GEMÜ P600 M-Block · 2020-07-07 · 1General information1.1Information ... – Personal hazard due to electrical, mechanical and chemical effects. – Hazard to nearby equipment

GEMÜ P600 M-BlockPlastic multi-port valve block

Operating instructionsEN

further informationwebcode: GW-P600

All rights including copyrights or industrial property rights are expressly reserved.

Keep the document for future reference.

© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG17.07.2019

www.gemu-group.com2 / 44GEMÜ P600

Contents1 General information ................................................... 4

1.1 Information ......................................................... 41.2 Definition of terms ............................................. 41.3 Warning notes .................................................... 4

2 Safety information .................................................... 53 Product description ................................................... 54 Correct use ................................................................ 65 Order data ................................................................. 76 Technical data ........................................................... 97 Dimensions ............................................................... 138 Manufacturer's information ....................................... 21

8.1 Delivery ............................................................... 218.2 Transport ............................................................ 218.3 Storage ............................................................... 218.4 Tools ................................................................... 21

9 Installation in piping .................................................. 219.1 Preparations for installation .............................. 219.2 Installation with clamp connections ................. 229.3 Installation with butt weld spigots .................... 229.4 Installation with threaded sockets .................... 229.5 Installation with flanged connection ................. 239.6 Installation with union ends .............................. 239.7 Installation with solvent cement spigots .......... 239.8 Installation with solvent cement sockets ......... 249.9 Socket installation for double nipple ................ 24

10 Assembly .................................................................. 2410.1 Assembling the actuator .................................... 2410.2 Modular block assemby ..................................... 30

11 Disassembly ............................................................. 3111.1 Removing the actuator ...................................... 3111.2 Modular block disassembly ............................... 34

12 Commissioning ......................................................... 3513 Operation .................................................................. 3514 Fault clearance .......................................................... 3615 Inspection and maintenance ...................................... 3716 Disposal .................................................................... 3717 Returns ..................................................................... 3718 Declaration of Incorporation according to 2006/42/

EC (Machinery Directive) ........................................... 3819 Declaration of conformity according to 2014/30/EU

(EMC Directive) ......................................................... 3920 Declaration of conformity according to 2014/68/EU

(Pressure Equipment Directive) ................................. 40

GEMÜ P600www.gemu-group.com 3 / 44


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 thisdocument, the basic information contained herein ap-plies in conjunction with the type documentation andthe technical drawing.

– Correct installation, operation, servicing and repairwork ensure faultless operation of the GEMÜ product.

1.2 Definition of terms

Working mediumThe medium that flows through the GEMÜ product.Diaphragm sizeUniform seat size of GEMÜ diaphragm valves for differentnominal sizes.

1.3 Warning notes

Wherever possible, warning notes are organised according tothe following scheme:

SIGNAL WORDType and source of the danger

Possiblesymbol forthe specificdanger

Possible consequences of non-observance.Measures for avoiding danger.

Warning notes are always marked with a signal word andsometimes also with a symbol for the specific danger.The following signal words and danger levels are used:

DANGERImminent danger!▶ Non-observance can cause death or

severe injury.

WARNINGPotentially dangerous situation!▶ Non-observance can cause death or

severe injury.

CAUTIONPotentially dangerous situation!▶ Non-observance can cause moderate

to light injury.

NOTICEPotentially dangerous situation!▶ Non-observance can cause damage to

property.

The following symbols for the specific dangers can be usedwithin a warning note:

Symbol MeaningDanger of explosion!

Corrosive chemicals

Hot plant components!

Danger from medium spurting out!

Leakage

www.gemu-group.com 5 / 44 GEMÜ P600

2 Safety informationThe safety information in this document refers only to an in-dividual product. Potentially dangerous conditions can arisein combination with other plant components, which need tobe considered on the basis of a risk analysis. The operator isresponsible for the production of the risk analysis and forcompliance with the resulting precautionary measures andregional safety regulations.The document contains fundamental safety information thatmust be observed during commissioning, operation andmaintenance. Non-compliance with these instructions maycause:– 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

A

1

2

3

Item NameA Actuators1 Body2 Diaphragms3 Control medium connections

3.2 Description

The GEMÜ P600 valve block comprises one or more dia-phragm valve seats. These can be equipped with manual,pneumatic and motorized actuators. The downstream mediais isolated using a diaphragm at the valve seat.

3.3 Function

Multi-port valves or multi-port valve blocks unite a variety offunctions in the smallest of spaces thanks to their individualdesign, such as:– Mixing– Dividing– Controlling– Draining– Feeding

They can also fulfil safety functions, double shut-off (doubleblock and bleed), cross connections and control functions.Specific tasks are assigned to these individual functions on acase-by-case basis.

3 Product description


4 Correct use

4 Correct use

DANGERDanger of explosion!▶ Risk of severe injury or death.● Only versions that have been ap-

proved according to their technicaldata may be used in potentially ex-plosive environments.

WARNINGImproper 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 andthis document.

● Use the product in accordance with the technical data.

5 Order dataThe order data provide an overview of standard configurations.

Please check the availability before ordering. Other configurations available on request.

For ordering and designing a P600, GEMÜ provides a specification sheet, which must be completely filled out.

Furthermore, the flow or functional diagram must be drawn on the specification sheet.

