GEM 768 User manual

GEMÜ 768
Motorized compact flanged ball valve
Operating instructions
EN
further information
webcode: GW-768

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
11.12.2019
www.gemu-group.com2 / 40GEMÜ 768

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
3.3 Function ............................................................... 6
4 GEMÜ CONEXO ......................................................... 6
5 Correct use ............................................................... 6
6 Order data ................................................................. 7
7 Technical data .......................................................... 9
8 Dimensions ............................................................... 13
9 Manufacturer's information ....................................... 17
9.1 Delivery ................................................................ 17
9.2 Packaging ............................................................ 17
9.3 Transport ............................................................. 17
9.4 Storage ................................................................. 17
10 Installation in piping .................................................. 17
10.1 Preparing for installation .................................... 17
10.2 Installation for flanged connection .................... 18
11 Electrical connection ................................................. 20
11.1 Connection and wiring diagram – actuator ver-
sion 1015, 2015, 3035 ......................................... 20
11.2 Connection and wiring diagram – actuator ver-
sion 2070, 4100, 4200 ......................................... 22
12 Limit switches ........................................................... 27
12.1 Setting the limit switch for 1015, 2015 and
3035 ..................................................................... 27
12.2 Setting the limit switch for 2070, 4100, 4200 .... 28
13 Commissioning ......................................................... 28
14 Operation .................................................................. 29
14.1 Normal operation ................................................ 29
14.2 Optical position indicator .................................... 29
14.3 Manual override ................................................... 29
15 Troubleshooting ........................................................ 31
16 Inspection/maintenance ............................................ 32
16.1 Spare parts .......................................................... 32
16.2 General information regarding actuator re-
placement ............................................................ 33
16.3 Replacing the actuator ........................................ 33
16.4 Replacing the seals ............................................. 34
17 Removal from piping ................................................. 36
18 Disposal .................................................................... 36
19 Returns ..................................................................... 36
20 Declaration of Incorporation according to 2006/42/
EC (Machinery Directive) ........................................... 37
21 Declaration of conformity according to 2014/30/EU
(EMC Directive) ......................................................... 38
22 EU Declaration of conformity 2-way metal ball valve . 39
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1 General information
1 General information
1.1 Information
– The descriptions and instructions apply to the stand-
ard versions. For special versions not described in this
document the basic information contained herein ap-
plies in combination with any additional special docu-
mentation.
– Correct installation, operation, maintenance and repair
work ensure faultless operation of the product.
– Should there be any doubts or misunderstandings, the
German 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.
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!
Risk of electric shock

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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 dan-
gerous 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 person-
nel.
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
2a
3
2b
Item Name Materials
1 Ball valve body 1.4408,
investment
casting (316)
2a Actuator housing cover
Actuator version 1015
Actuator version 2015, 3035
Actuator version 2070
Actuator version 4100, 4200
PPO (10% glass
fibre reinforced)
PP (30% glass
fibre reinforced)
ABS
Aluminium
2b Actuator housing base
Actuator version 1015, 2015, 3035
Actuator version 2070
Actuator version 4100, 4200
PP (30% glass
fibre reinforced)
ABS
Aluminium
3 Optical position indicator PP-R natural
Ball 1.4401,
investment
casting (316)
Seal material PTFE
Pressure-relief
hole
3 Product description

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4 GEMÜ CONEXO
3.2 Description
The GEMÜ 768 2/2-way metal ball valve is motorized. It has a
plastic actuator housing. A manual override and an optical po-
sition indicator are integrated as standard. The seat seal is
made of PTFE.
3.3 Function
The GEMÜ768 2/2-way ball valve made of stainless steel has
a one-piece body with an actuator flange and a low mainten-
ance electric actuator with a powerful DC motor.
The reduction gear in the motor, consisting of a threaded
spindle with a lever, provides the rotation through 90°.
The actuator has an optical position indicator and a manual
override as standard.
4 GEMÜ CONEXO
Installing the RFID chip
In the corresponding design with CONEXO, this product has
an RFID chip (1) for electronic recognition. The position of the
RFID chip can be seen below.
1
Reading out the RFID chip
DANGER
Danger of explosion
▶Death or severe injury
●Install the product in such a way that
explosion protection is not impaired by
external influences (e.g. mechanical,
thermal or electrical influences, etc.)
(see IEC/EN 60079-14).
The CONEXO pen helps read out information stored in the
RFID chip. The CONEXO app or CONEXO portal is required to
view this information.
For further information please read the operating instructions
for CONEXO products or the CONEXO datasheet.
Products such as the CONEXO app, the CONEXO portal and
the CONEXO pen are not included in the scope of delivery and
need to be ordered separately.
5 Correct use
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
this document.
The product is suitable for installation in piping and for con-
trolling a media flow. The operating conditions according to
the technical data apply to the media to be controlled.
The product is controlled via a motorized actuator.
The product is not intended for use in potentially explosive
areas.

