GEM 4240 User manual

GEMÜ 4240
Combi switchbox
Operating instructions
EN
further information
webcode: GW-4240

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
05.02.2021
www.gemu-group.com2 / 25GEMÜ 4240

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 ............................................................... 7
6 Order data ................................................................. 8
7 Technical data .......................................................... 9
8 Dimensions ............................................................... 10
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 ......................................... 11
11 Pneumatic connection ............................................... 17
12 Electrical connection ................................................. 18
13 Manual override ........................................................ 20
14 Troubleshooting ........................................................ 20
15 Inspection and maintenance ...................................... 21
16 Disassembly .............................................................. 21
17 Disposal .................................................................... 21
18 Returns ..................................................................... 21
19 Declaration of Incorporation according to 2006/42/
EC (Machinery Directive) ........................................... 22
20 Declaration of conformity according to 2014/30/EU
(EMC Directive) ......................................................... 23
21 Declaration of conformity according to 2014/35/EU
(Low Voltage Directive) ............................................. 24
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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:

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Symbol Meaning
Danger of explosion
Electric shock by high voltage
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

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3 Product description
3 Product description
3.1 Construction
1
2
5
3
4
Item Name Materials
1 Housing cover PC
2 Housing base PPS
3 Electrical connection SS, PP
4 Adapter piece SS
5 Mounting kit, valve specific SS, PP
Seals NBR
3.2 Description
The GEMÜ 4240 combi switchbox is suitable for mounting to pneumatically operated linear actuators. The position of the
valve spindle is reliably detected electronically and reported via microswitches or proximity switches, using play-free and non-
positive mounting. Integrated pilot valves enable direct activation of the process valve connected to them. The product has
been designed specially for valves with a stroke of 5 to 75 mm.
3.3 Function
The GEMÜ 4240 combi switchbox indicates the current position of the valve. When the valve is opened, the spindle in the
combi switchbox moves upwards and indicates that the valve is OPEN using the communication interface. When the valve is
closed, the spring in the mounting kit presses the spindle in the combi switchbox downwards and indicates that the valve is
CLOSED using the communication interface.

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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.
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 doc-
ument.
The product is not intended for use in potentially explosive areas.
The product is designed for mounting to pneumatically operated linear actuators. The position of the valve spindle is electron-
ically detected and reported via microswitches or proximity switches through play-free and non-positive mounting. Integrated
pilot valves enable direct activation of the process valve connected to them.
●Use the product in accordance with the technical data.
5 Correct use

