GEM 1205 User manual

GEMÜ 1205
Electrical position indicator ATEX
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
02.10.2018
www.gemu-group.com2 / 20GEMÜ 1205

Contents
1 General information ................................................... 4
1.1 Information ......................................................... 4
1.2 Symbols used ..................................................... 4
1.3 Warning notes .................................................... 4
2 Safety information .................................................... 4
3 Product description ................................................... 5
3.1 Construction ....................................................... 5
3.2 Description ......................................................... 5
3.3 Function .............................................................. 5
4 Correct use ................................................................ 5
5 Order data ................................................................. 6
6 Technical data ........................................................... 7
7 Dimensions ............................................................... 8
8 Manufacturer's information ....................................... 9
8.1 Delivery ............................................................... 9
8.2 Packaging ........................................................... 9
8.3 Transport ............................................................ 9
8.4 Storage ............................................................... 9
9 Assembly and installation ......................................... 9
9.2 Information on use in damp conditions ............ 10
9.3 Assembly of mounting kit with thread .............. 10
9.3.1 Assembly of mounting kit without
stroke limiter .......................................... 10
9.3.2 Assembly of mounting kit with stroke
limiter ..................................................... 10
9.4 Assembly of mounting kit without thread ........ 10
9.5 Assembly and installation of the electrical po-
sition indicator ................................................... 10
10 Electrical connection ................................................. 13
10.1 Terminals, microswitch (code 104) ................... 13
11 Fault clearance .......................................................... 14
12 Inspection and servicing ............................................ 14
12.1 Spare parts ......................................................... 14
12.2 Setting the limit switches .................................. 14
12.3 Cleaning the product .......................................... 14
13 Disassembly ............................................................. 14
14 Disposal .................................................................... 14
15 Returns ..................................................................... 15
16 EU declaration of conformity ..................................... 16
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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, servicing 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 Warning notes
Wherever possible, warning notes are organised according to
the following scheme:
SIGNAL WORD
Symbol for
the specific
danger
Type and source of the 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 – high voltage
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 ser-
vicing. 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 servicing.
– 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 installation, operating and
maintenance instructions 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.

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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 servicing work and repairs not de-
scribed 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
1
2
3
4
Item Name Materials
1 Cover Aluminium
diecasting
2 Base Aluminium
diecasting
3 Operating bush 1.4104
4 Guide piece 1.4305
3.2 Description
The GEMÜ 1205 electrical position indicator has electro-
mechanical microswitches in a flameproof enclosure. Two
valve positions, open and/or closed can be remotely indic-
ated.
3.3 Function
The GEMÜ 1205 is used to indicate and check the position of
valves operated with pneumatic linear actuators. The spindle
of the electrical position indicator is positively connected to
the spindle of the linear actuator and is moved with the linear
movement of the actuator. The cam attached to the spindle
activates the built-in microswitches, which are used for elec-
tronic signal transmission.
Depending on the version, the electrical position indicator is
equipped with 1 to 2 microswitches.
4 Correct use
DANGER
Danger of explosion
▶Danger of death or severe injury.
●Do not use the product as a step or
foothold.
●Prior to commissioning, ensure that
the cover is fully closed and that the
housing and the O-ring are not dam-
aged.
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 GEMÜ 1205 electrical position indicator is designed for
use in potentially explosive atmospheres of zones 1 and 2
with gases, mists or vapours and zones 21 and 22 with flam-
mable dusts.
The product has the following explosion protection marking:
Gas: II 2G Ex db eb IIC T6 Gb
Dust: II 2D Ex tb IIIC T80°C Db
EC type examination
certificate
IBExU18ATEX1008
For special conditions and operation limits see EC type ex-
amination certificate.
The product can be used in the following ambient temperat-
ure ranges: T6/T80 °C: -30 °C...+60 °C
1. Use the product in accordance with the technical data.
4.1 Use in potentially explosive environments
GEMÜ 1205 is certified in accordance with ATEX and has an
explosion protection approval according to 2014/34/EU (see
"Technical data").
The energy supply must be equipped with a switch or an
overcurrent protective device in the system.
The product user is responsible for providing connections
that comply with standards as well as cable compatibility
and warning signs. Only Ex t or Ex e cable glands with prop-
erties corresponding to at least those of the housing must be
used (IP protection, ambient temperature, explosion protec-
tion class, thread type and size). The materials of the cable
glands must be compatible with the housing materials. The
cable glands must comply with at least IP65. The connection
is designed as M20. Installation, operation and servicing
must only be carried out by qualified trained personnel with a
strong knowledge of the type of ignition protection
"Flameproof enclosure" db, eb and tb. Do not repair the
device yourself if it is faulty. Instead, replace it with an equi-
valent 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.
4 Correct use