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
Ball valve, metal, electrically operated 768
2 DN Code
DN 15 15
DN 20 20
DN 25 25
DN 32 32
DN 40 40
DN 50 50
DN 65 65
DN 80 80
DN 100 100
3 Ball configur./port position Code
2/2-way body D
4 Connection type Code
Flange ANSI class 125/150 RF,
up to DN 100 face-to-face dimension FTF EN 558
series 3,
ASME/ANSI B16.10 table 1, columns 8 and 9,
from DN 125 face-to-face dimension FTF EN 558
series 12,
ASME/ANSI B16.10 table 1, column 3
46
Flange EN 1092, PN 16/PN40, form B DN 15 to DN
80,
flange EN 1092, PN 16, form B DN 100 only
68
5 Ball valve material Code
Body 1.4408 (CF8M),
ball SS316 for DN 8 - DN 15,
ball CF8M for DN 20 - DN 100
37
6 Seal material Code
PTFE 5
TFM 1600 (FDA compliant), maximum -20 °C -
+220 °C
5T
7 Voltage/Frequency Code
12 VDC B1
12 V 50/60 Hz B4
24 VDC C1
24 V 50/60 Hz C4
120 V 50/60 Hz G4
230 V 50/60 Hz L4
100–250 V 50/60 Hz O4
8 Control module Code
On/Off actuator, relay, not reversible 00
On/Off actuator, two additional potential-free limit
switches,
relay, not reversible
0E
On/Off actuator, potentiometer output, relay, not
reversible
0P
On/Off actuator A0
On/Off actuator, two additional potential-free limit
switches, Class A (EN15714-2)
AE
On/Off actuator, potentiometer output, Class A
(EN15714-2)
AP
Control actuator, external set value 0–10 VDC E1
Control actuator, external set value 0/4–20 mA E2
9 Actuator version Code
GEMÜ actuator, motorized, size 1, operating time
11 s, torque 15 Nm,
supply voltage B1, C1
1015
GEMÜ actuator, motorized, size 3, operating time
15 s, torque 35 Nm,
supply voltage C1, O4
3035
GEMÜ actuator, motorized, size 2, operating time
15 s, torque 70 Nm,
supply voltage C1
2070
GEMÜ actuator, motorized, size 4, operating time
20 s, torque 100 Nm,
supply voltage C1
4100
GEMÜ actuator, motorized, size 4, operating time
16 s, torque 200 Nm,
supply voltage C1
4200
10 CONEXO Code
without
Integrated RFID chip for electronic identification
and traceability
C
6 Order data
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Order example
Order option Code Description
1 Type 768 Ball valve, metal, electrically operated
2 DN 25 DN 25
3 Ball configur./port position D 2/2-way body
4 Connection type 68 Flange EN 1092, PN 16/PN40, form B DN 15 to DN 80,
flange EN 1092, PN 16, form B DN 100 only
5 Ball valve material 37 Body 1.4408 (CF8M),
ball SS316 for DN 8 - DN 15,
ball CF8M for DN 20 - DN 100
6 Seal material 5 PTFE
7 Voltage/Frequency C1 24 VDC
8 Control module A0 On/Off actuator
9 Actuator version 1015 GEMÜ actuator, motorized, size 1, operating time 11 s, torque 15 Nm,
supply voltage B1, C1
10 CONEXO without
6 Order data
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GEMÜ 768

