GEM 1231 User manual

GEMÜ 1231
Electrical position indicator
Operating instructions
EN
further information
webcode: GW-1231

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
22.12.2021
www.gemu-group.com2 / 20GEMÜ 1231

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
4 GEMÜ CONEXO .................................................... 6
5 Correct use .......................................................... 6
6 Order data ........................................................... 7
7 Technical data ..................................................... 8
8 Dimensions .......................................................... 9
9 Manufacturer's information .................................. 10
9.1 Delivery .......................................................... 10
9.2 Packaging ...................................................... 10
9.3 Transport ....................................................... 10
9.4 Storage ........................................................... 10
10 Assembly and installation .................................... 10
11 Electrical connection ........................................... 14
12 Troubleshooting .................................................. 15
13 Inspection and maintenance ................................ 15
14 Disassembly ........................................................ 15
15 Disposal .............................................................. 15
16 Returns ................................................................ 16
17 Declaration of Incorporation according to
2006/42/EC (Machinery Directive) ....................... 17
18 Declaration of Conformity in accordance with
2014/34/EU (ATEX) ............................................. 18
19 Declaration of conformity according to 2014/30/
EU (EMC Directive) ............................................... 19
GEMÜ 1231www.gemu-group.com 3 / 20

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1 General information
1 General information
1.1 Information
•The descriptions and instructions apply to the standard ver-
sions. For special versions not described in this document
the basic information contained herein applies in combina-
tion 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 Ger-
man 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
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 from potentially explosive atmosphere
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 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.

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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 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.
3 Product description
3.1 Construction
1
2
3
4
Item Name Materials
1 Housing cover PSU
2 Housing base PP
3 Electrical connection PP
4 Mounting kit, valve spe-
cific (must be ordered sep-
arately)
SS
Seals NBR
3.2 Description
The GEMÜ 1231 electrical position indicator is suitable for
mounting to pneumatically operated linear actuators. The po-
sition of the valve spindle is reliably detected electronically
and fed back via proximity switches through play-free and
non-positive mounting. GEMÜ 1231 has been designed spe-
cially for valves with a stroke of 2 to 20 mm .
3.3 Function
The GEMÜ 1231 electrical position indicator is used for re-
porting and controlling the position of valves that are actuated
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 fixed to the spindle then actuates the integ-
rated proximity switches, which are used to transmit the elec-
tronic signal. Depending on the version, the electrical position
indicator is equipped with one to two proximity switches.
3.4 Product label
Device version Design in accordance with order data
Item number Traceability number Serial number
Device-specific data
Year of manufacture
The month of manufacture is encoded in the traceability num-
ber and can be obtained from GEMÜ. The product was manu-
factured in Germany.
3 Product description

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4 GEMÜ CONEXO
4 GEMÜ CONEXO
Order variant
In the corresponding design with CONEXO, this product has
an RFID chip (1) for electronic identification purposes. The po-
sition of the RFID chip can be seen below. The CONEXO pen
helps read out information stored in the RFID chips. The CON-
EXO app or CONEXO portal is required to view this informa-
tion.
RFID chip
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.
5 Correct use
DANGER
Danger of explosion
▶Danger of death or severe injury.
●Only use the product in potentially ex-
plosive zones confirmed in the declara-
tion of conformity.
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 GEMÜ 1231 is designed to be fitted on a GEMÜ
valve for electrical detection of the position of the linear actu-
ators. The product works with 2-wire NAMUR proximity
switches. The product is non-positively connected to the actu-
ator spindle by means of a mounting kit.
The product GEMÜ 1231 is intended for use in potentially ex-
plosive areas of zones 1 and 2 with gases, mists or vapours
and zones 21 and 22 with combustible dusts in accordance
with EU directive 2014/34/EU (ATEX).
The product has the following explosion protection marking:
ATEX:
Gas: II 2G Ex ib IIC T6 Gb
Dust: II 2D Ex ib IIIB T80°C Db
EU type examination certificate: IBExU04ATEX1175 X
Notified body: IBExU, No. 0637
IECEX:
Gas: Ex ib IIC T6 Gb
Dust: Ex ib IIIB T80°C Db
Certificate: IECEx IBE 21.0030 X
The product has been developed in compliance with the fol-
lowing harmonised standards:
•EN IEC 60079-0:2019 (IEC 60079-0, edition 7)
•EN 60079-11:2012 (IEC 60079-11, edition 6)
Use of the product is permissible in the following ambient
temperature ranges: -20°C to +60°C
For use in potentially explosive areas, the following
conditions or operation limits must be observed:
•When using the M12 connector, the differential voltage for
isolated intrinsically safe electric circuits must not exceed
30 V. The requirements for cables and lines from EN
60079-14, section 16.2.2, must be taken into account.
•Connectors that are not used must be protected against
dust penetration.