Order codes

1 Type CodeDiaphragm valve, manually operated, plastichandwheel, stainless steel distance piece, sealadjuster, optical position indicator

601

Diaphragm valve, manually operated,stainless steel handwheel,optical position indicator

602

Diaphragm valve, pneumatically operated, plasticpiston actuator, stainless steel distance piece,optical position indicator

605

Diaphragm valve, pneumatically operated 610Diaphragm valve, manually operated, plastichandwheel, stainless steel distance piece, sealadjuster, optical position indicator

612

Diaphragm valve, manually operated 617Diaphragm valve, pneumatically operated,stainless steel piston actuator electropolished,optical position indicator

650

Diaphragm valve, manually operated,plastic handwheel,stainless steel distance piece electropolished,optical position indicator

653

Diaphragm valve, manually operated,stainless steel handwheel electropolishedoptical position indicator

654

Diaphragm valve, manually operated,plastic handwheel, metal distance piece,seal adjuster,optical position indicator

673

Diaphragm valve, manually operated 677Diaphragm valve, pneumatically operated,plastic actuator,stainless steel distance piece

687

Diaphragm valve, pneumatically operated,plastic membrane actuator

690

Diaphragm valve, motorized,electric plastic actuator,stainless steel distance piece, opticalposition indicator, manual override

693

2 DN spigot 1 CodeDN 6 6DN 8 8DN 10 10DN 15 15DN 20 20DN 25 25DN 32 32DN 40 40DN 50 50

3 Connection type spigot 1 CodeSpigot DIN 0Spigot for IR butt welding 20Spigot for IR butt welding, BCF 28Threaded socket DIN ISO 228 1Union end with DIN insert (socket) 7Union end with DIN insert (for IR butt welding) 78Clamp connection similar to ASME-BPE, form A,clamp diameter 25 mm

CA

Clamp connection similar to ASME-BPE, form B,DN 25 and DN 40: clamp diameter 50.5 mm,DN 50: clamp diameter 77.5 mm

CB

Clamp connection similar to DIN 32676, series A,clamp diameter 25 mm

CC

Clamp connection similar to DIN 32676, series A,DN 10 to DN 20: clamp diameter 34.0 mm,DN 25 and DN 32: clamp diameter 50.5 mm,DN 40: clamp diameter 64.0 mm,DN 50: clamp diameter 77.5 mm

CD

Clamp connection similar to DIN 32676, series B,clamp diameter 25.0 mm

CE

Clamp connection similar to DIN 32676, series B,DN 15 to DN 32: clamp diameter 50.5 mm,DN 40: clamp diameter 64.0 mm,DN 50: clamp diameter 91.0 mm

CF

4 Valve body material CodePVC-U, grey 1PP-H, grey G5PP-H, natural N5PVDF 20

5 Order data


5 Diaphragm material CodeNBR 2FPM 4EPDM ethylene-propylene 14EPDM 17PTFE/EPDM 52

5 Order data


6 Technical data

6.1 Medium

Working medium: Corrosive, inert, gaseous and liquid media which have no negative impact on the physical andchemical properties of the body and diaphragm material.

6.2 Temperature

Media temperature: PVC-U, grey (code 1): 10 to 60 °CPVDF (code 20): -10 to 80 °CPP-H, grey (code G5): 5 to 80 °CPP natural (code N5): 5 to 80 °C

Ambient temperature: PVC-U, grey (code 1): 10 to 50 °CPVDF (code 20): -5 to 50 °CPP-H, grey (code G5): 5 to 50 °CPP natural (code N5): 5 to 50 °C

Note: Deviating operating parameters must be agreed on a case-by-case basis.

6.3 Pressure

Information: The maximum permissible operating pressure at room temperature can be read on the product la-bel.The smallest value as listed in the table below, depending on the GEMÜ actuator and diaphragmmaterial used, is decisive for the operating pressure of the entire system at room temperature.The permissible operating pressure of GEMÜ P600 is dependent on the installed GEMÜ actuator,diaphragm material, body material and media temperature. The maximum permissible operatingpressures for media temperatures deviating from room temperature can be found in the pressure/temperature correlation, depending on the body material used.


