GEM R639 User manual

GEMÜ R639 eSyStep
OPEN / CLOSE (Code AE)
Motorized diaphragm valve
Operating instructions
EN
further information
webcode: GW-R639

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
25.09.2023
www.gemu-group.com2 / 71GEMÜ R639 eSyStep
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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 Correct use .......................................................... 6
5 Order data ........................................................... 7
6 Technical data ..................................................... 9
7 Electrical connection ........................................... 15
8 Dimensions .......................................................... 18
9 Manufacturer's information .................................. 32
9.1 Delivery .......................................................... 32
9.2 Packaging ...................................................... 32
9.3 Transport ....................................................... 32
9.4 Storage ........................................................... 32
10 Installation in piping ............................................ 32
10.1 Preparing for installation .............................. 32
10.2 Installation position ....................................... 33
10.3 Installation with butt weld spigots ............... 33
10.4 Installation with threaded sockets ............... 33
10.5 Installation with union ends .......................... 33
10.6 Installation with solvent cement sockets .... 34
10.7 Installation with flare connection ................. 34
11 Specific data IO-Link (pin 6) ................................. 35
11.1 Operation on IO-Link ..................................... 35
11.2 Process data .................................................. 38
11.3 Parameter overview ...................................... 39
11.4 Parameter ...................................................... 43
11.5 Events ............................................................ 57
12 Operation ............................................................. 60
12.1 Initialization ................................................... 60
12.2 Manual override ............................................. 60
13 Inspection and maintenance ................................ 61
13.2 Removing the actuator .................................. 61
13.3 Removing the diaphragm .............................. 61
13.6 Mounting the actuator .................................. 63
14 Troubleshooting .................................................. 64
15 Removal from piping ............................................ 66
16 Disposal .............................................................. 66
17 Returns ................................................................ 66
18 EU Declaration of Incorporation according to the
EC Machinery Directive 2006/42/EC, Annex II B ... 67
19 EU Declaration of Conformity in accordance with
2014/68/EU (Pressure Equipment Directive) ........ 68
20 EU Declaration of Conformity in accordance with
2014/30/EU (EMC Directive) ................................ 69
21 EU Declaration of Conformity in accordance with
2011/65/EU (RoHS Directive) ............................... 70
GEMÜ R639 eSyStep
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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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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
5
3
2
4
7
Item Name Materials
1 Optical position indic-
ator
PA 12
2 Manual override
3 Actuator top with LED
display
Polyamide, 50% glass
fibre
4 Actuator base Polyamide, 50% glass
fibre
5 Electrical connection
6 Diaphragm NBR, FPM, CR, EPDM,
PTFE/EPDM
7 Valve body PVC-U (grey), PP, PVDF,
PP-H(natural)
3 Product description

