GEM 655 User manual

GEMÜ 655
Manually operated full bore diaphragm valve
Operating instructions
EN
further information
webcode: GW-655

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
11.04.2023
www.gemu-group.com2 / 30GEMÜ 655

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 ........................................................ 5
3.4 Product label ................................................ 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 ..................................... 10
7.5 Mechanical data ........................................... 10
8 Dimensions .......................................................... 11
8.1 Actuator dimensions .................................... 11
8.2 Body dimensions .......................................... 12
8.3 Diaphragm dimensions ................................ 18
9 Manufacturer's information .................................. 19
9.1 Delivery ......................................................... 19
9.2 Packaging ..................................................... 19
9.3 Transport ...................................................... 19
9.4 Storage .......................................................... 19
10 Installation in piping ............................................ 19
10.1 Preparing for installation ............................. 19
10.2 Installation position ..................................... 20
10.3 Installation with flanged connection ........... 20
11 Commissioning .................................................... 21
12 Operation ............................................................. 21
13 Troubleshooting ................................................... 22
14 Inspection and maintenance ................................ 23
14.1 Removing the actuator ................................. 23
14.2 Removing the diaphragm ............................. 23
14.3 Mounting the diaphragm ............................. 23
14.4 Mounting the actuator ................................. 25
16 Removal from piping ............................................ 28
17 Disposal .............................................................. 28
18 Returns ................................................................ 28
19 Declaration of conformity according to 2014/68/
EU (Pressure Equipment Directive) ....................... 29
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1 General information
1 General information
1.1 Information
- The descriptions and instructions apply to the standard
versions. For special versions not described in this docu-
ment the basic information contained herein applies in
combination 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.
- A supplement to Directive 2014/34/EU (ATEX Directive) is
included with the product, provided that it was ordered in
accordance with ATEX.
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!

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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 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 screws 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
1
2
3
Item Name Materials
1 Actuator Cast iron
2 Diaphragm CR
EPDM
IIR
NBR
NR
3 Valve body EN-GJL-250 (GG 25)
EN-GJL-250 (GG 25), soft rubber
lined
EN-GJL-250 (GG 25), hard rubber
lined
EN-GJL-250 (GG 25), butyl lined
EN-GJS-400-18-LT (GGG 40.3),
soft rubber lined
EN-GJS-400-18-LT (GGG 40.3),
hard rubber lined
EN-GJS-400-18-LT (GGG 40.3),
butyl lined
EN-GJS-500-7 (GGG 50), soft
rubber lined
EN-GJS-500-7 (GGG 50), hard
rubber lined
EN-GJS-500-7 (GGG 50), butyl
lined
3.2 Description
The GEMÜ 655 2/2-way diaphragm valve has a metal hand-
wheel and is manually operated. The valve body has a full
bore design.
3.3 Function
The product is designed for use in piping. It controls a flow-
ing medium by manual operation. The valve body and the
diaphragm are available in various designs as shown in the
datasheet. The valve can be retrofitted with a pneumatic ac-
tuator (GEMÜ 9656).
3 Product description

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4 GEMÜ CONEXO
3.4 Product label
Design in accordance with order data
Device-specific data
Year of manufacture
Item number Serial number
Traceability number
12103529 I 0001
The month of manufacture is encoded in the traceability
number and can be obtained from GEMÜ. The product was
manufactured 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
improves the "installation qualification" process, but also
makes the maintenance process much more transparent and
easier to document. The app actively guides the maintenance
technician through the maintenance schedule and directly
provides him with all the information assigned to the valve,
such as test reports, testing documentation and mainten-
ance histories. 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 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.

