GEM Q40 User manual

GEMÜ Q40
Pneumatically operated pinch valve
Operating instructions
EN

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
26.08.2020
www.gemu-group.com2 / 17GEMÜ Q40

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
1.5 Safety information on the product ..................... 5
2 Safety information .................................................... 5
3 Product description ................................................... 6
4 Correct use ............................................................... 6
5 Order data ................................................................. 7
6 Technical data .......................................................... 8
6.4 Actuator data ....................................................... 8
6.5 Control pressure .................................................. 8
8 Manufacturer's information ....................................... 10
8.1 Delivery ................................................................ 10
8.2 Packaging ............................................................ 10
8.3 Transport ............................................................. 10
8.4 Storage ................................................................. 10
9 Installation ................................................................ 10
9.1 Preparing for installation .................................... 10
9.2 Installation position ............................................ 10
9.3 Installing the valve on the housing ..................... 10
9.4 Installing on the housing using the mounting
flange ................................................................... 11
9.5 Pneumatic connection ........................................ 11
9.5.1 Connecting the control medium ............ 11
10 Inspection and maintenance ...................................... 12
12 Removal .................................................................... 15
13 Disposal .................................................................... 15
14 Returns ..................................................................... 15
15 Declaration of Incorporation according to 2006/42/
EC (Machinery Directive) ........................................... 16
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www.gemu-group.com4 / 17GEMÜ Q40
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 tube.
Control medium
The medium whose increasing or decreasing pressure causes
the GEMÜ product to be actuated and operated.
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!
Danger – bodily injury!
Risk of crushing!
Risk of crushing due to the compressor shutting
down!

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1.5 Safety information on the product
1
Item Symbol Meaning
1 Risk of crushing!
– Do not reach into the tube crushing
area.
The adhesive label on the product is printed in German, Eng-
lish and French as supplied. If the product is used in a country
where a different language is spoken, a label in the corres-
ponding language must be attached.
Missing or illegible adhesive labels on the product must be at-
tached or replaced.
If the adhesive label is required in other, not enclosed, lan-
guages, it must be produced and attached by the customer at
their own responsibility.
2 Safety information
The safety information in this document refers only to an indi-
vidual 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 re-
sponsible for the production of the risk analysis and for com-
pliance with the resulting precautionary measures and re-
gional safety regulations.
The document contains fundamental safety information that
must be observed during commissioning, operation and main-
tenance. 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 specifications.
13. Maintain the product correctly.
14. Do not carry out any maintenance work and repairs not de-
scribed in this document without consulting the manufac-
turer first.
In cases of uncertainty:
15. Consult the nearest GEMÜ sales office.
2 Safety information

