GEM R639 User manual

GEMÜ R639 eSyStep
Positioner (Code S0)
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
05.02.2021
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Positioner (Code S0)

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
4 Correct use ............................................................... 6
5 Order data ................................................................. 7
6 Technical data .......................................................... 8
7 Dimensions ............................................................... 13
8 Manufacturer's information ....................................... 21
8.1 Delivery ................................................................ 21
8.2 Packaging ............................................................ 21
8.3 Transport ............................................................. 21
8.4 Storage ................................................................. 21
9 Installation in piping .................................................. 21
9.1 Preparing for installation .................................... 21
9.2 Installation position ............................................ 22
9.3 Installation with butt weld spigots ..................... 22
9.4 Installation with threaded sockets ..................... 22
9.5 Installation with union ends ................................ 23
9.6 Installation with solvent cement sockets .......... 23
9.7 Installation with flare connection ....................... 23
10 Electrical connection ................................................. 24
11 Specific data IO-Link (pin 6) ...................................... 26
11.1 Operation on IO-Link ........................................... 26
11.2 Process data ........................................................ 29
11.3 Parameter overview ............................................ 30
11.4 Parameter ............................................................ 34
11.5 Events .................................................................. 51
12 Operation .................................................................. 53
12.1 Initialization ......................................................... 53
12.2 Manual override ................................................... 53
13 Inspection and maintenance ...................................... 54
14 Troubleshooting ........................................................ 57
15 Removal from piping ................................................. 59
16 Disposal .................................................................... 59
17 Returns ..................................................................... 59
18 Declaration of Incorporation according to 2006/42/
EC (Machinery Directive) ........................................... 60
19 Declaration of conformity according to 2014/68/EU
(Pressure Equipment Directive) ................................. 61
20 Declaration of conformity according to 2014/30/EU
(EMC Directive) ......................................................... 62
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www.gemu-group.com4 / 63GEMÜ R639 eSyStep
Positioner (Code S0)
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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Positioner (Code S0)
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
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 connections
6 Diaphragm NBR, FKM, 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 is a motorized 2/2-way diaphragm valve. The
eSyStep electric actuator is available as ON/OFF or with integ-
rated positioner. An integral optical and electrical position in-
dicator is standard. The self-locking actuator holds its posi-
tion 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
3 Body configuration Code
2/2-way body D
4 Connection type Code
Threaded socket
Threaded socket DIN ISO 228 1
Solvent cement socket
Solvent cement socket DIN 2
Union end
Union end with insert (socket) - DIN 7
Union end with inch insert - BS (socket) 33
Union end with insert (for IR butt welding) - DIN 78
Spigot
Spigot for IR butt welding, BCF 28
Flare
Flare connection with PVDF union nut 75
5 Valve body material Code
PVC-U, grey 1
PP, reinforced 5
PVDF 20
PP-H, natural N5
6 Diaphragm material Code
NBR 2
FKM 4
EPDM 29
PTFE/EPDM one-piece 54
7 Voltage/Frequency Code
24 V DC C1
8 Control module Code
Positioner S0
Positioner, configured for emergency power supply
module (NC)
S5
Positioner, configured for emergency power supply
module (NO)
S6
9 Actuator version Code
Actuator size 0
diaphragm size 10
0C
Actuator size 1 1A
10 Mounting plate Code
With mounting plate M
Without mounting plate O
without
Order example
Order 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 S0 Positioner
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: Code Valve body material
PVC-U, grey 10 — 60 °C
PP, reinforced 5 — 80 °C
PVDF -10 — 80 °C
PP-H, natural 5 — 80 °C
Ambient temperature: Code Valve body material
PVC-U, grey 10 — 50 °C *
PP, reinforced 5 — 50 °C *
PVDF 0 — 50°C *
PP-H, natural 5 — 50 °C *
* je nach Ausführung und/oder Betriebsparametern (siehe Kapitel Einschalt- und Lebensdauer)
6.3 Pressure
Operating pressure: MG DN EPDM / FKM PTFE
10 12 0 - 6 0 - 6
15 0 - 6 0 - 6
20 0 - 6 0 - 6
20 15 0 - 8 0 - 8
20 0 - 8 0 - 8
25 0 - 8 0 - 8
25 32 0 - 8 0 - 8
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.
Pressure/temperature
correlation:
Pressure/temperature correlation PN 6
Valve body material Temperature in °C (valve body)
Materials Code -20 -10 ±0 5 10 20 25 30 40 50 60 70 80
PVC-U 1 - - - - 6.0 6.0 6.0 4.8 3.6 2.1 0.9 - -
PP 5 - - - 6.0 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 5.4 4.8 4.3 3.8 3.2 2.8
PP-nat-
ural
N5 - - - 6.0 6.0 6.0 6.0 5.1 4.2 3.3 2.4 1.6 0.9
The pressure rating (PN) depends on the connection code.
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.
Leakage rate: Leakage rate A to P11/P12 EN 12266-1
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6 Technical data

