Gemu F40 User manual

GEMÜ F40
Pneumatically operated filling valve
Operating instructions
EN
further information
webcode: GW-F40

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
07.11.2019
www.gemu-group.com2 / 24GEMÜ F40

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
4 Correct use ............................................................... 6
5 Order data ................................................................. 7
6 Technical data .......................................................... 8
7 Dimensions ............................................................... 11
8 Manufacturer's information ....................................... 14
8.1 Delivery ............................................................... 14
8.2 Packaging ........................................................... 14
8.3 Transport ............................................................ 14
8.4 Storage ............................................................... 14
9 Installation in piping .................................................. 14
9.1 Preparing for installation ................................... 14
9.2 Installation with butt weld spigots .................... 15
9.3 Installation with clamp connections ................. 15
10 Commissioning ......................................................... 15
11 Error clearance .......................................................... 16
12 Inspection/servicing .................................................. 17
13 Removal from piping ................................................. 20
14 Disposal .................................................................... 20
15 Returns ..................................................................... 20
16 Declaration of Incorporation according to 2006/42/
EC (Machinery Directive) ........................................... 21
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1 General information
1 General information
1.1 Information
– The descriptions and instructions apply to the stand-
ard versions. For special versions not described in this
document the basic information contained herein ap-
plies in combination with any additional special docu-
mentation.
– Correct installation, operation, maintenance and repair
work ensure faultless operation of the product.
– Should there be any doubts or misunderstandings, the
German 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 Definition of terms
Working medium
The medium that flows through the GEMÜ product.
Control medium
The medium whose increasing or decreasing pressure
causes the GEMÜ product to be actuated and operated.
Control function
The possible actuation functions of the GEMÜ product.
PD
PD = Plug Diaphragm
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 of explosion
Corrosive chemicals
Hot plant components!

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2 Safety information
The safety information in this document refers only to an in-
dividual 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
responsible for the production of the risk analysis and for
compliance with the resulting precautionary measures and
regional safety regulations.
The document contains fundamental safety information that
must be observed during commissioning, operation and
maintenance. 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 dan-
gerous 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 person-
nel.
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 specifica-
tions.
13. Maintain the product correctly.
14. Do not carry out any maintenance work and repairs not
described in this document without consulting the manu-
facturer first.
In cases of uncertainty:
15. Consult the nearest GEMÜ sales office.
3 Product description
3.1 Construction
3.1.1 Flow direction
1
2
1 → 2, optimal draining and filling properties
over the seat
1
2
under the seat
2 -> 1, better pressure stability and higher flow
3 Product description