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3 Product description
3 Product description
3.1 Construction
2
10a
8
9
3
4
5
1
6
7a
10b
8
9
7b
11 11
Item Name Materials
1 Optical position
indicator
PP
2 Actuator 1.4301
3 Distance piece with
leak detection hole
1.4305/1.4408
4 Union nut 1.4408
5 Distance piece with
mounting flange
1.4404
6 Compressor 1.4404
7a Valve body PA6
7b Valve body 14404/PA6
8 Locking ring PA6
9 Tube holder PA6
10a Tube base carrier PA6
10b Tube base carrier 1.4404
11 CONEXO RFID chip
3.2 Description
The GEMÜ Q40 2/2-way pinch valve has a stainless steel pis-
ton actuator and is pneumatically operated. The valve guides
a tube which is compressed from above by a compressor to
control and regulate media. The compressor's specially de-
veloped contour and the inserts' contour minimise the strain
on the tube and thus increase the tubes' service life. Tubes
can be safely inserted and removed in simple steps and
without tools. The available control functions are "normally
closed (NC)" and "normally open (NO)". An integral optical po-
sition indicator is standard.
3.3 Function
The product controls a flowing medium by being closed or
opened by a control medium.
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 in
this document.
The product is designed to control a working medium guided
in a tube.
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
Pinch valve, pneumatically operated,
stainless steel piston actuator
Q40
2 Tube – inside diameter Code
ID 1/2" 8
3 Tube – outside diameter Code
OD 3/4" 12
OD 7/8" 14
4 Valve body material Code
1.4404/PA6 7P
4 Continuation of Valve body material Code
PA6 PA
5 Control function Code
Normally closed (NC) 1
Normally open (NO) 2
6 Actuator version Code
Actuator size 2G1 2G1
7 Mounting flange Code
Without mounting flange 0
With mounting flange F
Order example
Order option Code Description
1 Type Q40 Pinch valve, pneumatically operated,
stainless steel piston actuator
2 Tube – inside diameter 8 ID 1/2"
3 Tube – outside diameter 12 OD 3/4"
4 Valve body material 7P 1.4404/PA6
5 Control function 1 Normally closed (NC)
6 Actuator version 2G1 Actuator size 2G1
7 Mounting flange 0 Without mounting flange
5 Order data
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6 Technical data
6.1 Medium
Working medium: * Please observe the tube manufacturer's specifications
Control medium: Inert gases
6.2 Temperature
Media temperature: * Please observe the tube manufacturer's specifications
Ambient temperature: 0 to 60°C*
* Please observe the tube manufacturer's specifications
Control medium
temperature:
max. 60 °C
Storage temperature: 0 to 60 °C
6.3 Pressure
Operating pressure: * Please observe the tube manufacturer's specifications
6.4 Actuator data
Filling volume: Actuator size 2G1 0.084 dm³
Piston diameter: Actuator size 2G1 60 mm
6.5 Control pressure
Control pressure: Normally closed (NC) 4–6 bar
Normally open (NO) 2.5–4 bar
6.6 Product compliance
Machinery Directive: 2006/42/EU
6.7 Mechanical data
Weight: Actuator
Actuator size 2G1 1.3 kg
Valve body
PA6 0.066 kg
1.4404/PA6 0.228 kg
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6 Technical data

7 Dimensions
56
63
55
277
258
71,5
56
63
55
253
63,5
Dimensions in mm
Mounting options from below on the tube base carrier or on the flange plate
4,5
8x
12
LK
12
Dimensions in mm
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7 Dimensions

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8 Manufacturer's information
8 Manufacturer's information
8.1 Delivery
●Check that all parts are present and check for any damage
immediately upon receipt.
The product's performance is tested at the factory. The scope
of delivery is apparent from the dispatch documents and the
design from the order number.
8.2 Packaging
The product is packaged in a cardboard box which can be re-
cycled as paper.
8.3 Transport
1. Only transport the product by suitable means. Do not drop.
Handle carefully.
2. After the installation dispose of transport packaging ma-
terial according to relevant local or national disposal regu-
lations / environmental protection laws.
8.4 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 (see
chapter "Technical data").
4. Do not store solvents, chemicals, acids, fuels or similar
fluids in the same room as GEMÜ products and their spare
parts.
9 Installation
9.1 Preparing for installation
WARNING
The equipment is subject to pressure!
▶Risk of severe injury or death.
●Depressurize the plant.
●Completely drain the plant.
WARNING
Corrosive chemicals!
▶Risk of caustic burns.
●Wear suitable protective gear.
●Completely drain the plant.
CAUTION
Hot plant components!
▶Risk of burns.
●Only work on plant that has cooled
down.
CAUTION
Use 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.
NOTICE
Suitability of the product.
▶The product must be appropriate for the tube's operating
conditions (medium, medium concentration, temperature
and pressure) and the respective ambient conditions.
NOTICE
Tools
▶The tools required for installation and assembly are not
included in the scope of delivery.
●Use appropriate, functional and safe tools.
1. Ensure the product is suitable for the relevant application.
2. Check the technical data of the product and the materials.
3. Keep appropriate tools ready.
4. Use appropriate protective gear as specified in plant oper-
ator's guidelines.
5. Observe appropriate regulations for connections.
6. Installation work must be performed by trained personnel.
7. Shut off plant or plant component.
8. Secure the plant or plant component against recommis-
sioning.
9. Depressurize the plant or plant component.
10. Completely drain the plant or plant component and allow it
to cool down until the temperature is below the media va-
porization temperature and cannot cause scalding.
11. Pay attention to the installation position (see chapter "In-
stallation position").
9.2 Installation position
The installation position of the product is optional.
9.3 Installing the valve on the housing
1. Carry out preparations for installation (see chapter "Pre-
paring for installation").
2. Secure the valve body to the housing using four screws.
3. Re-attach or reactivate all safety and protective devices.

