GEM SU60 SUMONDO User manual

GEMÜ SU60 SUMONDO
Motorized actuator for single-use valves
Operating instructions
EN
further information
webcode: GW-SU60

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
06.09.2021
www.gemu-group.com2 / 36GEMÜ SU60 SUMONDO

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 ..................................................... 7
3.3 Function ......................................................... 8
3.4 Product label ................................................. 8
3.4.1 Actuator ............................................ 8
3.4.2 Valve body packaging ...................... 8
4 Correct use .......................................................... 8
5 Order data ........................................................... 9
5.1 SU60 motorized actuator .............................. 9
5.2 Diaphragm valve body SUB .......................... 10
6 Technical data ..................................................... 11
6.1 Medium .......................................................... 11
6.2 Temperature .................................................. 11
6.3 Pressure ......................................................... 11
6.4 Product conformity ....................................... 12
6.5 Mechanical data ............................................ 13
6.6 Electrical data ................................................ 13
7 Dimensions .......................................................... 17
7.1 Actuator dimensions ..................................... 17
7.2 Body dimensions ........................................... 18
7.3 Connection dimensions ................................ 21
8 Electrical connection ........................................... 22
9 Manufacturer's information .................................. 23
9.1 Delivery .......................................................... 23
9.2 Packaging ...................................................... 23
9.3 Transport ....................................................... 23
9.4 Storage ........................................................... 23
10 Installation in piping ............................................ 23
10.1 Preparing for installation .............................. 23
10.2 Assembling the motorized actuator in the
housing .......................................................... 24
10.3 Disassembling the motorized stainless
steel actuator – housing ............................... 25
10.4 Assembling the single-use diaphragm valve
body on the motorized stainless steel actu-
ator ................................................................. 26
10.5 Disassembling the single-use diaphragm
valve body – motorized stainless steel ac-
tuator .............................................................. 26
10.6 Installing the single-use diaphragm valve
body in the piping .......................................... 26
11 Network connection ............................................. 27
11.1 Network settings ........................................... 27
11.2 Connecting the network ................................ 27
11.3 Resetting the network settings ..................... 27
12 Commissioning .................................................... 28
13 Operation ............................................................. 28
13.1 Operation on the device ................................ 28
13.2 Operation via the web server ........................ 28
13.3 Manual override ............................................. 28
14 Troubleshooting .................................................. 30
15 Inspection and maintenance ................................ 32
16 Removal from piping ............................................ 32
17 Disposal .............................................................. 32
18 Returns ................................................................ 32
19 Declaration of Incorporation according to
2006/42/EC (Machinery Directive) ....................... 33
20 Manufacturer's declaration according to 2014/68/
EU (Pressure Equipment Directive) ...................... 34
21 Declaration of conformity according to 2014/30/
EU (EMC Directive) ............................................... 35
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www.gemu-group.com4 / 36GEMÜ SU60 SUMONDO
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
The following LED symbols are used in the documentation:
Symbol LED conditions
Off
Lit (on)
Flashing
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 - corrosive materials
Risk posed by sharp edges
Danger from potentially explosive atmosphere

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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
3.1.1 Valve assembly construction
1
2
3
4
5
6
7
9
10
8
11
Item Name Materials
1 Actuator base 1.4301
2 Mounting flange Stainless steel
3 O-ring EPDM
4 Clamping device Stainless steel
5 Valve body PP-R
6 Diaphragm TPE
7 Diaphragm pin PP-R
8 Distance piece Stainless steel
9 Gasket EPDM, angular
10 Actuator housing PESU
11 Cover with high visibility LED,
manual override and on-site control
PESU
3 Product description

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3 Product description
3.1.2 Buttons for on-site control
8
9
10
Fig.1: Position of the buttons
Item Name Function
8 DIP switch, "ON-
site" control
Switches the on-site
control on the device
on or off
9 "OPEN" button Moves actuator to the
open position
Resets the network
settings
10 "INIT/CLOSE" but-
ton
Moves actuator to the
closed position
Starting initialisation
3.1.3 LED displays
3.1.3.1 On-site status LEDs
LED MODE LED PWR
Fig.2: Position of the status LEDs
The user checks the following conditions directly on-site at
the valve using LED MODE and LED PWR:
Function LED MODE LED PWR
Yellow Blue Green Red
Automatic oper-
ation
Manual opera-
tion
Actuator
switched off
(OFF mode)
Manual opera-
tion (on-site)
Software update
alternating
On-site initialisa-
tion (buttons)
Remote initial-
isation (via Di-
gIn)