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, con-
trol function and actuator size must be stated.
Order codes
1 Type Code
Combi switchbox 4240
2 Fieldbus Code
Without 000
3 Accessory Code
Accessory Z
4 Housing material Code
PPS base, PC cover 01
5 Action Code
Single acting, with manual override 01
Double acting, with manual override 02
Single acting, without manual override E1
6 Electrical connection Code
M16 Skintop cable gland 03
7 Pneumatic connection Code
G1/8 connection thread 01
Air supply 6 mm angled connection,
exhaust air 6 mm angled connection
04
7 Continuation of Pneumatic connection Code
Air supply 6 mm T-connection,
exhaust air 6 mm angled connection
05
G1/8 connection thread
(for IP67 or piped air outlet)
E1
8 Switch Code
Change-over contact, microswitch, 24 V DC, 250 V
AC
Crouzet, V4S, SPDT
M1
Proximity switch, 2-wire, NAMUR
P+F, HJ1.5-6.5-15-N-Y180094
N1
Proximity switch, 3-wire, make contact, PNP, 10–
30 V DC
Balluff, BES 516-371-SA 16
P1
9 Connection diagram Code
Microswitch M1
Terminals, NAMUR N1
3-wire P1
10 Travel length Code
Potentiometer, 75 mm length 075
Order example
Order option Code Description
1 Type 4240 Combi switchbox
2 Fieldbus 000 Without
3 Accessory Z Accessory
4 Housing material 01 PPS base, PC cover
5 Action 01 Single acting, with manual override
6 Electrical connection 03 M16 Skintop cable gland
7 Pneumatic connection 04 Air supply 6 mm angled connection,
exhaust air 6 mm angled connection
8 Switch M1 Change-over contact, microswitch, 24 V DC, 250 V AC
Crouzet, V4S, SPDT
9 Connection diagram M1 Microswitch
10 Travel length 075 Potentiometer, 75 mm length
6 Order data
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7 Technical data
7.1 Medium
Working medium: Quality classes to DIN ISO 8573-1
Dust content: Class 3, max. particle size 5 μm, max. particle density 5 mg/m³
Oil content: Class 5, max. oil concentration 25 mg/m³
7.2 Temperature
Ambient temperature: 0 to 60 °C
Media temperature: 0 — 50 °C
Storage temperature: -10 — 70 °C
7.3 Pressure
Operating pressure: 2 to 7 bar
Observe the maximum control pressure of the valve actuator.
Flow rate: 250 Nl/min
7.4 Product compliance
Machinery Directive: 2006/42/EC
EMC Directive: 2014/30/EU
Low Voltage
Directive:
2014/35/EU
7.5 Mechanical data
Installation position: Optional
Weight: 420 g
Protection class: IP 65 acc. to EN 60529
IP 67 acc. to EN 60529, is reached with piped air outlet
Travel sensor: 5 to 75 mm
7.6 Electrical data
Switch type: Code M1 Code N1 Code P1
Microswitch SPDT 2-wire NAMUR 3-wire, make contact, PNP
Supply voltage: Switch
Code M1 Code N1 Code P1
24 V DC, 250 V AC 8 V NAMUR 10 to 30 V DC
Current consumption: Switch
Code M1 Code N1 Code P1
5 mA to 5 A DC
100 mA to 6 A AC
≥ 3 mA (undamped)
≤ 1 mA (damped)
0–200 mA
Electrical connection
type:
Connection thread: M16 x 1.5, WAF 19
Cable diameter: 4.5 to 10mm
Recommended wire cross section: 0.75 mm² x 8 cables
7 Technical data

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8 Dimensions
8 Dimensions
142
Ø 90
14,5
86,5 26
11
SW 24
Square
Dimensions in mm
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.

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10 Assembly and installation
1. Observe the national regulations and provisions.
2. Observe the installer provisions.
3. Lay cables securely and protect them from damage.
4. Connect open wire ends in a junction box with protection class IP20 and higher or outside the EX area
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 Information on use in damp conditions
1
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.
10 Assembly and installation

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10 Assembly and installation
10.3 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
3. Tighten the operating bush 3 by turning it
clockwise.
4. Affix the O-ring 5 and the adapter 6.

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7
8
5. Attach the flange plate 76. 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 necessary to fit a pressure disc between the threaded adapter and
the actuator head. This is included in the required 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 adapter
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 included) into the corresponding groove
on the adapter 6.
If included: Push the pressure disc 9 over the adapter 6 and in-
sert the O-ring 10 in the intended groove of the pressure disc.
10 Assembly and installation

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10 Assembly and installation
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 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.

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10.6 Assembling and installing the combi switchbox
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. Move the actuator into the OPEN position.
2. Place the product as far as it will go into the actuator opening, insert adapter 3 (see chapter 9.3) or stroke limiter 1 (see
chapter 9.4) and screw 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. Set the switch on the product (see “Setting the switching positions“, page16).
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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10 Assembly and installation
10.7 Setting the switching positions
2
1. Turn the cover anticlockwise to open the bayonet fitting. 2. Remove cover 2.
3
4
5
6
Setting the upper switching position: Setting the lower switching position:
3. Move the valve to the OPEN position.
4. Squeeze and hold red levers 3.
5. Push switch 4 on the toothed bar into the desired position.
6. Release red levers 3.
ðSwitch 4 engages.
ðThe upper switching position is set.
7. Move the valve to the CLOSED position.
8. Squeeze and hold red levers 5.
9. Push switch 6 on the toothed bar into the desired position.
10. Release red levers 5.
ðSwitch 6 engages.
ðThe lower switching position is set.
11. Make the electrical connection.