6 Technical data

Operating pressure: GEMÜType

Actu-ator

Diaphragm ma-terial

MG 8 MG 10 MG 20 MG 25 MG 40 MG 50

601 P601 EPDM / FPM 0 - 10 - - - - -PTFE 0 - 6 - - - - -

602 P602 EPDM / FPM 0 - 10 - - - - -PTFE 0 - 6 - - - - -

605 P605 EPDM / FPM 0 - 8 - - - - -PTFE 0 - 6 - - - - -

610 P610 EPDM / FPM - 0 - 6 - - - -PTFE - 0 - 6 - - - -

612 P612 EPDM / FPM - 0 - 10 - - - -PTFE - 0 - 6 - - - -

617 P617 EPDM / FPM - 0 - 6 - - - -PTFE - 0 - 6 - - - -

650 P650 EPDM / FPM 0 - 10 0 - 10 - 0 - 10 0 - 10 0 - 10PTFE 0 - 6 0 - 6 - 0 - 6 0 - 6 0 - 6

653 P653 EPDM / FPM 0 - 10 0 - 10 - 0 - 10 0 - 10 0 - 10PTFE 0 - 6 0 - 6 - 0 - 6 0 - 6 0 - 6

654 P654 EPDM / FPM 0 - 10 0 - 10 - 0 - 10 0 - 10 0 - 10PTFE 0 - 6 0 - 6 - 0 - 6 0 - 6 0 - 6

673 P673 EPDM / FPM - - - 0 - 10 0 - 10 0 - 10PTFE - - - 0 - 6 0 - 6 0 - 6

R677 P677 EPDM / FPM - - 0 - 10 0 - 10 0 - 10 0 - 10PTFE - - 0 - 10 0 - 10 0 - 10 0 - 10

687 P687 EPDM / FPM - 0 - 10 - 0 - 10 0 - 10 0 - 10PTFE - 0 - 6 - 0 - 6 0 - 6 0 - 6

R690 P690 EPDM / FPM - - 0 - 10 0 - 10 0 - 10 0 - 10PTFE - - 0 - 10 0 - 10 0 - 10 0 - 10

R693 P693 EPDM / FPM - - 0 - 10 0 - 6 0 - 6 -PTFE - - 0 - 6 0 - 6 0 - 6 -

MG = diaphragm size

All pressures are gauge pressures. Operating pressure values were determined with static operat-ing pressure applied on one side of a closed valve. Sealing at the valve seat and atmospheric seal-ing is ensured for the given values.Information on operating pressures applied on both sides and for high purity media on request.


6 Technical data

Pressure/temperature correlation:

Connection type Pressure ratingSpigot PN 10

Threaded socket PN 10Union end PN 10

Clamp PN 6

Pressure/temperature correlation PN 6

Materialcode

Temperature in °C (valve body)-20 -10 ±0 5 10 20 25 30 40 50 60 70 80

PVC-U Code 1

- - - - 6.0 6.0 6.0 4.8 3.6 2.1 0.9 - -

PP-H, grey Code G5

- - - 6.0 6.0 6.0 6.0 5.1 4.2 3.3 2.4 1.6 0.9

PP-natural Code N5

- - - 6.0 6.0 6.0 6.0 5.1 4.2 3.3 2.4 1.6 0.9

PVDF Code 20

- 6.0 6.0 6.0 6.0 6.0 6.0 5.4 4.8 4.3 3.8 3.2 2.8

Pressure/temperature correlation PN 10

MaterialsCode

Temperature in °C (valve body)-20 -10 ±0 5 10 20 25 30 40 50 60 70 80

PVC-U Code 1

- - - - 10.0 10.0 10.0 8.0 6.0 3.5 1.5 - -

PP-H, grey Code G5

- - - 10.0 10.0 10.0 10.0 8.5 7.0 5.5 4.0 2.7 1.5

PP-natural Code N5

- - - 10.0 10.0 10.0 10.0 8.5 7.0 5.5 4.0 2.7 1.5

PVDF Code 20

- 10.0 10.0 10.0 10.0 10.0 10.0 9.0 8.0 7.0 6.3 5.4 4.7

The pressure rating (PN) depends on the connection code.


6 Technical data

6.4 Product compliance

Pressure EquipmentDirective:

2014/68/EU

Machinery Directive: 2006/42/EU

EMC Directive: 2014/30/EU when using a motorized actuator

Low VoltageDirective:

2014/35/EU when using a motorized actuator

6.5 Materials

Materials: Diaphragm material O-ring materialPTFE FPMNBR EPDMFPM FPM

EPDM EPDM

6.6 Mechanical data

The mechanical data can be found in the product types' datasheets in conjunction with the technical drawing of the valveblock.


6 Technical data

7 DimensionsThe dimensions can be found in the product types' datasheets in conjunction with the technical drawing of the valve block.

7.1 Body dimensions

7.1.1 Spigot

Ø d

c

s

Connection typescode 1)

0

Material code 2) 1 20 G5, N5min.MG

DN ød s c ød s c ød s c

10 10 16.0 1.2 14.0 16.0 1.9 15.50 - - -10 15 20.0 1.5 16.0 20.0 1.9 17.50 20.0 2.6 17.5020 20 25.0 1.9 19.0 25.0 1.9 19.00 25.0 2.8 19.0025 25 32.0 2.4 22.0 32.0 2.4 22.00 32.0 3.0 22.0040 32 40.0 3.0 32.0 40.0 2.4 24.00 40.0 4.0 24.0050 40 50.0 3.7 35.0 50.0 3.0 26.00 50.0 4.6 26.0050 50 63.0 4.7 38.0 63.0 3.0 33.25 63.0 5.8 33.25

Dimensions in mm, MG = diaphragm size1) Connection type spigot 1

Code 0: Spigot DIN

2) Valve body materialCode 1: PVC-U, greyCode 20: PVDFCode G5: PP-H, greyCode N5: PP-H, natural


7 Dimensions

7.1.2 Spigot for IR butt welding code 20

Ø d

c

s

Connection types code 1) 20Material code 2) 20, G5, N5 20 G5, N5

min. MG DN ød c s s10 15 20 33 1.9 1.920 20 25 33 1.9 2.325 25 32 33 2.4 2.940 32 40 33 2.4 3.750 40 50 33 3.0 4.650 50 63 33 3.0 5.8


Code 20: Spigot for IR butt welding

2) Valve body materialCode 20: PVDFCode G5: PP-H, greyCode N5: PP-H, natural


7 Dimensions

7.1.3 Spigot for IR butt welding code 28

sØ d

cc1

3

Connection types code 1) 28Material code 2) 20, G5, N5 20 G5, N5

min. MG DN ød c c1 s s10 15 20 31 37 1.9 1.920 20 25 31 37 1.9 2.325 25 32 31 37 2.4 2.940 32 40 40 46 2.4 3.750 40 50 40 46 3.0 4.650 50 63 40 46 3.0 5.8