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Function LED MODE LED PWR
Yellow Blue Green Red
Operation via
emergency
power supply
module
3.1.3.2 High visibility LEDs
11
11 11
11 11
11
Fig.3: Position of the high visibility LEDs
Item Name
11 High visibility LEDs
Function High visibility LED
Green Orange
OPEN position Position indicator
LEDs,
standard
OPEN position Position indicator
LEDs,
inversed
CLOSED position Position indicator
LEDs,
standard
CLOSED position Position indicator
LEDs,
inversed
Position unknown (e.g. 50%)
Initialisation
Function High visibility LED
Green Orange
alternating
Location function
3.1.4 LED messages
Error Possible cause Troubleshooting
LED 1 and 2 are
flashing yellow and
red simultaneously
High visibility LED
flashes orange
Internal error Contact GEMÜ
LED 1 flashes yel-
low
LED 2 lights up red
High visibility LED
flashes orange
Actual value signal
outside of the area
Check actual value
signal
Check precise error
description using
the eSy-Web web
interface
LED 1 is not lit
LED2 is flashing red
High visibility LED
flashes orange
No initialisation Initialise valve
LED 1 and 2 are
flashing yellow and
red simultaneously
High visibility LED
flashes orange
No calibration Contact GEMÜ
LED 1 lights up yel-
low
LED 2 lights up red
High visibility LED
flashes orange
Set value signal
outside of the area
Check set value sig-
nal
Check precise error
description using
the eSy-Web web
interface
LED 1 lights up yel-
low
LED 2 flashes red
High visibility LED
flashes orange
Temperature error Check temperature
Allow device to
cool down
Check precise error
description using
the eSy-Web web
interface
LED 1 is not lit
LED 2 lights up red
High visibility LED
flashes orange
Supply voltage too
low
Check supply
voltage
Check precise error
description using
the eSy-Web web
interface
3.2 Description
The GEMÜ SU60 motorized hollow shaft actuator is based on
technology that does not use brushes or sensors and there-
fore guarantees high performance and a long service life.
3 Product description

