GEM 1242 User manual

GEMÜ 1242
Electrical position indicator
Operating instructions
EN
further information
webcode: GW-1242

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
21.01.2022
www.gemu-group.com2 / 41GEMÜ 1242

Contents
1 General information ............................................. 4
1.1 Information .................................................... 4
1.2 Symbols used ................................................ 4
1.3 Definition of terms ........................................ 4
1.4 Warning notes ............................................... 4
2 Safety information ............................................... 5
3 Product description ............................................. 5
3.1 Construction .................................................. 5
3.2 LED displays .................................................. 6
3.3 Description ..................................................... 7
3.4 Function ......................................................... 7
3.5 Product label ................................................. 7
4 GEMÜ CONEXO .................................................... 7
5 Correct use .......................................................... 7
6 Order data ........................................................... 9
7 Technical data ..................................................... 10
8 Dimensions .......................................................... 13
8.1 Size 1 .............................................................. 13
8.2 Size 2 .............................................................. 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
10.1 Mounting kit assembly .................................. 14
10.2 Installing the electrical position indicator on
linear actuators ............................................. 15
10.3 Mounting kit assembly (quarter turn actu-
ator) ................................................................ 17
10.4 Installing the electrical position indicator on
quarter turn actuators ................................... 17
11 Electrical connection ........................................... 18
11.1 Electrical connection ..................................... 18
11.2 Potential equalization – special function X
and Y .............................................................. 18
11.3 24 V / IO-Link, ordering option Fieldbus
code 000, electrical connection code 01 ..... 19
11.3.2 Inputs (pin 5) .................................... 19
11.3.3 Outputs (pin 2, 4) .............................. 19
11.4 24 V / IO-Link, ordering option Fieldbus
code 000, electrical connection code 02 ..... 19
11.4.2 Inputs (pin 5) .................................... 19
11.4.3 Outputs (pin 2, 4) .............................. 19
11.5 AS-Interface, ordering option Fieldbus, code
A2, A3, A4 ....................................................... 20
11.6 DeviceNet, ordering option Fieldbus, code
DN ................................................................... 20
12 Commissioning .................................................... 20
12.1 Programming the end positions ................... 21
12.1.1 On-site end position programming . 21
12.1.2 Initialization of the end positions
via IO-Link ......................................... 22
12.1.3 End position programming via Devi-
ceNet ................................................. 22
12.1.4 Initialization of end positions via
ASI ..................................................... 22
12.1.5 End position programming via pro-
gramming input (pin 5) .................... 23
13 Specific data – IO-Link ........................................ 24
13.1 Process data .................................................. 24
13.2 Parameter overview ...................................... 24
13.3 Description of parameter values .................. 26
13.4 Events ............................................................ 30
14 Specific data - AS-Interface ................................. 30
14.1 Inputs ............................................................. 30
14.2 Outputs .......................................................... 30
14.3 Switch point parameters ............................... 31
14.4 Error analysis ................................................. 32
15 Specific data - DeviceNet ..................................... 32
15.1 General data .................................................. 32
15.2 Net topology - DeviceNet system ................. 32
15.3 Inputs ............................................................. 33
15.4 Outputs .......................................................... 33
15.5 Parameter overview ...................................... 33
16 Troubleshooting .................................................. 36
17 Inspection and maintenance ................................ 36
18 Disassembly ........................................................ 37
19 Disposal .............................................................. 37
20 Returns ................................................................ 37
21 Declaration of Incorporation according to
2006/42/EC (Machinery Directive) ....................... 38
22 Declaration of conformity according to 2014/30/
EU (EMC Directive) ............................................... 39
23 Declaration of Conformity in accordance with
2014/34/EU (ATEX) ............................................. 40
GEMÜ 1242www.gemu-group.com 3 / 41