Code 28: Spigot for IR butt welding, BCF

2) Valve body materialCode 20: PVDFCode G5: PP-H, greyCode N5: PP-H, natural


7 Dimensions

7.1.4 Threaded socket

t

Ø R

Connection types code 1) 1Material code 2) 1, 20, G5, N5

min. MG DN R t8 6 G 1/8 7.48 8 G 1/4 11.0

10 10 G 3/8 11.410 15 G 1/2 15.020 20 G 3/4 16.325 25 G 1 19.140 32 G 1¼ 21.450 40 G 1½ 21.450 50 G 2 25.7


Code 1: Threaded socket DIN ISO 228

2) Valve body materialCode 1: PVC-U, greyCode 20: PVDFCode G5: PP-H, greyCode N5: PP-H, natural


7 Dimensions

7.1.5 Union end code 7

Ø dR

Connection types code 1) 7Material code 2) 1, 20, G5

min. MG DN R ød10 15 G 1 2020 20 G 1¼ 2525 25 G 1½ 3240 32 G 2 4050 40 G 2¼ 5050 50 G 2¾ 63


Code 7: Union end with DIN insert (socket)

2) Valve body materialCode 1: PVC-U, greyCode 20: PVDFCode G5: PP-H, grey

7.1.6 Union end code 78

Ø dR

s

c

Connection types code 1) 78Material code 2) 20, G5 20 G5

min. MG DN R ød c s s10 15 G 1 20 36 1.9 1.920 20 G 1¼ 25 37 1.9 2.325 25 G 1½ 32 39 2.4 2.940 32 G 2 40 39 2.4 3.750 40 G 2¼ 50 43 3.0 4.650 50 G 2¾ 63 43 3.0 5.8


Code 78: Union end with DIN insert (for IR butt welding)

2) Valve body materialCode 20: PVDFCode G5: PP-H, grey


7 Dimensions

7.1.7 Clamp ASME-BPE

Ø d

c

Ø D

Material code 1) 20, G5, N5min. MG DN Connection types

code 2)øD ød c

8 8 CA 25.0 4.57 208 10 CA 25.0 7.75 208 15 CA 25.0 9.40 20

10 20 CA 25.0 15.75 2020 25 CB 50.5 22.10 2040 40 CB 64.0 34.80 2050 50 CB 77.5 47.50 28

Dimensions in mm, MG = diaphragm size1) Valve body material

Code 20: PVDFCode G5: PP-H, greyCode N5: PP-H, natural

2) Connection type spigot 1Code CA: Clamp connection similar to ASME-BPE, form A,clamp diameter 25 mmCode CB: Clamp connection similar to ASME-BPE, form B,DN 25 and DN 40: clamp diameter 50.5 mm,DN 50: clamp diameter 77.5 mm


7 Dimensions

7.1.8 Clamp DIN 32676, series A

Ø d

c

Ø D


code 2)øD ød c

8 2 CC 25.0 2.00 208 4 CC 25.0 4.00 208 6 CC 25.0 6.00 208 8 CC 25.0 8.00 208 10 CC 25.0 10.00 208 10 CD 34.0 10.00 20

10 15 CD 34.0 16.00 2020 20 CD 34.0 20.00 2025 25 CD 50.5 26.00 2040 32 CD 50.5 32.00 2040 40 CD 64.0 38.00 2050 50 CD 77.5 50.00 28



2) Connection type spigot 1Code CC: Clamp connection similar to DIN 32676, series A,clamp diameter 25 mmCode CD: Clamp connection similar to DIN 32676, series A,DN 10 to DN 20: clamp diameter 34.0 mm,DN 25 and DN 32: clamp diameter50.5 mm,DN 40: clamp diameter 64.0 mm,DN 50: clamp diameter 77.5 mm


7 Dimensions

7.1.9 Clamp DIN 32676, series B

Ø d

c

Ø D


code 2)øD ød c

8 6 CE 25.0 7.00 2010 8 CE 25.0 10.30 2010 10 CE 25.0 14.00 2010 15 CF 50.5 18.10 2020 20 CF 50.5 23.70 2040 25 CF 50.5 29.70 2025 32 CF 64.0 38.40 2050 40 CF 64.0 44.30 2050 50 CF 91.0 56.30 28



2) Connection type spigot 1Code CE: Clamp connection similar to DIN 32676, series B,clamp diameter 25.0 mmCode CF: Clamp connection similar to DIN 32676, series B,DN 15 to DN 32: clamp diameter 50.5 mm,DN 40: clamp diameter 64.0 mm,DN50: clamp diameter 91.0 mm


7 Dimensions


8 Manufacturer's information

8.1 Delivery

● Check that all parts are present and check for any dam-age immediately upon receipt. The scope of delivery isapparent from the dispatch documents and the designfrom the order number.

8.2 Transport

1. Only transport the product by suitable means. Do notdrop. Handle carefully.

2. After the installation dispose of transport packing mater-ial according to relevant local or national disposal regula-tions / environmental protection laws.

8.3 Storage

1. Store the product free from dust and moisture in its ori-ginal packaging.

2. Avoid UV rays and direct sunlight.3. Do not exceed the maximum storage temperature.4. Do not store solvents, chemicals, acids, fuels or similar

fluids in the same room as GEMÜ products and theirspare parts.

8.4 Tools

1. The tools required for installation and assembly are notincluded in the scope of delivery.

2. Use appropriate, functional and safe tools.

9 Installation in piping

9.1 Preparations for installation

WARNINGThe equipment is subject to pressure!▶ Risk of severe injury or death.● Depressurize the plant.● Completely drain the plant.

