GEM Q30 - User Manual

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Summary

General Information

Information

Details applicability to standard versions and need for additional documentation.

Symbols Used

Explains symbols for tasks, responses, and lists used in the document.

Definition of Terms

Defines 'working medium' and 'control medium' for clarity.

Warning Notes

Describes the structure and levels of warning notes, including signal words.

Safety Information on the Product

Illustrates product-specific safety symbols and warnings.

Product Description

Construction

Details the components and assembly of the GEMÜ Q30 pinch valve.

Description

Describes the GEMÜ Q30 pinch valve, its actuator, and tube handling features.

Function

Explains the product's operational principle of controlling flow via a control medium.

Product Label

Illustrates the product label and explains its encoded data.

Order Data

Type

Specifies the product type: GEMÜ Q30 pinch valve.

Tube Inside Diameter

Lists available inside diameter options for the tube.

Tube Outside Diameter

Lists available outside diameter options for the tube.

Tube Carrier Version

Defines the material options for the tube carrier and tube holder.

Control Function

Specifies the available control functions: Normally closed (NC) and Normally open (NO).

Actuator Version

Lists the available actuator sizes: 0P1, 1P1, and 2P1.

Mounting Option

Details the available mounting configurations for the valve.

CONEXO

Refers to the option for an integrated RFID chip for traceability.

Technical Data

Medium

Specifies the working and control media requirements.

Temperature

Lists temperature limits for media, ambient, and control medium.

Pressure

Details operating and control pressure specifications.

Actuator Data

Provides filling volume and piston diameter for actuator sizes.

Product Compliance

Confirms compliance with the Machinery Directive 2006/42/EC.

Mechanical Data

Lists weight and installation position details.

Dimensions

Actuator Size 0 P1

Presents dimensional drawings and specifications for actuator size 0P1.

Actuator Size 1 P1

Presents dimensional drawings and specifications for actuator size 1P1.

Actuator Size 2 P1

Presents dimensional drawings and specifications for actuator size 2P1.

Valve Body, Without Mounting Flange

Provides dimensions for the valve body without a mounting flange.

Manufacturers Information

Delivery

Instructions for checking product delivery and scope.

Packaging

Describes the product's packaging material.

Transport

Guidelines for the safe transport of the product.

Storage

Recommendations for storing the product correctly.

Installation

Preparing for Installation

Outlines safety measures and tools needed before installation.

Installation Position

States that the installation position is optional.

Mounting Without Mounting Flange

Steps for mounting the valve body without a flange.

Mounting With Mounting Flange

Steps for mounting the valve with a flange.

Pneumatic Connection

Details pneumatic connection types and procedures.

Connecting the Control Medium

Instructions for connecting the control medium lines.

Inspection and Maintenance

Spare Parts

Information on the availability of spare parts.

Removing the Tube

Procedure for safely removing the tube, including warnings.

Disassembling the Tube Holder

Steps for disassembling the tube holder.

Disassembling the Compressor

Procedure for disassembling the compressor, with safety warnings.

Installing the Compressor

Instructions for installing the compressor.

Inserting the Tube

Procedure for inserting the tube into the valve.

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

The GEMÜ Q30 is a pneumatically operated pinch valve designed for controlling and regulating media in tube systems. It features a plastic piston actuator and is available in both "normally closed (NC)" and "normally open (NO)" control functions. An integral optical position indicator is standard for ease of monitoring.

Function Description

The GEMÜ Q30 valve operates by guiding a tube which is compressed from above by a compressor to control and regulate the flowing medium. The compressor's specially developed contour and the tube holder's contour are designed to minimize strain on the tube, thereby increasing its service life. Tubes can be safely inserted and removed without the need for tools, simplifying maintenance and replacement.

Normally Closed (NC) Function: In its resting position, the actuator is closed by spring force. Activation of the actuator (via control medium connector 2) opens the actuator. When the actuator is vented, it returns to the closed position.
Normally Open (NO) Function: In its resting position, the actuator is opened by spring force. Activation of the actuator (via control medium connector 4) closes the actuator. When the actuator is vented, it returns to the open position.