6 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 1231 S01 Z...dependent on valve type. Please order separately. Data required on valve type, DN, control func-
tion and actuator size.
For possible combinations see availability table.
Order codes
1 Type Code
Electrical position indicator ATEX 1231
2 Fieldbus Code
Without 000
3 Accessory Code
Accessory Z
4 Device version Code
Open/Closed A00
Open A01
Closed A02
5 Switch Code
Proximity switch, 2-wire, NAMUR
P+F, NJ1,5-6,5-15-N-Y180094
207
6 Electrical connection Code
M16 cable gland 1101
M16 Skintop cable gland 1103
M12 plug connector, 4-pin 1110
7 Connection diagram Code
Terminals, NAMUR 202
M12 plug, 4-pin 203
8 CONEXO Code
Without
Integrated RFID chip for electronic identification
and traceability
C
Order example
Ordering option Code Description
1 Type 1231 Electrical position indicator ATEX
2 Fieldbus 000 Without
3 Accessory Z Accessory
4 Device version A00 Open/Closed
5 Switch 207 Proximity switch, 2-wire, NAMUR
P+F, NJ1,5-6,5-15-N-Y180094
6 Electrical connection 1101 M16 cable gland
7 Connection diagram 202 Terminals, NAMUR
8 CONEXO Without
6 Order data
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7 Technical data
7.1 Temperature
Ambient temperature: -20 — 60 °C
Storage temperature: 0 — 40 °C
7.2 Product conformity
EMC Directive: 2014/30/EU
Explosion protection: ATEX (2014/34/EU)
IECEx
EAC according to TR CU 012/211 - ATEX
ATEX marking: ATEX:
Gas: II 2G Ex ib IIC T6 Gb
Dust: II 2D Ex ib IIIB T80°C Db
EU type examination certificate: IBExU04ATEX1175 X
Notified body: IBExU, No. 0637
IECEx marking: Gas: Ex ib IIC T6 Gb
Dust: Ex IIIB T80°C Db
Certificate: IECEx IBE 21.0030 X
EAC marking: 1Ex ib IIC T6 Gb
Certificate: ЕАЭС RU C-DE.BH02.B.00231/19
7.3 Mechanical data
Installation position: Optional
Weight: 420 g
Protection class: IP 65
Travel sensor: 2 — 20 mm
7.4 Electrical data
Electrical connection
type:
M12 plug, 4-pin (code 1110)
M16x1.5 cable gland for cable dia. 4.5 to 7 mm, recommended wire cross section 0.75 mm² (code
1101)
M16x1.5 Skintop cable gland for cable dia. 4 to 10 mm, recommended wire cross section 0.75 mm²
(code 1103)
7.4.1 2-wire proximity switch
Switch type: 2-wire, NAMUR, switch (code 207)
Supply voltage: 8 V DC
Current consumption: ≤ 0.1 mA (damped)
≥ 3 mA (undamped)
Max. switching fre-
quency:
1 kHz
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7 Technical data

8 Dimensions
70
□ 50
72
M 4x6
Dimensions in mm
GEMÜ 1231www.gemu-group.com 9 / 20
8 Dimensions

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9 Manufacturer's information
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 packaged in a cardboard box which can be re-
cycled 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 ma-
terial according to relevant local or national disposal regu-
lations / environmental protection laws.
9.4 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.
10 Assembly and installation
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
●Pay attention to the information on product labels, in
product documentation and EC type examination certific-
ate.
●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 fer-
rules 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 cir-
cuits: 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 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 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.

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1
10.3 Assembly of mounting kit with thread
1. Before beginning assembly, check the type of mounting
kit.
•Without stroke limiter (see “Assembly of mounting kit
without stroke limiter“, page11).
•With stroke limiter (see “Assembly of mounting kit with
stroke limiter“, page11).
•Without thread (see “Assembly of mounting kit without
thread“, page11).
10.3.1 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.
10.3.2 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 lim-
iters in case of control functions 2 and3
10.4 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.
10 Assembly and installation

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10 Assembly and installation
10.5 Assembly and installation of the electrical position indicator
DANGER
Danger of explosion
▶Risk 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 damaged.
1
2
1
2
1. Disconnect the power supply and secure against recommis-
sioning.
2. Undo screws 1.
3. Remove cover 2.
4. Undo grub screw 1 (do not unscrew completely).
5. Carefully attach the base of the electrical position indicator
onto guide piece 2 so that switches are not damaged by trip
cams!
6. Turn the electrical position indicator into the desired con-
nection direction and fix the position with grub screw 1.
7. Make the electrical connection.