WARNINGCorrosive chemicals▶ Risk of caustic burns● Wear suitable protective gear.● Completely drain the plant.

CAUTIONHot plant components!▶ Risk of burns!● Only work on plant that has cooled

down.

CAUTIONExceeding the maximum permissible pressure.▶ Damage to the GEMÜ product.● Provide precautionary measures against exceeding the

maximum permitted pressures caused by pressuresurges (water hammer).

CAUTIONUse as step.▶ Damage to the product.▶ Risk of slipping-off.● Choose the installation location so that the product can-

not be used as a foothold.● Do not use the product as a step or a foothold.

NOTICESuitability of the product!▶ The product must be appropriate for the piping system

operating conditions (medium, medium concentration,temperature and pressure) and the prevailing ambientconditions.




NOTICETools▶ The tools required for installation and assembly are not

included in the scope of delivery.● Use appropriate, functional and safe tools.

1. Ensure the suitability of the GEMÜ product for each re-spective use.

2. Check the technical data of the GEMÜ product and thematerials.

3. Keep appropriate tools ready.4. Ensure appropriate protective gear as specified in the

plant operator's guidelines.5. Observe appropriate regulations for connections.6. Have installation work carried out by trained personnel.7. Shut off plant or plant component.8. Secure plant or plant component against recommission-

ing.9. Depressurize the plant or plant component.10. Completely drain the plant (or plant component) and let it

cool down until the temperature is below the media va-porization temperature and scalding can be ruled out.

11. Correctly decontaminate, rinse and ventilate the plant orplant component.

12. Lay piping so that the GEMÜ product is protected againsttransverse and bending forces, and also vibrations andtension.

13. Only install the product between matching aligned pipes(see chapters below).

14. Observe the flow direction if necessary.15. The installation position varies depending on version. Ob-

serve the technical drawing.16. The plant operator is responsible for ensuring that the

weight of the product and the actuators is suitably sup-ported depending on the installation position.

9.2 Installation with clamp connections

Fig. 1: Clamp connection

NOTICEGasket and clamp▶ The gasket and clamps for clamp connections are not in-

cluded in the scope of delivery.

1. Keep ready gasket and clamp.2. Carry out preparation for installation (see chapter "Pre-

paring for installation").3. Insert the corresponding gasket between the body of the

product and the pipe connection.4. Connect the gasket between the body of the product and

the pipe connection using clamps.5. Re-attach or reactivate all safety and protective devices.

9.3 Installation with butt weld spigots

Fig. 2: Butt weld spigots1. Carry out preparations for installation (see chapter "Pre-

parations for installation").2. Adhere to good welding practices!3. Remove actuator A (see chapter "Removing the actu-

ator").4. Weld the body of the product in the piping.5. Allow butt weld spigots to cool down.6. Mount actuator A (see chapter "Mounting the actuator").7. Re-attach or reactivate all safety and protective devices.8. Flush the system.

9.4 Installation with threaded sockets

NOTICESealing material▶ The sealing material is not included in the scope of deliv-

ery.● Only use appropriate sealing material.

1. Keep thread sealant ready.2. Carry out preparations for installation (see chapter "Pre-

parations for installation").3. Screw the threaded connections into the pipe in accord-

ance with valid standards.4. Screw the body of the product onto the piping using ap-

propriate thread sealant.5. Re-attach or reactivate all safety and protective devices.


9.5 Installation with flanged connection

Fig. 3: Flanged connection

NOTICESealing material▶ The sealing material is not included in the scope of deliv-

ery.● Only use appropriate sealing material.

NOTICEConnector elements▶ The connector elements are not included in the scope of

delivery.● Only use connector elements made of approved materi-

als.● Observe permissible tightening torque of the bolts.

1. Keep sealing material ready.2. Carry out preparations for installation (see chapter "Pre-

parations for installation").3. Ensure clean, undamaged sealing surfaces on the con-

nection flanges.4. Align flanges carefully before installing them.5. Clamp the product centrally between the piping with

flanges.6. Centre the gaskets.7. Connect the valve flange and the piping flange using ap-

propriate sealing materials and matching bolting.8. Use all flange holes.

9. Tighten the bolts diagonally.10. Re-attach or reactivate all safety and protective devices.

9.6 Installation with union ends

Fig. 4: Threaded spigot

NOTICE▶ The solvent cement is not included in the scope of deliv-

ery.● Only use suitable solvent cement!

1. Carry out preparations for installation (see chapter "Pre-parations for installation").

2. Depending on the application, comply with the weldingstandards and the specifications of the solvent cementmanufacturer for adhesive bonds.

3. Screw the threaded connections into the piping in accord-ance with valid standards.

4. Unscrew the union nut from the body of the product.5. Reinsert the O-ring if necessary.6. Push the union nut over the piping.7. Connect the insert with the piping by solvent cementing/

welding.8. Screw the union nut back onto the body of the product.9. Connect the other side of the body of the product with the

piping in the same way.10. Reactivate all safety and protective devices.

9.7 Installation with solvent cement spigots

Fig. 5: Solvent cement spigot




2. Apply solvent cement on the outside of the valve bodyspigots and on the inside of the piping as specified by thesolvent cement manufacturer.

3. Connect the body of the product with the piping.4. Reactivate all safety and protective devices.



10 Assembly

9.8 Installation with solvent cement sockets




2. Apply solvent cement on the inside of the valve body andon the outside of the piping as specified by the solventcement manufacturer.