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2
12. After completing the electrical connection, carefully pull the connection cable taut.
13. Make sure that seal 1 is fitted correctly and is not damaged.
14. Put on cover 2 so that the bayonet fitting is inserted correctly and turn cover 2 clockwise.
15. Restore the power supply.
16. To check that everything is working correctly, open and close the valve and observe the signalling.
17. If the settings need to be readjusted, switch off power to the product again and repeat the steps in "Setting the switching
positions".
11 Pneumatic connection
11.1 Standard, single acting
Connection Designation Connection size
1 Air supply connection P G 1/8
2 Working connection for process valve A1 G 1/8
3 Venting connection R with silencer (integrated housing ventilation) G 1/8 1)
1) only relevant for exhaust air duct and/or increase of protection class
11.2 Standard, double acting
Connection Designation Connection size
1 Air supply connection P G 1/8
2 Working connection for process valve A1 G 1/8
3 Venting connection R with silencer (integrated housing ventilation) G 1/8 1)
4 Working connection for process valve A2 G 1/8
1) only relevant for exhaust air duct and/or increase of protection class
11 Pneumatic connection

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12 Electrical connection
12 Electrical connection
CAUTION
Electric shock by high voltage
▶Danger of injury or death caused by electric shock.
●Power supply varies depending on version.
●Switch off power to the product when working on the product.
●Work on electrical connections only by qualified trained personnel.
12.1 Microswitch, ordering option Connection diagram code M1
12.1.1 Connection diagram
1
4
2 1
4
2
1
4
2
3
24 V DC +
S1
5
8
6
7
S2
CLOSED
OPEN
Pin Signal name
1 Break contact limit switch OPEN
2 Make contact limit switch OPEN
3 Change-over contact limit switch OPEN
4 GND, solenoid valve actuation
5 Change-over contact limit switch CLOSED
6 Make contact limit switch CLOSED
7 Break contact limit switch CLOSED
8 24 V DC, solenoid valve actuation

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12.2 2-wire NAMUR proximity switch, ordering option Connection diagram code N1
12.2.1 Connection diagram
OPEN
24 V DC +
S1
L+
L-
L+
L-
1
2
3
4
5
6
S2
CLOSED
Pin Signal name
1 L+, OPEN switch
2 L-, OPEN switch
3 GND, solenoid valve actuation
4 L+, CLOSED switch
5 L-, CLOSED switch
6 24 V DC, solenoid valve actuation
12.3 3-wire proximity switch, ordering option Connection diagram code P1
12.3.1 Connection diagram
24 V DC +
S2
L+L+
L- L-
1
4
2
3
5
6
7
8
S1
CLOSED
OPEN
Pin Signal name
1 L+, supply voltage
2 Signal output OPEN
3 L-, GND
4 GND, solenoid valve actuation
5 L+, supply voltage
6 Signal output CLOSED
7 L-, GND
8 24 V DC, solenoid valve actuation
12 Electrical connection

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13 Manual override
13 Manual override
The combi switchbox has a manual override which enables the process valve to be actuated manually while de-energized.
3
12
Activating the manual override:
1. Press in the manual override 3 using a flathead screwdriver (maximum slot width of 4 mm) as far as it will go and turn it
90° clockwise.
ðThe groove is horizontal.
Deactivating the manual override:
2. Turn the manual override 3 90° anticlockwise using a flathead screwdriver (maximum slot width of 4 mm) and release it.
ðThe groove is vertical.
NOTICE
▶Control air and the minimum pressure must be available to use the manual override.
14 Troubleshooting
Error Error cause Troubleshooting
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