GEM 615 User manual

GEMÜ 615
Pneumatically operated diaphragm valve
Operating instructions
EN
further information
webcode: GW-615

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
28.04.2023
www.gemu-group.com2 / 27GEMÜ 615

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 GEMÜ CONEXO .................................................... 6
5 Order data ........................................................... 7
6 Technical data ..................................................... 9
6.1 Medium .......................................................... 9
6.2 Temperature .................................................. 9
6.3 Pressure ......................................................... 10
6.4 Product conformity ....................................... 11
6.5 Mechanical data ............................................ 11
7 Dimensions .......................................................... 12
7.1 Actuator dimensions ..................................... 12
7.2 Body dimensions ........................................... 13
8 Manufacturer's information .................................. 18
8.1 Packaging ...................................................... 18
8.2 Transport ....................................................... 18
8.3 Storage ........................................................... 18
8.4 Delivery .......................................................... 18
9 Installation in piping ............................................ 18
9.1 Preparing for installation .............................. 18
9.2 Installation position ....................................... 18
9.3 Installation with butt weld spigots ............... 19
9.4 Installation with threaded spigots ................ 19
9.5 Installation with threaded sockets ............... 19
9.6 Installation with clamp connections ............ 19
9.7 After the installation ...................................... 19
9.8 Operation ....................................................... 20
10 Pneumatic connections ....................................... 20
10.1 Control function ............................................. 20
10.2 Connecting the control medium ................... 21
11 Commissioning .................................................... 21
12 Operation ............................................................. 21
13 Troubleshooting .................................................. 22
14 Inspection and maintenance ................................ 23
14.1 Spare parts .................................................... 23
14.2 Fitting/removing spare parts ........................ 23
15 Removal from piping ............................................ 25
16 Disposal .............................................................. 25
17 Returns ................................................................ 25
18 EU Declaration of Incorporation according to the
EC Machinery Directive 2006/42/EC, Annex II B ... 26
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www.gemu-group.com4 / 27GEMÜ 615
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.
Control function
The possible actuation functions of the GEMÜ product.
Control medium
The medium whose increasing or decreasing pressure causes
the GEMÜ product to be actuated and operated.
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
Corrosive chemicals!
Hot plant components!

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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
3
4
5
6
7
2
8
Item Name Materials
1 Position indicator
2 Control air connectors
3 Diaphragm EPDM
FKM
PTFE/EPDM (one-piece)
4 Valve body 1.4408, investment casting
1.4435, investment casting
1.4435 (F316L), forged body
1.4435 (BN2), forged body, Δ
Fe < 0.5 %
1.4539, forged body
CW614N, CW617N (brass)
5 CONEXO diaphragm
RFID chip
(see Conexo informa-
tion)
6 CONEXO body RFID
chip
(see Conexo informa-
tion)
7 CONEXO actuator RFID
chip
(see Conexo informa-
tion)
8 Piston actuator PP, glass fibre reinforced
3.2 Description
The GEMÜ 615 2/2-way diaphragm valve has a low-mainten-
ance plastic piston actuator and is pneumatically operated.
An integrated optical position indicator is standard. Normally
Closed (NC), Normally Open (NO) and Double Acting (DA) con-
trol functions are available.
3 Product description

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4 GEMÜ CONEXO
3.3 Function
The product is designed for use in piping. It can be closed or
opened by a control medium, which is how it controls the
flow.
3.4 Product label
Item number Traceability number Consecutive number
- XXXXXXXX|YYYY
Design in accordance with order data
Device-specific data
Year of manufacture
Device version
The month of manufacture is encoded in the traceability num-
ber and can be obtained from GEMÜ. The product was manu-
factured in Germany.
4 GEMÜ CONEXO
The interaction of valve components that are equipped with
RFID chips and an associated IT infrastructure actively in-
crease process reliability.
Thanks to serialization, every valve and every relevant valve
component such as the body, actuator or diaphragm, and
even automation components, can be clearly traced and read
using the CONEXO pen RFID reader. The CONEXO app, which
can be installed on mobile devices, not only facilitates and im-
proves the "installation qualification" process, but also makes
the maintenance process much more transparent and easier
to document. The app actively guides the maintenance techni-
cian through the maintenance schedule and directly provides
him with all the information assigned to the valve, such as
test reports, testing documentation and maintenance histor-
ies. The CONEXO portal acts as a central element, helping to
collect, manage and process all data.
For further information on GEMÜ CONEXO please visit:
www.gemu-group.com/conexo