5 Order data
The order data provide an overview of standard configurations.
Please check the availability before ordering. Other configurations available on request.
Note: Mounting kit 1205 S01 Z...AT dependent on valve type. Please order separately specifying valve type, DN, control func-
tion and actuator size.
Order codes
1 Type Code
Electrical position indicator ATEX
for linear actuators
1205
2 Fieldbus Code
Without 000
3 Accessory Code
Accessory Z
4 Housing material Code
Aluminium diecasting AL
5 Function Code
Open / Closed A00
Open A01
Closed A02
6 Electrical connection Code
M20 cable gland 03
7 Options Code
Without 00
8 Switch Code
SPDT (Single Pole Double Throw) contact,
microswitch
M2
9 Connection diagram Code
Microswitch PNP M2
10 Special version Code
ATEX 2014/34/EU X
Order example
Order option Code Description
1 Type 1205 Electrical position indicator ATEX
for linear actuators
2 Fieldbus 000 Without
3 Accessory Z Accessory
4 Housing material AL Aluminium diecasting
5 Function A00 Open / Closed
6 Electrical connection 03 M20 cable gland
7 Options 00 Without
8 Switch M2 SPDT (Single Pole Double Throw) contact, microswitch
9 Connection diagram M2 Microswitch PNP
10 Special version X ATEX 2014/34/EU
5 Order data
www.gemu-group.com
6 / 20
GEMÜ 1205

6 Technical data
6.1 Temperature
6.2 Product compliance
Explosion protection: ATEX (2014/34/EU), order code special version X
only for order code Display (code 0)
ATEX marking: Gas: II 2G Ex db eb IIC T6 Gb
Dust: II 2D Ex tb IIIC T80°C Db
Type examination
certificate:
IBExU18ATEX1008
6.3 Mechanical data
Weight: 1146.5 g
Protection class: IP 65 acc. to EN 60529
Range of limit switch: 2 to 70 mm continuous
Mechanical stability: 7 Nm, impact energy acc. to EN 60079-0
Max. switching frequency: ≤ 1000 switching cycles/h
6.4 Electrical data
Switch type: Microswitch
Switch rating: Switch rating AC
Voltage Ohmic load Inductive load (cosϕ = 0.6)
250 V
30 V
5 A
7 A
3 A
5 A
Switch rating DC
Voltage Ohmic load Inductive load (cosϕ = 0.6)
250 V
30 V
0.4 A
7 A
0.03 A
5 A
Information applies to 40 °C ambient temperature
Thermal rated current: 6 A
Electrical connection
type:
M20 cable gland 1 x available (Type Bartec 03-6020-0016)
1 x prepared (blanking cover)
Cable diameter: 7 to 13 mm
Terminal diameter: 2.5 mm²
Earth terminal: 4.0 mm²
Potential equalisation: Stranded wire, yellow/green, H 07 V-K 4.0
Tightening torque 10 Nm
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6 Technical data

7 Dimensions
55
Ø100
125
119
14
20 20
Dimensions in mm
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8 / 20
GEMÜ 1205
7 Dimensions

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8 Manufacturer's information
8.1 Delivery
1. Check that all parts are present and check for any dam-
age 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 packed 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 packing mater-
ial according to relevant local or national disposal regula-
tions / 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 Assembly and installation
DANGER
Risk of electric shock
▶Risk of injury or death (if operating
voltage is higher than safe extra low
voltage).
▶Electric shock can cause severe burns
and fatal injury.
●Work on electrical connections only by
qualified trained personnel.
●Disconnect the cable from the power
supply before making the electrical
connection.
●Connect the protective earth con-
ductor.
CAUTION
Danger - high voltage!
▶Electric shock.
●Before performing any work on the
GEMÜ product switch off power and
protect circuit from being switched on
again.
CAUTION
Fitted electrical position indicator
▶Destruction of the electrical position indicator when dis-
assembling the valve body
●Disassemble the electrical position indicator before dis-
assembling the valve body
NOTICE
●Observe the data on the product labels, product docu-
mentation and the EC type examination certificate.
●Connect cable carefully, do not damage individual wires.
●Prepare the wire ends when connecting several cables or
fine-wired cables.
●Always attach wire end ferrule stops using pinch tools to
achieve consistent quality.
●Tighten all clamping points, even the ones not being
used.
9.1 Preparations for assembly 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.
9 Assembly and installation