7 Technical data
7.1 Medium
Working medium: Corrosive, inert, gaseous and liquid media and steam which have no negative impact on the phys-
ical and chemical properties of the body and seal material.
7.2 Temperature
Media temperature: -20 to 180 °C
Ambient temperature: -20 to 60 °C
Higher temperatures on request
Storage temperature: 0 to 40 °C
7.3 Pressure
Leakage rate: Leakage rate according to ANSI FCI70 – B16.104
Leakage rate according to EN12266, 6 bar air, leakage rate A
Pressure/temperature
diagram:
-20 204
28
21
1414
7
0
38 93
-18
PN16
180°C
PN40
260
34
41
48
-5 400
100 200 300
0500
400
300
200
100
0
500
600
700
149
Temperature [°C]
Operating pressure [bar]
Operating pressure [PSIG]
Temperature [°F]
Pressure rating: PN 16
PN 40
Kv values: DN NPS Kv values
15 1/2” 12.8
20 3/4” 29.1
25 1” 47.8
32 1¼” 2.6
40 1½” 0.2
50 2” 213.7
65 2½” 273.3
80 3” 495.3
100 4” 871.1
Kv values in m³/h
7.4 Product compliance
Machinery Directive: 2006/42/EC
EMC Directive: 2014/30/EU
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7 Technical data

Low Voltage
Directive:
2014/35/EU
7.5 Mechanical data
Torques: DN NPS Torque
15 1/2” 5
20 3/4” 7
25 1” 29.1
32 1¼” 1.7
40 1½” 0.2
50 2” 36
65 2½” 60
80 3” 74
100 4” 90
Torques in Nm
Weight: Ball valve
DN NPS Weight
15 1/2” 1.1
20 3/4” 1.7
25 1” 72.6
32 1¼” 3.9
40 1½” 0.3
50 2” 6.0
65 2½” 10.8
80 3” 12.5
100 4” 18
Actuator
Actuator version 1015: 1.0
Actuator version 2015 (12/24
V):
1.0
Actuator version 2015 (100–
250 V):
2.4
Actuator version 3035: 2.4
Actuator version 2070: 4.6
Actuator version 4100: 11.6
Actuator version 4200: 11.6
Weights in kg
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GEMÜ 768
7 Technical data

7.6 Electrical data
Duty cycle: Supply voltage 12 V / 24 V: Continuous duty
Supply voltage 100 - 250 V: 40 % duty
Electrical protection: Potential-free limit switches (change-over contact 250 V AC/6 A)
Actual value potentiometer: 3 kΩ (± 20 %)
Electrical protection
class:
I (DIN EN 61140)
Input signals: 24 V DC, 24 V AC, 120 V AC, 230 V AC
dependent on rated voltage
Recommended motor
protection:
Voltage 12 V DC 24 V DC 120 V AC 230 V AC
Motor protection
switch type
Siemens 3RV
1011-1CA10
Siemens 3RV
1011-1BA10
Siemens 3RV
1011-OGA10
Siemens 3RV
1011-OGA10
Set current 2.20 1.70 0.60 0.45
Current data in A
Cable diameter: Supply voltage 12 V / 24 V: 7.5 to 12.5 mm
Supply voltage 100 - 250 V: 7.0 to 9.0 mm
Max. cross section of wire: 1.5 mm²
Power consumption: Actuator ver-
sion
Code
Control mod-
ule
Code
12 V DC
(Code B1)
12 V AC
(Code B4)
24 V DC
(Code C1)
24 V AC
(Code C4)
100-250
V AC
(Code O4)
1006 A0, AE 30 30 30 30 -
1015 A0, AE 30 - 30 - -
2006 A0, AE - - - - 60
2015 A0, AE - 30 - 30 50
3035 A0, AE - - 30 - 50
2070 00, 0E, 0P - - 63 - -
4100 00, 0E, 0P - - 105 - -
4200 00, 0E, 0P - - 90 - -
Power consumption in W
Max. current at start up: Actuator ver-
sion
Code
Control mod-
ule
Code
12 V DC
(Code B1)
12 V AC
(Code B4)
24 V DC
(Code C1)
24 V AC
(Code C4)
100-250
V AC
(Code O4)
1006 A0, AE 6.3 2.4 4.0 1.8 -
1015 A0, AE 9.2 - 3.8 - -
2006 A0, AE - - - - 0.3
2015 A0, AE - 2.3 - 1.8 0.4
3035 A0, AE - - 3.3 - 0.2
2070 00, 0E, 0P - - 14.0 -
4100 00, 0E, 0P - - 35.0 - -
4200 00, 0E, 0P - - 35.0 -
Current data in A
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7 Technical data