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4 Correct use
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 R639 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.
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 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 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, motorized,
eSyStep
R639
2 DN Code
DN 12 12
DN 15 15
DN 20 20
DN 25 25
DN 32 32
DN 40 40
DN 50 50
3 Body configuration Code
2/2-way body D
4 Connection type Code
Spigot
Spigot DIN 0
Spigot for IR butt welding 20
Spigot for IR butt welding, BCF 28
Spigot – inch,
for welding or bonding, depending on the body material
30
Body with threaded spigots for unions 7X
Union end
Union end with insert (socket) – DIN 7
Union end with insert (Rp threaded socket) – DIN 7R
Union end with inch insert – BS (socket) 33
Union end with inch insert – ASTM (socket) 3M
Union end with insert – JIS (socket) 3T
Union end with insert (for IR butt welding) – DIN 78
Threaded socket
Threaded socket DIN ISO 228 1
Solvent cement socket
Solvent cement socket DIN 2
Flange
Flange EN 1092, PN 10, form B,
face-to-face dimension FTF EN 558 series 1, ISO 5752,
basic series 1
4
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
Flare
Flare connection with PVDF union nut 75
5 Valve body material Code
PVC-U, grey 1
ABS 4
PP, reinforced 5
5 Valve body material Code
PVDF 20
Inliner PP-H, grey,
outliner PP, reinforced
71
Inliner PVDF/outliner PP, reinforced 75
PP-H, natural N5
6 Diaphragm material Code
Elastomer
NBR 2
FKM 4
EPDM 29
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
On/Off actuator, additional end position indicators AE
ON/OFF actuator, additional end position indicators,
configured for emergency power supply module (NC)
A5
ON/OFF actuator, additional end position indicators,
configured for emergency power supply module (NO)
A6
9 Actuator version Code
Actuator size 0
diaphragm size 10
0C
Actuator size 1 1A
10 Mounting plate Code
Including mounting plate M
Without
5 Order data
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Order example
Ordering option Code Description
1 Type R639 Diaphragm valve, motorized,
eSyStep
2 DN 15 DN 15
3 Body configuration D 2/2-way body
4 Connection type 7 Union end with insert (socket) – DIN
5 Valve body material 1 PVC-U, grey
6 Diaphragm material 29 EPDM
7 Voltage/Frequency C1 24V DC
8 Control module AE On/Off actuator, additional end position indicators
9 Actuator version 0C Actuator size 0
diaphragm size 10
10 Mounting plate 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.
6.2 Temperature
Media temperature: Valve body material Media temperature
PVC-U, grey (code 1) 10 — 60 °C
ABS (code 4) -10 — 60 °C
PP, reinforced (code 5) 5 – 80 °C
PVDF (code 20) -10 — 80 °C
Inliner PP-H grey / outliner PP, reinforced (code
71)
5 – 80 °C
Inliner PVDF / outliner PP, reinforced (code 75) -10 — 80 °C
PP-H, natural (code N5) 5 – 80 °C
Ambient temperature: Valve body material Ambient temperature
PVC-U, grey (code 1) 10 — 50 °C
ABS (code 4) -10 — 50 °C
PP, reinforced (code 5) 5 — 50 °C
PVDF (code 20) -10 — 50 °C
Inliner PP-H grey / outliner PP, reinforced (code
71)
5 — 50 °C
Inliner PVDF / outliner PP, reinforced (code 75) -5 — 50 °C
PP-H, natural (code N5) 5 — 50 °C
6.3 Pressure
Operating pressure: MG DN Actuator
version
Diaphragm materials
Elastomer PTFE
10 12 - 20 0C 0 - 6 0 - 6
20 15 - 25 1A 0 - 8 0 - 8
25 32 1A 0 - 8 0 - 8
40 40 - 50 1A 0 - 8 0 - 4
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.
The operating pressures apply at room temperature. In case of deviating temperatures, observe the
pressure / temperature correlation.
Pressure rating: PN 10
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6 Technical data

Pressure/temperature
correlation:
MG Actuator
version
Materials Code Temperatures in °C (valve body)
-10 0 5 10 20 30 40 50 60 70 80
10 0C PVC-U 1 - - - 6.0 6.0 6.0 6.0 3.5 1.5 - -
PP-H 5 - - 6.0 6.0 6.0 6.0 6.0 5.5 4.0 2.7 1.5
PVDF 20 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 6.0 5.4 4.7
PP-H-
Natur
N5 - - 6.0 6.0 6.0 6.0 6.0 5.5 4.0 2.7 1.5
20,
25
1A PVC-U 1 - - - 8.0 8.0 8.0 6.0 3.5 1.5 - -
ABS 4 8.0 8.0 8.0 8.0 8.0 8.0 6.0 4.0 2.0 - -
PP-H 71 - - 8.0 8.0 8.0 8.0 7.0 5.5 4.0 2.7 1.5
PVDF 75 8.0 8.0 8.0 8.0 8.0 8.0 8.0 7.1 6.3 5.4 4.7
MG = diaphragm size
Actuator version 1A with PTFE diaphragm can be used up to max. 4 bar. At temperatures above 30 °C the max-
imum operating pressure decreases.
The pressure rating (PN) depends on the diaphragm size.
Data for extended temperature ranges on request. Please note that the ambient temperature and media temper-
ature generate a combined temperature at the valve body which must not exceed the above values.
Depending on the valve configuration, the maximum operating pressure of the pressure rating may be lower.
Observe the operating pressure table.
Leakage rate: Leakage rate A to P11/P12 EN 12266-1
Kv values: MG Nominal size Kv value
MG 10 DN 12 2.8
DN 15 3.5
DN 20 3.5
MG 20 DN 15 6.0
DN 20 10.0
DN 25 12.0
MG 25 DN 32 20.0
MG 40 DN 40 42.0
DN 50 46.0
Kv values in m³/h
MG = diaphragm size
Kv values determined acc.to DIN EN 60534 standard, inlet pressure 5 bar, Δp 1 bar, PVC-U 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 standard.
The Kv value curve (Kv value dependent on valve stroke) can vary depending on the diaphragm material and dur-
ation of use.
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6 Technical data

6.4 Product compliance
Machinery Directive: 2006/42/EC
Pressure Equipment Dir-
ective:
2014/68/EU
FDA*
* depending on version and / or operating parameters
EMC Directive: 2014/30/EU
RoHS Directive: 2011/65/EU
6.5 Materials
Materials: Diaphragm material O-ring material
PTFE FKM
NBR EPDM
FKM FKM
EPDM EPDM
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6 Technical data