Kv values: MG DN Kv values
10 12 2.8
15 3.5
20 3.5
20 15 6.0
20 10.0
25 12.0
25 32 20.0
MG = diaphragm size, Kv values in m³/h
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.
6.4 Product compliance
Pressure Equipment Dir-
ective:
2014/68/EU
Machinery Directive: 2006/42/EU
FDA*
USP* Class VI
* depending on version and/or operating parameters
EMC Directive: 2014/30/EU
Interference resistance: DIN EN 61000-6-2
DIN EN 61326-1 (industrial processes)
Interference emission: DIN EN 61000-6-4 (Sep. 2011)
Interference emission class: Class A
Interference emission group: Group 1
6.5 Materials
Materials: Diaphragm material O-ring material
PTFE FKM
NBR EPDM
FKM FKM
EPDM EPDM
6.6 Mechanical data
Protection class: IP 65 acc. to EN 60529
Actuating speed: Max. 3 mm/s
Weight: Actuator
Actuator size 0 (code 0C) 0.95 kg
Actuator size 1 (code 1A) 1.88 kg
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6 Technical data

Weight: Valve body
MG DN Threaded
socket
Solvent
cement
socket
Union end Spigot Flare
Connection types code
1 2 7 33 78 28 75
10 12 0.08 0.06 - - - - -
15 - - 0.18 0.13 0.20 0.13 0.08
20 - - - - - - 0.125
20 15 - - 0.17 0.26 0.27 - -
20 - - 0.21 0.30 0.36 - -
25 - - 0.26 0.38 0.37 - -
25 32 - - 0.40 0.73 0.63 - -
MG = diaphragm size, weight in kg
Mechanical environ-
mental conditions:
Class 4M8 acc. to EN 60721-3-4:1998
Vibration: 5g acc. to IEC 60068-2-6 Test Fc
Shock: 25g acc. to 60068-2-27 Test Ea
6.7 Duty cycle and service life
Service life: Control operation - Class C according to EN 15714-2 (1,800,000 starts and 1200 starts per hour).
Open/Close duty - At least 500,000 switching cycles at room temperature and permissible duty
cycle.
Duty cycle: Control module Positioner (code S0, S5, S6), Open/Close duty
0 10 20 30 40 50 60 70
0
10
20
30
40
50
60
70
80
90
100
Duty cycle [%]
Ambient temperature [°C]
Diaphragm valve DN 12 - 20 (code 0C / 1A)
NOTICE
▶The specified characteristics and values apply to the factory 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
6.8 Electrical data
Supply voltage Uv: 24 V DC ± 10%
Rating: Actuator size 0 (code 0A) 20 W
Actuator size 1 (code 1A) 60 W
Operation: Stepper motor, self-locking
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6 Technical data

Reverse battery protec-
tion:
Yes
6.8.1 Analogue input signals – Control module Positioner (code S0, S5, S6)
6.8.1.1 Set value
Input signal: 0/4 - 20 mA; 0 - 10 V (function selectable via IO-Link)
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:
Yes (up to ± 24 V DC)
6.8.2 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
6.8.3 Analogue output signals – Control module Positioner (code S0, S5, S6)
6.8.3.1 Actual value
Output signal: 0/4 - 20 mA; 0 - 10 V (function selectable via IO-Link)
Output type: active
Accuracy: ≤ ±1% of full flow
Temperature drift: ≤ ±0.1% / 10°K
Load resistor: ≤ 750 kΩ
Resolution: 12 bit
Short-circuit proof: Yes
6.8.4 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
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6 Technical data

Short-circuit proof: Yes
6.8.5 Communication
Interface: IO-Link
Function: Parameterization/process data
Transmission rate: 38400 baud
Frame type in Operate: 2.V (eSyStep positioner, code S0, S5, S6),
PDout 3Byte; PDin 3 Byte; OnRequestData 2 Byte
Min. cycle time: 20 ms (eSyStep positioner, code S0, S5, S6)
Vendor-ID: 401
Device-ID: 1906801 (eSyStep positioner, code S0, S5, S6),
Product-ID: eSyStep Positioner (code S0, S5, S6)
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

7 Dimensions
7.1 Installation and actuator dimensions
7.1.1 Actuator version code 0C
B2
B1
A
A1
B
CT*
A2
MG DN Actuator version A A1 A2 B B1 B2
10 12 0C 203.5 39.0 33.2 59.4 81.0 133.5
15 0C 203.5 39.0 33.2 59.4 81.0 133.5
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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7 Dimensions

7.1.2 Actuator version code 1A
B2
B1
A
A1
B
CT*
A2
MG DN Actuator version A A1 A2 B B1 B2
20 15 1A 298.0 116.0 32.5 70.0 82.0 150.0
20 1A 298.0 116.0 32.5 70.0 82.0 150.0
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
Dimensions in mm, MG = diaphragm size
* CT = A + H1 (see body dimensions)
7.2 Body dimensions
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7 Dimensions

