GEM 4242 User manual

GEMÜ 4242
IO-Link
Combi switchbox with integrated pilot valve
Operating instructions
EN
further information
webcode: GW-4242

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
14.01.2021
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Contents
1 General information .................................................. 4
1.1 Information ......................................................... 4
1.2 Symbols used ..................................................... 4
1.3 Definition of terms ............................................. 4
1.4 Warning notes .................................................... 5
2 Safety information .................................................... 6
3 Product description ................................................... 7
3.1 Construction ....................................................... 7
3.2 LED displays ....................................................... 8
3.4 Function .............................................................. 9
3.5 Product label ...................................................... 9
4 GEMÜ CONEXO ......................................................... 9
5 Correct use ............................................................... 10
6 Order data ................................................................. 12
7 Technical data .......................................................... 14
8 Dimensions ............................................................... 16
8.1 Size 1 ................................................................... 16
8.2 Size 2 ................................................................... 16
9 Manufacturer's information ....................................... 17
9.1 Delivery ............................................................... 17
9.2 Packaging ........................................................... 17
9.3 Transport ............................................................ 17
9.4 Storage ............................................................... 17
10 Assembly and installation ......................................... 17
10.2 Mounting the combi switchbox on linear actu-
ators .................................................................... 19
10.3 Mounting the combi switchbox on quarter turn
actuators ............................................................. 22
11 Pneumatic connection ............................................... 24
11.1 Size 1, standard, single acting ........................... 24
11.2 Size 1, standard, double acting ......................... 24
11.3 Size 1, compact version ..................................... 25
11.4 Size 2, standard, single acting ........................... 25
11.5 Size 2, standard, double acting ......................... 26
12 Electrical connection ................................................. 27
12.1 Potential equalization – special function X and
Y .......................................................................... 27
12.2 IO-Link, ordering option Fieldbus, code IOL ..... 28
12.2.1 Pin assignment ...................................... 28
13 Commissioning ......................................................... 29
13.1 Initialization of end positions ............................ 29
14 Specific data - IO-Link ............................................... 31
14.1 Inputs .................................................................. 31
14.2 Outputs ............................................................... 31
14.3 Parameter ........................................................... 31
14.4 Diagnostic messages (Event Codes) ................ 33
15 Manual override ........................................................ 34
16 Troubleshooting ........................................................ 35
16.1 LED error message ............................................. 35
16.2 Troubleshooting ................................................. 36
17 Inspection and maintenance ...................................... 37
18 Disassembly .............................................................. 37
19 Disposal .................................................................... 37
20 Returns ..................................................................... 37
21 Declaration of conformity according to 2014/30/EU
(EMC Directive) ......................................................... 38
22 EU Declaration of conformity in accordance with
2014/34/EU (ATEX) ................................................... 39
GEMÜ 4242
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1 General information
1 General information
1.1 Information
•The descriptions and instructions apply to the standard versions. For special versions not described in this document the
basic information contained herein applies in combination with any additional special documentation.
•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
The following LED symbols are used in the documentation:
Symbol LED conditions
Off
Lit (on)
Flashing
1.3 Definition of terms
Speed-APfunction
Speed Assembly and Programming, a particularly user-friendly commissioning function for fast mounting, automated setting
and initialization of GEMÜ products. Dependent on type, activation uses an external impulse signal or existing precautions on
the device (magnetic or housing switch). Changeover to normal operating mode takes place automatically after successful
completion.
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.

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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 - corrosive materials
Danger - hot surfaces
1 General information

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2 Safety information
2 Safety information
The safety information in this document refers only to an individual 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 compliance with the resulting precautionary measures and regional
safety regulations.
The document contains fundamental safety information that must be observed during commissioning, operation and mainten-
ance. 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 dangerous 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 personnel.
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 described in this document without consulting the manufacturer
first.
In cases of uncertainty:
15. Consult the nearest GEMÜ sales office.