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4 Correct use
Thanks to its integrated positioner and process controller, the
actuator is not only ideal for OPEN/CLOSE applications, but
also for variable and complex control applications.
The actuator is joined to the media wetted GEMÜ SUB unit,
comprising a valve body and welded sealing diaphragm, by
means of a clamp connection.
After use, the media wetted GEMÜ SUB unit can easily be dis-
connected from the actuator and replaced. The actuator re-
mains in the plant.
3.3 Function
The product, consisting of the SUB single-use diaphragm
valve and the SU60 motorized actuator, is designed for use in
single-use systems in plastic pipe and hose lines.
The product controls or regulates (depending on version) a
flowing medium by being closed or opened by a motorized ac-
tuator.
The product has an optical position indicator as standard. The
optical position indicator indicates the OPEN and CLOSED po-
sitions.
3.4 Product label
3.4.1 Actuator
Design in accordance with order data
Item number
Device-specific data
Year of manufacture
Traceability number Counting number
12103529 I0001
SU60C C1L0
0A
2021
88744763
24V DC 48W
DE
Fritz-Müller-Str. 6-8
D-74653 Ingelfingen
3.4.2 Valve body packaging
Design in accordance with order data
Item number
Device-specific data
Year of manufacture
Traceability number Counting number
12103529 I0001
SUB B15DHBB8D8 15HB
2021
88380690
PS 4,0 bar
DE
Fritz-Müller-Str. 6-8
D-74653 Ingelfingen
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.
Because the actuator remains in the plant, there is a complete SUMONDO valve consisting of the SU60 motorized actuator (with
distance piece and clamping device) and the SUB diaphragm valve body (with a fixed internally welded diaphragm).
5.1 SU60 motorized actuator
Order codes
1 Type Code
Single-use actuator, motorized
metal version
SU60
2 Diaphragm size Code
Diaphragm size B B
Diaphragm size C C
Diaphragm size D D
3 Diaphragm mounting Code
Pin G
4 Voltage/Frequency Code
24 V DC C1
5 Control module Code
OPEN/CLOSE, positioner and process controller L0
6 Actuator version Code
Actuator size 0 0A
Order example SU60
Ordering option Code Description
1 Type SU60 Single-use actuator, motorized
metal version
2 Diaphragm size B Diaphragm size B
3 Diaphragm mounting G Pin
4 Voltage/Frequency C1 24 V DC
5 Control module L0 OPEN/CLOSE, positioner and process controller
6 Actuator size 0A Actuator size 0
5 Order data
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5.2 Diaphragm valve body SUB
Order codes
1 Type Code
Single-use body SUB
2 Diaphragm size Code
Diaphragm size B B
Diaphragm size C C
Diaphragm size D D
3 Connection size 1 Code
1/4" (DN 8) 8
3/8" (DN 10) 10
1/2" (DN 15) 15
3/4" (DN 20) 20
1" (DN 25) 25
4 Body configuration Code
2/2-way body D
Angle valve body, right R
T body T
5 Connection Code
Clamp connection similar to ASME-BPE CA
Hose barb HB
6 Body material Code
PP-R, natural B8
7 Diaphragm material Code
TPE K8
8 Connection size 2 Code
1/4" (DN 8) 8
3/8" (DN 10) 10
1/2" (DN 15) 15
3/4" (DN 20) 20
1" (DN 25) 25
9 Connection of spigot 2 Code
Clamp connection similar to ASME-BPE CA
Hose barb HB
Order example SUB
Ordering option Code Description
1 Type SUB Single-use body
2 Diaphragm size B Diaphragm size B
3 Connection size 1 10 3/8" (DN 10)
4 Body configuration T T body
5 Connection HB Hose barb
6 Body material B8 PP-R, natural
7 Diaphragm material K8 TPE
8 Connection size 2 10 3/8" (DN 10)
9 Connection of spigot 2 HB Hose barb
5 Order data
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6 Technical data
6.1 Medium
Working medium: Corrosive, inert, liquid media which have no negative impact on the
physical and chemical properties of the body and diaphragm material.
6.2 Temperature
Media temperature: 5 — 40 °C
Ambient temperature: 0 — 40 °C
Storage temperature: 0 — 40 °C
6.3 Pressure
Operating pressure: 0 – 4.9 bar (Diaphragm size code B, C),
0 – 4.5 bar (Diaphragm size code D)
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6 Technical data

6.3.1 Kv values
AG 1) MG Connection
type
code 2)
Body config-
uration
code 3)
Kv value [m³/h] Cv value [US-gpm]
8 B HB D 0.47 0.55
10 HB D 1.08 1.26
T1.03 1.21
R1.02 1.19
15 HB D 1.59 1.86
T1.47 1.72
R1.44 1.68
15 C HB D 2.17 2.54
20 HB D 3.29 3.85
T2.15 2.52
CA D 3.29 3.85
T2.15 2.52
25 HB D 4.55 5.32
T3.81 4.46
CA D 4.55 5.32
T3.81 4.46
20 D CA, HB D 9.21 10.78
25 CA, HB D 12.19 14.26
AG = connection size
MG = diaphragm size
Kv values determined based on DIN EN 60534-2-3:1998 standard, inlet pressure 4 bar, Δp 1 bar
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 and temperature from the process. Therefore the Kv values may exceed the tolerance limits of the standard.
1) Connection size 1
Code 8: 1/4" (DN 8)
Code 10: 3/8" (DN 10)
Code 15: 1/2" (DN 15)
Code 20: 3/4" (DN 20)
Code 25: 1" (DN 25)
2) Connection
Code CA: Clamp connection similar to ASME-BPE
Code HB: Hose barb
3) Body configuration
Code D: 2/2-way body
Code R: Angle valve body, right
Code T: T body
6.4 Product conformity
NOTICE
Certifications
▶The certifications only apply to the diaphragms and valve bodies (medium wetted parts) and not the actuator.
Certifications: - USP Bacterial Endotoxins Test, USP <85>
- USP Biological Reactivity Test in vitro, USP <87>
- USP Biological Reactivity Tests in vivo for Class VI, USP <88>
- USP Physicochemical Tests for Plastics, USP <661>
- USP Particulate Matter in Injections, USP <788>, USP <790>
- Validation guide on request
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6 Technical data