Current consumption: Actuator ver-
sion
Code
Control mod-
ule
Code
12 V DC
(Code B1)
12 V AC
(Code B4)
24 V DC
(Code C1)
24 V AC
(Code C4)
100-250
V AC
(Code O4)
1006 A0, AE 2.2 2 1.2 1.5 -
1015 A0, AE 2.2 - 1.2 - -
2006 A0, AE - - - - 0.25
2015 A0, AE - 2 - 1.2 0.2
3035 A0, AE - - 1.3 - 0.2
2070 00, 0E, 0P - - 2.6 - -
4100 00, 0E, 0P - - 4.4 - -
4200 00, 0E, 0P - - 3.6 - -
Current data in A
Supply voltage 12 V / 24 V:
Motor protective system by customer
Supply voltage 100 - 250 V:
Integrated stall and overload protection
plus excess current release T 1A 5x20 mm
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GEMÜ 768
7 Technical data

8 Dimensions
8.1 Actuators
8.1.1 Actuator version 1006, 1015, 2006, 2015
A
B
145
40
80
55
C
62*
* Standard with supply voltage code O4
Actuator ver-
sion
A B C
1006, 1015 69 94 49
2006, 2015 96 122 53
Dimensions in mm
8.1.2 Actuator version 3035
66 76
172 208
94
B
Voltages B
24 V 100.5
100 V - 250 V 124.5
Dimensions in mm
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8 Dimensions

8.1.3 Actuator version 2070
83,5 121,5
40
51
235
167
155
Dimensions in mm
8.1.4 Actuator version 4100, 4200
277,5
131
207
105 145
Dimensions in mm
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GEMÜ 768
8 Dimensions

8.1.5 Connection dimensions actuator
8.1.5.1 Connection dimensions
LK ØA
G1
G2
SW 2
T
LK ØB
SW 1
DIN ISO 5211
Actuator version
code
Connection
size code
With flange type LK øA LK øB G1 G2 SW1 SW2* SW3* T
2070 F07 F05 / F07 70 50 M8 M6 17 14 11 19.5
4100 F10 F07 / F10 102 70 M10 M8 17 14 - 23.0
4200 F10 F07 / F10 102 70 M10 M8 22 17 - 23.0
Dimensions in mm
8.1.5.2 Connection dimensions actuator version (10XX, 20XX, 3035)
LK
G
SW
T
DIN ISO 5211
Actuator version
(code)
Connection size
(code)
Location spigot
(code)
SW G LK T
10XX / 20XX G05 Y S08 Ø5.5 48 15
10XX / 20XX F03 N S09 M5 36 16
10XX / 20XX F04 N S09 M5 42 16
10XX / 20XX F05 N S09 M6 50 16
10XX / 20XX F05 N S11 M6 50 16
3035 F05 Y S14 M6 50 22
Dimensions in mm
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8 Dimensions

8.2 Ball valve body
f
b
L
øg
øe
h
øk
ØD
45°
22,5°
Ø
d xY
F2
F1
h1
B
Actuator flange
DN Actuator flange ØD L Z b d Øe f Øg h h1 Øk
F1 F2 B
15 F03 36 ø6x4 F04 ø6x4 9 81 41 4 16 M12 15 2 45 49 7 65
20 F03 36 ø6x4 F04 ø6x4 9 99 44 4 18 M12 20 2 58 54 8 75
25 F04 42 ø6x4 F05 ø7x4 11 115 50 4 18 M12 25 2 68 65 12 85
32 F04 42 ø6x4 F05 ø7x4 11 140 60 4 18 M16 32 2 78 77 11.3 100
40 F05 50 ø7x4 F07 ø9x4 14 150 65 4 18 M16 38 3 88 88.5 15.5 110
50 F05 50 ø7x4 F07 ø9x4 14 165 80 4 20 M16 50 3 102 93 16 125
65 F07 70 ø9x4 F10 ø11x4 17 185 110 4 22 M16 65 3 122 109.7 15.8 145
80 F07 70 ø9x4 F10 ø11x4 17 200 120 8 24 M16 80 3 138 119.5 16 160
100 F07 70 ø9 x 4 F10 ø11x4 17 220 150 8 24 M16 100 3 158 132.7 17.8 180
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GEMÜ 768
8 Dimensions

