GEM 639 eSyStep User manual

GEMÜ 639 eSyStep
Positioner (Code S0)
Motorized diaphragm valve
Operating instructions
EN
TYPE EL
CLASS I
AUGUST 2021
further information
webcode: GW-639

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
03.07.2023
www.gemu-group.com2 / 75GEMÜ 639 eSyStep
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 ............................................... 5
3 Product description ............................................. 5
3.2 LED displays .................................................. 6
4 GEMÜ CONEXO .................................................... 7
5 Correct use .......................................................... 7
6 Order data ........................................................... 8
7 Technical data ..................................................... 11
7.2 Temperature .................................................. 11
8 Electrical connection ........................................... 17
9 Dimensions .......................................................... 22
10 Manufacturer's information .................................. 35
10.1 Delivery .......................................................... 35
10.2 Packaging ...................................................... 35
10.3 Transport ....................................................... 35
10.4 Storage ........................................................... 35
11 Installation in piping ............................................ 35
11.1 Preparing for installation .............................. 35
11.2 Installation position ....................................... 35
11.3 Installation with clamp connections ............ 36
11.4 Installation with butt weld spigots ............... 36
11.5 Installation with threaded sockets ............... 36
11.6 Installation with threaded spigots ................ 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 ............................................................ 62
13 Operation ............................................................. 64
13.1 Initialization ................................................... 64
13.2 Manual override ............................................. 64
14 Inspection and maintenance ................................ 65
14.2 Removing the actuator .................................. 65
14.3 Removing the diaphragm .............................. 65
14.6 Mounting the actuator .................................. 67
15 Troubleshooting .................................................. 68
16 Removal from piping ............................................ 70
17 Disposal .............................................................. 70
18 Returns ................................................................ 70
19 EU Declaration of Incorporation according to the
EC Machinery Directive 2006/42/EC, Annex II B ... 71
20 EU Declaration of Conformity in accordance with
2014/68/EU (Pressure Equipment Directive) ........ 72
21 EU Declaration of Conformity in accordance with
2014/30/EU (EMC Directive) ................................ 73
22 EU Declaration of Conformity In accordance with
2011/65/EU (RoHS Directive) ............................... 74
GEMÜ 639 eSyStep
Positioner (Code S0)
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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!

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Positioner (Code S0)
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
6
7
3
2
4
5
8
9
10
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 Valve body EN-GJS-400-18-LT (GGG 40.3)
EN-GJS-400-18-LT (GGG
40.3), PFA lined
EN-GJS-400-18-LT (GGG
40.3), PP lined
EN-GJS-400-18-LT (GGG
40.3), hard rubber lined
1.4408, investment casting
1.4408, PFA lined
1.4435 (F316L), forged body
1.4435 (BN2), forged body, Δ
Fe < 0.5 %
1.4435, investment casting
1.4539, forged body
CW614N, CW617N (brass)
6 Diaphragm CR, EPDM, FKM, NBR,
PTFE/EPDM (one-piece),
PTFE/EPDM (two-piece)
7 CONEXO diaphragm
RFID chip
(see Conexo informa-
tion)
3 Product description

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Positioner (Code S0)
3 Product description
Item Name Materials
8 CONEXO body RFID
chip
(see Conexo informa-
tion)
9 Electrical connections
10 CONEXO actuator RFID
chip
(see Conexo informa-
tion)
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 639 eSyStep 2/2-way diaphragm valve is electric-
ally operated. The eSyStep electric actuator is available as
On/Off actuator or with integrated positioner. An integral op-
tical 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 failure.

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Positioner (Code S0)
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 without CONEXO
If you have ordered the product without CONEXO functionality,
the RFID chip is used for traceability in the production process
and quality assurance. Expansion to include the CONEXO
functionality at a later date must be coordinated with GEMÜ.
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
1
Actuator RFID chip Diaphragm 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.
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
Diaphragm valve, electrically operated,
eSyStep
639
2 DN Code
DN 4 4
DN 6 6
DN 8 8
DN 10 10
DN 12 12
DN 15 15
DN 20 20
DN 25 25
DN 32 32
DN 40 40
3 Body configuration Code
Tank bottom valve body B
Body configuration code B: Dimensions and designs on
request
2/2-way body D
T body T
Body configuration code T: For dimensions, see T
Valves brochure
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 3447 35
Spigot JIS-G 3459 schedule 10s 36
Spigot SMS 3008 37
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
NPT female thread 31
Threaded spigot DIN 11851 6
Cone spigot and union nut DIN 11851 6K
4 Connection type Code
Flange
Flange EN 1092, PN 16, form B,
face-to-face dimension FTF EN 558 series 1, ISO 5752,
basic series 1,
length only for body configuration D
8
Flange ANSI Class 150 RF,
face-to-face dimension FTF MSS SP-88,
length only for body configuration D
38
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
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 ISO 2852 for pipe ISO 2037,
clamp SMS 3017 for pipe SMS 3008
face-to-face dimension FTF EN 558 series 7,
length only for body configuration D
8E
Clamp DIN 32676 series C,
face-to-face dimension FTF ASME BPE,
length only for body configuration D
8P
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
SG iron material
EN-GJS-400-18-LT (GGG 40.3),
PFA lined
17
EN-GJS-400-18-LT (GGG 40.3),
PP lined
18
EN-GJS-400-18-LT (GGG 40.3),
hard rubber lined
83
EN-GJS-400-18-LT (GGG 40.3) 90
Investment casting material
1.4408, investment casting 37
1.4408, PFA lined 39
1.4435, investment casting C3
Forged material
1.4435 (F316L), forged body 40
6 Order data
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Positioner (Code S0)

5 Valve body material Code
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
NBR 2
EPDM 3A
FKM 4
FKM 4A
CR 8
EPDM 13
EPDM 17
EPDM 19
EPDM 28
EPDM 29
EPDM 36
PTFE
PTFE/EPDM one-piece 54
PTFE/EPDM two-piece 5M
Note: The PTFE/EPDM diaphragm (code 5M) is
available from diaphragm size 25.
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 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
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
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 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
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 Actuator version Code
Actuator size 0 0A
Actuator size 0
diaphragm size 8
0B
Actuator size 1 1A
11 Special version Code
Without
BELGAQUA certification B
Special version for oxygen,
maximum medium temperature: 60°C
S
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 639 Diaphragm valve, electrically operated,
eSyStep
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 40 1.4435 (F316L), forged body
6 Diaphragm material 54 PTFE/EPDM one-piece
7 Voltage/Frequency C1 24V DC
8 Control module S0 Positioner
9 Surface 1503 Ra ≤ 0.8 µm (30 µin.) for media wetted surfaces,
in accordance with DIN 11866 HE3,
electropolished internal/external
10 Actuator version 0A Actuator size 0
11 Special version Without
12 CONEXO C Integrated RFID chip for electronic identification and traceability
6 Order data
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Positioner (Code S0)