Gemu 653 Operating and maintenance manual

VMS - Rev.02 26.04.2004 1
Aseptic Diaphragm Valves
Maintenance & Operating
Guidelines

VMS - Rev.02 26.04.2004 2
Maintenance Overview
Travel Stops
Diaphragm Replacement
Torquing Guideline
Accessories

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Travel Stop Setting
Travel Stops
Prevent Over-closure
•Remove the cap screw.
•Remove the handle, invert it and remount it on
the spindle
•Turn the handle clockwise until the resistance of
the diaphragm seating is felt. Turn the handle
another 180 degrees.
•Tighten the travel stop clockwise until it is tight
against the bonnet
•Re-assemble the handle and cap screw

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653 / 654 Operating Instructions
Setting stroke limiter (opening) and seal adjuster (closing)
1. Remove the cap (12) from the center of the handwheel.
Turn the hand wheel away from its stop position
so that it can be turned freely in both directions.
2. Turn the stroke limiter (9) counter-clockwise until its
thread becomes visible.
Setting the seal adjuster (closed position)
3. Turn the seal adjuster (6) down clockwise until it stops.
4. Rotate the hand wheel clockwise until the desired
CLOSED position is reached.
Turn the seal adjuster (6) up counter clock-wise until it
stops.
Setting the stroke limiter (open position)
5. Rotate the hand wheel counter-clockwise until the
desired OPEN position is reached.
Turn the stroke limiter (9) down clockwise until it stops.
NOTE: The seal adjuster must not turn during this
procedure.
6. Align the cap and replace it.

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Removing the Process Diaphragm
•Move the valve to the open position
•Remove the fasteners
•Move the valve to the closed position
•Unscrew the diaphragm counter-clockwise or for the
button style push one side down with your index finger
while lifting the other side with your thumb

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Installing the Diaphragm (Concave)
•Type 1: Screw the diaphragm clockwise into the compressor so that the cylindrical boss
around the diaphragm stud fits into the recess of the compressor. When contact (resistance)
is felt, turn the diaphragm back (counterclockwise) until the bolt holes in the diaphragm and
bonnet flange are correctly aligned. Do not continue to tighten.
•Type 2: Place the button of the diaphragm at an angle so that part of the button fits in the
recess of the compressor. Push firmly in the center of the diaphragm while turning it back
and forth until the button seats in the compressor

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Installing the Diaphragm (Convex)
•Position rubber backing on compressor
•Invert the Teflon portion by pressing the center with your thumbs while holding the edges
•Screw the the Teflon face back, clockwise so that the cylindrical boss of the rubber backing fits
completely in the recess of the compressor
•When contact (resistance) is felt turn the Teflon face counterclockwise until the bolt holes in
the diaphragm and the bonnet flange are correctly aligned
•Press the edges of the diaphragm face so that it moves back to the close position
Types 5E and 5S only

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Assembling Actuator to Body
•Align the diaphragm tab with the weir
and install fasteners hand tight
•Bring the valve to the open position
•Close the valve
•Open manual and motorized valves 20%
•Cycle pneumatically actuated valves
3times prior to final tightening
•Tighten the bolts using a cross pattern
•Retighten after the system reaches
operating temperature and pressure

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Torque Guidelines
Seat Thread Units
Min Max Min Max
8
1/2" 4x M 4 [Nm] 0.6 0.8 0.8 1.2
22 x 22 [lbf-in] 5.3 7.1 7.1 10.6
10
3/4" 4x M 5 [Nm] 3 4 3.5 4.5
44 x 39 [lbf-in] 27 35 30 40
25
1" 4x M 8 [Nm] 6.5 8 13 16
54 x 46 [lbf-in] 58 72 115 140
40
1 1/2" 4x M10 [Nm] 12 14 24 28
70 x 65 [lbf-in] 107 125 215 250
50
2" 4x M12 [Nm] 17 19 34 38
82 x 78 [lbf-in] 152 169 300 340
80
3" 4x M16 [Nm] 50 60 100 120
127 x 114 [lbf-in] 445 534 890 1070
100
4" 8x M12 [Nm] 40 50 80 100
LK 194 [lbf-in] 356 445 700 890
125
5" 8x M16 [Nm] 50.0 60 100 120
[lbf-in] 445 534 890 1070
150
6" 8x M16 [Nm] 50 60 100 120
[lbf-in] 445 534 890 1070
EPDM PTFE
Standard values for sealing material
Seat Actuation Type
8601, 602, 603, 605, 618, 640, 641, 650
10 612, 615, 618, 625, 640, 650, 653, 654
620, 640, 650, 653, 654, 671, 672, 673
675, 687, 688, 695, 698
25-150
The specified torques are standard values for
A2 70 screws with light PTFE film.
After repeated maintenance cycles, the
torques necessary for tightening may increase
significantly.
As diaphragms may set in the course of time,
the nuts and bolts on the body should be
checked for tightness and re-tightened if
necessary before commissioning the valve (and
certainly after the first sterilization cycle).
The fasteners must be tightened diagonally
and uniformly. Over-tightening of the screws
will damage the diaphragm.

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Influence on Bolting Torque
Suggested torque values are guidelines
Bolt Characteristics:
Property class of the bolt
Bolt surface treatment
Thread manufacturing (rolled or machine cut)
Lubricants / anti-seize agents
New or used (friction factors)
Tightening procedure
Diaphragm material properties
Diaphragm compression should be
.15-20% of original thickness

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Diaphragm Compression
Extreme

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Diaphragm Compression
Excessive

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Optimum Compression

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Accessory Assembly
1
2
•Remove the actuator cap to
provide access to the fastening
threads
•The first (1) assembly point is
between the indicator stem and
the actuator spindle
•The second (2) assembly point is
between the stroke limiter and the
actuator housing

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Optimum Compression