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9 Manufacturer's information
9.1 Delivery
●Check that all parts are present and check for any damage
immediately upon receipt.
The product's performance is tested at the factory. The scope
of delivery is apparent from the dispatch documents and the
design from the order number.
9.2 Packaging
The product is packed in a cardboard box which can be re-
cycled as paper.
9.3 Transport
1. Only transport the product by suitable means. Do not drop.
Handle carefully.
2. After the installation dispose of transport packing material
according to relevant local or national disposal regula-
tions / environmental protection laws.
9.4 Storage
1. Store the product free from dust and moisture in its ori-
ginal packaging.
2. Avoid UV rays and direct sunlight.
3. Do not exceed the maximum storage temperature (see
chapter "Technical data").
4. Do not store solvents, chemicals, acids, fuels or similar
fluids in the same room as GEMÜ products and their spare
parts.
10 Installation in piping
10.1 Preparing for installation
WARNING
The equipment is subject to pressure!
▶Risk of severe injury or death.
●Depressurize the plant.
●Completely drain the plant.
WARNING
Corrosive chemicals
▶Risk of caustic burns
●Wear suitable protective gear.
●Completely drain the plant.
CAUTION
Hot plant components!
▶Risk of burns!
●Only work on plant that has cooled
down.
CAUTION
Exceeding the maximum permissible pressure.
▶Damage to the GEMÜ product.
●Provide precautionary measures against exceeding the
maximum permitted pressures caused by pressure
surges (water hammer).
CAUTION
Use as step.
▶Damage to the product.
▶Risk of slipping-off.
●Choose the installation location so that the product can-
not be used as a foothold.
●Do not use the product as a step or a foothold.
NOTICE
Suitability of the product!
▶The product must be appropriate for the piping system
operating conditions (medium, medium concentration,
temperature and pressure) and the prevailing ambient
conditions.
10 Installation in piping

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10 Installation in piping
NOTICE
Tools
▶The tools required for installation and assembly are not
included in the scope of delivery.
●Use appropriate, functional and safe tools.
1. Ensure the product is suitable for the relevant application.
2. Check the technical data of the product and the materials.
3. Keep appropriate tools ready.
4. Wear appropriate protective gear, as specified in the plant
operator's guidelines.
5. Observe appropriate regulations for connections.
6. Have installation work carried out by trained personnel.
7. Shut off plant or plant component.
8. Secure plant or plant component against recommission-
ing.
9. Depressurize the plant or plant component.
10. Completely drain the plant (or plant component) and let it
cool down until the temperature is below the media vapor-
ization temperature and cannot cause scalding.
11. Decontaminate, rinse and ventilate the plant or plant com-
ponent properly.
12. Lay piping so that the product is protected against trans-
verse and bending forces, and also from vibrations and
tension.
13. Only mount the product between matching aligned pipes
(see following chapters).
14. Flow direction and installation position are optional.
10.2 Installation for flanged connection
NOTICE
▶Observe valid standards for mounting flanges!
SW3
Attention!
Only
actuate when
power is switched off
Manual override
F1 D1 D F2
1. Ensure sealing surfaces on the mating flanges are clean
and undamaged.
2. Only use connector elements made of approved materials!
3. Install the ball valve in the state it is delivered.
4. Carefully align the ball valve body 1 centrally between the
pipes with flanges (F1 and F2).
5. Centre the seals D accurately. Seals are not included in the
scope of delivery.
6. Connect the ball valve flange and the piping flange using
appropriate sealing material and matching bolting. Sealing
material and bolts are not included in the scope of deliv-
ery.

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SW3
Attention!
Only
actuate when
power is switched off
Manual override
SN M
7. Insert bolts SN in all holes in the flange.
8. Slightly tighten the bolts SN and nuts M diagonally.
9. Check the alignment of the piping.
10. Tighten nuts M diagonally.
Comply with appropriate regulations for the connections!
After the installation:
11. Re-attach or reactivate all safety and protective devices.
10 Installation in piping

11 Electrical connection
11.1 Connection and wiring diagram – actuator version 1015, 2015, 3035
11.1.1 Control module A0/AE
12 V DC (code B1) / 24 V DC (code C1)
Assignment of the terminal strips
1
2
3
4
5
Item Description
1 Uv+, direction of travel CLOSED
2 Uv-, direction of travel CLOSED
3 Uv+, direction of travel OPEN
4 Uv-, direction of travel OPEN
5 PE, protective earth conductor
Connection diagram
+− PE
1
2
3
4
5
0
S3
Limit switch OPEN
Limit switch CLOSED
Terminal strip
CLOSED
OPEN
Motor
External
wiring
S3 Actuator
CLOSED Direction of travel CLOSED
0 OFF
OPEN Direction of travel OPEN
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GEMÜ 768
11 Electrical connection