3. Connect the body of the product with the piping.4. Reactivate all safety and protective devices.

9.9 Socket installation for double nipple

Fig. 6: Socket for double nipple1. Carry out preparations for installation (see chapter "Pre-

parations for installation").2. Lubricate the O-rings (grease not included in the scope of

delivery).3. Insert O-rings in the double nipple.4. Insert the double nipple with the O-ring in the body.

10 Assembly

10.1 Assembling the actuator

NOTICE▶ Assemby is shown using the example of a pneumatic ac-

tuator. The assemby of manual and motorized actuatorsis analogous. Only carry out the actuator assemby incompliance with the operating instructions of the GEMÜtype.

10.1.1 Assemby with threaded studs and nuts

6a 6b

1. Mount diaphragm(s) 6 (see respective installation, oper-ating and maintenance instructions).

5

78

2. Place the actuator 5 with the mounted diaphragm 6 onthe block 8 using the threaded studs 7.


374

3. Lay the washers 4 and spring washers 3 over thethreaded studs 7.

4. Screw the nuts 2 onto the threaded studs 7 until they arehand tight.

5. Secure the threaded studs 7 with a hexagon wrench.6. Tighten the nuts 2 with a wrench.7. Tighten the screws with an appropriate tool. Ensure the

even compression of the diaphragm 6. Even compressionis detected by an even outer bulge.

Dia-phragm

size

Elastomer torque[Nm]

PTFE torque [Nm]

Min Max Min MaxMG 8 0.6 0.8 0.8 1.2

MG 10 1.2 1.6 1.2 2.0MG 20 2.0 3.0 4.0 5.0MG 25 5.0 6.5 10.0 12.0MG 40 8.0 10.0 14.0 16.0MG 50 12.0 14.0 20.0 22.0

10 Assembly


10 Assembly

1

2

8. Mount the protective caps 1 on the nuts 2.

10.1.2 Assemby with cylindrical screws and bushes in thebody

6

5

1. Mount the diaphragm 6 on the actuator 5 (see respectiveinstallation, operating and maintenance instructions).

5

8

6

2. Align the actuator 5 with the mounted diaphragm 6 withthe valve seat of the body 8.

7

34

5

3. Fit the spring washers 3 and washers 4 to the screws 7and insert them in the bolt holes of the actuator 5.


6

7

4. Tighten the screws with an appropriate tool. Ensure theeven compression of the diaphragm 6. Even compressionis detected by an even outer bulge.

Dia-phragm

size


PTFE torque [Nm]


MG 10 1.2 1.6 1.2 2.0MG 20 2.0 3.0 4.0 5.0MG 25 5.0 6.5 10.0 12.0MG 40 8.0 10.0 14.0 16.0MG 50 12.0 14.0 20.0 22.0

1

1

1

5. Mount the protective caps 1.

10 Assembly


10 Assembly

10.1.3 Assemby with cylindrical screws and nuts

5

6


5

43

8

7

2. Align the actuator 5 with the body 8.3. Push the spring washers 3 and washers 4 onto the

screws 7.

5

8

4. Insert the screws with the spring washers and washers inthe body 8.

5

124

86

5. Tighten the actuator 5 and the body 8 with the washer 4and nut 2.



Dia-phragm

size


PTFE torque [Nm]


MG 10 1.2 1.6 1.2 2.0MG 20 2.0 3.0 4.0 5.0MG 25 5.0 6.5 10.0 12.0MG 40 8.0 10.0 14.0 16.0MG 50 12.0 14.0 20.0 22.0

10.1.4 Assemby with cylindrical screws and bushes in theactuator

5

6


5

8

43

7

2. Push the spring washers 3 and washers 4 onto thescrews 7.

8

5

3. Insert the screws 7 with the spring washers 3 and wash-ers 4 in the bolt hole of the body 8.

4. Align the actuator 5 with the body 8.

10 Assembly


10 Assembly

5

6

8

5. Tighten the screws 7, thereby bolting together the body 8and the actuator 5.


Dia-phragm

size


PTFE torque [Nm]


MG 10 1.2 1.6 1.2 2.0MG 20 2.0 3.0 4.0 5.0MG 25 5.0 6.5 10.0 12.0MG 40 8.0 10.0 14.0 16.0MG 50 12.0 14.0 20.0 22.0

10.2 Modular block assemby

1. Carry out preparations for installation (see “Preparationsfor installation“, page 21).

1 12

2. Grease the O-rings 1 with a suitable grease/oil.3. Fit the greased O-rings 1 in the groove of the double

nipple 2 (arrows).

2 3

4. Install the double nipple 2 on the valve body 3.

2

3.2 3.1

5. Connect valve body 3.2 to valve body 3.1.

4

4

5

5

6. Fit the brackets 4 and screws 5 on the valve bodies.

7. Tighten screws 5.


11 Disassembly


WARNINGDanger from medium spurting out!▶ Danger of injury.● Maintenance work on the diaphragm

valve should only be carried out afterthe piping has been depressurized anddrained!


down.

11.1 Removing the actuator

NOTICE▶ Disassembly is shown using the example of a pneumatic

actuator. The disassembly of manual and motorized ac-tuators is analogous. Only carry out the actuator disas-sembly in compliance with the operating instructions ofthe GEMÜ type.

