GEM 656 User manual

GEMÜ 656
Pneumatically operated full bore diaphragm valve
Operating instructions
EN
further information
webcode: GW-656

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
25.06.2021
www.gemu-group.com2 / 36GEMÜ 656

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 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 ......................................................... 10
7.4 Product compliance ...................................... 12
7.5 Mechanical data ............................................ 13
8 Dimensions .......................................................... 14
8.1 Actuator dimensions ..................................... 14
8.2 Body dimensions ........................................... 17
8.3 Diaphragm dimensions ................................. 23
9 Manufacturer's information .................................. 24
9.1 Delivery .......................................................... 24
9.2 Packaging ...................................................... 24
9.3 Transport ....................................................... 24
9.4 Storage ........................................................... 24
10 Installation in piping ............................................ 24
10.1 Preparing for installation .............................. 24
10.2 Installation position ....................................... 25
10.3 Installation with flanged connection ............ 25
11 Pneumatic connections ....................................... 25
11.1 Control functions ........................................... 25
11.2 Connecting the control medium ................... 26
12 Commissioning .................................................... 26
13 Operation ............................................................. 26
14 Troubleshooting .................................................. 27
15 Inspection and maintenance ................................ 28
15.1 Removing the actuator .................................. 28
15.2 Removing the diaphragm .............................. 28
15.3 Mounting the diaphragm .............................. 29
15.4 Mounting the actuator .................................. 31
16 Spare parts .......................................................... 32
17 Removal from piping ............................................ 33
18 Disposal .............................................................. 33
19 Returns ................................................................ 33
20 Declaration of Incorporation according to
2006/42/EC (Machinery Directive) ....................... 34
21 Declaration of conformity according to 2014/68/
EU (Pressure Equipment Directive) ...................... 35
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www.gemu-group.com4 / 36GEMÜ 656
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.
•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.
Control medium
The medium whose increasing or decreasing pressure causes
the GEMÜ product to be actuated and operated.
Control function
The possible actuation functions of 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 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
materials.
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
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 rub-
ber lined
EN-GJS-500-7 (GGG 50), hard rub-
ber lined
EN-GJS-500-7 (GGG 50), butyl
lined
3.2 Description
The GEMÜ 656 2/2-way diaphragm valve has a low mainten-
ance metal membrane actuator and is pneumatically oper-
ated. Normally Closed (NC), Normally Open (NO) and Double
Acting (DA) control functions are available. The valve body
has a full bore design.
3 Product description

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4 GEMÜ CONEXO
3.3 Function
The product is designed for use in piping. It controls a flowing
medium by being closed or opened by a control medium. The
valve has a low maintenance membrane actuator which can
be controlled by inert gases. The valve body and the dia-
phragm are available in various designs as shown in the data-
sheet.
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 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 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
Diaphragm valve, pneumatically operated 656
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
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
5 Continuation of Valve body material Code
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
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
Normally Closed (NC) 1
Normally Open (NO) 2
Double Acting (DA) 3
8 Actuator version Code
Actuator size 2R2, for DN 25 and 40 2R2
Actuator size 3R1, for DN 50 and 65 3R1
Actuator size 4R1, for DN 80 and 100 4R1
Actuator size 5R2, for DN 125 and 150 5R2
Actuator size 6R2, for DN 200 and 250 6R2
Actuator size 6R3, for DN 200 and 250 6R3
Actuator size 2RF, for DN 25 and 40 2RF
Actuator size 3RF, for DN 50 and 65 3RF
Actuator size 4RF, for DN 80 and 100 4RF
Actuator size 5RF, for DN 125 and 150 5RF
Actuator size 6RF, for DN 200 and 250 6RF
Actuator size 2RD, for DN 25 and 40 2RD
Actuator size 3RD, for DN 50 and 65 3RD
Actuator size 4RD, for DN 80 and 100 4RD
Actuator size 5RD, for DN 125 and 150 5RD
Actuator size 6RD, for DN 200 and 250 6RD
6 Order data
www.gemu-group.com 7 / 36 GEMÜ 656