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
Diaphragm valve, pneumatically operated,
plastic piston actuator,
optical position indicator
615
2 DN Code
DN 10 10
DN 12 12
DN 15 15
DN 20 20
3 Body configuration Code
2/2-way body D
4 Connection type Code
Spigot
Spigot DIN 0
Spigot EN 10357 series B,
formerly DIN 11850 series 1
16
Spigot EN 10357 series A/DIN 11866 series A
formerly DIN 11850 series 2
17
Spigot DIN 11850 series 3 18
Spigot JIS-G 3459 schedule 10s 36
Spigot BS 4825, part 1 55
Spigot ASME BPE/DIN 11866 series C 59
Spigot ISO 1127/EN 10357 series C/DIN 11866 series B 60
Spigot ANSI/ASME B36.19M schedule 10s 63
Spigot ANSI/ASME B36.19M schedule 5s 64
Spigot ANSI/ASME B36.19M schedule 40s 65
Threaded connection
Threaded socket DIN ISO 228 1
Threaded spigot DIN 11851 6
Cone spigot and union nut DIN 11851 6K
Clamp
Clamp ASME BPE,
face-to-face dimension FTF ASME BPE,
length only for body configuration D
80
Clamp DIN 32676 series B,
face-to-face dimension FTF EN 558 series 7,
length only for body configuration D
82
Clamp ASME BPE,
for pipe ASME BPE,
face-to-face dimension FTF EN 558 series 7,
length only for body configuration D
88
Clamp DIN 32676 series A,
face-to-face dimension FTF acc. to EN 558 series 7,
length only for body configuration D
8A
Clamp DIN 32676 series C,
face-to-face dimension FTF ASME BPE,
length only for body configuration D
8P
4 Connection type Code
Clamp DIN 32676 series C,
face-to-face dimension FTF EN 558 series 7,
length only for body configuration D
8T
5 Valve body material Code
Investment casting material
1.4408, investment casting 37
1.4435, investment casting C3
Forged material
1.4435 (F316L), forged body 40
1.4435 (BN2), forged body, Δ Fe < 0.5% 42
1.4539, forged body F4
Brass
CW614N, CW617N (brass) 12
6 Diaphragm material Code
Elastomer
FKM 4
EPDM 13
EPDM 17
EPDM 19
EPDM 28
EPDM 29
EPDM 36
PTFE
PTFE/EPDM one-piece 54
7 Control function Code
Normally closed (NC) 1
Normally open (NO) 2
Double acting (DA) 3
8 Actuator version Code
Actuator size 1/N 1/N
9 Surface Code
Ra ≤ 6.3 μm (250 μin.) for media wetted surfaces,
mechanically polished internal
1500
Ra ≤ 0.8 µm (30 µin.) for media wetted surfaces,
in accordance with DIN 11866 H3,
mechanically polished internal
1502
Ra ≤ 0.8 µm (30 µin.) for media wetted surfaces,
in accordance with DIN 11866 HE3,
electropolished internal/external
1503
Ra ≤ 0.6 μm (25 μin.) for media wetted surfaces,
mechanically polished internal
1507
Ra ≤ 0.6 µm (25 µin.) for media wetted surfaces,
electropolished internal/external
1508
5 Order data
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9 Surface Code
Ra ≤ 0.25 μm (10 µin.) for media wetted surfaces *),
in accordance with DIN 11866 HE5,
electropolished internal/external,
*) for inner pipe diameters < 6 mm, in the spigot Ra ≤
0.38 μm
1516
Ra ≤ 0.25 μm (10 µin.) for media wetted surfaces *),
in accordance with DIN 11866 H5,
mechanically polished internal,
*) for inner pipe diameters < 6 mm, in the spigot Ra ≤
0.38 μm
1527
Ra ≤ 0.4 µm (15 µin.) for media wetted surfaces,
in accordance with DIN 11866 H4,
mechanically polished internal
1536
Ra ≤ 0.4 µm (15 µin.) for media wetted surfaces,
in accordance with DIN 11866 HE4,
electropolished internal/external
1537
Ra max. 0.51 µm (20 µin.) for media wetted surfaces,
in accordance with ASME BPE SF1,
mechanically polished internal
SF1
Ra max. 0.64 µm (25 µin.) for media wetted surfaces,
in accordance with ASME BPE SF2,
mechanically polished internal
SF2
9 Surface Code
Ra max. 0.76 µm (30 µin.) for media wetted surfaces,
in accordance with ASME BPE SF3,
mechanically polished internal
SF3
Ra max. 0.38 µm (15 µin.) for media wetted surfaces,
in accordance with ASME BPE SF4,
electropolished internal/external
SF4
Ra max. 0.51 µm (20 µin.) for media wetted surfaces,
in accordance with ASME BPE SF5,
electropolished internal/external
SF5
Ra max. 0.64 µm (25 µin.) for media wetted surfaces,
in accordance with ASME BPE SF6,
electropolished internal/external
SF6
10 Special version Code
Without
BELGAQUA certification B
Special version for oxygen,
maximum medium temperature: 60°C
S
11 CONEXO Code
Without
Integrated RFID chip for electronic identification and
traceability
C
Order example
Ordering option Code Description
1 Type 615 Diaphragm valve, pneumatically operated,
plastic piston actuator,
optical position indicator
2 DN 15 DN 15
3 Body configuration D 2/2-way body
4 Connection type 60 Spigot ISO 1127/EN 10357 series C/DIN 11866 series B
5 Valve body material C3 1.4435, investment casting
6 Diaphragm material 17 EPDM
7 Control function 1 Normally closed (NC)
8 Actuator version 1/N Actuator size 1/N
9 Surface 1500 Ra ≤ 6.3 μm (250 μin.) for media wetted surfaces,
mechanically polished internal
10 Special version S Special version for oxygen,
maximum medium temperature: 60°C
11 CONEXO Without
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 diaphragm material.
For special oxygen version (code S): only gaseous oxygen
Control medium: Inert gases
6.2 Temperature
Media temperature: Diaphragm material Standard Special version
for oxygen
FKM (code 4) -10 — 80 °C -
EPDM (code 13) -10 — 80 °C 0 — 60 °C
EPDM (code 17) -10 — 80 °C -
EPDM (code 19) -10 — 80 °C 0 — 60 °C
EPDM (code 28) -10 — 80 °C -
EPDM (code 29) -10 — 80 °C -
EPDM (code 36) -10 — 80 °C -
PTFE/EPDM (code 54) -10 — 80 °C 0 — 60 °C
Ambient temperature: 0 — 60 °C
Control medium temper-
ature:
0 — 40 °C
Storage temperature: 0 — 40 °C
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6 Technical data