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9 Assembly and installation
A
12
9.2 Information on use in damp conditions
The following information is intended to help when installing
and operating the product in damp conditions.
1. Lay cables and pipework so that no condensate or rain
water that remains on the pipework / cables can enter the
cable glands or plugs of the product.
2. Check that all cable glands or plugs are positioned cor-
rectly
3. Check the sealing ring 1 for any damage and correct posi-
tioning before tightening the cover.
1
9.3 Assembly of mounting kit with thread
1. Before beginning assembly, check the type of mounting
kit.
9.3.1 Assembly of mounting kit without stroke limiter
1
2
3
1. Screw in adapter 2 using wrench surface 1.
2. Screw in guide piece 3 using the wrench surface.
9.3.2 Assembly of mounting kit with stroke limiter
2
1
4
56
1. Screw in adapter 2 using wrench surface 1.
2. Set stroke limiter to the desired height using wrench sur-
face4.
3. Secure nut 5 against the actuator top.
4. Only use thread sealing ring 6 for installation of stroke
limiters in case of control functions 2 and3
9.4 Assembly of mounting kit without thread
1
1
2
1. Insert spindle of mounting kit 1 into actuator.
2. Carefully knock down the spindle of mounting kit 1 with
an appropriate tool 2 until it stops.
3
4
3. Screw in guide piece 3 using the wrench surface.
4. Mounting kit 1 is correctly assembled.
9.5 Assembly and installation of the electrical position
indicator
DANGER
Danger of explosion
▶Danger of death or severe injury.
●Do not use the product as a step or
foothold.
●Prior to commissioning, ensure that
the cover is fully closed and that the
housing and the O-ring are not dam-
aged.

www.gemu-group.com 11 / 20 GEMÜ 1205
DANGER
Risk of electric shock
▶Risk of injury or death (if operating
voltage is higher than safe extra low
voltage).
▶Electric shock can cause severe burns
and fatal injury.
●Work on electrical connections only by
qualified trained personnel.
●Disconnect the cable from the power
supply before making the electrical
connection.
●Connect the protective earth con-
ductor.
1
2
1
2
1. Disconnect the power sup-
ply and secure against re-
commissioning.
2. Undo nuts 1 and leave
them in cover 2.
3. Remove cover 2.
4. Undo grub screw 1 (do not
unscrew completely).
5. Put the base of the elec-
trical position indicator
onto guide piece 2 (taking
care that the trip cams do
not damage the switches!
6. Turn the electrical position
indicator into the desired
connection direction and
fix the position with grub
screw 1.
Setting the upper switching
position:
Setting the lower switching
position:
1
2
3
4
6
5
1
2
3
4
6
5
7. Move the valve to the
OPEN position.
8. Undo screws 1.
9. Use the left screw 2 to
move switch 3 to the de-
sired position.
10. Tighten screws 1.
ðThe upper switching
position is set.
11. Move the valve to the
CLOSED position.
12. Undo screws 4.
13. Use the right screw 6 to
move switch 5 to the de-
sired position.
14. Tighten screws 4.
ðThe lower switching
position is set.
15. Insert the connection cable through the cable gland.
16. Only strip the connection cable directly before the switch
mounting plate.
17. Guide the individual wires to the terminals.
18. Cut the individual wires to the appropriate length in order
to avoid having unnecessarily long cable loops.
19. Compress the individual wires with wire end ferrules .
20. Connect the individual wires to the connection terminals
in accordance with the connection diagram.
6
5
4
3
2
1
x1
4
2
1S2
S1
4
2
1
On-site
wiring
On-site
wiring
Limit switch OPEN Limit switch CLOSED
Connecting the potential equalisation
M4x6
21. Use a screw M4x6 to attach the potential equalisation to
the electrical position indicator.
ðPotential equalisation for metal housings in poten-
tially explosive areas at least 4 mm²:
22. Secure the connection against working itself loose.
9 Assembly and installation