www.gemu-group.com4 / 41GEMÜ 1242
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
The following LED symbols are used in the documentation:
Symbol LED conditions
Off
Lit (on)
Flashing
1.3 Definition of terms
Speed-APfunction
Speed Assembly and Programming, a particularly user-
friendly commissioning function for fast mounting, automated
setting and initialization of GEMÜ products. Dependent on
type, activation uses an external impulse signal or existing
precautions on the device (magnetic or housing switch).
Changeover to normal operating mode takes place automatic-
ally after successful completion.
1.4 Warning notes
Wherever possible, warning notes are organised according to
the following scheme:
SIGNAL WORD
Type and source of the danger
Possible
symbol for the
specific
danger
Possible consequences of non-observance.
Measures for avoiding danger.
Warning notes are always marked with a signal word and
sometimes also with a symbol for the specific danger.
The following signal words and danger levels are used:
DANGER
Imminent danger!
▶Non-observance can cause death or
severe injury.
WARNING
Potentially dangerous situation!
▶Non-observance can cause death or
severe injury.
CAUTION
Potentially dangerous situation!
▶Non-observance can cause moderate
to light injury.
NOTICE
Potentially dangerous situation!
▶Non-observance can cause damage to
property.
The following symbols for the specific dangers can be used
within a warning note:
Symbol Meaning
Danger of explosion
Hazardous situation

www.gemu-group.com 5 / 41 GEMÜ 1242
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.
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
Size 1, 50 mm Size 2, 75 mm
1
2
4
3
5
1
2
4
3
5
Item Name Materials
Size 1, 50 mm Size 2, 75 mm
1 Housing cover –
standard version:
PC PC
2 Housing base Anodized alu-
minium or SS
PPS
3 Electrical connec-
tion
Threaded
piece: SS
Insert: PA
Threaded
piece: PPS or
SS
Insert: PA
4 Adapter piece SS SS
5 Mounting kit, valve-
specific
Valve-specific
materials
Valve-specific
materials
Seals EPDM and
NBR
NBR
3 Product description

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3 Product description
3.2 LED displays
3.2.1 Status LEDs
As well as the electrical position feedback and error analysis,
a visual signal is emitted by LEDs that can be seen from
above as well as a high visibility LED.
24 V / AS-Interface / IO-Link
version
DeviceNet version
LED Colour Function
Standard 1) Inversed 2)
CLOSED Green Orange Process valve
in CLOSED po-
sition
ERROR Red Red Error
OPEN Orange Green Process valve
in OPEN posi-
tion
High visibility
LED
Green Orange Process valve
in CLOSED po-
sition
Orange Green Process valve
in OPEN posi-
tion
Alternating
green/orange
Alternating
green/orange
Programming
mode
Flashes or-
ange
Flashes or-
ange
Error
PWR/FAULT
(24 V version,
code 000)
Green Power on
Red Supply voltage
too low
PWR/FAULT
(ASi version,
code A2, A3,
A4)
Green Communica-
tion active
Red Communica-
tion error/ad-
dress 0
Flashes red Device error
PWR/FAULT
(IO-Link ver-
sion, code
IOL)
Green SIO operation
Flashes green Communica-
tion active
Red Communica-
tion error or
supply voltage
too low
LED Colour Function
Standard 1) Inversed 2)
MNS
(DeviceNet
version, code
DN)
Flashes green Ready for
communica-
tion
Green Communica-
tion active
Flashes red Communica-
tion error
Red Communica-
tion error,
device has
disconnected
independently
from the bus
1) Option
Code 00: Without
2) Option
Code 40: Inversed LED feedback
For order codes see chapter "Order data"
3) The flash codes of the PWR/FAULT LED are specified ac-
cording to AS-Interface and provide feedback about the status
of the AS-Interface communication.
4) The flash codes of the MNS LEDs are specified according to
DeviceNet and give feedback about the status of the Devi-
ceNet communication.