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4 Correct use
3.1.2 PD seal system
Vent hole
Leak detection hole
Actuator
Opening protection
PTFE diaphragm
(PD)
Stainless steel
body
3.2 Description
The GEMÜ F40 2/2-way filling valve is designed for filling
processes in aseptic and hygienic areas of application. Flow
rates up to 6,600 l/h are possible depending on the version.
The sealing concept of the valve is based on the GEMÜ PD
design, whereby the actuator is hermetically separated from
the medium. All actuator parts (except the seals) are made
from stainless steel. Normally Closed and Normally Open
control functions are available.
3.3 Function
The product is a pneumatically operated 2/2-way filling valve
in stainless steel. The GEMÜ F40 2/2-way filling valve is de-
signed for installation in piping systems.
The filling valve can be opened or closed via 2 control func-
tions (Normally open and Normally closed).
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
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
Stainless steel PD valve, pneumatic F40
2 DN Code
DN 10 10
DN 15 15
DN 20 20
3 Body configuration Code
2/2-way body D
4 Connection type Code
Spigot
Spigot DIN 0
Spigot EN 10357 series B,
formerly DIN 11850 series 1
16
Spigot EN 10357 series A (formerly DIN 11850
series 2) / DIN 11866 series A
17
Spigot ASME BPE / DIN 11866 series C 59
Clamp
Clamp DIN 32676 series A 86
Clamp ASME BPE 88
5 Valve body material Code
1.4435, investment casting C3
6 Seal material Code
PTFE 5
7 Valve body adaptor Code
Adaptor for PD size 3 3
8 Control function Code
Normally closed (NC) 1
Normally open (NO) 2
9 Actuator version Code
Actuator without accessories, with standard
spring set
0N
Actuator with M12x1 thread for accessories with
standard spring set
1N
10 Bypass Code
On request
11 Surface Code
Ra ≤ 0.8 µm (30 µin.) for media wetted surfaces,
in accordance with DIN 11866 H3,
mechanically polished internal
1502
12 Seat diameter Code
20 mm H
13 Special version Code
Special version for 3A M
Order example
Order option Code Description
1 Type F40 Stainless steel PD valve, pneumatic
2 DN 15 DN 15
3 Body configuration D 2/2-way body
4 Connection type 17 Spigot EN 10357 series A (formerly DIN 11850 series 2) / DIN 11866
series A
5 Valve body material C3 1.4435, investment casting
6 Seal material 5 PTFE
7 Valve body adaptor 3 Adaptor for PD size 3
8 Control function 1 Normally closed (NC)
9 Actuator version 0N Actuator without accessories, with standard spring set
10 Bypass On request
11 Surface 1502 Ra ≤ 0.8 µm (30 µin.) for media wetted surfaces,
in accordance with DIN 11866 H3,
mechanically polished internal
12 Seat diameter H 20 mm
13 Special version M Special version for 3A
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.
Control medium: Inert gases
6.2 Temperature
Media temperature: -10 to 140 °C
Sterilisation temperature: Hot water max. 4 bar at 140 °C, max. 60 min
Steam max. 2 bar at 140 °C, max. 60 min
Control medium
temperature:
max. 60 °C
Ambient temperature: -10 to 60 °C
Storage temperature: 0 to 40 °C
6.3 Pressure
Operating pressure: C.f. 1 over the seat max. 7 bar (1 → 2)
C.f. 1 under the seat max. 6 bar (2 → 1)
C.f.2 max. 7 bar
Control pressure: C.f. 1 6 to 7 bar
C.f.2 max. 6 bar
Control pressure – Operating pressure characteristic
0123456789
6
5.5
5
4.5
4
3.5
3
2.5
2
1.5
1
0.5
0
Control pressure [bar]
Operating pressure [bar]
Flow direction
under the seat Flow direction
over the seat
Filling volume: C.f. 1 0.017 dm³
C.f.2 0.010 dm³
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GEMÜ F40
6 Technical data

Pressure/temperature
correlation:
Process:
-30 -10 10 30 50 70 90 110 130 150
9
8
7
6
5
4
3
2
1
00
Pressure [bar]
Temperature [°C]
Hot water, steam
9
8
7
6
5
4
3
2
1
0
80 90 100 110 120 130 140 150
Temperature [°C]
Temperature [C]
Pressure [bar]
Hot water
Steam
Hot water max. 4 bar at 140 °C, max. 60 min
Steam max. 2 bar at 140 °C, max. 60 min
Leakage rate: Seat seal Standard Test procedure Leakage rate Test medium
EPDM, FPM, PTFE DIN EN 12266-1 P12 A Air
Kv values: DN Code Flow direction
over the seat [1 → 2]
Flow direction
under the seat [2 → 1]
10 17 2.7 m³/h 2.8 m³/h
15 17 6.1 m³/h 6.6 m³/h
Kv values in m³/h
6.4 Product compliance
Machinery Directive: 2006/42/EU
Food: FDA
USP Class VI
Regulation (EC) No. 1935/2004
Regulation (EC) No. 10/2011
EHEDG certified
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6 Technical data

6.5 Mechanical data
Cycle duties: Cycle duties (over 10 million)
The cycle duties depend on the operating parameters. High pressures and media temperatures
can lead to a shorter service life.
Weight: Actuator
Control function 1 1.24 kg
Control function 2 1.10 kg
Body
Spigot 0.30 kg
Clamp 0.22 kg
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GEMÜ F40
6 Technical data