Order example
Ordering option Code Description
1 Type 656 Diaphragm valve, pneumatically operated
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 1 Normally Closed (NC)
8 Actuator version 3R1 Actuator size 3R1, for DN 50 and 65
6 Order data
www.gemu-group.com8 / 36GEMÜ 656

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.
Control medium: Inert gases
7.2 Temperature
Media temperature: 0 — 100 °C
Control medium temper-
ature:
0 — 40 °C
Ambient temperature: 0 — 60 °C
Storage temperature: 0 — 40 °C
GEMÜ 656www.gemu-group.com 9 / 36
7 Technical data

7.3 Pressure
Operating pressure: MG DN NPS Control
function
Actuator
size
Operating
pressure
40 25 1" 1 2R2 7.0
2 2RF 7.0
3 2RD 7.0
40 1½" 1 2R2 7.0
2 2RF 7.0
3 2RD 7.0
65 50 2" 1 3R1 7.0
2 3RF 7.0
3 3RD 7.0
65 2½" 1 3R1 7.0
2 3RF 7.0
3 3RD 7.0
100 80 3" 1 4R1 6.0
2 4RF 7.0
3 4RD 7.0
100 4" 1 4R1 6.0
2 4RF 7.0
3 4RD 7.0
150 125 5" 1 5R2 4.0
2 5RF 5.5
3 5RD 5.5
150 6" 1 5R2 4.0
2 5RF 5.5
3 5RD 5.5
200 200 8" 1 6R2 3.0
1 6R3 3.5
2 6RF 3.5
3 6RD 3.5
250 250 10" 1 - -
2 6RF 3.5
3 6RD 3.5
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
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7 Technical data

Control pressure: MG DN NPS Control func-
tion
Actuator size Control pres-
sure
40 25 1" 1 2R2 3.8 – 7.0
2 2RF max. 3.0 1)
3 2RD max. 3.0 1)
40 1½" 1 2R2 3.8 – 7.0
2 2RF max. 3.0 1)
3 2RD max. 3.0 1)
65 50 2" 1 3R1 3.0 – 7.0
2 3RF max. 3.0 1)
3 3RD max. 3.0 1)
65 2½" 1 3R1 3.0 – 7.0
2 3RF max. 3.0 1)
3 3RD max. 3.0 1)
100 80 3" 1 4R1 5.5 – 7.0
2 4RF max. 3.0 1)
3 4RD max. 3.0 1)
100 4" 1 4R1 5.5 – 7.0
2 4RF max. 3.0 1)
3 4RD max. 3.0 1)
150 125 5" 1 5R2 4.5 – 7.0
2 5RF max. 7.0 2)
3 5RD max. 7.0 2)
150 6" 1 5R2 4.5 – 7.0
2 5RF max. 7.0 2)
3 5RD max. 7.0 2)
200 200 8" 1 6R2 5.5 – 7.0
2 6RF max. 7.0 2)
3 6RD max. 7.0 2)
200 8" 1 6R3 5.5 – 7.0
2 6RF max. 7.0 2)
3 6RD max. 7.0 2)
250 250 10" 1 - -
2 6RF max. 7.0 2)
3 6RD max. 7.0 2)
MG = diaphragm size
1) max. recommended control pressure (max. permissible control pressure is 5 bar)
2) max. recommended and permissible control pressure
Filling volume: Actuator size 2R2, 2RF, 2RD 0.625 dm³
Actuator size 3R1, 3RF, 3RD 2.5 dm³
Actuator size 4R1, 4RF, 4RD 6.8 dm³
Actuator size 5R2, 5RF, 5RD 9.0 dm³
Actuator size 6R2, 6R3, 6RF, 6RD 19.0 dm³
GEMÜ 656www.gemu-group.com 11 / 36
7 Technical data

