GEM 543 eSyStep User manual

GEMÜ 543 eSyStep
OPEN / CLOSE (Code AE)
Motorized angle seat globe valve
Operating instructions
EN
further information
webcode: GW-543

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
13.12.2023
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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 ............................................... 5
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
6.1.12 Special version ................................. 9
7 Technical data ..................................................... 10
8 Electrical connection ........................................... 16
9 Dimensions .......................................................... 19
10 Manufacturer's information .................................. 34
10.1 Delivery .......................................................... 34
10.2 Packaging ...................................................... 34
10.3 Transport ....................................................... 34
10.4 Storage ........................................................... 34
11 Installation in piping ............................................ 34
11.1 Preparing for installation .............................. 34
11.2 Installation position ....................................... 35
11.3 Installation with butt weld spigots ............... 35
11.4 Installation with threaded sockets ............... 35
11.5 Installation with threaded spigots ................ 35
11.6 Installation with flanged connection ............ 35
11.7 Installation with clamp connections ............ 36
12 Specific data IO-Link (pin 6) ................................. 37
12.1 Operation on IO-Link ..................................... 37
12.2 Process data .................................................. 40
12.3 Parameter overview ...................................... 41
12.4 Parameter ...................................................... 45
12.5 Events ............................................................ 59
13 Operation ............................................................. 62
13.1 Initialization ................................................... 62
13.2 Manual override ............................................. 62
14 Inspection and maintenance ................................ 63
15 Troubleshooting .................................................. 65
16 Removal from piping ............................................ 67
17 Disposal .............................................................. 67
18 Returns ................................................................ 67
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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!

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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
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
7
6
4
3
5
2
Item Name Materials
1 Optical position indic-
ator
PA 12
2 Manual override
3 Actuator top with LED
display
Polyamide, 50% glass
fibre
4 Actuator base Polyamide, 50% glass
fibre
5 Electrical connection
6 Distance piece with
leak detection hole
1.4305 / 1.4408
7 Valve body 1.4408, 1.4435
3 Product description

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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 543 eSyStep is an electrically operated 2/2-way
angle seat globe valve. The eSyStep electric actuator is avail-
able 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 actuator holds its position in a
stable manner when idle and in the event of power supply fail-
ure.
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.
The CONEXO pen helps read out information stored in these
RFID chips. The CONEXO app or CONEXO portal is required to
view this information.
1
Actuator RFID chip
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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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
Angle seat globe valve, electrically operated,
eSyStep
543
2 DN Code
DN 6 6
DN 8 8
DN 10 10
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
Angle valve body E
4 Connection type Code
Spigot
Spigot DIN 0
Spigot DIN EN 10357 series B (2014 edition; formerly
DIN 11850 series 1)
16
Spigot EN 10357 series A/DIN 11866 series A
formerly DIN 11850 series 2
17
Spigot SMS 3008 37
Spigot ASME BPE/DIN EN 10357 series C (from 2022
edition)/DIN 11866 series C
59
Spigot ISO 1127/DIN EN 10357 series C (2014 edition)/
DIN 11866 series B
60
Threaded connection
Threaded socket DIN ISO 228 1
Threaded socket Rc ISO 7-1,
EN 10226-2, JIS B 0203, BS 21,
end-to-end dimension ETE DIN 3202-4 series M8
3C
Threaded socket NPT,
end-to-end dimension ETE DIN 3202-4 series M8
3D
Threaded spigot DIN ISO 228 9
Flange
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 25, form B 13
Flange ANSI Class 150 RF 47
Clamp
Clamp ASME BPE,
face-to-face dimension FTF ASME BPE
80
Clamp DIN 32676 series B,
face-to-face dimension FTF EN 558 series 1
82
4 Connection type Code
Clamp DIN 32676 series A,
face-to-face dimension FTF EN 558 series 1
86
Clamp ASME BPE,
for pipe ASME BPE,
face-to-face dimension FTF EN 558 series 1
88
5 Valve body material Code
Investment casting material
1.4435, investment casting 34
1.4408, investment casting 37
1.4435, investment casting C2
Forged material
1.4435 (F316L), forged body 40
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
ON/OFF actuator, additional end position indicators AE
ON/OFF actuator, additional end position indicators,
configured for emergency power supply module (NC)
A5
ON/OFF actuator, additional end position indicators,
configured for emergency power supply module (NO)
A6
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 Type of design Code
Without
Ra ≤ 0.6 μm (25 μinch) for media wetted surfaces,
in accordance with ASME BPE SF2 + SF3
mechanically polished internal
1903
Ra ≤ 0.8 µm (30 µinch) for media wetted surfaces,
in accordance with DIN 11866 H3,
mechanically polished internal
1904
Ra ≤ 0.4 μm (15 μinch) for media wetted surfaces,
in accordance with DIN 11866 H4, ASME BPE SF1
mechanically polished internal
1909
Spindle seal PTFE-PTFE 2013
11 Actuator version Code
Actuator size 0 0A
Actuator size 0
seat diameter 9 mm
0E
6 Order data
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11 Actuator version Code
Actuator size 1 1A
12 Special version Code
Without
Special version for oxygen,
(max. temperature 60 °C; max. operating pressure 10
bar),
S
12 Special version Code
only flow direction under the seat possible!
Media wetted seal materials and auxiliary materials with
BAM testing
13 CONEXO Code
Without
Integrated RFID chip for electronic identification and
traceability
C
Order example
Ordering option Code Description
1 Type 543 Angle seat globe valve, electrically operated,
eSyStep
2 DN 25 DN 25
3 Body configuration D 2/2-way body
4 Connection type 1 Threaded socket DIN ISO 228
5 Valve body material 37 1.4408, investment casting
6 Seat seal 5 PTFE
7 Voltage/frequency C1 24V DC
8 Control module AE ON/OFF actuator, additional end position indicators
9 Regulating cone Without
10 Actuator version 0A Actuator size 0
11 Type of design Without
12 Special version Without
13 CONEXO C Integrated RFID chip for electronic identification and traceability
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.
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 version
0A
Actuator version
0E
Actuator version
1A
Open/Close
valve
(code A0)
Control valve
(code S0)
6 - 25 - -
8 25 - -
10 - 25 - -
15 15 25 25 25
20 10 - 25 15
25 6 - 23 10
32 - - 15 6.5
40 - - 9 4
50 - - 6 1
Pressures in bar
All pressures are gauge pressures.
For max. operating pressures the pressure / temperature correlation must be observed.
Higher operating pressures on request
Leakage rate: Open/Close valve
Seat seal Standard Test procedure Leakage rate Test medium
Metal DIN EN 12266-1 P12 F Air
EPDM, FKM, PTFE DIN EN 12266-1 P12 A Air
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7 Technical data