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3 Product description
3.1 Construction
1
2
4
3
5
Size 1 Size 2
1
2
5
3
4
Item Name Materials
Size 1 Size 2
1 Housing cover - standard version: PC PC
Housing cover - compact version: PP -
2 Housing base Anodised aluminium or SS PPS
3 Electrical connection SS, PP SS, PP
4 Adapter piece SS SS
5 Mounting kit, valve specific SS SS
Seals EPDM and NBR NBR
3 Product description

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3 Product description
3.2 LED displays
3.2.1 Status LEDs
As well as the electrical position feedback and error analysis a visual signal is emitted by LEDs that can be seen from above.
LED Colour Function
Standard 1) Inversed 2)
CLOSED green orange Process valve in CLOSED pos-
ition
ERROR red red Error
OPEN orange green Process valve in OPEN posi-
tion
PWR/FAULT green green Communication existing
red red Communication error
High visibility LED green orange Process valve in CLOSED pos-
ition
orange green Process valve in OPEN posi-
tion
green / orange green / orange Programming mode
1) Option
Code 00: Without
Code 01: Manual override
2) Option
Code 40: Inversed LED colours
Code 41: Inversed LED colours, manual override
For order codes see chapter "Order data"
3.2.2 LED conditions
Function CLOSED ERROR OPEN High visibility LED
Valve in OPEN position
Valve in CLOSED position
Programming mode
OPEN / CLOSED flash alternately flashes alternately
LED conditions
lit (on) ~ irrelevant flashes off
3.3 Description
The GEMÜ 4242 combi switchbox is suitable for mounting to pneumatically operated linear actuators. The position of the
valve spindle is reliably electronically detected and evaluated using play-free and non-positive mounting. Integrated pilot
valves enable direct activation of the process valve connected to them. Intelligent microprocessor controlled functions make
commissioning and support during operation easier. The current position of the valve is displayed via high visibility LEDs and
fed back via electrical signals.

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3.4 Function
The GEMÜ 4242 combi switchbox shows the current position of the valve. When the valve is opened, the spindle in the combi
switchbox moves upwards and indicates that the valve is OPEN using the high visibility LEDs and communication interface.
When the valve is closed, the spring in the mounting kit pushes the spindle in the combi switchbox downwards and indicates
that the valve is CLOSED using the high visibility LEDs and communication interface.
3.5 Product label
Device version Design in accordance with
order data
Item number Traceability number Serial number
Device-specific data
Year of manufacture
The manufacturing month is coded under the traceability number and can be requested from GEMÜ. The product was manu-
factured in Germany.
4 GEMÜ CONEXO
Order variant
In the corresponding design with CONEXO, this product has an RFID chip (1) for electronic identification purposes. The posi-
tion of the RFID chip can be seen below. The CONEXO pen helps read out information stored in the RFID chips. The CONEXO
app or CONEXO portal is required to view this information.
1
1
Size 1 Size 2
For further information please read the operating instructions for CONEXO products or the CONEXO datasheet.
Products such as the CONEXO app, the CONEXO portal and the CONEXO pen are not included in the scope of delivery and need
to be ordered separately.
4 GEMÜ CONEXO

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5 Correct use
5 Correct use
DANGER
Danger of explosion
▶Risk of severe injury or death.
●Only versions that have been approved according to their technical data may be used in potentially explos-
ive environments.
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 doc-
ument.
The GEMÜ 4242 with integrated pilot valve is designed for linear actuators. The product has a microprocessor controlled intel-
ligent position sensor as well as an analogue travel sensor system (potentiometer) which is positively connected with the ac-
tuator spindle by means of a mounting kit (spring, operating bush). The valve end positions and the integrated travel sensor
can be controlled via the electrical connections. The pneumatic valve actuator is directly activated by an integrated 3/2-way
pilot valve. The housing cover must not be removed.
5.1 Product without special function X or Y
The product is not intended for use in potentially explosive areas.
5.2 Product with special function Y
The product with special function Y is UL/CSA certified and protected against explosion in accordance with ISA 12.12.01 (see
"Technical data").
The product with special function Y can be connected to switches, power supplies, PLC outputs and PLC inputs.
The energy supply must be equipped with a switch or an overcurrent protective device in the system. The switch or overcur-
rent protective device must be placed in a suitable and accessible position and also labelled as an isolating device for the
product with special function Y.
The product user is responsible for providing connections that comply with standards, a locking mechanism, cable compatibil-
ity and warning signs.
Suitable locking clips must be used to secure the circular connectors against becoming unintentionally loose or being
loosened without the use of tools
Installation, operation and maintenance must only be carried out by qualified trained personnel.
Do not repair the device yourself if it is faulty. Instead, replace it with an equivalent new device. Repairs must only be carried
out by the manufacturer!
The device must only be used if its materials are resistant against mechanical and/or chemical influences or corrosion under
the respective operating conditions to such a sufficient degree that the explosion protection is not impaired or nullified.