Machinery Directive: 2006/42/EC
Pressure Equipment Dir-
ective:
2014/68/EU
EMC Directive: 2014/30/EU
6.5 Mechanical data
Service life: Diaphragm valve body
(SUB):
1000 switching cycles (according to GEMÜ product validation)
or max. 4.5 years from production date (1.5 years before steril-
ization/3 years after sterilization)
Protection class: Protection class IP 65 acc. to EN 60529
Actuating speed: Adjustable, max. 6 mm/s
Weight: Body
Type Con-
nec-
tion
Code
1)
Body
con-
figur-
ation
Code
2)
MG B MG C MG D
1/4”
(DN 8)
3/8”
(DN 10)
1/2”
(DN 15)
1/2”
(DN 15)
3/4”
(DN 20)
1”
(DN 25)
3/4”
(DN 20)
1”
(DN 25)
SUB HB D 36 40 42 91 94 99 80 80
T- 44 47 - 108 113 - -
R- 43 46 - - - - -
CA D - - - - 97 100 99 100
T- - - - 111 112 - -
Weight in g, MG = diaphragm size
1) Connection
Code CA: Clamp connection similar to ASME-BPE
Code HB: Hose barb
2) Body configuration
Code D: 2/2-way body
Code R: Angle valve body, right
Code T: T body
Complete unit (actuator, distance piece and body)
MG Weight
B 3.9
C 4.0
D 4.1
Weights in kg
6.6 Electrical data
Supply voltage: Actuator size 0
Voltage Uv = 24 V DC ± 10%
Power Max. 14 W
Operating mode (OPEN/CLOSED operation) Continuous duty
Operating mode (control operation) Class C acc. to EN 15714-2
Reverse battery protection Yes
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6 Technical data

6.6.1 Analogue input signals
6.6.1.1 Set value
Input signal: 0/4 - 20 mA; 0 – 10 V DC (selectable using software)
Input type: passive
Input resistance: 250 Ω
Accuracy/linearity: ≤ ±0.3% of full flow
Temperature drift: ≤ ±0.1% / 10°K
Resolution: 12 bit
Reverse battery protec-
tion:
No
Overload proof: Yes (up to ± 24 V DC)
6.6.1.2 Process actual value
Input signal: 0/4 - 20 mA; 0 – 10 V DC (selectable using software)
Input type: passive
Input resistance: 250 Ω
Accuracy/linearity: ≤ ±0.3% of full flow
Temperature drift: ≤ ±0.1% / 10°K
Resolution: 12 bit
Reverse battery protec-
tion:
No
Overload proof: Yes (up to ± 24 V DC)
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6 Technical data

6.6.2 Digital input signals
Digital inputs: 3
Function: selectable using software
Voltage: 24 V DC
Logic level "1": >14 V DC
Logic level "0": < 8 V DC
Input current: typ. 2.5 mA (at 24 V DC)
6.6.3 Analogue output signals
6.6.3.1 Actual value
Output signal: 0/4 - 20 mA; 0 – 10 V DC (selectable using software)
Output type: Active (AD5412)
Accuracy: ≤ ±1% of full flow
Temperature drift: ≤ ±0.1% / 10°K
Load resistor: ≤ 750 kΩ
Resolution: 10 bit
Overload proof: Yes (up to ± 24 V DC)
Short-circuit proof: Yes
6.6.4 Digital output signals
6.6.4.1 Switching outputs 1 and 2
Design: 2x change-over contact, potential-free
Switch rating: 125 V AC / 2 A
48 V DC / 2 A
Switch points: Adjustable 0 - 100 %
6.6.4.2 Switching output 3
Function: Signal fault
Type of contact: Push-Pull
Switching voltage: Supply voltage
Switching current: ≤ 0.1 A
Drop voltage: Max. 2.5 V DC at 0.1 A
Overload proof: Yes (up to ± 24 V DC)
Short-circuit proof: Yes
Pull-Down resistance: 120 kΩ
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6 Technical data

