Active
Accuracy: ≤ ±1% of full flow
Temperature drift: ≤ ±0.1% / 10°K
Load resistor: ≤ 750 kΩ
Resolution: 12 bit
Short-circuit proof: Yes
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Positioner (Code S0)
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7 Technical data

7.7.4 Digital output signals
Outputs: Function selectable via IO-Link (see table Overview of available functions – Input and output sig-
nals)
Type of contact: Push-Pull
Switching voltage: Power supply Uv
Switching current: ≤ 140 mA
Short-circuit proof: Yes
7.7.5 Communication
Interface: IO-Link
Function: Parameterization/process data
Transmission rate: 38400 baud
Frame type in Operate: 2.V (eSyStep positioner, code S0, S5, S6),
PDout 3Byte; PDin 3 Byte; OnRequestData 2 Byte
Min. cycle time: 20 ms (eSyStep positioner, code S0, S5, S6)
Vendor-ID: 401
Device-ID: 1906801 (eSyStep positioner, code S0, S5, S6),
Product-ID: eSyStep Positioner (code S0, S5, S6)
ISDU support: Yes
SIO operation: Yes
IO-Link specification: V1.1
IODD files can be downloaded via https://ioddfinder.io-link.com/ or www.gemu-group.com.
7.7.6 Behaviour in the event of an error
Function: In the event of an error the valve moves to the error position.
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.
Error position: Closed, open or hold (adjustable via IO-Link).
8 Electrical connection
NOTICE
Appropriate cable socket/appropriate mating connector
▶The appropriate connectors are included for X1 and X2.
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8 Electrical connection

8.1 Position of the connectors
X1
X2
8.2 Electrical connection
8.2.1 Connection X1
13
2
654
7-pin plug, Binder, type 693
Pin Signal name
1 Uv, 24 V DC supply voltage
2 GND
3 Digital input 1
4 Digital input 2
5 Digital input/output
6 Digital output, IO-Link
7 n.c.
GEMÜ 533 eSyStep
Positioner (Code S0)
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8 Electrical connection

8.2.2 Connection X2 (only for positioner design)
1
4
3
2
5
5-pin M12 plug, A-coded
Pin Signal name
1 I+/U+, set value input
2 I-/U-, set value input
3 I+/U+, actual value output
4 I-/U-, actual value output
5 n.c.
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Positioner (Code S0)
8 Electrical connection

8.3 Overview of available functions – Input and output signals
NOTICE
▶The factory default setting "Configured for emergency power supply module" is reset to default settings when a reset is car-
ried out.
NOTICE
▶When the digital inputs for OPEN and CLOSE are activated simultaneously, the defined error position is approached.
Function Control module S0 Control module S5, S6
Default settings Factory default setting "Con-
figured for emergency power
supply module"
Digital input 1 Off/Open/Closed/Safe/On/Ini-
tialization
Initialization Initialization
Digital input 2 Off/Open/Closed/Safe/On/Ini-
tialization
Off Safe/On
Digital input/output Open/Closed/Error/Error and
warning/Initialization
Error Error
Digital output Open/Closed/Error/Error and
warning
Closed Closed
Analogue input 4–20mA/0–20mA/0–10V 4–20 mA 4–20 mA
Analogue output 4–20mA/0–20mA/0–10V 4–20 mA 4–20 mA
GEMÜ 533 eSyStep
Positioner (Code S0)
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8 Electrical connection

8.4 Connection diagram
X1
Device side Connections / customer
eSyStep
Uv 24 V DC
Uv GND Power supply
PLC
Digital input 1
Digital input 2
24 V DC
24 V DC
Digital input/output 24 V DC
Digital output / IO-Link 24 V DC
1
2
3
4
5
6
or
or
IO-Link master
CQ
Only with type S0, S5, S6 PLC
Set value (X)+
Set value (X)-
Actual value (Y)+
Actual value (Y)-
Analogue output
Default setting 4 -20mA
Adjustable 0-20mA / 0-10V
Analogue input
Default setting 4 -20mA
Adjustable 0-20mA / 0-10V
Only with type S0, S5, S6
7-pin plug
Binder, type 693
5-pin M12 plug
A-coded
1
2
3
4
X2
Switch
Consumer
Signal direction
Power supply
=
=
=
=
13
2
654
1
4
3
2
5
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Positioner (Code S0)
8 Electrical connection