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9.4 Installing on the housing using the mounting flange
1. Before installing the actuator, machine the housing in ac-
cordance with the borehole pattern in the chapter "Dimen-
sions" so that the actuator can be guided through the re-
cess.
2. Guide the actuator through the recess in the housing. The
actuator's mounting flange must be flush with the hous-
ing.
3. Connect the mounting flange and housing using appropri-
ate screws and washers (not included in the scope of de-
livery).
9.5 Pneumatic connection
The following types are available:
Normally closed (NC):
Actuator resting position: closed by spring force. Activation of
the actuator (connector 2) opens the actuator. When the actu-
ator is vented, the actuator is closed by spring force.
Normally open (NO):
Actuator resting position: opened by spring force. Activation
of the actuator (connector 4) closes the actuator. When the
actuator is vented, the actuator is opened by spring force.
2 (NO) – +
9.5.1 Connecting the control medium
1. Use suitable connectors.
2. Connect the control medium lines tension-free and
without any bends or knots.
Thread size of the control medium connectors: G1/8
Control function Connections
1 Normally closed (NC) 2: Control medium
(open)
2 Normally open (NO) 4: Control medium
(close)
2
4
3. If necessary, remove the blanking plug from the control
medium connector.
4. Control function 1: Screw the control medium line into
control medium connector 2 of the actuator.
5. Control function 2: Screw the control medium line into
control medium connector 4 of the actuator.
9 Installation

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10 Inspection and maintenance
10 Inspection and maintenance
WARNING
The equipment is subject to pressure!
▶Risk of severe injury or death.
●Depressurize the plant.
●Completely drain the plant.
CAUTION
Use of incorrect spare parts!
▶Damage to the GEMÜ product.
▶Manufacturer liability and guarantee will be void.
●Use only genuine parts from GEMÜ.
CAUTION
Hot plant components!
▶Risk of burns.
●Only work on plant that has cooled
down.
CAUTION
Danger – bodily injury!
▶Risk of severe injury!
●Before performing any work on the
GEMÜ product, depressurize the plant.
NOTICE
Exceptional maintenance work!
▶Damage to the GEMÜ product.
●Any maintenance work and repairs not described in these
operating instructions must not be performed without
consulting the manufacturer first.
The operator must carry out regular visual examination of the
GEMÜ products depending on the operating conditions and
the potential danger in order to prevent leakage and damage.
The product also must be disassembled and checked for
wear 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 po-
sition four times a year.
10.1 Spare parts
1
2
A
Item Name Order designation
A Actuator A
1 Tube holder … (OD 3/4")
… (OD 7/8")
2 Compressor … (ID 1/2")

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10.2 Removing the tube
CAUTION
Risk of crushing!
▶While the tube holder is open, the actu-
ator can move. Severe injury due to
crushing or shearing of the fingers.
●Ensure that the actuator remains in the
open position during tube replace-
ment.
●Do not reach into the tube crushing
area.
1. Move the actuator A to the open position.
WARNING!Pneumatic actuator with control function 1:
Risk of crushing due to the compressor shutting down.
Ensure that the actuator remains in the open position dur-
ing tube replacement. Do not reach into the tube crushing
area.
b
2. Turn the locking ring b by 90° in the direction of the arrow.
ðThe word "unlocked" can be read on the tube holder.
1
3. Open the tube holder 1.
4. Remove the tube.
10.3 Disassembling the tube holder
1. Remove the tube (see “Removing the tube“, page13).
1
c
2. Loosen the fixing screw c using a hex driver.
3. Remove the tube holder 1.
10.4 Disassembling the compressor
CAUTION
Risk of crushing due to the compressor
shutting down!
▶Severe injury due to crushing or shear-
ing of the fingers.
●Ensure that the actuator remains in the
open position while replacing the com-
pressor.
●Do not reach into the tube crushing
area.
1. Remove the tube (see “Removing the tube“, page13).
2. Disassemble the tube holder (see “Disassembling the tube
holder“, page13).
3. Move the actuator A to the closed position.
2
4. Pull the compressor 2 out downwards.
10 Inspection and maintenance