7.2.1 Union end DIN (code 7 / MG 20 - 25)
L1
H1
H
L2
R
ØD
Ød
MG DN Connection type code 7 1)
Material code 1 2)
R NPS øD L1 H H1 ød L2
20 15 G 1 1/2" 43.0 108.0 36.0 10.0 20.0 146.0
20 G 1¼ 3/4" 53.0 108.0 38.0 12.0 25.0 152.0
25 G 1½ 1" 60.0 116.0 39.0 13.0 32.0 166.0
25 32 G 2 1¼" 74.0 134.0 41.0 15.0 40.0 192.0
Dimensions in mm, MG = diaphragm size
1) Connection type
Code 7: Union end with insert (socket) - DIN
2) Connection type
Code 1: Threaded socket DIN ISO 228
L1
L2
ØD
ød
R
H1
H
MG DN Connection type code 7 1)
Material code 2)
1, 20 5, N5 1, 20 5, N5 1, 20 5, N5
R øD ød L1 L2 H H1
10 15 G1 43.0 20.0 90.0 128.0 125.0 30.0 41.0 15.0 16.0
Dimensions in mm, MG = diaphragm size
1) Connection type
Code 7: Union end with insert (socket) - DIN
2) Valve body material
Code 1: PVC-U, grey
Code 5: PP, reinforced
Code 20: PVDF
Code N5: PP-H, natural
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7 Dimensions

See also
2Union end DIN (code 7 / MG 20 - 25) [}15]
7.2.2 Union end code 78
L1
L2
ØD
Ød
R
H1
H
s
c
MG DN Connection type code 78 1)
Material code 2)
5 20, N5 5 20, N5
R L1 L2 øD ød s c H H1
10 15 G 1 90.0 196.0 42.0 20.0 1.9 36.0 30.0 41.0 15.0 16.0
Dimensions in mm, MG = diaphragm size
1) Connection type
Code 78: Union end with insert (for IR butt welding) - DIN
2) Valve body material
Code 5: PP, reinforced
Code 20: PVDF
Code N5: PP-H, natural
7.2.3 Union end code 33
L1
L2
ØD
ød
R
H1
H
MG DN Connection type code 33 1)
Material code 1 2)
L1 L2 H H1 øD ød R
10 15 90.0 128.0 30.0 15.0 43.0 21.4 G1
Dimensions in mm, MG = diaphragm size
1) Connection type
Code 33: Union end with inch insert - BS (socket)
2) Valve body material
Code 1: PVC-U, grey
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7 Dimensions

7.2.4 Threaded socket code 1
L
t
H
H1
R
MG DN Connection type code 1 1)
Material code 2)
1, 5 20 1, 5 20
L R t H H H1 H1
10 12 55.0 G3/8 13.0 27.5 31.5 12.5 12.5
Dimensions in mm, MG = diaphragm size
1) Connection type
Code 1: Threaded socket DIN ISO 228
2) Valve body material
Code 1: PVC-U, grey
Code 5: PP, reinforced
Code 20: PVDF
7.2.5 Solvent cement socket code 2
L
t
H
H1
øD
MG DN Connection type code 1)
Material code 2)
ø D t H H1 L
10 12 16.0 13.0 27.5 12.5 55.0
Dimensions in mm, MG = diaphragm size
1) Connection type
Code 2: Solvent cement socket DIN
2) Valve body material
Code 1: PVC-U, grey
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7 Dimensions

7.2.6 Spigot, connection type code 28
c1
L
ød
H1
H
c
3
s
c1
L
ød
H1
H
c
3
s
MG DN Connection type code 28 1)
Material code 20 2)
L H H1 ød s c c1
10 15 134 41 16 20 1.9 31 37
Dimensions in mm, MG = diaphragm size
1) Connection type
Code 28: Spigot for IR butt welding, BCF
2) Valve body material
Code 20: PVDF
Dimensions in mm
MG = diaphragm size
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7 Dimensions

7.2.7 Flare connection, code 75
L
D
H1
H
N2
N1
N3
MG DN Connection type code 75 1)
Material code N5 2)
L H H1 øD N1 N2 øN3
10 15 132.0 38.1 10.0 26.5 40.0 62.0 5.5
20 134.0 44.5 15.0 26.5 40.0 62.0 5.5
Dimensions in mm, MG = diaphragm size
1) Connection type
Code 75: Flare connection with PVDF union nut
2) Valve body material
Code N5: PP-H, natural
7.3 Valve body mounting
M
f
Dimensions in mm
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7 Dimensions

7.4 Mounting plate
HM
62
40
ø5,5
MG DN HM
10 12 5.0
15 4.5
20 4.5
Dimensions in mm, MG = diaphragm size
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7 Dimensions