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3
2
1
8. After completing the electrical connection, carefully pull the connection cable taut.
9. Ensure that the O-ring has been mounted properly and is not damaged.
10. Fit the cover 2 with screws 3.
11. Screw in and tighten screws 3.
12. Ensure all seals and threaded connections are correctly installed.
13. Restore the power supply.
14. For function control, open and close the valve and pay attention to signalling.
15. If the settings need to be readjusted again, switch off power to the electrical position indicator and repeat the steps of the
chapter "Setting the switching positions".
10.6 Setting the switching positions
52
41
63
Picture 1: Setting the switching position
x
Picture 2: Setting the switch distance
Setting the upper switching position: Setting the lower switching position:
1. Move the valve to the OPEN position.
2. Undo screws 1.
3. With the left screw 2, move switch 3 to the desired position.
ðThe switch can be aligned axially and radially.
4. Check the switch distance:
x = 0.7 - 1.1 mm
5. Tighten screws 1.
ðThe upper switching position is set.
6. Move the valve to the CLOSED position.
7. Undo screws 4.
8. With the right screw 6, move switch 5 to the desired posi-
tion.
ðThe switch can be aligned axially and radially.
9. Check the switch distance:
x = 0.7 - 1.1 mm
10. Tighten screws 4.
ðThe lower switching position is set.
10 Assembly and installation

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11 Electrical connection
11 Electrical connection
11.1 Potential equalisation
Connecting the potential equalisation device
1. Use a screw M4x6 to attach the potential equalisation
device to the electrical position indicator.
ðPotential equalisation for metal housings in potentially
explosive areas: At least 4 mm².
2. Secure the connection against independently becoming
loose.
11.2 Electrical connection with cable gland (code 1101)
or Skintop cable gland (code 1103)
11.2.1 Connection diagram (code 202)
1
2
3
4
L-
L+
L-
L+
br/bn
bl/bl
br/bn
bl/bl
On-site
connection
OPEN CLOSED
11.2.2 Electrical connection
1. Insert the connection cable through the cable gland.
2. Only strip the connection cable directly before switch
mounting plate.
3. Lay individual wires to the terminals.
4. Cut the individual wires to the appropriate length in order
to avoid having unnecessarily long cable loops.
5. Compress the individual wires with wire end ferrules.
6. Connect the individual wires to the terminals in accord-
ance with the connection diagram.
11.3 Electrical connection with M12 plug (code 1110)
DANGER
Danger of explosion
▶Risk of severe injury or death.
●Danger from sparking. Never discon-
nect the connection cables when live.
11.3.1 Connection diagram (code 203)
1
4
3
2
5
Pin Signal name
1 L+, OPEN
2 L-, OPEN
3 L+, CLOSED
4 L-, CLOSED
5 n.c. *
* Pin 5 is not connected.
11.3.2 Electrical connection
The M12 plugs may only be assembled, connected and com-
missioned by trained personnel. The trained personnel must
have expertise in types of ignition protection, and regulations
and provisions for operating media in EX areas.
1. Securely lay the connection cables or ensure sufficient
tension relief.
2. Refer to the technical data and cable gland documentation
for details of the wire cross sections.
3. Protect the product and the cables from damage.
4. Only clean the product with an anti-static or damp cloth.
5. Only operate the product when it is fully assembled.
6. Only connect the product to intrinsically safe electric cir-
cuits that are approved with an EC type examination certi-
ficate and which do not exceed the maximum values of
the respective sensors for Ui, Ii, Pi, Ci and Li.

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12 Troubleshooting
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 connec-
tion
Switch not set Set switch
Wrong mounting kit
installed
Replace mounting
kit
Voltage is not con-
nected
Connect voltage
Cover cannot be at-
tached
Sealing ring inser-
ted incorrectly
Insert sealing ring
correctly
Sealing ring dam-
aged
Replace sealing
ring
Cables protruding
over the edge of the
base
Check the cable
routing and shorten
the cables if neces-
sary
Grub screw not
working
Grub screw un-
screwed too far, nut
fell out
Reinsert the nut,
screw in the grub
screw (during as-
sembly, only undo
the grub screw, do
not unscrew it com-
pletely)
13 Inspection and maintenance
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
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.
7. Carry out inspection and maintenance for products in the
potentially explosive area to DIN EN 60079-17.
13.1 Spare parts
No spare parts are available for this product. If it is faulty,
please return it to GEMÜ for repair.
13.2 Setting the switching positions
For limit switch setting see chapter "Assembly and installation
of the electrical position indicator" steps 1 to 14.
13.3 Cleaning the product
DANGER
Danger of explosion
▶Risk of death or severe injury.
●Danger from sparking. Only clean the
product with an anti-static or damp
cloth.
•Do not clean the product with a high pressure cleaning
device.
14 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 chapter.
15 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.
15 Disposal

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16 Returns
16 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.

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

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18 Declaration of Conformity in accordance with 2014/34/EU (ATEX)
18 Declaration of Conformity in accordance with 2014/34/EU (ATEX)

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19 Declaration of conformity according to 2014/30/EU (EMC Directive)
19 Declaration of conformity according to 2014/30/EU (EMC 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
12.2021 | 88586125