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
Full bore diaphragm valve, manually operated,
metal handwheel, metal bonnet
655
2 DN Code
DN 25 25
DN 40 40
DN 50 50
DN 65 65
DN 80 80
DN 100 100
DN 125 125
DN 150 150
DN 200 200
DN 250 250
DN 300 300
3 Body configuration Code
2/2-way body D
4 Connection type Code
Flange EN 1092, PN 10, form B,
face-to-face dimension FTF EN 558 series 1, ISO 5752,
basic series 1
4
Flange EN 1092, PN 16, form B,
face-to-face dimension FTF EN 558 series 1, ISO 5752,
basic series 1
8
Flange ANSI Class 125/150 RF,
face-to-face dimension FTF EN 558 series 1, ISO 5752,
basic series 1
39
Flange EN 1092, PN 10, form A,
face-to-face dimension FTF EN 558 series 7, ISO 5752,
basic series 7
52
Flange EN 1092, PN 16, form A,
face-to-face dimension FTF EN 558 series 7, ISO 5752,
basic series 7
53
Flange ANSI Class 125/150 FF,
face-to-face dimension FTF EN 558 series 7, ISO 5752,
basic series 7
58
5 Valve body material Code
Cast iron material
EN-GJL-250 (GG 25) 8
EN-GJL-250 (GG 25),
hard rubber lined
13
EN-GJL-250 (GG 25),
soft rubber lined
52
EN-GJL-250 (GG 25),
butyl lined
58
SG iron material
EN-GJS-500-7 (GGG-50), hard rubber lined 16
EN-GJS-400-18-LT (GGG 40.3),
soft rubber lined
82
EN-GJS-400-18-LT (GGG 40.3),
hard rubber lined
83
EN-GJS-400-18-LT (GGG 40.3),
butyl lined
88
5 Valve body material Code
EN-GJS-500-7 (GGG 50),
soft rubber lined
92
EN-GJS-500-7 (GGG 50),
butyl lined
98
6 Diaphragm material Code
NBR 2
IIR 6
CR 8
EPDM 14
NR 15
7 Control function Code
Manually operated 0
8 Actuator version Code
Actuator size 2, for DN 25 and 40 2
Actuator size 4, for DN 50 and 65 4
Actuator size 6, for DN 80 and 100 6
Actuator size 7, for DN 125 and 150 7
Actuator size 8, for DN 200 8
Actuator size 9, for DN 250 9
Actuator size A, for DN 300 and 350 A
6 Order data
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Order example
Ordering option Code Description
1 Type 655 Full bore diaphragm valve, manually operated,
metal handwheel, metal bonnet
2 DN 50 DN 50
3 Body configuration D 2/2-way body
4 Connection type 53 Flange EN 1092, PN 16, form A,
face-to-face dimension FTF EN 558 series 7, ISO 5752, basic series 7
5 Valve body material 8 EN-GJL-250 (GG 25)
6 Diaphragm material 14 EPDM
7 Control function 0 Manually operated
8 Actuator version 4 Actuator size 4, for DN 50 and 65
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 diaphragm material.
7.2 Temperature
Media temperature: 0 — 100 °C
Ambient temperature: 0 — 60 °C
Storage temperature: 0 — 40 °C
7.3 Pressure
Operating pressure: MG DN NPS Operating pressure
40 25 1" 0 - 7.0
40 1½" 0 - 7.0
65 50 2" 0 - 7.0
65 2½" 0 - 7.0
100 80 3" 0 - 7.0
100 4" 0 - 7.0
150 125 5" 0 - 5.5
150 6" 0 - 5.5
200 200 8" 0 - 3.5
250 250 10" 0 - 3.5
350 300 12" 0 - 3.0
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.
Valve not suitable for vacuum applications
Kv values: MG DN NPS Kv values
40 25 1" 35
40 1½" 38
65 50 2" 108
65 2½" 114
100 80 3" 284
100 4" 298
150 125 5" 650
150 6" 680
200 200 8" 1790
250 250 10" 2920
350 300 12" 5180
MG = diaphragm size, Kv values in m³/h
Kv values determined in accordance with EN 60534, inlet pressure 5 bar, Δp 1 bar, valve body material cast
iron EN-GJL-250 with connection flange EN 1092 length EN 558 series 7 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 standard.
The Kv value curve (Kv value dependent on valve stroke) can vary depending on the diaphragm material and
duration of use.
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7 Technical data

7.4 Product compliance
Pressure Equipment Dir-
ective:
2014/68/EU
EAC: TR CU 010/2011
7.5 Mechanical data
Weight: Actuator
Actuator version Weight
2 2.0
4 7.0
6 13.0
7 34.0
8 55.0
9 97.0
A 222.0
Weights in kg
Body
MG DN Weight
40 25 2.2
40 5.4
65 50 6.3
65 8.3
100 80 12.0
100 17.1
150 125 28.4
150 31.9
200 200 76.6
250 250 99.2
350 300 181.6
MG = diaphragm size, weight in kg
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7 Technical data