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3.2.2 LED conditions
Function CLOSED ERROR OPEN High vis-
ibility
LED
Valve in OPEN posi-
tion
Valve in CLOSED po-
sition
Programming mode
OPEN / CLOSED flash altern-
ately
flashes
altern-
ately
LED conditions
lit (on) ~ irrelevant flashes off
3.3 Description
The GEMÜ 1242 electrical position indicator is suitable for in-
stallation on pneumatically operated linear actuators. The po-
sition of the valve spindle is reliably electronically detected
and evaluated using play-free and non-positive mounting. In-
telligent microprocessor-controlled functions facilitate com-
missioning and support during operation. The current position
of the valve is displayed via high-visibility LEDs and fed back
via electrical signals. The GEMÜ 1242 has been specially de-
signed for valves with a stroke of 2 to 46 mm.
3.4 Function
The GEMÜ 1242 electrical position indicator shows the posi-
tion of the valve. When the valve is opened, the spindle in the
electrical position indicator moves upwards and indicates that
the valve is OPEN using the high visibility LEDs and electrical
signals. When the valve is closed, the spring in the mounting
kit pushes the spindle in the electrical position indicator
downwards and indicates that the valve is CLOSED using the
high visibility LEDs and electrical signals.
3.5 Product label
Device version Design in accordance with order data
Item number Traceability number Serial number
Device-specific data
Year of manufacture
The manufacturing month is coded under the traceability
number and can be requested from GEMÜ. The product was
manufactured in Germany.
4 GEMÜ CONEXO
Order variant
In the corresponding design with CONEXO, this product has
an RFID chip (1) for electronic identification purposes. The 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.
Installing the RFID chip (1)
Size 1, 50 mm Size 2, 75 mm
1
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
▶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 GEMÜ 1242 is designed to be fitted to a GEMÜ valve in or-
der to detect the position of linear actuators optically and
electrically. The product has a microprocessor controlled in-
telligent position sensor as well as an analogue travel sensor
system (potentiometer) and is connected in a force-locking
way with the actuator spindle by means of a mounting kit
5 Correct use

www.gemu-group.com8 / 41GEMÜ 1242
5 Correct use
(spring, operating bush). The valve end positions and the in-
tegrated travel sensor can be controlled via the electrical con-
nections.
5.1 Product without special function X or Y
The product is not intended for use in potentially explosive
areas.
5.2 Product with special function Y
The product with special function Y is UL/CSA certified and
protected against explosion in accordance with ISA 12.12.01
(see "Technical data").
The product with special function Y can be connected to
switches, power supplies, PLC outputs and PLC inputs.
The energy supply must be equipped with a switch or an over-
current protective device in the system. The switch or overcur-
rent protective device must be placed in a suitable and ac-
cessible position and also labelled as an isolating device for
the product with special function Y.
The product user is responsible for providing connections that
comply with standards, a locking mechanism, cable compat-
ibility and warning signs.
Suitable locking clips must be used to secure the circular con-
nectors against becoming unintentionally loose or being
loosened without the use of tools.
Installation, operation and maintenance must only be carried
out by qualified trained personnel.
Do not repair the device yourself if it is faulty. Instead, replace
it with an equivalent new device. Repairs must only be carried
out by the manufacturer!
The device must only be used if its materials are resistant
against mechanical and/or chemical influences or corrosion
under the respective operating conditions to such a sufficient
degree that the explosion protection is not impaired or nulli-
fied.
5.3 Product with special function X
The product with the special version X order option is inten-
ded for use in potentially explosive areas of zone 2 with
gases, mists or vapours and zone 22 with combustible dusts
in accordance with EU directive 2014/34/EU (ATEX).
The product has the following explosion protection marking:
ATEX
Gas: II 3G Ex ec nC IIC T4 Gc X
Dust: II 3D Ex tc IIIC T 80 °C Dc X
IECEx
Gas: Ex ec nC IIC T4 Gc
Dust: Ex tc IIIC T80°C Dc
Certificate: IECEx IBE 18.0029 X
The product has been developed in compliance with the fol-
lowing harmonised standards:
•DIN EN 60079-0:2012+A11:2013
•DIN EN 60079-7+A1:2015-12-31
•DIN EN 60079-15:2010-09-30
•DIN EN 60079-31:2014-07-31
Use of the product is permissible in the following ambient
temperature ranges: 0 to +60°C
For use in potentially explosive areas, the following
conditions or operation limits must be observed:
Index X is applied to the ATEX marking.
The following special conditions must be complied with:
1. Connection cables and connectors must be protected
from damage.
2. Layers of dust > 5 mm must be removed.
3. Warning label "Danger from electrostatic build-up".
4. Warning label "Do not disconnect when live".
The housing must be installed protected from mechanical in-
fluences.
RFID chips must not be read out in potentially explosive areas.