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
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 val-
ues for other product configurations (e.g. other diaphragm or body materials) may differ. In general, all dia-
phragms are subject to the influences of pressure, temperature, the process and their tightening torques. There-
fore 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 dur-
ation of use.
7.4 Product compliance
Pressure Equipment Dir-
ective:
2014/68/EU
EAC: TR CU 010/2011
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7 Technical data

7.5 Mechanical data
Weight: Actuator
MG DN Control function
1
Control function
2 and 3
20 15 2.5 2.5
20 3.0
40 25 5.0 5.0
40 5.5
65 50 23.0 23.0
65 25.0
100 80 48.0 48.0
100 51.0
150 125 90.0 90.0
150 100.0
200 200 164.0 164.0
250 250 179.0 180.0
MG = diaphragm size, weight 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
MG = diaphragm size, weight in kg
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7 Technical data

8 Dimensions
8.1 Actuator dimensions
8.1.1 Actuator size 2, 3
B
M
A
CT*
M
B
A
CT*
Actuator size 2
MG DN NPS A B M
40 25 1" 270.5 164.0 M22x1.5
40 1 ½" 270.5 164.0 M22x1.5
Actuator size 3
MG DN NPS A B M
Control function
1 2, 3
65 50 2" 303.5 263.5 256.0 M22x1.5
65 2 ½" 303.5 263.5 256.0 M22x1.5
Dimensions in mm, MG = diaphragm size
* CT = A + H1 (see body dimensions)
G1/4 connectors are available for connecting the control air.
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8 Dimensions

8.1.2 Actuator size 4
M
B
A
CT*
MG DN NPS A B M
Control function Control function
1 2, 3 1 2, 3
100 80 3" 457.5 369.5 360.0 M26x1.5 M22x1.5
100 4" 457.5 369.5 360.0 M26x1.5 M22x1.5
Dimensions in mm, MG = diaphragm size
* CT = A + H1 (see body dimensions)
G1/4 connectors are available for connecting the control air.
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8 Dimensions

8.1.3 Actuator size 5 and 6
B
A
CT*
Actuator size 5
MG DN NPS A B
Control function
1 2, 3
150 125 5" 1093.5 737.0 388.0
150 6" 1093.5 737.0 388.0
Actuator size 6
MG DN NPS A B
Control function
1 2, 3
200 200 8" 1278.0 907.0 440.0
250 250 10" - 1033.0 440.0
Dimensions in mm, MG = diaphragm size
* CT = A + H1 (see body dimensions)
G1/4 connectors are available for connecting the control air.
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8 Dimensions

8.2 Body dimensions
8.2.1 Flange EN (code 4)
H1
FTF
øk
ØD
ØL
Connection type flange, length EN 558 (code 4) 1), SG iron material (code 82, 83, 88) 2)
MG DN NPS øD FTF H1 øk øL n
200 200 8" 340.0 600.0 64.0 295.0 22.0 8
Dimensions in mm
MG = diaphragm size
n = number of bolts
1) Connection type
Code 4: Flange EN 1092, PN 10, form B, face-to-face dimension FTF EN 558 series 1, ISO 5752, basic series 1
2) Valve body material
Code 82: EN-GJS-400-18-LT (GGG 40.3), soft rubber lined
Code 83: EN-GJS-400-18-LT (GGG 40.3), hard rubber lined
Code 88: EN-GJS-400-18-LT (GGG 40.3), butyl lined
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8 Dimensions

