Gemini Valve 600 Series Instruction Manual

2 Otter Court, Raymond, New Hampshire 03077 Tel. [phone] FAX [phone] www.geminivalve.com
TECHNICALDATASHEET
600 Series Electric Actuators
MATERIALS OF CONSTRUCTION
ENCLOSURE: Dupont®FR50 Cover, Teflon®Coated Cast Aluminum Base
SHAFT: 18-8 Stainless Steel
EXTERNAL TRIM: 300 Series Stainless Steel
RATINGS / SPECIFICATIONS
TEMPERATURE: 40° F to 150°F
ENCLOSURE: NEMA 4X, UL® 508 AC Models Only
MOTOR: Reversing,Brushless,Capacitor-RunwithAuto-ResetThermalOverloadProtection.
GEAR TRAIN: Permanently Lubricated, Maintenance Free
POWER: 120VAC 50/60 Hz Single Phase
PORTS: (2) 1/2” N.P.T. Conduit
CYCLE TIME: 6 Seconds
DUTY CYCLE: AC Models 615 & 630 78%, DC Models 615 100%, 630 75%
TORQUE OUTPUT: Models; 615 AC - 150 in-lbs, 630AC - 300 in-lbs., all 12 & 24DC 250 in-lbs.
OVERRIDE: Manual - Fold Out Lever Handle
DESCRIPTION
The 600 Series electric actuators can be used with all sizes of
the Gemini 76, 86, 96, 82, 89 and 309 Series ball valves. Two
modelsizesareavailable,the 150 in-lb model615andthe300
in-lb model 630.
TDS013-1406

MANUAL OVERRIDE OPERATION
The push-button manual override system allows the user to easily disengage the electric drive gear train for
manual operation of the actuator. All external power must be off prior to using the manual override feature.
The actuator manual override handle can be used in the closed or open (lever extended) position to provide
additional leverage. To open the handle, pinch the Lever Release Buttons and pull up. Press down the
manual override button (atop the center) and turn the handle to manually open or close the actuated valve
assembly. To reengage the drive train, release the override button and turn the handle until the manual
override button ‘clicks’ signaling the re-engagement of the drive train. The manual override lever handle can
then be closed.
Lever Release Buttons Manual Override Button
DIMENSIONS
Model Output
(Inch Lbs.) Cycle Time (Seconds) Amps (Full Load) Duty Cycle* HI
UL®
A508
615-120AC 150 6 0.3 78% 10.35 7.19 Yes
630-120AC 300 6 0.5 78% 10.85 7.69 Yes
615-12VDC 250 6 1 100% 10.35 7.19 -
630-12VDC 250 6 1 75% 10.85 7.69 -
615-24VDC 250 6 .5 100% 10.35 7.19 -
630-24VDC 250 6 .5 75% 10.85 7.69 -
*DutyCycle Measured at Maximun Output 40°C Ambiemt

These instructions detail the procedure for installing a Gemini 600 Series electric actuator on a drive-key
equipped Gemini 76, 82, 86, 96 & 89 Series ball valve. Valves may be purchased with the drive-key as-
sembled or may be retrofitted with a drive-key conversion kit.
76, 82, 86 & 96 Series:
1. Install locator screws in bottom of the elec-
tric actuator and tighten with 4mm hex drive
torqued to 30-40 inch lbs. (Figure 1)
2. Place the mounting bracket on actuator so
that locator screws fit into blind holes on bot-
tom of bracket.
3. Check to make sure the bracket is seated
flush against bottom of electric actuator mount-
ing pad. Install bracket mounting screws with
5mm hex drive torqued to 65-75 inch lbs.
4. Checkto makesurethatvalveisintheclosed
position and that the stem nut is in the proper
orientation with respect to the drive key (Figure
2). Note: Valve will not engage driver unless
stem nut is in proper orientation.
5. Verify that the actuator is in the closed posi-
tion. The override handle should be parallel to
the short side of the unit as illustrated.
6. Installthevalveinto the mountingbracketas
shown in Figure 3. Engagement of the valve
and drive mechanism should require little ef-
fort. The top of the valve should lie flat in the
appropriate step so that the bracket straddles
the sides of the hex to resist any rotation.
7. Position the retainer on the underside of the
valve and fasten to the actuator bracket with
the two hex head cap screws. Alternate tight-
ening the screws to ensure balanced tension
and to avoid skewing of the valve retainer strap
relative to the valve body. Agap should remain
between the lower surface of the bracket and
the retainer ‘ears’ when the assembly is com-
plete (Figure 4). Your Gemini actuated valve is
now ready for service.
Figure 1
Figure 2
Figure 3
Figure 4
ACTUATOR TO VALVE MOUNTING INSTRUCITONS
76, 82, 86, & 96 SERIES