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 1242
2 Fieldbus Code
Without, 24 V version, with IO-Link 000
AS-Interface, 31 slaves, 4I/4O A2
AS-Interface, 62 slaves, 4I/3O A3
AS-Interface, 62 slaves, 8I/8O A4
DeviceNet DN
3 Accessory Code
Accessory Z
4 Housing material Code
PPS base, PC cover 01
Stainless steel base, PC cover 07
Aluminium base, PC cover 14
5 Function Code
Position feedback Open / Closed 00
6 Electrical connection Code
M12 plug, 5-pin 01
6 Electrical connection Code
M12 plug, 8-pin 02
7 Option Code
Without 00
Inversed LED feedback 40
8 Switch Code
Electronics E0
9 Connection diagram Code
M12 plug, 5-pin 01
M12 plug, 8-pin 02
10 Travel length Code
Potentiometer, 50 mm length 050
Potentiometer, 75 mm length 075
11 Special version Code
Without
NEC 500 and UL/CSA approval Y
ATEX (2014/34/EU), IECEx X
Order example
Ordering option Code Description
1 Type 1242 Electrical position indicator
2 Fieldbus 000 Without, 24 V version, with IO-Link
3 Accessory Z Accessory
4 Housing material 14 Aluminium base, PC cover
5 Function 00 Position feedback Open / Closed
6 Electrical connection 01 M12 plug, 5-pin
7 Option 00 Without
8 Switch E0 Electronics
9 Connection diagram 01 M12 plug, 5-pin
10 Travel length 050 Potentiometer, 50 mm length
11 Special version Without
6 Order data
www.gemu-group.com 9 / 41 GEMÜ 1242

7 Technical data
7.1 Temperature
Ambient temperature: 0 — 60 °C
Storage temperature: -10 — 70 °C
7.2 Product compliance
EMC Directive: 2014/30/EU
Technical standards used:
Explosion protection: ATEX (2014/34/EU) and IECEx, order code Special version X
NEC 500 (ISA 12.12.01), order code Special version Y
EAC according to TR CU 012/211 - ATEX
ATEX marking: Gas: II 3G Ex ec nC IIC T4 Gc X
Dust: II 3D Ex tc IIIC T 80 °C Dc X
IECEx marking: Gas: Ex ec nC IIC T4 Gc
Dust: Ex tc IIIC T80°C Dc
Certificate: IECEx IBE 18.0029 X
NEC marking: Class I, Division II, Groups C & D, T4
EAC marking: 2Ex e nC IIC T4 Gc X
Certificate: ЕАЭС RU C-DE.BH02.B.00231/19
Approvals: 24 V AS-Interface IO-Link DeviceNet
Fieldbus/
communication
- Travel sensor ver-
sion 050: AS-Inter-
face certificate
no. 96001
Travel sensor ver-
sion 075: AS-Inter-
face certificate
no. 125601
Travel sensor ver-
sion 050: IO-Link
specification V
1.1
Travel sensor ver-
sion 075: IO-Link
specification V
1.1
n.n.
SIL: Product description: GEMÜ electrical position indicator 1242
Device type: B
Valid software version: V1.1.X.X
Safety function: The fail-safe state is defined as a High (24 V DC) signal
at pin4 (device version 24 V IO-Link), if the current posi-
tion 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): 232 years
Further information, see SIL safety manual
www.gemu-group.com10 / 41GEMÜ 1242
7 Technical data

7.3 Mechanical data
Installation position: Optional
Weight: Size 1 Size 2
Aluminium: 320 g
Stainless steel: 600g
420 g
Protection class: IP 67
IP 64 for special version code X
IP NEMA 4X (UL 61010-1, UL 50E), only available as special version code Y
Travel sensor: Size 1 Size 2
Minimum stroke: 2 mm 5 mm
Maximum stroke: 46 mm 75 mm
Hysteresis: 0.2 mm 0.5 mm
Accuracy: 0.2% Full Scale
GEMÜ 1242www.gemu-group.com 11 / 41
7 Technical data

