GEM 4241 User manual

GEMÜ 4241
Combi switchbox
Operating instructions
EN
further information
webcode: GW-4241

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
04.03.2020
www.gemu-group.com2 / 27GEMÜ 4241

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 ............................................................... 12
9 Manufacturer's information ....................................... 12
9.1 Delivery ............................................................... 12
9.2 Packaging ........................................................... 12
9.3 Transport ............................................................ 12
9.4 Storage ............................................................... 12
10 Assembly and installation ......................................... 13
11 Pneumatic connection ............................................... 20
12 Electrical connection ................................................. 20
13 Manual override ........................................................ 23
14 Troubleshooting ........................................................ 24
15 Inspection and maintenance ..................................... 24
16 Disassembly .............................................................. 25
17 Disposal .................................................................... 25
18 Returns ..................................................................... 25
19 EU Declaration of conformity in accordance with
2014/34/EU (ATEX) ................................................... 26
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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!
Danger of explosion
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 4241 combi switchbox is suitable for mounting to pneumatically operated linear actuators. The position of the
valve spindle is reliably electronically detected and fed back via the play-free and non-positive mounting by means of a 2-wire
proximity switch (NAMUR). Integrated pilot valves enable direct activation of the process valve connected to them.
3.3 Function
The GEMÜ 4241 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.
3.4 Product label
Device version Design in accordance with order data
Item number Traceability number Serial number
Device-specific data
Year of manufacture
The manufacturing month is coded under the traceability number and can be requested from GEMÜ. The product was manu-
factured in Germany.

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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 components included in the scope of de-
livery and need to be ordered separately.
4 GEMÜ CONEXO

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5 Correct use
5 Correct use
DANGER
Danger of explosion!
▶Risk of severe injury or death.
●Do not use the product in potentially explosive zones.
●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 in this doc-
ument.
The product with the special version X order option is intended 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 2G Ex ib IIB T4 Gb
Dust: II 2D Ex ib IIIC T120°C Db
EC type examination certificate: IBExU17ATEX 1160 X
Notified body: IBExU, No. 0637
IECEx
Gas: Ex ib IIB T4 Gb
Dust: Ex IIIC T120°C Db
Certificate: IECEx IBE 19.0017 X
The product has been developed in compliance with the following harmonised standards:
– EN 60079-0:2012+A11:2013
– EN 60079-11:2012
The product can be used in the following ambient temperature ranges: 0°C to +50°C
For use in potentially explosive areas, the following conditions or operation limits must be observed:
Special conditions of use
1. The special conditions of the Ex components used must be observed.
2. The housing must be installed protected against mechanical influences.
3. Layers of dust > 5 mm must be avoided.

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 4241
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
6 Electrical connection Code
M12 plug, 5-pin; connection diagram "P" 01
M16 Skintop cable gland; connection diagram "N" 03
7 Pneumatic connection Code
Without 00
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
Proximity switch, 2-wire, NAMUR
P+F, NJ1,5-6,5-15-N-Y180094
N1
9 Connection diagram Code
NAMUR terminals OPEN/CLOSE
8 V NAMUR sensor; 24 V DC pilot valve
N1
NAMUR terminals OPEN/CLOSE
8 V NAMUR sensor; 12 V DC pilot valve
N2
M12 plug, 5-pin CLOSED
8 V NAMUR sensor; 12 V DC pilot valve
P5
10 Travel sensor version Code
Potentiometer, 75 mm length 075
11 Special version Code
ATEX (2014/34/EU), IECEx X
Order example
Order option Code Description
1 Type 4241 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; connection diagram "N"
7 Pneumatic connection 00 Without
8 Switch N1 Proximity switch, 2-wire, NAMUR
P+F, NJ1,5-6,5-15-N-Y180094
9 Connection diagram N1 NAMUR terminals OPEN/CLOSE
8 V NAMUR sensor; 24 V DC pilot valve
10 Travel sensor version 075 Potentiometer, 75 mm length
11 Special version X ATEX (2014/34/EU), IECEx
6 Order data
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7 Technical data
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 50 °C
Media temperature: 0 to 50 °C
Storage temperature: 0 to 40 °C
7.3 Pressure
Operating pressure: 2 to 7 bar
Flow rate: 250 Nl/min
The applied pressure must not exceed the maximum control pressure of the process valve.
7.4 Product compliance
Machinery Directive: 2006/42/EC
Explosion protection: ATEX (2014/34/EU)
ATEX marking: Gas: II 2G Ex ib IIB T4 Gb
Dust: II 2D Ex ib IIIC T120°C Db
EC type examination certificate: IBExU17ATEX 1160 X
Notified body: IBExU, No. 0637
IECEx marking: Gas: Ex ib IIB T4 Gb
Dust: Ex IIIC T120°C Db
Certificate: IECEx IBE 19.0017 X
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
Stroke: 5 to 75 mm

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7.6 Electrical data
7.6.1 2-wire proximity switch (NAMUR)
Supply voltage: 8 V DC
Current consumption: ≤ 0.1 A (damped)
≥ 3 mA (undamped)
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
7.6.2 Pilot valve
Rated voltage: 24 V DC ±10 % (code N1)
12 V DC -5/+10 % (code N2)
Rated power: 0.5 W
Resistance: 1152 Ω ± 5 % (code N1)
288 Ω ± 5 % (code N2)
Duty cycle: Continuous duty
7.7 Intrinsically safe characteristic values
7.7.1 Proximity switch
Proximity switch: Ui = 16 V
Ii = 52 mA
Pi = 169 mW
Li = 50 µH
Ci = 30 nF
7.7.2 Pilot valve
Pilot valve, code N1: Ui = 30 V
Ii = 330 mA
Li negligible
Ci negligible
Pilot valve, code N2: Ui = 30 V
Li negligible
Ci negligible
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 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.

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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
insert 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
Option 1 Option 2
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) Disc 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
▶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.
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.
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
1
2
1. Press clamping tie bar 1 in with a
screwdriver.
2. Turn the cover anticlockwise to open
the bayonet fitting. 3. Remove cover 2.
3
4
5
6
Setting the upper switching position: Setting the lower switching position:
4. Move the valve to the OPEN position.
5. Squeeze and hold red levers 3.
6. Push switch 4 on the toothed bar into the desired position.
7. Release red levers 3.
ðSwitch 4 engages.
ðThe upper switching position is set.
8. Move the valve to the CLOSED position.
9. Squeeze and hold red levers 5.
10. Push switch 6 on the toothed bar into the desired position.
11. Release red levers 5.
ðSwitch 6 engages.
ðThe lower switching position is set.
12. Make the electrical connection (see “Electrical connection“, page20).

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2
13. After completing the electrical connection, carefully pull the connection cable taut.
14. Make sure that seal 1 is fitted correctly and is not damaged.
15. Put on cover 2 so that the bayonet fitting is inserted correctly and turn cover 2 clockwise.
16. Restore the power supply.
17. To check that everything is working correctly, open and close the valve and observe the signalling.
18. If the settings need to be readjusted, switch off power to the product again and repeat the steps in "Setting the switching
positions".
10 Assembly and installation

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11 Pneumatic connection
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
12 Electrical connection
DANGER
Danger of explosion
▶Risk of injury or death!
●Do not connect or disconnect when connected to the power supply.
●Do not disconnect the device until the power has been switched off or the area has been classified as non-
hazardous.
DANGER
Danger of explosion
▶Risk of severe injury or death.
●Danger from sparking. Never disconnect the connection cables when live.