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5.3 Product with special function X
The product with ordering option Special version X is intended for use in potentially explosive areas of zone 2 with gases,
mists or vapours and zone 22 with combustible dusts in accordance with EU directive 2014/34/EU (ATEX) and IECEx.
The product has the following explosion protection marking:
ATEX
Gas: II 3G Ex ec nC IIC T4 Gc X
Dust: II 3D Ex tc IIIC T 80 °C Dc X
IECEx
Gas: Ex ec nC IIC T4 Gc
Dust: Ex tc IIIC T80°C Dc
Certificate: IECEx IBE 19.0011 X
The product has been developed in compliance with the following harmonised standards:
•IEC 60079-0: 2011 (EN 60079-0:2012+A11:2013)
•IEC 60079-15: 2010 (EN 60079-15:2010)
•IEC 60079-31: 2013 (EN 60079-31:2014)
•IEC 60079-7: 2017 (EN 60079-7+A1:2015)
Use of the product is permissible in the following ambient temperature ranges: 0°C to +40°C
For use in potentially explosive areas, the following conditions or operation limits must be observed:
Index X is applied to the explosion protection marking.
The following special conditions must be complied with:
1. Connection cables and connectors must be protected from damage.
2. Layers of dust > 5 mm must be removed.
3. Warning label "Danger from electrostatic build-up".
4. Warning label "Do not disconnect when live".
The housing must be installed protected from mechanical influences.
RFID chips must not be read out in potentially explosive areas.
5 Correct use

6 Order data
The order data provide an overview of standard configurations.
Please check the availability before ordering. Other configurations available on request.
Note: A valve specific mounting kit is required for assembly. For designing the mounting kit, the valve type, nominal size, con-
trol function and actuator size must be stated.
Order codes
1 Type Code
Combi switchbox 4242
2 Fieldbus Code
Without, 24 V DC version 000
AS-Interface, 31 slaves, 4I/4O A2
AS-Interface, 62 slaves, 4I/3O A3
AS-Interface, 62 slaves, 8I/8O A4
DeviceNet DN
IO-Link IOL
3 Accessory Code
Accessory Z
4 Housing material Code
Stainless steel base, PC cover 07
Aluminium base, PC cover 14
PPS base, PC cover 01
5 Function Code
Combi switchbox, single acting 01
Combi switchbox, double acting 02
Combi switchbox, compact version,
single acting
K1
6 Electrical connection Code
M12 plug, 5-pin 01
M12 plug, 8-pin 02
M12 plug, 5-pin, stainless steel, size 2 S1
M12 plug, 8-pin, stainless steel, size 2 S2
7 Pneumatic connection Code
Connection thread M5 for size 1,
connection thread G1/8 for size 2
01
Air supply 4 mm angled connection,
exhaust air 4 mm angled connection
02
Air supply 4 mm T-connection,
exhaust air 4 mm angled connection
03
Air supply 6 mm angled connection,
exhaust air 6 mm angled connection
04
Air supply 6 mm T-connection,
exhaust air 6 mm angled connection
05
Connection thread M5 for size 1,
connection thread G1/8 for size 2
(for IP67 or piped air outlet)
E1
Air supply 6 mm angled connection,
exhaust air 6 mm angled connection
(for IP67 or piped air outlet)
E4
Air supply 1/4" angled connection,
exhaust air 1/4" angled connection
U8
8 Option Code
Without 00
Manual override 01
Inversed LED colours 40
Inversed LED colours, manual override 41
Inversed LED colours
deactivated high visibility position feedback
80
9 Flow rate Code
14 Nl/min, size 1 01
23 Nl/min (Booster), size 1 02
250 Nl/min, size 2 03
10 Travel sensor version Code
Potentiometer 30 mm length, size 1 030
Potentiometer 75 mm length, size 2 075
11 Special version Code
Without
ATEX (2014/34/EU), IECEx X
NEC 500 and UL/CSA approval Y
6 Order data
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Order example
Order option Code Description
1 Type 4242 Combi switchbox
2 Fieldbus 000 Without, 24 V DC version
3 Accessory Z Accessory
4 Housing material 07 Stainless steel base, PC cover
5 Function 01 Combi switchbox, single acting
6 Electrical connection 01 M12 plug, 5-pin
7 Pneumatic connection 01 Connection thread M5 for size 1,
connection thread G1/8 for size 2
8 Option 01 Manual override
9 Flow rate 01 14 Nl/min, size 1
10 Travel sensor version 030 Potentiometer 30 mm length, size 1
11 Special version Without
6 Order data
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7 Technical data
7 Technical data
7.1 Medium
Working medium: Quality classes to DIN ISO 8573-1
Dust content: Class 3, max. particle size 5 μm, max. particle density 5 mg/m³
Oil content: Class 5, max. oil concentration 25 mg/m³
7.2 Temperature
Ambient temperature: Standard or with special version code Y 0 to 60 °C
Special version code X 0 to 40 °C
Media temperature: 0 to 50 °C
Storage temperature: -10 to 70 °C
7.3 Pressure
Operating pressure: Size 1 Size 2
1 to 9 bar (at 40 °C)
1 to 8 bar (at 60 °C)
2 to 7 bar
Observe the maximum control pressure of the valve actuator.
Flow rate: Size 1 Size 2
14 Nl/min
23 Nl/min
250 Nl/min
7.4 Product conformities
EMC Directive: 2014/30/EU
Technical standards used:
IO-Link
Interference emission EN 61000-6-3
Interference resistance EN 61000-6-2
Explosion protection: ATEX (2014/34/EU) and IECEx, order code Special version X
NEC 500 (ISA 12.12.01), order code for special version Y
ATEX marking: Gas: II 3G Ex ec nC IIC T4 Gc X
Dust: II 3D Ex tc IIIC T 80 °C Dc X
IECEx marking: Gas: Ex ec nC IIC T4 Gc
Dust: Ex tc IIIC T80°C Dc
Certificate: IECEx IBE 19.0011 X
NEC marking: Class I, Division II, Groups C & D, T4
Approvals: IO-Link
Fieldbus /
Communication
Travel sensor version 030: IO-
Link specification V1.0
Travel sensor version 075: IO-
Link specification V1.1
7.5 Mechanical data
Installation position: Optional