7.4 Electrical data
Electrical connection
type:
1 x 5-pin M12 plug (A-coded)
1 x 8-pin M12 plug (A-coded)
Supply voltage: 24 V DC (18 to 30 V DC) (according to IO-Link specifications)
26.5 to 31.6 V DC (according to AS-Interface specifications)
11 to 25 V DC (according to DeviceNet specifications)
Duty cycle: Continuous duty
Electrical protection
class:
III
Reverse battery protec-
tion:
yes
Switching characteristic:
100%
0%
td1 td1
td1 td2
td1
ta
t/ms
t/ms
t/ms
Stroke %
Switch point "Open"
Switching hysteresis
Switching hysteresis
Switching output "Open"
Switch point "Closed"
active
inactive
active
inactive
Switching output "Closed"
td1: Signal delay
td2: Signal delay
ta: Signal interval
Switch points: The data in percent refer to the programmed stroke, before each end position
Switch points: Size 1 Size 2
Default setting switch point CLOSED 12% 12%
Default setting switch point OPEN 25% 25%
Min. switch point CLOSED 0.8 mm 2 mm
Min. switch point OPEN 0.5 mm 1.25 mm
If the percentage switch points dependent on the programmed stroke are smaller than the permiss-
ible min. switch points, the min. switch points apply automatically.
www.gemu-group.com12 / 41GEMÜ 1242
7 Technical data

8 Dimensions
8.1 Size 1
98
Ø57
X
13
16,6
47
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
dependent on valve used
Dimensions in mm
8.2 Size 2
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
depending on the valve that is used
Dimensions in mm
GEMÜ 1242www.gemu-group.com 13 / 41
8 Dimensions

www.gemu-group.com14 / 41GEMÜ 1242
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
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 Mounting kit assembly
Item Name Item Name
1 Spindle 7 Flange plate
2 Spring 8 Screws
3 Operating bush 9 Pressure disc*
4 Distance piece 10 O-ring*
5 O-ring 11 O-ring*
6 Adapter
* Included depending on version.
CAUTION
Pretensioned spring!
▶Damage to the device.
●Slowly release the tension in the spring.
CAUTION
Do not scratch the spindle!
▶A damaged spindle surface may cause failure of the
travel sensor.
1
4
1
2
3
1. Pull out the spindle
1.
2. Align the indentation of the distance
piece 4 to the spring and push it over
the spindle 1 using the spring 2 and fix
it in place using the operating bush 3.
5
6

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3. Tighten the operat-
ing
bush 3 by turning it
clockwise.
4. Affix the O-ring 5 and the adapter 6.
7
8
5. Attach the flange
plate
7
6. Screw the flange plate on tight using
screws 8 (1–1.5 Nm).
•Push in the spindle until it pushes against the spring and
then slowly release the pressure on the spring.
NOTICE
▶For some valves (e.g. GEMÜ 650 and GEMÜ 687) it is ne-
cessary to fit a pressure disc between the threaded ad-
apter and the actuator head. This is included in the re-
quired mounting kits, sometimes with an additional O-ring
(only GEMÜ 650 with normally open and double-acting
control function – code 2+3).
▶If the pressure disc does not have a groove for a seal, this
will already be inserted in the groove provided at the ad-
apter opening of the actuator head (e.g. GEMÜ 687 with
normally open control function – code 2).
9
6
11
10
Insert the O-ring 11 (if in-
cluded)
into the corresponding groove
on the adapter 6.
If included: Push the pressure
disc 9 over the adapter 6 and
insert the O-ring 10 in the in-
tended groove of the pressure
disc.
10.2 Installing the electrical position indicator on linear
actuators
10.2.1 Preparations for mounting to the valve
1. Move the actuator A into zero position (actuator vented).
2. Remove optical position indicator 2 and / or protective cap
1 from the actuator top.
A
12
10.2.2 Assembling the adapter (linear actuator)
With some mounting kits it is necessary to install an adapter
as well. This adapter is enclosed with the required mounting
kits. Valves with a normally open and double acting control
function (code 2+3) also include additional O-rings (1+2).
1
3
2
1. Move the actuator to the closed position.
2. Place O-rings 1 and 2 into adapter 3.
3. Screw adapter 3 into the actuator opening as far as it will
go and tighten.
10 Assembly and installation

