GEM 1235 User manual

GEMÜ 1235
24V / IO-Link, 3E, 4E
Electrical position indicator
Operating instructions
EN
further information
webcode: GW-1235

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
16.11.2022
www.gemu-group.com2 / 26GEMÜ 1235
24V / IO-Link, 3E, 4E

Contents
1 General information ............................................. 4
1.1 Information .................................................... 4
1.2 Symbols used ................................................ 4
1.3 Warning notes ............................................... 4
2 Safety information ............................................... 6
3 Product description ............................................. 7
4 GEMÜ CONEXO .................................................... 10
5 Correct use .......................................................... 10
6 Order data ........................................................... 11
7 Technical data ..................................................... 12
8 Dimensions .......................................................... 13
9 Manufacturer's information .................................. 14
9.1 Delivery .......................................................... 14
9.2 Packaging ...................................................... 14
9.3 Transport ....................................................... 14
9.4 Storage ........................................................... 14
10 Assembly and installation .................................... 14
10.5 Mounting kit assembly (quarter turn actu-
ator) ................................................................ 15
11 Electrical connection ........................................... 18
12 Programming the end positions ........................... 18
12.2 Initialization of the end positions via IO-
Link ................................................................. 20
12.3 End position programming via program-
ming input (pin 5) .......................................... 20
13 Troubleshooting .................................................. 21
14 Inspection and maintenance ................................ 23
15 Disassembly ........................................................ 23
16 Disposal .............................................................. 23
17 Returns ................................................................ 23
18 Declaration of conformity according to 2014/30/
EU (EMC Directive) ............................................... 24
19 UL certificate ....................................................... 25
GEMÜ 1235
24V / IO-Link, 3E, 4E
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24V / IO-Link, 3E, 4E
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 ba-
sic 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 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.

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NOTICE
Potentially dangerous situation!
▶Non-observance can cause damage to property.
The following symbols for the specific dangers can be used within a warning note:
Symbol Meaning
Danger of explosion!
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 com-
bination 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 regula-
tions.
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 substances.
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 screws 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
Item Name Materials
1 Housing cover PPR
2 Housing base PVDF
3 Electrical connection PVDF
4 Adapter piece PVDF
5 Mounting kit, valve specific Stainless steel
Seals EPDM, PUR
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.
CLOSED
ERROR
OPEN
PWR/COM
FAU LT
LED Colour Function
Standard 1) Inversed 2)
FAULT red red Communication error
PWR/COM green green Power / communication
CLOSED green orange Process valve in CLOSED posi-
tion
ERROR red red Error
OPEN orange green Process valve in OPEN posi-
tion
High visibility LED green orange Process valve in CLOSED posi-
tion
orange green Process valve in OPEN posi-
tion
Alternating green/orange Alternating green/orange Programming mode
Flashes orange Flashes orange Error
Flashes green Flashes green Location function*
*The location function is used for the optical identification of a device in a plant. In this case, all high visibility LEDs flash green.
The location function can always be started and overrides all other flash codes of the high visibility LEDs.
The rest of the device function is not affected..
1) Device version
Code 3E: Open/Closed position feedback, programming input, high visibility optical position indicator, IO-Link communication
Code 3S: Open/Closed position feedback, high visibility optical position indicator
2) Device version
Code 4E: Open/Closed position feedback inversed, programming input, high visibility optical position indicator, IO-Link communication
Code 4S: Open/Closed position feedback inversed, high visibility optical position indicator
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

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3.3 Description
The GEMÜ 1235 electrical position indicator is suitable for installation on pneumatically operated linear actuators and, with spe-
cific mounting parts, likewise suitable for pneumatically operated quarter turn actuators as well as further selected actuator ver-
sions. The position of the valve spindle is reliably electronically detected and evaluated using play-free and non-positive mount-
ing. Intelligent microprocessor-controlled functions facilitate commissioning and support during operation. The current position
of the valve is displayed via high-visibility LEDs and fed back via electrical signals.
3.4 Function
The GEMÜ 1235 electrical position indicator shows the position of the valve. When the valve is opened, the spindle in the elec-
trical position indicator 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 electrical position indicator down-
wards 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 bumber Traceability number Serial number
Device-spezific data
Year of manufacture
The manufacturing month is coded under the traceability number and can be requested from GEMÜ. The product was manufac-
tured 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 position
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
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!
▶Risk of death or severe injury
●Do not use the product in potentially explosive zones.
WARNING
Improper use of the product!
▶Risk of severe injury or death
▶Manufacturer liability and guarantee will be void
●Only use the product in accordance with the operating conditions specified in the contract documentation and in this docu-
ment.
The product is not intended for use in potentially explosive areas.
The product is designed for fitting to a GEMÜ valve in order to detect the position of linear actuators visually and electrically.
The product has a microprocessor controlled intelligent position sensor as well as an analogue travel sensor system (poten-
tiometer) which is positively connected with the actuator 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.
●Use the product in accordance with the technical data.

