GEM 1231 User manual

GEMÜ 1231
Electrical position indicator ATEX
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
19.11.2019
www.gemu-group.com2 / 24GEMÜ 1231

Contents
1 General information .................................................. 4
1.1 Information ......................................................... 4
1.2 Symbols used ..................................................... 4
1.3 Warning notes .................................................... 4
2 Safety information .................................................... 5
3 Product description ................................................... 6
4 GEMÜ CONEXO ......................................................... 7
5 Correct use ............................................................... 8
6 Order data ................................................................. 9
7 Technical data .......................................................... 10
8 Dimensions ............................................................... 10
9 Manufacturer's information ....................................... 11
9.1 Delivery ............................................................... 11
9.2 Packaging ........................................................... 11
9.3 Transport ............................................................ 11
9.4 Storage ............................................................... 11
10 Assembly and installation ......................................... 11
11 Electrical connection ................................................. 15
12 Error clearance .......................................................... 17
13 Inspection and servicing ........................................... 18
14 Disassembly .............................................................. 18
15 Disposal .................................................................... 18
16 Returns ..................................................................... 18
17 Declaration of conformity according to 2014/30/EU
(EMC Directive) ......................................................... 19
18 EU Declaration of conformity in accordance with
2014/34/EU (ATEX) ................................................... 20
GEMÜ 1231www.gemu-group.com 3 / 24

www.gemu-group.com4 / 24GEMÜ 1231
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
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:

www.gemu-group.com 5 / 24 GEMÜ 1231
Symbol Meaning
Danger from potentially explosive atmosphere
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.
2 Safety information

www.gemu-group.com6 / 24GEMÜ 1231
3 Product description
3 Product description
3.1 Construction
1
2
5
3
4
Item Name Materials
1 Housing cover PSU
2 Housing base PSU
3 Electrical connection PP
4 Adapter piece Stainless steel
5 Mounting kit, valve-specific Stainless steel
Seals NBR
3.2 Description
The GEMÜ 1231 electrical position indicator is suitable for mounting to pneumatically operated linear actuators. The position
of the valve spindle is reliably electronically detected and reported via proximity switches through play-free and non-positive
mounting. GEMÜ 1231 has been designed specially for valves with a stroke of 2 to 20 mm .
3.3 Function
The GEMÜ 1231 electrical position indicator is used for reporting 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 integrated
proximity switches, which are used to transmit the electronic signal. Depending on the version, the electrical position indicator
is equipped with one to two proximity switches.
3.4

www.gemu-group.com 7 / 24 GEMÜ 1231
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.
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 components included in the scope of de-
livery and need to be ordered separately.
4 GEMÜ CONEXO

www.gemu-group.com8 / 24GEMÜ 1231
5 Correct use
5 Correct use
DANGER
Danger of explosion
▶Danger of death or severe injury.
●Only use the product in potentially explosive zones confirmed in the declaration 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 this docu-
ment.
The product GEMÜ 1231 is designed to be fitted on a GEMÜ valve for electrical detection of the position of the linear actuators.
The product works with 2-wire NAMUR proximity switches. The product is non-positively connected to the actuator spindle by
means of a mounting kit.
The product GEMÜ 1231 is intended for use in potentially explosive 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:
Gas: II 2G Ex ib IIC/IIB T6 Gb
Dust: II 2D Ex ib IIIC T80°C Db
EU type examination certificate: IBExU04ATEX1175 X
Notified body: IBExU, No. 0637
The product has been developed in compliance with the following harmonised standards:
– EN 60079-0 : 2012 + A11 : 2013
– EN 60079-11 : 2012
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:
– For the explosion group IIC, a warning note in accordance with 29.12 g) is required:
WARNING – danger of electrostatic discharges!
– If the device is equipped with an M12 connector, only pre-fitted cables approved for the intrinsic safety "i" type of igni-
tion protection may be used. The differential voltage for isolated intrinsically safe electric circuits must not exceed 30
V. The cables and connectors must be laid in a way that avoids damage. The operating instructions for the separately
certified connectors with cables must be observed.
– Open connectors must be suitably protected to prevent the penetration of dust.

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
function and actuator size.
Order codes
1 Type Code
Electrical position indicator ATEX 1231
2 Fieldbus Code
Without 000
3 Accessories Code
Accessories Z
4 Device version Code
Open/close 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
Order option Code Description
1 Type 1231 Electrical position indicator ATEX
2 Fieldbus 000 Without
3 Accessories Z Accessories
4 Device version A00 Open/close
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
www.gemu-group.com 9 / 24 GEMÜ 1231www.gemu-group.com 9 / 24 GEMÜ 1231