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10 Assembly and installation
10.2.3 Assembling the stroke limiter (linear actuator)
5
5
4
3
2
1
6
8
9
7.1
7.2
Option1 Option2
1. Screw distance piece 5 onto/
into actuator spindle 6.
2. Move the actuator to the
closed position.
3. Insert the O-ring 7.1 in the
stroke limiter 1.
4. Insert the O-ring 7.2 in the
washer 4.
5. Screw stroke limiter 1 with
nut 2, seal 3 and washer 4
into the actuator opening.
6. Set stroke limiter 1 to the re-
quired 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.
10.2.4 Assembling and installing the electrical position
indicator (linear actuator)
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 dam-
aged.
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 (lin-
ear actuator)“, page15) or the stroke limiter 1 (see “As-
sembling 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 elec-
trical connections.
5. Initialize the product.
CAUTION
Incorrect installation of the product.
▶Damage to the housing.
●Only tighten the product using the spanner flats provided
for this purpose.

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NOTICE
Wrong mounting kit
▶If no initial spring tension can be felt, it may be the case
that the wrong mounting kit with too short an operating
bush has been used.
▶If the spring locks and the positioner cannot be correctly
mounted on the valve, it may be the case that the wrong
mounting kit with too long an operating bush has been
used or that a required adapter has not been used.
●In both cases, check that the mounting kit parts are being
used correctly and in their entirety.
6. The product with mounting kit is fully assembled.
7. The product with mounting kit and adapter is fully as-
sembled.
8. The product with mounting kit and stroke limiter is fully
assembled.
10.3 Mounting kit assembly (quarter turn actuator)
3
4
A
4
55
1. Adjust the mounting bracket to the required borehole pat-
tern.
ðTo do this, loosen the side screws 5 and set the retain-
ing 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 do-
ing so, the tap shaft must sit free of play in the shaft of the
actuator.
10.4 Installing the electrical position indicator on
quarter turn actuators
10.4.1 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.
10.4.2 Contents of PTAZ mounting kit for quarter turn actuator
The PTAZ mounting kit contains the following items:
Item
PTAZ adapter
PTAZ mounting kit
Flange plate
O-ring
Screws (4x)
Adapter (M16x1)
Operating bush
Compression spring
10 Assembly and installation

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11 Electrical connection
10.4.3 NAMUR sizes, quarter turn actuator, PTAZ
The following borehole patterns are available:
80 x 30 x 20
80 x 30 x 30
130 x 30 x 30
130 x 30 x 50
10.4.4 Assembling and 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.
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 elec-
trical connections.
4. Initialize the product.
11 Electrical connection
DANGER
Danger of explosion
▶Risk of severe injury or death.
●Danger from sparking. Never discon-
nect the connection cables when live.
DANGER
Danger of explosion
▶Risk of severe injury or death.
●Do not connect or disconnect the
device until the power has been
switched off or the area has been clas-
sified as non-hazardous.
●The standard version of the product
(without special function X or Y) must
not be used in potentially explosive
zones.
●Danger from sparking. Never discon-
nect the connection cables when live.
11.1 Electrical connection
1. Connect the product in accordance with the pin assign-
ment.
For electrical connection, we recommend the M12 connectors
for EX areas from IFM, series EVCxxA.
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.
2. Securely lay the connection cables or ensure sufficient
tension relief.
3. Refer to the technical data and cable gland documentation
for details of the wire cross sections.
4. Protect the product and the cables from damage.
5. Only clean the product with an anti-static or damp cloth.
6. Only operate the product when it is fully assembled.
11.2 Potential equalization – special function X and Y
Connecting the potential equalization device
1. Use a screw M4x6 to attach the potential equalization
device to the electrical position indicator.
ðPotential equalization for metal housings in potentially
explosive areas: Minimum 4 mm².
2. Secure the connection against working itself loose.