8.2.2 Flange EN (code 8)
H1
FTF
øk
ØD
ØL
Connection type flange, length EN 558 (code 8) 1), SG iron material (code 82, 83, 88) 2)
MG DN NPS øD FTF H1 øk øL n
40 25 1" 115.0 160.0 24.0 85.0 14.0 4
40 1½" 150.0 200.0 24.0 110.0 18.0 4
65 50 2" 165.0 230.0 32.0 125.0 18.0 4
65 2½" 185.0 290.0 32.0 145.0 18.0 4
100 80 3" 200.0 310.0 40.0 160.0 18.0 8
100 4" 220.0 350.0 40.0 180.0 18.0 8
150 125 5" 250.0 400.0 55.0 210.0 18.0 8
150 6" 285.0 480.0 55.0 240.0 22.0 8
Dimensions in mm
MG = diaphragm size
n = number of bolts
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
2) Valve body material
Code 82: EN-GJS-400-18-LT (GGG 40.3), soft rubber lined
Code 83: EN-GJS-400-18-LT (GGG 40.3), hard rubber lined
Code 88: EN-GJS-400-18-LT (GGG 40.3), butyl lined
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8 Dimensions

8.2.3 Flange EN (code 52)
H1
FTF
øk
ØD
ØL
Connection type flange, length EN 558 (code 52) 1), cast iron material (code 8), SG iron material (code 16, 92, 98) 2)
MG DN NPS øD FTF H1 øk øL n
Material Material
8 16, 92, 98 8, 16, 92,
98
200 200 8" 340.0 521.0 531.0 59.0 295.0 22.0 8
Connection type flange, length EN 558 (code 52) 1), cast iron material (code 8, 13, 52, 58) 2)
MG DN NPS øD FTF H1 øk øL n
Material Material
8 13, 52, 58 8, 13, 52,
58
250 250 10" 400.0 635.0 647.0 78.0 350.0 22.0 12
Dimensions in mm
MG = diaphragm size
n = number of bolts
1) Connection type
Code 52: Flange EN 1092, PN 10, form A, face-to-face dimension FTF EN 558 series 7, ISO 5752, basic series 7
2) Valve body material
Code 8: EN-GJL-250 (GG 25)
Code 13: EN-GJL-250 (GG 25), hard rubber lined
Code 16: EN-GJS-500-7 (GGG-50), hard rubber lined
Code 52: EN-GJL-250 (GG 25), soft rubber lined
Code 58: EN-GJL-250 (GG 25), butyl lined
Code 92: EN-GJS-500-7 (GGG 50), soft rubber lined
Code 98: EN-GJS-500-7 (GGG 50), butyl lined
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8 Dimensions

8.2.4 Flange EN (code 53)
H1
FTF
øk
ØD
ØL
Connection type flange, length EN 558 (code 53) 1), cast iron material (code 8), SG iron material (code 16, 92, 98) 2)
MG DN NPS øD FTF H1 øk øL n
Material Material
8 16, 92, 98 8 16, 92, 98
40 25 1" 115.0 127.0 127.0 20.0 22.0 85.0 14.0 4
40 1½" 150.0 159.0 159.0 18.0 24.0 110.0 18.0 4
65 50 2" 165.0 191.0 191.0 39.0 32.0 125.0 18.0 4
65 2½" 185.0 216.0 216.0 28.0 32.0 145.0 18.0 4
100 80 3" 200.0 254.0 254.0 40.0 40.0 160.0 18.0 8
100 4" 220.0 305.0 305.0 40.0 40.0 180.0 18.0 8
150 125 5" 250.0 356.0 366.0 50.0 55.0 210.0 18.0 8
150 6" 285.0 406.0 416.0 52.0 55.0 240.0 22.0 8
Dimensions in mm
MG = diaphragm size
n = number of bolts
1) Connection type
Code 53: Flange EN 1092, PN 16, form A, face-to-face dimension FTF EN 558 series 7, ISO 5752, basic series 7
2) Valve body material
Code 8: EN-GJL-250 (GG 25)
Code 16: EN-GJS-500-7 (GGG-50), hard rubber lined
Code 92: EN-GJS-500-7 (GGG 50), soft rubber lined
Code 98: EN-GJS-500-7 (GGG 50), butyl lined
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8 Dimensions