6.6 Mechanical data
Protection class: IP 65 acc. to EN 60529
Actuating speed: Actuator size 0 Max. 3 mm/s
Actuator size 1 max. 2.5 mm/s
Max. 3 mm/s
Weight: Actuator
Actuator size 0 (code 0C) 0.95 kg
Actuator size 1 (code 1A) 1.88 kg
Valve body
MG DN Spigot Union end Flange Threade
d socket
Solvent
cement
socket
Flare
Connection type code
0, 30 20 28 7, 7R 33 3M,
3T
78 4, 39 1 2 75
10 12 - - - - - - - - 0.08 0.06 -
15 - - 0.13 0.18 0.13 - 0.20 - - - 0.08
20 - - - - - - - - - - 0.125
20 15 0.12 0.10 - 0.17 0.24 0.26 0.27 0.67 - - -
20 0.13 0.12 - 0.21 0.28 0.30 0.36 0.84 - - -
25 0.16 0.14 - 0.26 0.33 0.38 0.37 1.28 - - -
25 32 0.22 0.18 - 0.40 0.70 0.73 0.63 1.89 - - -
40 40 0.50 0.40 - 0.73 0.83 0.93 1.13 2.36 - - -
50 0.57 0.47 - 1.00 1.40 1.50 1.60 3.08 - - -
MG = diaphragm size, weight in kg
Installation position: Optional
Flow direction: Optional
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6 Technical data

6.7 Actuator duty cycle and service life
Service life: At least 500,000 switching cycles at room temperature and permissible duty cycle.
Duty cycle: Control module Open/Close control (code AE, A5, A6)
Duty cycle with full valve lift and playing time 10 minutes.
0
10
20
30
40
50
60
70
80
90
100
0 10 20 30 40 50 60 70 80
Duty cycle [%]
Ambient temperature [°C]
Diaphragm valve DN 12 - 20 (code 0C)
Diaphragm valve DN 15 - 32 (code 1A)
Diaphragm valve DN 40 - 50 (code 1A)
NOTICE
▶The specified characteristics and values apply to the default setting.
▶With reduced forces, higher duty cycles and/or higher ambient temperatures are possible. At higher force settings the duty
cycle and/or ambient temperature is reduced.
▶IO-Link: Index 0x90 - Subindex 2 - Force
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6 Technical data

6.8 Electrical data
Supply voltage Uv: 24 V DC ± 10%
Rating: Actuator size 0 (code 0C) 20 W
Actuator size 1 (code 1A) 60 W
Operation: Stepper motor, self-locking
Reverse battery protec-
tion:
Yes
6.8.1 Digital input signals
Inputs: Function selectable via IO-Link (see table Overview of available functions – Input and output sig-
nals)
Input voltage: 24 V DC
Logic level "1": > 15.3 V DC
Logic level "0": < 5.8 V DC
Input current: typically < 0.5 mA
6.8.2 Digital output signals
Outputs: Function selectable via IO-Link (see table Overview of available functions – Input and output sig-
nals)
Type of contact: Push-Pull
Switching voltage: Power supply Uv
Switching current: ≤ 140 mA
Short-circuit proof: Yes
6.8.3 Communication
Interface: IO-Link
Function: Parameterization/process data
Transmission rate: 38400 baud
Frame type in Operate: 2.5 (eSyStep ON/OFF, code AE, A5, A6)
Min. cycle time: 2.3 ms (eSyStep ON/OFF, code AE, A5, A6)
Vendor-ID: 401
Device-ID: 1906701 (eSyStep ON/OFF, code AE, A5, A6)
Product-ID: eSyStep On/Off (code AE, A5, A6)
ISDU support: Yes
SIO operation: Yes
IO-Link specification: V1.1
IODD files can be downloaded via https://ioddfinder.io-link.com/ or www.gemu-group.com.
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6 Technical data

6.9 Behaviour in the event of an error
Function: In the event of an error the valve moves to the error position.
Notes: Moving to the error position is only possible with full power supply. This behaviour is not a
safety position. The valve must be operated with a GEMÜ 1571 emergency power supply module
(see accessories) to ensure the function in case of voltage loss.
Error position: Closed, open or hold (adjustable via IO-Link).
7 Electrical connection
NOTICE
Appropriate cable socket/appropriate mating connector
▶The appropriate connector is included for X1.
7.1 Position of the connectors
X1
7.2 Electrical connection
7.2.1 Connection X1
13
2
654
7-pin plug, Binder, type 693
Pin Signal name
1 Uv, 24 V DC supply voltage
2 GND
3 Digital input 1
4 Digital input 2
5 Digital input/output
6 Digital output, IO-Link
7 n.c.
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7 Electrical connection