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Weight: Size 1 Size 2
Aluminium: 320 g
Stainless steel: 600g
420 g
Protection class: IP 65 acc. to EN 60529
IP 67 acc. to EN 60529, is reached with piped air outlet
IP NEMA 4X (UL 61010-1, UL 50E), only available as special version code Y
Travel sensor: Size 1 Size 2
Minimum stroke: 2 mm 5 mm
Maximum stroke: 30 mm 75 mm
Hysteresis: 0.2 mm 0.5 mm
Accuracy: 0.2 % Full Scale
7.6 Electrical data
Supply voltage: 24 V DC (18 to 30 V DC)
Duty cycle: Continuous duty
Reverse battery protec-
tion:
yes
Electrical protection
class:
III
Current consumption: Flow rate Code IO-Link
01 typically 80 mA
02 typically 120 mA
03 typically 100 mA
Electrical connection
type:
1 x 5-pin M12 plug (A-coded) or 1 x 8-pin plug (A-coded)
Switching characteristic:
100%
0%
td1 td1
td1 td2
td1
ta
t/ms
t/ms
t/ms
Stroke %
Switch point "Open"
Switching hysteresis
Switching hysteresis
Switching output "Open"
Switch point "Closed"
active
inactive
active
inactive
Switching output "Closed"
td1: Signal delay
td2: Signal delay
ta: Signal interval
Switch points: The data in percent refer to the programmed stroke, before each end position
7 Technical data

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8 Dimensions
Switch points: Size 1 Size 2
Default setting switch point CLOSED 12 % 12 %
Default setting switch point OPEN 25 % 25 %
Min. switch point CLOSED 0.8 mm 2 mm
Min. switch point OPEN 0.5 mm 1.25 mm
If the percentage switch points dependent on the programmed stroke are smaller than the per-
missible min. switch points, the min. switch points apply automatically.
8 Dimensions
8.1 Size 1
98
Ø57
X
13
16,6
47
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
dependent on valve used
X
□42
95
20
13,6
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
dependent on valve used
Standard Compact
Dimensions in mm
8.2 Size 2
142
Ø 90
14,5
86,5 19
X
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
dependent on valve used
Dimensions in mm