www.gemu-group.com 19 / 41 GEMÜ 1242
11.3 24 V / IO-Link, ordering option Fieldbus code 000,
electrical connection code 01
Observe the safety information and general information in the
"Electrical connection" section.
11.3.1 Pin assignment
1
4
3
2
5
Pin Signal name
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
Pin 5 is highly active. If not used, connect to GND or leave open.
11.3.2 Inputs (pin 5)
Input impedance
Min. 27 kΩ
Input voltage
max. 30 V DC
High level
≥ 18 V DC
Low level
≤ 5 V DC
11.3.3 Outputs (pin 2, 4)
Internal wiring
Push-Pull
Max. switching current
± 100 mA
Max. voltage drop Vdrop
3 V DC at 100 mA
Switching voltage
+Uv - Vdrop push high
-Uv + Vdrop pull low
11.4 24 V / IO-Link, ordering option Fieldbus code 000,
electrical connection code 02
Observe the safety information and general information in the
"Electrical connection" section.
11.4.1 Pin assignment
6
5
3
2
47
8
1
Pin Signal name
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
5 24 V DC, programming input
6 n.c.
7 24 V DC, error output
8 n.c.
Pin 5 is highly active. If not used, connect to GND or leave open.
The following errors are indicated via pin 7 (error output): Sensor er-
ror, pneumatic error, programming error, internal error
11.4.2 Inputs (pin 5)
Input impedance
Min. 27 kΩ
Input voltage
max. 30 V DC
High level
≥ 18 V DC
Low level
≤ 5 V DC
11.4.3 Outputs (pin 2, 4)
Internal wiring
Push-Pull
Max. switching current
± 100 mA
Max. voltage drop Vdrop
3 V DC at 100 mA
Switching voltage
+Uv - Vdrop push high
-Uv + Vdrop pull low
11 Electrical connection

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12 Commissioning
11.5 AS-Interface, ordering option Fieldbus, code A2,
A3, A4
Observe the safety information and general information in the
"Electrical connection" section.
11.5.1 Pin assignment
1
4
3
Pin Signal name
1 AS-Interface +
2 -
3 AS-Interface -
4 n.c.
5 -
Carry out potential equalisation via pre-assembled earthing
kit.
Connect yellow/green stranded wire H07 V-K 4.0 on site.
11.5.2 Potential equalisation and electrical connection
The potential equalisation can be established using the fol-
lowing methods:
•Pre-assembled earthing kit for the on-site wiring of the earth
via a stranded wire, yellow/green H07 V-K 4.0
•Conductive connection via the mechanically coupled valve
fitting to the system earth
The maximum permissible resistance of the potential equal-
isation connection is defined as R ≤ 100 Ω. During the plant-
specific maintenance cycle, the potential equalisation connec-
tion must be checked to ensure that it has been connected
correctly and that the maximum resistance has not been ex-
ceeded.
Procedure
1. Establish the potential equalisation using one of the spe-
cified methods.
2. Check the maximum permissible resistance value and
check the connections if this is exceeded.
3. Include the check of the potential equalisation in the main-
tenance cycle.
4. Connect the product in accordance with the pin assign-
ment.
11.6 DeviceNet, ordering option Fieldbus, code DN
Observe the safety information and general information in the
"Electrical connection" section.
11.6.1 Pin assignment
1
4
3
2
5
Pin Signal name
1 Shield
2 V+
3 V-
4 CAN_H
5 CAN_L
12 Commissioning
CAUTION
Hazardous situation
▶Risk of injury or damage possible.
●For correct commissioning, the
product must be calibrated to the pro-
cess valve by means of the initializa-
tion process.
●During this commissioning, the valve is
opened and closed. It must therefore
be ensured in advance that this does
not lead to a dangerous situation.
NOTICE
Incorrect initialization
●Always carry out initialization without operating medium
pressure on the process valve. Carry out initialization of
the process valve in neutral position (NO/NC).
NOTICE
●For delivery of the product assembled on a valve at the
factory, the complete construction is already ready for op-
eration at a control pressure of 5.5 to 6 bar without oper-
ating pressure. A reinitialization is recommended if the
plant is operated with a different control pressure or if the
mechanical end positions have been changed (e.g. seal
replacement on the valve or actuator replacement). The
initialization is retained even in the event of voltage
cutoff.