Important Technical Specifications

The technical specifications for the GEMÜ Q30 are crucial for its correct application and operation:

Working Medium: Please observe the tube manufacturer's specifications.
Control Medium: Inert gases.
Media Temperature: Please observe the tube manufacturer's specifications.
Ambient Temperature:
- Actuator: 0 – 60 °C
- Tube: Please observe the tube manufacturer's specifications
Control Medium Temperature: Max. 60 °C
Storage Temperature: 0 – 60 °C
Operating Pressure: Please observe the tube manufacturer's specifications.
Control Pressure:
- Normally closed (NC): 4 – 7 bar
- Normally open (NO): 2 – 3.5 bar
Actuator Data:
- Filling Volume:
  - Actuator size 0P1: 0.05 dm³
  - Actuator size 1P1: 0.125 dm³
  - Actuator size 2P1: 0.625 dm³
- Piston Diameter:
  - Actuator size 0P1: 50 mm
  - Actuator size 1P1: 70 mm
  - Actuator size 2P1: 120 mm
Product Compliance: Machinery Directive: 2006/42/EC.
Mechanical Data (Weight):
- Actuator:
  - Actuator size 0P1: 0.9 kg
  - Actuator size 1P1: 1.3 kg
  - Actuator size 2P1: 6.9 kg
- Valve Body:
  - Actuator size 0P1: Stainless steel/PA6 (0.2 kg)
  - Actuator size 1P1: PA6 (0.066 kg), Stainless steel/PA6 (0.228 kg)
  - Actuator size 2P1: Stainless steel/PA6 (4.74 kg)
Installation Position: Optional.

Usage Features

The GEMÜ Q30 is designed for user-friendliness and reliability:

Easy Tube Insertion/Removal: Tubes can be inserted and removed in simple steps without tools, facilitating quick changes and reducing downtime.
Optical Position Indicator: An integrated optical position indicator provides clear visual feedback on the valve's current state (open or closed).
Minimized Tube Strain: The specialized contours of the compressor and tube holder are engineered to reduce stress on the tube, extending its operational life.
Robust Construction: The valve components are made from durable materials such as PA6 (glass fibre reinforced) for the actuator, and stainless steel/PA6 for the valve body, ensuring longevity and resistance to various media.
CONEXO RFID Chip (Optional): Some versions include an integrated RFID chip for electronic identification and traceability, enhancing inventory management and maintenance tracking.
Mounting Options: The valve can be mounted without a mounting flange (secured directly to the housing) or with a mounting flange (above or below), offering flexibility in installation.

Maintenance Features

Maintenance of the GEMÜ Q30 is streamlined to ensure continuous and safe operation:

Regular Visual Examination: Operators should perform regular visual examinations of the product to prevent leakage and damage, with frequency depending on operating conditions and potential dangers.
Disassembly for Inspection: The product should be disassembled and checked for wear at corresponding intervals.
Trained Personnel Requirement: All servicing and maintenance work must be performed by trained personnel.
Protective Gear: Appropriate protective gear, as specified in plant operator's guidelines, must be worn during maintenance.
Plant Depressurization: Before any work on the GEMÜ product, the plant or plant component must be shut off, secured against recommissioning, depressurized, and completely drained. It should also be allowed to cool down to a safe temperature.
Genuine Spare Parts: Only genuine GEMÜ parts should be used for replacement to avoid damage to the product and to maintain manufacturer liability and guarantee.
Tube Replacement: The tube can be removed and replaced by turning the locking ring and opening the tube holder. It is critical to ensure the actuator remains in the open position during tube replacement to prevent crushing injuries.
Compressor Disassembly/Assembly: The compressor can be removed by pulling it downwards after the tube and tube holder have been disassembled. Installation involves inserting the compressor and pressing upwards until it engages.
Tube Holder Disassembly/Assembly: The tube holder can be removed by loosening a fixing screw with an Allen key. Assembly involves inserting the tube holder and tightening the fixing screw.
Troubleshooting Guide: The manual provides a troubleshooting section to address common issues such as leaks, failure to open/close, and suggests corrective actions like checking operating pressure, replacing tubes, or cleaning foreign matter.
Return Procedure: For returns, the product must be cleaned, and a completed return delivery note from GEMÜ must be included to ensure proper processing for credits or repairs.