11.1.1 Disassembly for threaded studs with nuts

1. Disassemble in reverse order to assembly.2. Deactivate the control medium.3. Disconnect the control medium line(s).

1

4. Remove the protective caps 1 with a screw driver.

5. Secure the threaded studs 7 with a hexagon wrench.

6. Undo and remove the nuts 2 with a wrench.

3

47

7. Remove the spring washers 3 and washers 4 from thethreaded studs 7.

11 Disassembly


11 Disassembly

5

7

8

8. Evenly lift the actuator 5 and carefully pull it off the block8.

5 6a 6b

9. Remove the diaphragm(s) 6 from the actuator 5 (see re-spective mounting instructions).

11.1.2 Disassembly for cylindrical screws and bushes in thebody

1 1

1

1. Remove the protective caps 1.

6

7

2. Undo the screws 7 with a hexagon wrench.

43

7

5

3. Remove the spring washers 3, washers 4 and screws 7from the bolt holes of the actuator 5.


5

6

8

4. Remove the actuator 5 with the mounted diaphragm 6from the valve seat of the body 8.

5

6

5. Remove the diaphragm 6 from the actuator 5 (see re-spective mounting instructions).

11.1.3 Disassembly for cylindrical screws with nuts

5

124

86

1. Remove the protective caps 1. Undo the nuts 2 and re-move them and the washers 4.

5

43

8

7

2. Remove the screws 7 with the spring washers 3 andwashers 4 from the body 8.

3. Remove the actuator 5 from the body 8.

11 Disassembly


11 Disassembly

5

6


11.1.4 Disassembly for cylindrical screws and bushes in theactuator

7

8

5

1. Undo and unscrew the screws 7, thereby separating thebody 8 and the actuator 5.

5

8

43

7

2. Remove the screws 7 with the spring washers 3 andwashers 4 from the bolt holes of the body 8.

5

6


11.2 Modular block disassembly

1. Undo screws 5.


4

4

5

5

2. Remove the brackets 4 and screws 5 from the valve bod-ies.

2

3.2 3.1

3. Disconnect valve body 3.2 from valve body 3.1.

2 3

4. Remove the double nipple 2 from the valve body 3.5. Carry out the actuator disassembly (see “Removing the

actuator“, page 31).6. Carry out the diaphragm replacement (see respective

mounting instructions).

12 Commissioning


CAUTIONLeakage▶ Emission of dangerous materials.● Provide precautionary measures

against exceeding the maximum per-mitted pressures caused by pressuresurges (water hammer).

CAUTIONCleaning agent▶ Damage to the GEMÜ product.● The plant operator is responsible for selecting the clean-

ing material and performing the procedure.

1. Check the tightness and the function of the product(close and reopen the product). Due to the setting beha-viour of elastomers, the screws may need to beretightened following the installation and commissioningof the valve.

2. Flush the piping system of new plant and following repairwork (the product must be fully open).

ð Harmful foreign matter has been removed.

ð The product is ready for use.3. Commission the product.4. Use suitable connectors.5. Connect the control medium lines tension-free and

without any bends or knots.

13 OperationThe product is operated via manual, pneumatic or motorizedactuators.

● Observe the enclosed actuator instructions.

13 Operation

14 Fault clearance

Error Possible cause Error clearanceThe product leaks downstream (doesn'tclose or doesn't close fully)

Operating pressure too high Operate the product with operatingpressure specified in datasheet

Foreign matter between shut offdiaphragm and valve body weir

Remove the actuator, remove foreignmatter, check diaphragm and valve bodyweir for potential damage, replaceactuator if necessary

Valve body leaks or is damaged Check valve body for potential damage,replace valve body if necessary

Shut off diaphragm faulty Check shut off diaphragm for potentialdamage, replace diaphragm if necessary

The product doesn't close or doesn'tclose fully

The actuator design is not suitable forthe operating conditions

Use an actuator that is designed for theoperating conditions

Foreign matter in the product Remove and clean the productVoltage is not connected Connect voltage

The product doesn't open or doesn'topen fully

Actuator defective Replace the actuatorShut off diaphragm incorrectly mounted Remove actuator, check diaphragm

mounting, replace if necessaryOperating pressure too high Operate the product with operating

pressure specified in datasheetForeign matter in the product Remove and clean the productThe actuator design is not suitable forthe operating conditions

Use an actuator that is designed for theoperating conditions

Voltage is not connected Connect voltageCable ends incorrectly wired Wire cable ends correctly

The product leaks between actuator andvalve body

Shut off diaphragm incorrectly mounted Remove actuator, check diaphragmmounting, replace if necessary

Bolting between valve body and actuatorloose

Retighten bolting between valve bodyand actuator

Shut off diaphragm faulty Check shut off diaphragm for damage,replace diaphragm if necessary

Actuator/valve body damaged Replace actuator/valve bodyThe product leaks between actuatorflange and valve body

Mounting parts loose Retighten mounting partsValve body / actuator damaged Replace valve body/actuator

Body of the GEMÜ product is leaking Body of the GEMÜ product is faulty orcorroded

Check the body of the GEMÜ product forpotential damage, replace body ifnecessary

Incorrect installation Check installation of valve body in pipingValve body connection to piping leaks Incorrect installation Check installation of valve body in piping

14 Fault clearance



15 Inspection and maintenance

WARNINGThe equipment is subject to pressure!▶ Risk of severe injury or death.● Depressurize the plant.● Completely drain the plant.

CAUTIONUse of incorrect spare parts!▶ Damage to the GEMÜ product.▶ Manufacturer liability and guarantee will be void.● Use only genuine parts from GEMÜ.


down.

NOTICEExceptional maintenance work!▶ Damage to the GEMÜ product.● Any maintenance work and repairs not described in

these operating instructions must not be performedwithout consulting the manufacturer first.