www.gemu-group.com10 / 24GEMÜ 1231
7 Technical data
7 Technical data
7.1 Temperature
Storage temperature: 0 to 40 °C
Ambient temperature: -20 to 60 °C
7.2 Product conformities
Explosion protection: ATEX (2014/34/EU)
ATEX marking: Gas: II 2G Ex ib IIC/IIB T6 Gb
Dust: II 2D Ex ib IIIC T80°C Db
EU type examination certificate: IBExU04ATEX1175 X
Notified body: IBExU, No. 0637
7.3 Mechanical data
Installation position: Optional
Weight: 420 g
Protection class: IP 65
Travel sensor: 2 to 20 mm
7.4 Electrical data
Switch type: 2-wire proximity switch (NAMUR)
Supply voltage: 8 V DC
Current consumption: ≤ 0.1 A (damped)
≥ 3 mA (undamped)
Electrical connection
type:
M16
cable gland
M16
Skintop cable gland
M12 plug,
4-pin
Connection thread M16 x 1.5 M16 x 1.5 M12
Cable diameter 4.5 to 7mm 4 to 10mm -
Recommended
wire cross section
0.75 mm² 0.75 mm² -
8 Dimensions
70
□ 50
72
M 4x6
Dimensions in mm

www.gemu-group.com 11 / 24 GEMÜ 1231
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 packing 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
CAUTION
Fitted electrical position indicator
▶Destruction of the electrical position indicator when disassembling the valve body
●Disassemble the electrical position indicator before disassembling the valve body
NOTICE
●Observe the data on the product labels, product documentation 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.
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 Assembly and installation

www.gemu-group.com12 / 24GEMÜ 1231
10 Assembly and installation
10.1 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.
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 correctly
3. Check the sealing ring 1 for any damage and correct positioning before tightening the cover.
1
10.3 Assembly of mounting kit with thread
1. Before beginning assembly, check the type of mounting kit.
– Without stroke limiter (see chapter 9.3.1, 'Mounting kit assembly without stroke limiter').
– With stroke limiter (see chapter 9.3.2 'Mounting kit assembly with stroke limiter').
– Without thread (see chapter 9.4 'Mounting kit assembly without thread').
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.

www.gemu-group.com 13 / 24 GEMÜ 1231
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 surface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
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.
10.5 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
damaged.
10 Assembly and installation

www.gemu-group.com14 / 24GEMÜ 1231
10 Assembly and installation
1
2
1
2
1. Disconnect the power supply and secure against recom-
missioning.
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.
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".

www.gemu-group.com 15 / 24 GEMÜ 1231
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.
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 Electrical connection

www.gemu-group.com16 / 24GEMÜ 1231
11 Electrical connection
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 accordance 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 disconnect 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.

www.gemu-group.com 17 / 24 GEMÜ 1231
11.3.2 Electrical connection
For the electrical connection (code 1110) (M12 plug), we recommend the M12 connectors for EX areas from IFM, series
ENC**A.
The M12 plugs may only be assembled, connected and commissioned 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 circuits that are approved with an EC type examination certificate and
which do not exceed the maximum values of the respective sensors for Ui, Ii, Pi, Ci and Li.
12 Error 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 Error clearance

www.gemu-group.com18 / 24GEMÜ 1231
13 Inspection and servicing
13 Inspection and servicing
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 consult-
ing the manufacturer first.
The operator must carry out regular visual examination of the products depending on the operating conditions and the poten-
tial 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 operator's guidelines.
3. Shut off plant or plant component.
4. Secure plant or plant component against recommissioning.
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 servicing 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 diffusion from penetrated media.
2. Dispose of all parts in accordance with the disposal regulations/environmental protection laws.
3. Dispose of electronic components separately.
16 Returns
Legal regulations for the protection of the environment and personnel require that the completed and signed return delivery
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 op-
erator'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.

17 Declaration of conformity according to 2014/30/EU (EMC Directive)
EU Declaration of Conformity
according to 2014/30/EU (EMC Directive)
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 safety requirements of the EMC Directive 2014/30/EU.
Description of the product: Electrical position indicator GEMÜ 1231
Technical standards used:
– EN60947-5-2:2007+ A1:2012
– EN50581:2012
Ingelfingen-Criesbach 29-05-2018
Joachim Brien
Head of Technical Department
GEMÜ 1231www.gemu-group.com 19 / 24
17 Declaration of conformity according to 2014/30/EU (EMC Directive)

18 EU Declaration of conformity in accordance with 2014/34/EU (ATEX)
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 1231
Marking: – 1231 000 Z A00 207 1101 202
– 1231 000 Z A01 207 1101 202
– 1231 000 Z A02 207 1101 202
– 1231 000 Z A00 207 1103 202
– 1231 000 Z A01 207 1103 202
– 1231 000 Z A02 207 1103 202
– 1231 000 Z A00 207 1110 203
– 1231 000 Z A01 207 1110 203
– 1231 000 Z A02 207 1110 203
Explosion protection marking: Gas: II 2G Ex ib IIC/IIB T6 Gb
Dust: II 2D Ex ib IIIC T80°C Db
EU type examination certificate: IBExU04ATEX1175 X
Notified body: IBExU, No. 0637
Explanations: For special conditions or operation limits see chapter "Correct use" in the operating
instructions.
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 60079-11 : 2012
Ingelfingen-Criesbach 2019-07-25
Joachim Brien
Head of Technical Department
www.gemu-group.com
20 / 24
GEMÜ 1231
18 EU Declaration of conformity in accordance with 2014/34/EU (ATEX)