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9 Manufacturer's information
9.1 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.
9.2 Packaging
The product is packed in a cardboard box which can be recycled as paper.
9.3 Transport
1. Only transport the product by suitable means. Do not drop. Handle carefully.
2. After the installation dispose of transport packaging material according to relevant local or national disposal regulations /
environmental protection laws.
9.4 Storage
1. Store the product free from dust and moisture in its original 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.
10 Assembly and installation
NOTICE
●Pay attention to the information on product labels, in product documentation and EC type examination certificate.
●Connect cable carefully, do not damage individual wires.
●When connecting multiwire or finewire cables, prepare the wire ends.
●Always use suitable pinch tools for pinching wire end ferrules in order to achieve consistent quality.
●Tighten all clamping points, even the ones not being used.
1. Observe the national regulations and provisions.
2. Observe the installer provisions.
3. Protect M12 plugs against electrostatic build-up.
4. Protect M12 plugs against damage.
5. Lay cables securely and protect them from damage.
6. Differential voltage for two intrinsically safe electric circuits: maximum 30 V.
7. Connect open wire ends in a junction box with protection class IP20 and higher or outside the EX area.
10.1 Mounting kit assembly
Item Name Item Name
1 Spindle 7 Flange plate
2 Spring 8 Screws
3 Operating bush 9 Pressure disc*
4 Distance piece 10 O-ring*
5 O-ring 11 O-ring*
6 Adapter
* Included depending on version.
CAUTION
Pretensioned spring!
▶Damage to the device.
●Slowly release the tension in the spring.
10 Assembly and installation

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10 Assembly and installation
CAUTION
Do not scratch the spindle!
▶A damaged spindle surface may cause failure of the travel sensor.
1
4
1
2
3
1. Pull out the spindle 1. 2. Align the indentation of the distance piece 4 to the spring and push it over the
spindle 1 using the spring 2 and fix it in place using the operating bush 3.
5
6
3. Tighten the operating bush 3 by turning it
clockwise.
4. Affix the O-ring 5 and the adapter 6.
7
8
5. Attach the flange plate 76. Screw the flange plate on tight using screws 8 (1 – 1.5 Nm).
•Push in the spindle until it pushes against the spring and then slowly release the pressure on the spring.

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NOTICE
▶For some valves (e.g. GEMÜ 650 and GEMÜ 687) it is necessary to fit a pressure disc between the threaded adapter and
the actuator head. This is included in the required mounting kits, sometimes with an additional O-ring (only GEMÜ 650
with normally open and double-acting control function – code 2+3).
▶If the pressure disc does not have a groove for a seal, this will already be inserted in the groove provided at the adapter
opening of the actuator head (e.g. GEMÜ 687 with normally open control function – code 2).
9
6
11
10
Insert the O-ring 11 (if included) into the corresponding groove
on the adapter 6.
If included: Push the pressure disc 9 over the adapter 6 and in-
sert the O-ring 10 in the intended groove of the pressure disc.
10.2 Mounting the combi switchbox on linear actuators
10.2.1 Preparations for mounting to the valve
1. Move the actuator A into zero position (actuator vented).
2. Remove optical position indicator 2 and / or protective cap 1 from the actuator top.
A
12
10.2.2 Assembling the adapter (linear actuator)
With some mounting kits it is necessary to install an adapter as well. This adapter is enclosed with the required mounting kits.
Valves with a normally open and double acting control function (code 2+3) also include additional O-rings (1+2).
1
3
2
1. Move the actuator to the closed position.
2. Place O-rings 1 and 2 into adapter 3.
3. Screw adapter 3 into the actuator opening as far as it will go and tighten.
10 Assembly and installation

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10 Assembly and installation
10.2.3 Assembling the stroke limiter (linear actuator)
5
5
4
3
2
1
6
8
9
7.1
7.2
Option1 Option2
1. Screw distance piece 5 onto/into actuator spindle
6.
2. Move the actuator to the closed position.
3. Insert the O-ring 7.1 in the stroke limiter 1.
4. Insert the O-ring 7.2 in the washer 4.
5. Screw stroke limiter 1 with nut 2, seal 3 and washer
4 into the actuator opening.
6. Set stroke limiter 1 to the required stroke.
7. Make sure that the minimum stroke is reached.
8. Secure stroke limiter 1 with nut 2.
Key
1 Stroke limiter 7.1 1)
7.2 1)
O-ring
2 Nut 8 Protective cap
3 1) Seal 9 Position indicator
4 1) Washer 10 Operating bush
5 2) Distance piece 11 Spindle
6 Actuator spindle 12 Travel sensor
1) Only available for valves with the NO and DA control functions.
2) Only included in required mounting kits. The design depends on the valve.