6.3 Pressure
Operating pressure: MG DN Diaphragm material
Elastomer PTFE
10 10 - 20 0 - 6 0 - 6
MG = diaphragm size
All pressures are gauge pressures. Operating pressure values were determined with static operating pressure
applied on one side of a closed valve. Sealing at the valve seat and atmospheric sealing is ensured for the given
values.
Information on operating pressures applied on both sides and for high purity media on request.
Pressure rating: PN 16
Leakage rate: Leakage rate A to P11/P12 EN 12266-1
Control pressure: MG DN Control function 1 Control function 2 Control function 3
10 10 - 20 5 - 7 max. 5.5 max. 5.0
MG = diaphragm size
All pressures are gauge pressures.
Control pressure/operating pressure diagram – Control function 2 and 3
Operating pressure [bar]
Control pressure [bar]
Control function 3
Control function 2
The control pressure depending on the prevailing operating pressure, as shown in the diagram, is intended as a
guide for operating the system with low wear on the diaphragm.
Filling volume: 0.02 dm³
Kv values: MG DN Connection type code
0 16 17 18 59 60 1
10 10 - 2.4 2.4 2.4 2.2 3.3 -
12 ------3.2
15 3.3 3.8 3.8 3.8 2.2 4.0 3.4
20 - - - - 3.8 - -
MG = diaphragm size
Kv values in m³/h
Kv values determined in accordance with DIN EN 60534 standard, inlet pressure 5 bar, Δp 1 bar, stainless steel
valve body and soft elastomer diaphragm. The Kv values for other product configurations (e.g. other diaphragm
or body materials) may differ. In general, all diaphragms are subject to the influences of pressure, temperature,
the process and their tightening torques. Therefore the Kv values may exceed the tolerance limits of the stand-
ard.
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6 Technical data