ACTUATOR TO VALVE MOUNTING INSTRUCITONS
89 SERIES
89 Series:
1. Install locator screws in bottom of the elec-
tric actuator and tighten with 4mm hex drive
torqued to 30-40 inch lbs. (Figure 1)
2. Place the mounting bracket on actuator so
that locator screws fit into blind holes on bot-
tom of bracket.
3. Check to make sure the bracket is seated
flush against bottom of electric actuator mount-
ing pad. Install bracket mounting screws with
5mm hex drive torqued to 65-75 inch lbs. .
4. Checkto makesurethatvalveisintheclosed
position and that the stem nut is in the proper
orientation with respect to the drive key (Figure
2). Note: Valve will not engage driver unless
stem nut is in proper orientation.
5. Verify that the actuator is in the closed posi-
tion. The override handle should be parallel to
the short side of the unit as illustrated.
6. Installthevalveinto the mountingbracketas
shown in Figure 3. Engagement of the valve
and drive mechanism should require little ef-
fort. Installvalvemountingscrews. YourGemini
actuated valve is now ready for service.
Figure 3
Figure 2
Figure 1

WIRING INSTRUCTIONS - AC MODELS
These instructions detail the procedure for wiring Gemini 600 Series AC model electric actuators.
1. Unlatch and open the override handle to
access the handle nut. Remove nut with 3/4”
wrench.
2. Remove eight (8) socket head screws with
3mm hex wrench. Remove cover by pulling
straight up.
3. Route the wire to be terminated through con-
duit hub and up through the access space to the
terminal block. Strip insulation back 1/4”, insert
the stripped ends directly into the proper terminal
clamps and tighten screws. All internal connec-
tions are labeled in the diagram below.
4. Attach grounding wire to green screw that is
located on top of conduction bar.
5. Verify that cover o-ring is properly seated in
groove. Replace cover and screws.
Connections 1 through 5 are to be made by field electrician

120AC Wiring Schematic

WIRING INSTRUCTIONS - DC MODELS
These instructions detail the procedure for wiring Gemini 600 Series DC model electric actuators.
1. Unlatch and open the override handle to access
the handle nut. Remove nut with 3/4” wrench.
2. Remove eight (2) socket head screws with 4mm
hex wrench. The other (6) screws used to secure
thecoverare locatedinsideenclosedin aplasticbag.
Remove cover by pulling straight up.
3. Route the wire to be terminated through conduit
hub and up through the access space to the terminal
block. Strip insulation back 1/4”, insert the stripped
ends directly into the proper terminal clamps and
tighten screws. All internal connections are labeled
in the diagram below.
Negative(-)to Terminal1 and Positive(+)toTerminal
2 Ball Valve / Actuator will Open. Positive (+) to Ter-
minal 1 and Negative (-) to Terminal 3 Ball Valve /
Actuator will Close. CAUTION: Positive (+) should
only be applied to Terminal 1 & 2 independent of each
other by using a Double-Pole / Double-Throw (DPDT)
switch or device.
4. Verify that cover o-ring is properly seated in groove.
Replace cover and screws.