Gemu F40 Manual de usuario

GEMÜ F40

Pneumatically operated filling valve

Operating instructions

further information

webcode: GW-F40

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

Keep the document for future reference.

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

GEMÜ F40www.gemu-group.com 3 / 24

www.gemu-group.com4 / 24GEMÜ F40

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 = 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!

www.gemu-group.com 5 / 24 GEMÜ F40

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, optimal draining and filling properties

over the seat

under the seat

2 -> 1, better pressure stability and higher flow

3 Product description

www.gemu-group.com6 / 24GEMÜ F40

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

Spigot EN 10357 series A (formerly DIN 11850

series 2) / DIN 11866 series A

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

Actuator with M12x1 thread for accessories with

standard spring set

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

www.gemu-group.com 7 / 24 GEMÜ F40

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

5.5

4.5

3.5

2.5

1.5

0.5

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

www.gemu-group.com

8 / 24

GEMÜ F40

6 Technical data

Pressure/temperature

correlation:

Process:

-30 -10 10 30 50 70 90 110 130 150

Pressure [bar]

Temperature [°C]

Hot water, steam

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

GEMÜ F40www.gemu-group.com 9 / 24

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

www.gemu-group.com

10 / 24

GEMÜ F40

6 Technical data

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