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9 Assembly and installation
3
2
1
23. After completing the electrical connection, carefully pull
the connection cable taut.
ðAvoid pulling too hard!
24. Make sure that the O-ring is properly mounted and not
damaged.
25. Attach the cover 2 with the nuts 3.
26. Screw in and tighten nuts 3.
ðEnsure all seals and threaded connections are cor-
rectly installed.
27. Supply power to the electrical position indicator.
28. For function control, open and close the valve and pay at-
tention to signalling.
29. If the settings need to be readjusted, disconnect the elec-
trical position indicator from the power supply and repeat
step 7 to step 26.

10 Electrical connection
10.1 Terminals, microswitch (code 104)
6
5
4
3
2
1
x1
4
2
1S2
S1
4
2
1
On-site
wiring
On-site
wiring
Limit switch OPEN Limit switch CLOSED
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10 Electrical connection

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11 Fault clearance
11 Fault clearance
Error Error cause Error clearance
No stroke No mounting kit
available
Check mounting kit
Process valve
faulty
Replace process
valve
Wrong mounting kit
installed
Replace mounting
kit
No feedback Incorrect assembly Check assembly,
wiring and
connection
Switch not set Set switch
Wrong mounting kit
installed
Replace mounting
kit
Voltage is not
connected
Connect voltage
Cover cannot be
attached
Sealing ring
inserted incorrectly
Insert sealing ring
correctly
Sealing ring
damaged
Replace sealing
ring
Cables protruding
over the edge of
the base
Check the cable
routing and shorten
the cables if
necessary
Grub screw not
working
Grub screw
unscrewed too far,
nut fell out
Reinsert the nut,
screw in the grub
screw (during
assembly, only
undo the grub
screw, do not
unscrew it
completely)
12 Inspection and servicing
CAUTION
Use of incorrect spare parts!
▶Damage to the GEMÜ product.
▶Manufacturer liability and guarantee will be void.
●Use only genuine parts from GEMÜ.
NOTICE
Exceptional servicing work!
▶Damage to the GEMÜ product.
●Any servicing 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
products depending on the operating conditions and the po-
tential danger in order to prevent leakage and damage.
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 products which are always in the same position
four times a year.
12.1 Spare parts
No spare parts are available for this product. If it is faulty,
please return it to GEMÜ for repair.
12.2 Setting the limit switches
For limit switch setting see chapter "Assembly and installa-
tion of the electrical position indicator" steps 1 to 14.
12.3 Cleaning the product
– Do not clean the product with a high pressure clean-
ing device.
13 Disassembly
1. Switch off power to the product.
2. Remove the potential equalisation device.
3. Remove the cover 2.
4. Remove the individual wires from the terminal strip.
5. Remove the connection cable.
6. Dismantle the mounting kit/product in the opposite order
to that described in the Assembly (see “Assembly and in-
stallation“, page9) chapter.
14 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.
3. Dispose of electronic components separately.

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15 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.
15 Returns

16 EU declaration of conformity
EU Declaration of Conformity
in accordance with 2014/34/EU (ATEX)
We, GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8
74653 Ingelfingen-Criesbach, Germany
declare that the product listed below complies with the requirements of directive 2014/34/EU for intended use in potentially
explosive areas.
Description of the product: Electrical position indicator GEMÜ 1205
Marking – 1205 000 Z AL A00 03 00 M2 M2 X
– 1205 000 Z AL A01 03 00 M2 M2 X
– 1205 000 Z AL A02 03 00 M2 M2 X
EC type examination certificate IBExU18ATEX1008.
The notified body IBExU, No. 0637 has certified the above mentioned product and issued the following certificate:
IBExU18ATEX1008.
The Essential Safety and Health Requirements are met by compliance with the standards listed below that are applicable for
the above mentioned product:
– EN 60079-0:2012+A11:2013
– EN 60079-1:2014
– EN 60079-7:2015
– EN 60079-31:2014
Ingelfingen-Criesbach 29-05-2018
Joachim Brien
Head of Technical Department
www.gemu-group.com
16 / 20
GEMÜ 1205
EU Declaration of Conformity

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GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8, 74653 Ingelfingen-Criesbach,
Germany
Tel. [phone] · [email protected]
www.gemu-group.com
10.2018 | 88593512
*88593512*