7.3 Overview of available functions – Input and output signals
NOTICE
▶The factory default setting "Configured for emergency power supply module" is reset to default settings when a reset is car-
ried out.
NOTICE
▶When configuring the emergency power module (code A5 / A6), the control of the valve changes. Valve is controlled 1-pole
via digital input 1. Level logic 1 moves the valve OPEN, level logic 0 moves the valve CLOSE.
NOTICE
▶When the digital inputs for OPEN and CLOSE are activated simultaneously, the defined error position is approached.
Function Control module AE Control module A5, A6
Default settings Factory default setting
"Configured for emergency
power supply module"
Digital input 1 Off/Open/Closed/Safe/On/
Initialization
Open Open
Digital input 2 Off/Open/Closed/Safe/On/
Initialization
Closed Safe/On
Digital input/output Open/Closed/Error/Error and
warning/Initialization
Open Open
Digital output Open/Closed/Error/Error and
warning
Closed Closed
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7 Electrical connection

7.4 Connection diagram
X1
Device side Connections / customer
eSyStep
Uv 24 V DC
Uv GND Power supply
PLC
Digital input 1
Digital input 2
24 V DC
24 V DC
Digital input/output 24 V DC
Digital output / IO-Link 24 V DC
1
2
3
4
5
6
or
or
IO-Link master
CQ
Only with type S0, S5, S6 PLC
Set value (X)+
Set value (X)-
Actual value (Y)+
Actual value (Y)-
Analogue output
Default setting 4 -20mA
Adjustable 0-20mA / 0-10V
Analogue input
Default setting 4 -20mA
Adjustable 0-20mA / 0-10V
Only with type S0, S5, S6
7-pin plug
Binder, type 693
5-pin M12 plug
A-coded
1
2
3
4
X2
Switch
Consumer
Signal direction
Power supply
=
=
=
=
13
2
654
1
4
3
2
5
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7 Electrical connection

8 Dimensions
8.1 Installation and actuator dimensions
8.1.1 Actuator version code 0C
B2
B1
A
A1
B
CT*
MG DN Actuator
version
A A1 A2 B B1 B2
10 12 - 20 0C 203.5 39.0 33.2 59.4 81.0 133.5
Dimensions in mm, MG = diaphragm size
* CT = A + H1 (see body dimensions)
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8 Dimensions

8.1.2 Actuator version code 1A
B2
B1
A
A1
B
CT*
MG DN Actuator
version
A A1 A2 B B1 B2
20 15 - 25 1A 298.0 116.0 32.5 70.0 82.0 150.0
25 32 1A 306.0 124.0 32.5 70.0 82.0 150.0
40 40 - 50 1A 304.0 122.0 32.5 70.0 82.0 150.0
Dimensions in mm, MG = diaphragm size
* CT = A + H1 (see body dimensions)
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8 Dimensions

8.2 Body dimensions
8.2.1 Spigot DIN / inch (code 0, 30)
L
c
Ød
H1
H
Connection type spigot DIN (code 0) 1), body material PVC-U (code 1), inliner/outliner (code 71, 75) 2)
MG DN NPS c ød H H1 L
Material Material
1 71, 75 1 71, 75
20 15 1/2" 16.0 18.0 20.0 36.0 36.0 10.0 124.0
20 3/4" 19.0 19.0 25.0 38.0 38.0 12.0 144.0
25 1" 22.0 22.0 32.0 39.0 39.0 13.0 154.0
25 32 1¼" 32.0 32.0 40.0 41.0 41.0 15.0 174.0
40 40 1½" 35.0 26.0 50.0 63.2 63.2 23.2 194.0
50 2" 38.0 33.0 63.0 63.2 63.2 23.2 224.0
Connection type spigot – inch (code 30) 1), body material PVC-U (code 1), ABS (code 4) 2)
MG DN NPS c ød H H1 L
20 15 1/2" 24.0 21.4 36.0 10.0 141.0
20 3/4" 27.0 26.7 38.0 12.0 144.0
25 1" 30.0 33.6 39.0 13.0 154.0
25 32 1¼" 33.0 42.2 41.0 15.0 174.0
40 40 1½" 35.0 48.3 63.2 23.2 194.0
50 2" 40.0 60.3 63.2 23.2 224.0
Dimensions in mm
MG = diaphragm size
1) Connection type
Code 0: Spigot DIN
Code 30: Spigot – inch, for welding or bonding, depending on the body material
2) Valve body material
Code 1: PVC-U, grey
Code 4: ABS
Code 71: Inliner PP-H, grey, outliner PP, reinforced
Code 75: Inliner PVDF/outliner PP, reinforced
www.gemu-group.com20 / 71GEMÜ R639 eSyStep
OPEN / CLOSE (Code AE)
8 Dimensions