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, control
function and actuator size must be stated.
Order codes
1 Type Code
Electrical position indicator 1235
2 Fieldbus Code
Without 000
3 Accessory Code
Accessory Z
4 Device version Code
Open/Closed position feedback,
programming input,
high visibility optical position indicator,
IO-Link communication
3E
Open/Closed position feedback,
high visibility optical position indicator
3S
Open/Closed position feedback inversed,
programming input,
high visibility optical position indicator,
IO-Link communication
4E
4 Device version Code
Open/Closed position feedback inversed,
high visibility optical position indicator
4S
5 Electrical connection Code
M12 plug, 5-pin M125
6 Travel sensor version Code
Potentiometer, 30 mm length 030
Potentiometer, 50 mm length 050
Potentiometer, 75 mm length 075
7 Housing material Code
PVDF base, black, PPR natural cover,
M16 thread PEEK
G10
8 Special version Code
UL approval U
Order example
Ordering option Code Description
1 Type 1235 Electrical position indicator
2 Fieldbus 000 Without
3 Accessory Z Accessory
4 Device version 3E Open/Closed position feedback,
programming input,
high visibility optical position indicator,
IO-Link communication
5 Electrical connection M125 M12 plug, 5-pin
6 Travel sensor version 030 Potentiometer, 30 mm length
7 Housing material G10 PVDF base, black, PPR natural cover,
M16 thread PEEK
8 Special version U UL approval
6 Order data
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7 Technical data
7 Technical data
7.1 Temperature
Ambient temperature: -10 to 70 °C
Storage temperature: 0 — 40 °C
7.2 Product compliance
EMC Directive: 2014/30/EU
SIL: Product description: Electrical position indicator GEMÜ 1235
Device type: B
Valid software version: V1.0.0.4
Safety function: The safety function is defined as a High (24 V DC) signal
at pin5 (device version 3S/4S) and at pin 4 (device ver-
sion 3E/4E), if the current position of the integrated travel
sensor is smaller than the switch point CLOSED (default
setting 12%).
HFT (Hardware Fault Tolerance): 0
MTTR (Mean Time To Restoration): 24 hours
MTBF (Mean Time Between Failures): 346 years
Further information, see SIL safety manual
UL listed for Canada and USA
Certificate: E515574
7.3 Mechanical data
Installation position: Optional
Weight: Travel length code 030: 115g
Travel length code 050: 138g
Travel length code 075: 160g
Protection class: IP 67
Travel sensor: Travel sensor version Code
Code 030 Code 050 Code 075
Minimum stroke: 2.0 mm 3.5 mm 5.0 mm
Maximum stroke: 30.0 mm 50.0 mm 75.0 mm
Hysteresis: 0.2 mm 0.4 mm 0.5 mm
Accuracy: 0.2% Full Scale
7.4 Electrical data
Supply voltage Uv: 24 V DC (18 to 30 V DC)
Duty cycle: Continuous duty
Reverse battery protec-
tion:
yes
Electrical protection
class:
III
Line fuse 630 mA medium time lag (not applicable for operation with IO-Link Master)
Current consumption: typically 30 mA

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Electrical connection
type:
1 x 5-pin M12 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 refers to the programmed stroke, with reference to the lower end position (0%)
Switch points: Travel sensor version Code
030 050 075
Default setting switch point CLOSED 12 %
Default setting switch point OPEN 25 %
Min. switch point CLOSED 0.8 mm 1.4 mm 2.0 mm
Min. switch point OPEN 0.5 mm 0.9 mm 1.25 mm
If the percentage switch points dependent on the programmed stroke are smaller than the permiss-
ible min. switch points, the min. switch points apply automatically.
8 Dimensions
PULL
TURN
PROG
A
B
SW 27
C
M12
ø 60
Travel sensor version Code
030 050 075
A65.5 87.5 112.5
B8.5 30.5 55.5
C19.0 41.0 66.0
Dimensions in mm
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 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
10.1 Preparations for installing the valve (linear actuator)
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 Preparations for installation of the valve (quarter turn actuator)
1. Move the actuator A into zero position (actuator vented).
1
2
A
2. Remove the screw 1 from the trigger cam 2.