Pressure/temperature
correlation:
Connection
types
code
Material
code
Max. allowable operating pressures in bar at temperature in °C
RT 100 150 200
1, 9, 17, 37, 60,
63, 3C, 3D
37 25.0 23.8 21.4 18.9
0, 16, 17, 37,
59, 60, 65
34 25.0 24.5 22.4 20.3
13 (DN 15 - DN
50)
34 25.0 23.6 21.5 19.8
80, 88 (DN 15 -
DN 40)
34 25.0 21.2 19.3* -
80, 88 (DN 50 -
DN 80)
34 16.0 16.0 16.0* -
82 (DN 15 - DN
32)
34 25.0 21.2 19.3* -
82 (DN 40 - DN
65)
34 16.0 16.0 16.0* -
86 (DN 15 - DN
40)
34 25.0 21.2 19.3* -
86 (DN 50 - DN
65)
34 16.0 16.0 16.0* -
47 (DN 15 - DN
50)
34 15.9 13.3 12.0 11.1
17, 59, 60 C2 25.0 21.2 19.3 17.9
* max. temperature 140 °C
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7 Technical data

Kv values: Open/Close valve
DN Butt weld spigot
DIN 11850
actuator
version 0E
Butt weld spigot
DIN 11866
Threaded socket
DIN ISO 228
61.6 - -
81.8 2.2 -
10 2.4 4.5 4.5
15 2.4 5.5 5.4
20 - 11.7 10.0
25 - 20.5 15.2
32 - 33.0 23.0
40 - 51.0 41.0
50 - 61.0 68.0
Kv values in m³/h
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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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: Actuator size 0 Max. 3 mm/s
Actuator size 1 max. 2.5 mm/s
Weight: Actuator
Actuator size 0 (Code 0A / 0E) 0.95 kg
Actuator size 1 (Code 1A) 1.88 kg
Valve body
DN Spigot
K514
Threaded
socket
Threaded
spigot
Flange
K514
Clamp
Connection types code
0, 16, 17, 37, 59,
60
1, 3D, 3C 9 8, 10, 13, 47 80, 82, 86, 88
60.12 - 0.14 - -
80.12 0.25 0.12 - -
10 0.12 0.25 0.14 - -
15 0.16 0.25 0.14 - -
10 0.25 0.25 - - -
15 0.24 0.35 0.31 1.80 0.37
20 0.50 0.35 0.50 2.50 0.63
25 0.50 0.35 0.65 3.10 0.63
32 0.90 0.75 1.00 4.60 1.08
40 1.10 0.98 1.30 5.10 1.28
50 1.80 1.70 1.80 7.20 2.07
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
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7 Technical data