6.6.5 eSy-Web communication
Interface: Ethernet
Function: Parameterisation via web browser
IP address: 192.168.2.1 alterable via web browser
Subnet screen: 255.255.252.0 alterable via web browser
The actuator and the PC must be in the same network to use the web server. The IP address of the actuator is entered in the
web browser and the actuator can then be parametrised. In order to use more than one actuator, a definitive IP address must be
assigned to each actuator in the same network.
6.6.6 Modbus TCP communication
Interface: Modbus TCP
IP address: 192.168.2.1 alterable via web browser
Subnet screen: 255.255.252.0 alterable via web browser
Port: 502
Supported function
codes:
Code Dezimal Code Hex Function
3 0x03 Read Holding Registers
4 0x04 Read Input Registers
6 0x06 Write Single Register
16 0x10 Write Multiple Registers
23 0x17 Read/Write Multiple Registers
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6 Technical data

7 Dimensions
7.1 Actuator dimensions
A
D
MG DN A A1 A2 A3 ∅B B1 B2 B3 B4 ∅C∅D
B 1/4'' (DN 8),
1/2" (DN 15)
274.6 269.5 232.1 10.0 91.0 125.5 160.0 184.1 34.7 64.0 62.0
C 3/4'' (DN 20),
1'' (DN 25)
275.9 256.3 221.9 10.0 91.0 125.5 160.0 184.1 34.7 91.0 62.0
D 3/4'' (DN 20),
1'' (DN 25)
272.9 249.1 210.3 10.0 91.0 125.5 160.0 184.1 34.7 91.0 62.0
Dimensions in mm, MG = diaphragm size
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7 Dimensions

7.2 Body dimensions
7.2.1 Angle valve body, right (code R)
H1
H2
L1
Ø D
L3
L2
Connection type hose barb (code HB)
MG DN øD H1 H2 L1 L2 L3
B 3/8” (DN 10) 64.0 33.3 22.3 48.0 58.0 10.0
1/2” (DN 15) 64.0 33.3 22.3 55.8 66.8 10.0
Dimensions in mm, MG = diaphragm size
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7 Dimensions

7.2.2 2/2-way body (code D)
H1
H2
ØD
L L
Clamp (CA) Hose barb (HB)
Connection type clamp (code CA) 1)
MG DN øD H1 H2 L
C 3/4”(DN 20) 91.0 60.0 35.3 128.0
1”(DN 25) 91.0 60.0 35.3 137.4
D 3/4”(DN 20) 91.6 58.5 38.0 134.6
1”(DN 25) 91.6 58.5 39.5 134.6
Connection type hose barb (code HB) 1)
MG DN øD H1 H2 L
B 1/4” (DN 8) 64.0 33.3 22.3 80.6
3/8” (DN 10) 64.0 33.3 22.3 95.9
1/2” (DN 15) 64.0 33.3 22.3 111.5
C 1/2” (DN 15) 91.0 60.0 35.3 126.0
3/4” (DN 20) 91.0 60.0 35.3 128.0
1” (DN 25) 91.0 60.0 35.3 140.0
D 3/4” (DN 20) 91.6 58.5 38.0 139.0
1” (DN 25) 91.6 58.5 39.5 139.0
Dimensions in mm, MG = diaphragm size
1) Connection
Code CA: Clamp connection similar to ASME-BPE
Code HB: Hose barb
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7 Dimensions

7.2.3 T valve body (Code T)
H1
H2
ØD
L2
L2
L3
L1
L1
Clamp (CA) Hose barb (HB)
Hose barb (HB)
Clamp (CA)
Connection type clamp (code CA) 1)
MG DN ØD H1 H2 L1 L2 L3
C 3/4” (DN 20) 91.0 60.0 35.3 128.0 82.0 18.0
1” (DN 25) 91.0 60.0 35.3 137.4 82.0 18.0
Connection type hose barb (code HB) 1)
MG DN ØD H1 H2 L1 L2 L3
B 3/8” (DN 10) 64.0 33.3 22.3 96.0 58.0 10.0
1/2” (DN 15) 64.0 33.3 22.3 111.5 65.8 10.0
C 3/4” (DN 20) 91.0 60.0 35.3 128.0 82.0 18.0
1” (DN 25) 91.0 60.0 35.3 140.0 88.0 18.0
Dimensions in mm, MG = diaphragm size
1) Connection
Code CA: Clamp connection similar to ASME-BPE
Code HB: Hose barb
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7 Dimensions