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10.3 Mounting kit assembly on electrical position indicator
CAUTION
Do not scratch the spindle!
▶A damaged spindle surface may cause failure of the travel sensor.
CAUTION
Pretensioned spring!
▶Damage to the device.
●Slowly release the tension in the spring.
1
2
3
1. Pull out spindle 1 as far as it will go.
2. Push spring 2 over spindle 1.
3. Mount operating spindle 3.
4. Push in spindle 1 until it pushes against spring 2.
10.4 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.
10.5 Mounting kit assembly (quarter turn actuator)
3
4
A
4
55
1. Adjust the mounting bracket to the required borehole pattern.
ðTo do this, loosen the side screws 5 and set the retaining feet onto the thread of the actuator, and install it using screws
4.
2. Secure the bracket 3 to the retaining feet as shown. In doing so, the tap shaft must sit free of play in the shaft of the actu-
ator.
10 Assembly and installation

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10 Assembly and installation
10.6 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.
10.7 Installing the electrical position indicator (linear actuator)
CAUTION
Incorrect installation of the product.
▶Damage to the housing.
●Only tighten the product using the spanner flats provided for this purpose.
9 (SW 27)

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1. Move the actuator to the OPEN position.
2. Guide the product as far as it will go into the actuator opening, the adapter 3 (see “Assembling the adapter (linear actuator)“,
page15) or the stroke limiter 1 (see “Assembling the stroke limiter (linear actuator)“, page16), and screw it in clockwise
against the initial spring tension.
3. Use the spanner flat of the travel sensor to tighten the product.
4. Turn the housing clockwise to align the pneumatic or electrical connections.
5. Initialize the product.
6. The product with mounting kit is fully assembled.
7. The product with mounting kit and adapter is fully assembled.
8. The product with mounting kit and stroke limiter is fully assembled.
10.8 Installing the electrical position indicator (quarter turn actuator)
CAUTION
Incorrect installation of the product.
▶Damage to the housing.
●Only tighten the product using the spanner flats provided for this purpose.
10 Assembly and installation

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11 Electrical connection
6
7
8
1. Screw the electrical position indicator 6 onto the adapter 7.
2. Use the spanner flat 8 (WAF 27) of the travel sensor to tighten the electrical position indicator.
3. Turn the housing clockwise to align the pneumatic or electrical connections.
4. Initialize the product.
11 Electrical connection
11.1 IO-Link, device version 3E / 4E
1
4
3
2
5
Description
1 U, 24 V DC, supply voltage
2 24 V DC, Open end position output
3 U, GND
4 24 V DC, Closed end position output, C/Q IO-Link
5 24 V DC, programming input (speedAP function)
Device version 3S / 4S is pin compatible with the previous version 2SM125, pin 5 is highly active
but without potential-free contacts. The device has 24 V DC Push-Pull outputs
12 Programming the end positions
The end positions must be programmed under the following conditions:
- Retrofitting an electrical position indicator
- Replacing the actuator
- Replacing the diaphragm
If electrical position indicators have been fitted to the process valve at the factory, the end positions will already have been pro-
grammed.
The end positions can be programmed as follows:
- On-site programming
- Programming input (pin 5)
- Communication interface
When programming via the communication interface, automatic programming is recommended.

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12.1 On-site end position programming
PULL
TURN
PROG
CLOSED
ERROR
OPEN
PWR/COM
FA U LT
CLOSED
ERROR
OPEN
PWR/COM
FA U LT
PULL
TURN
PROG
1. Pull the housing cover of the electrical position indic-
ator up (approx. 2 mm).
2. Turn the housing cover anticlockwise (until it stops).
3. Electrical position indicator is in the programming
mode.
ðOPEN and CLOSED LEDs flash alternately
ðHigh visibility LED flashes alternately green / or-
ange
4. Open valve until end position is reached.
5. Close valve until end position is reached.
6. Turn the housing cover back clockwise and press it
down.
ðThe end positions are set.
12 Programming the end positions

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12 Programming the end positions
12.2 Initialization of the end positions via IO-Link
1. Select automatic programming mode (parameter data "Programming mode").
2. Briefly (>100 ms) activate programming mode (process data "Programming mode").
ðOPEN and CLOSED LEDs flash alternately
ðHigh visibility LED flashes alternately green / orange
3. Open valve until end position is reached.
4. Close valve until end position is reached.
5. Programming mode is automatically terminated if the valve does not move for 5 seconds.
ðThe end positions are set.
12.3 End position programming via programming input (pin 5)
1. Connect supply voltage.
2. Briefly connect a 24 V DC signal (>100 ms) to programming input (pin 5).
ðOPEN and CLOSED LEDs flash alternately.
ðHigh visibility LED flashes alternately green / orange.
3. Open valve until end position is reached.
4. Close valve until end position is reached.
5. Programming mode is automatically terminated if the valve does not move for 5 seconds.
ðThe end positions are set.