7.6 Actuator duty cycle and service life
Service life: At least 500,000 switching cycles at room temperature and permissible duty cycle.
Duty cycle: Control module Open/Close control (code AE, A5, A6)
Duty cycle with full valve lift and playing time 10 minutes.
0
10
20
30
40
50
60
70
80
90
100
0 10 20 30 40 50 60 70 80
Duty cycle [%]
Ambient temperature [°C]
Globe valve DN 6 - 25 (code 0A / 0E)
Globe valve DN 15 - 50 (code 1A)
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
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 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
7.7.2 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
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7 Technical data

Short-circuit proof: Yes
7.7.3 Communication
Interface: IO-Link
Function: Parameterization/process data
Transmission rate: 38400 baud
Frame type in Operate: 2.5 (eSyStep ON/OFF, code AE, A5, A6)
Min. cycle time: 2.3 ms (eSyStep ON/OFF, code AE, A5, A6)
Vendor-ID: 401
Device-ID: 1906701 (eSyStep ON/OFF, code AE, A5, A6)
Product-ID: eSyStep On/Off (code AE, A5, A6)
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.
7.7.4 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).
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7 Technical data

8 Electrical connection
NOTICE
Appropriate cable socket/appropriate mating connector
▶The appropriate connector is included for X1.
8.1 Position of the connectors
X1
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.
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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 configuring the emergency power module (code A5 / A6), the control of the valve changes. Valve is controlled 1-pole
via digital input 1. Level logic 1 moves the valve OPEN, level logic 0 moves the valve CLOSE.
NOTICE
▶When the digital inputs for OPEN and CLOSE are activated simultaneously, the defined error position is approached.
Function Control module AE Control module A5, A6
Default settings Factory default setting
"Configured for emergency
power supply module"
Digital input 1 Off/Open/Closed/Safe/On/
Initialization
Open Open
Digital input 2 Off/Open/Closed/Safe/On/
Initialization
Closed Safe/On
Digital input/output Open/Closed/Error/Error and
warning/Initialization
Open Open
Digital output Open/Closed/Error/Error and
warning
Closed Closed
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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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8 Electrical connection

9 Dimensions
9.1 Installation and actuator dimensions - Valve with 2/2-way body
B2
B1
B3
A1
B
CT
LA
SW 1
DN Actuator
version
SW1 A1 A2 B B1 B2 B3 CT LA
60A 24 33.2 32.0 59.4 81.0 133.5 200.5 210.0 209.2
80A 24 33.2 32.0 59.4 81.0 133.5 200.5 210.0 209.2
10 0A 24 33.2 32.0 59.4 81.0 133.5 200.5 210.2 209.2
15 0A 36 33.2 32.0 59.4 81.0 133.5 200.5 228.8 227.8
1A 70.0 32.5 70.0 82.0 150.0 252.0 254.7 260.8
20 0A 41 33.2 32.0 59.4 81.0 133.5 200.5 234.2 233.1
1A 70.0 32.5 70.0 82.0 150.0 252.0 260.0 266.1
25 0A 46 33.2 32.0 59.4 81.0 133.5 200.5 239.1 238.1
1A 70.0 32.5 70.0 82.0 150.0 252.0 265.0 271.1
32 1A 55 70.0 32.5 70.0 82.0 150.0 252.0 271.5 277.6
40 1A 60 70.0 32.5 70.0 82.0 150.0 252.0 278.5 284.6
50 1A 75 70.0 32.5 70.0 82.0 150.0 252.0 288.4 294.5
Dimensions in mm
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9 Dimensions

9.2 Installation dimensions - Valve with angle valve body
G
DN Actuator
version
SW1 G A2 B B1 B2 B3 CT CT1
15 0A 36 M35x1.5 32.0 59.4 81.0 133.5 200.5 300.8 136.3
1A 36 M35x1.5 32.5 70.0 82.0 150.0 252.0 350.8 218.8
20 0A 41 M40x1.5 32.0 59.4 81.0 133.5 200.5 304.3 139.8
1A 41 M40x1.5 32.5 70.0 82.0 150.0 252.0 354.3 222.3
25 0A 46 M45x1.5 32.0 59.4 81.0 133.5 200.5 308.3 143.8
1A 46 M45x1.5 32.5 70.0 82.0 150.0 252.0 358.3 226.3
32 1A 55 M52x1.5 32.5 70.0 82.0 150.0 252.0 360.1 228.1
40 1A 60 M60x2.0 32.5 70.0 82.0 150.0 252.0 365.5 233.5
50 1A 75 M72x2.0 32.5 70.0 82.0 150.0 252.0 370.5 238.5
Dimensions in mm
www.gemu-group.com20 / 68GEMÜ 543 eSyStep
OPEN / CLOSE (Code AE)
9 Dimensions