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11 Troubleshooting
10.5 Installing the compressor
CAUTION
Risk of crushing due to the compressor
shutting down!
▶Severe injury due to crushing or shear-
ing of the fingers.
●Ensure that the actuator remains in the
open position while replacing the com-
pressor.
●Do not reach into the tube crushing
area.
1. Remove the tube (see “Removing the tube“, page13).
2. Disassemble the tube holder (see “Disassembling the tube
holder“, page13).
3. Disassemble the compressor (see “Disassembling the
compressor“, page13).
2
4. Insert the compressor 2 and press upwards until the com-
pressor engages.
5. Move the actuator A to the open position.
10.6 Assembling the tube holder
1. Disassemble the tube holder (see “Disassembling the tube
holder“, page13).
1
c
2. Insert the tube holder 1.
3. Tighten the fixing screw c using a hex driver.
10.7 Inserting the tube
1. Remove the tube (see “Removing the tube“, page13).
2. Insert the tube.
1
3. Close the tube holder 1.
b
4. Turn the locking ring b by 90° in the direction of the arrow.
ðThe word "locked" can be read on the tube holder.
5. With the valve fully assembled, check the function and
tightness.
11 Troubleshooting
Error Possible cause Troubleshooting
The product leaks
downstream
(doesn't close or
doesn't close fully)
Operating pressure
too high
Operate the
product with
operating pressure
specified in
datasheet
Tube leaking or
damaged
Check tube for
potential damage,
replace tube if
necessary
The product
doesn't open or
doesn't open fully
Actuator defective Replace valve
Control pressure
too low (for control
function NC)
Operate the
product at the
specified control
pressure (see
chapter "Technical
data")
Foreign matter in
the product
Remove and clean
the product

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Error Possible cause Troubleshooting
The actuator
design is not
suitable for the
operating
conditions
Use an actuator
that is designed for
the operating
conditions
The product
doesn't close or
doesn't close fully
The actuator
design is not
suitable for the
operating
conditions
Use an actuator
that is designed for
the operating
conditions
Foreign matter in
the product
Remove and clean
the product
Control pressure
too low (for control
function NO)
Operate the
product at the
specified control
pressure (see
chapter "Technical
data")
12 Removal
1. Remove in reverse order to installation.
2. Deactivate the control medium.
3. Disconnect the control medium line(s).
4. Disassemble the product. Observe warning notes and
safety information.
13 Disposal
1. 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.
14 Returns
Legal regulations for the protection of the environment and
personnel require that the completed and signed return deliv-
ery note is included with the dispatch documents. Returned
goods can be processed only when this note is completed. If
no return delivery note is included with the product, GEMÜ
cannot process credits or repair work but will dispose of the
goods 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.
14 Returns

15 Declaration of Incorporation according to 2006/42/EC (Machinery Directive)
Declaration of Incorporation
according to the EC Machinery Directive 2006/42/EC, Annex II, 1.B for partly
completed machinery
We, GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8
74653 Ingelfingen-Criesbach, Germany
declare that the following product
Make: GEMÜ pinch valve
Serial number: From 1st October 2020
Project number: Q30/40
Commercial name: GEMÜ Q40
meets the following essential requirements of the Machinery Directive 2006/42/EC:
1.1.5, 1.2.1, 1.2.2, 1.2.3, 1.2.5, 1.3., 1.3.2, 1.3.4, 1.3.7, 1.3.8, 1.3.9, 1.5.3, 1.5.5, 1.5.14, 1.6.1, 1.6.3
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 national au-
thorities, relevant information on the partly completed machinery. This transmission takes place:
Electronically
Authorised documentation officer GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8
74653 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 the
machinery into which the partly completed machinery is to be installed meets the provisions of this Directive.
2020-08-13
Joachim Brien
Head of Technical Department
www.gemu-group.com16 / 17GEMÜ Q40
15 Declaration of Incorporation according to 2006/42/EC (Machinery Directive)

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8, 74653 Ingelfingen-Criesbach, Germany
Phone [phone] · [email protected]
www.gemu-group.com
Subject to alteration
08.2020 | 88723850
*88723850*