The operator must carry out regular visual examination of theGEMÜ products depending on the operating conditions andthe potential danger in order to prevent leakage and damage.The product also must be disassembled and checked forwear in the corresponding intervals.1. Have servicing and maintenance work performed by

trained personnel.2. Wear appropriate protective gear as specified in plant op-

erator's guidelines.3. Shut off plant or plant component.4. Secure plant or plant component against recommission-

ing.5. Depressurize the plant or plant component.6. Actuate GEMÜ products which are always in the same

position four times a year.

15.1 Cleaning the product

– Clean the product with a damp cloth.– Do not clean the product with a high pressure clean-

ing device.

16 Disposal1. Pay attention to adhered residual material and gas diffu-

sion from penetrated media.2. Dispose of all parts in accordance with the disposal regu-

lations/environmental protection laws.

17 ReturnsLegal regulations for the protection of the environment andpersonnel require that the completed and signed return deliv-ery note is included with the dispatch documents. Returnedgoods can be processed only when this note is completed. Ifno return delivery note is included with the product, GEMÜcannot process credits or repair work but will dispose of thegoods at the operator's expense.1. Clean the product.2. Request a return delivery note from GEMÜ.3. Complete the return delivery note.4. Send the product with a completed return delivery note to

GEMÜ.

17 Returns

18 Declaration of Incorporation according to 2006/42/EC (Machinery Directive)

Declaration of Incorporationaccording to the EC Machinery Directive 2006/42/EC, Annex II, 1.B for

partly completed machinery

We, GEMÜ Gebr. Müller Apparatebau GmbH & Co. KGFritz-Müller-Straße 6-874653 Ingelfingen-Criesbach, Germany

declare that the following product

Make: GEMÜ

Serial number: from 06.10.2010Project number: MV-Pneum-2010-10

Commercial name: GEMÜ P600

meets the following essential requirements of the Machinery Directive 2006/42/EC:1.1.3.; 1.1.5.; 1.1.7.; 1.2.1.; 1.3.; 1.3.2.; 1.3.3.; 1.3.4.; 1.3.7.; 1.3.9.; 1.5.3.; 1.5.5.; 1.5.6.; 1.5.7.; 1.5.8.; 1.5.9.; 1.6.5.; 2.1.1.; 3.2.1.;3.2.2.; 3.3.2.; 3.4.4.; 3.6.3.1.; 4.1.2.1.; 4.1.2.3.; 4.1.2.4.; 4.1.2.5.; 4.1.2.6. a); 4.1.2.6. b); 4.1.2.6. c); 4.1.2.6. d); 4.1.2.6. e); 4.1.3.;4.2.1.; 4.2.1.4.; 4.2.2.; 4.2.3.; 4.3.1.; 4.3.2.; 4.3.3.; 4.4.1.; 4.4.2.; 5.3.; 5.4.; 6.1.1.; 6.3.3.; 6.4.1.; 6.4.3.We also declare that the specific technical documentation has been compiled in accordance with part B of Annex VII. The manufacturer or his authorised representative undertake to transmit, in response to a reasoned request by the nationalauthorities, relevant information on the partly completed machinery. This transmission takes place:Electronically

Authorised documentation officer GEMÜ Gebr. Müller Apparatebau GmbH & Co. KGFritz-Müller-Straße 6-874653 Ingelfingen, Germany

This does not affect the industrial property rights!Important note! The partly completed machinery may be put into service only if it was determined, where appropriate, that themachinery into which the partly completed machinery is to be installed meets the provisions of this Directive.

Ingelfingen-Criesbach 29-05-2018

Joachim BrienHead of Technical Department


18 Declaration of Incorporation according to 2006/42/EC (Machinery Directive)

19 Declaration of conformity according to 2014/30/EU (EMC Directive)

EU Declaration of Conformityaccording to 2014/30/EU (EMC Directive)


declare that the product listed below complies with the safety requirements of the EMC Directive 2014/30/EU.

Description of the product: GEMÜ P600

Technical standards used:– DIN EN 61326-1 (industrial processes)




19 Declaration of conformity according to 2014/30/EU (EMC Directive)

20 Declaration of conformity according to 2014/68/EU (Pressure Equipment Directive)

EU Declaration of Conformityin accordance with 2014/68/EU (Pressure Equipment Directive)


declare that the product listed below complies with the safety requirements of the Pressure Equipment Directive 2014/68/EU.

Description of the pressure equipment: GEMÜP600Notified body: TÜV Rheinland Industrie Service GmbHNumber: 0035Certificate no.: 01 202 926/Q-02 0036Conformity assessment procedure: Module HTechnical standard used: AD 2000

Note for products with a nominal size ≤ DN 25: The products are developed and produced according to GEMÜ process instructions and quality standards which comply withthe requirements of ISO 9001 and ISO 14001.According to Article 4, Paragraph 3 of the Pressure Equipment Directive 2014/68/EU these products must not be identified bya CE-label.




20 Declaration of conformity according to 2014/68/EU (Pressure Equipment Directive)




GEMÜ Gebr. Müller Apparatebau GmbH & Co. KGFritz-Müller-Straße 6-8, 74653 Ingelfingen-Criesbach,GermanyTel. +49 (0)7940 123-0 · [email protected]

Subject to alteration

07.2019 | 88605751

*88605751*

mailto:[email protected]

http://www.gemu-group.com

Documents

GEMÜ P600 M-Block · 2020-07-07 · 1General information1.1Information ... – Personal hazard due to electrical, mechanical and chemical effects. – Hazard to nearby equipment