GEM 4242 User manual

GEMÜ 4242
Combi switchbox with integrated pilot valve
Operating instructions
ASi-5
EN
further information
webcode: GW-4242

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
21.02.2024
www.gemu-group.com2 / 51GEMÜ 4242

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 ............................................... 4
3 Product description ............................................. 5
3.1 Construction .................................................. 5
3.2 Description ..................................................... 5
3.3 Function ......................................................... 5
3.4 LEDs ............................................................... 6
3.5 Product label ................................................. 6
4 GEMÜ CONEXO .................................................... 6
5 Correct use .......................................................... 7
6 Order data ........................................................... 8
6.1 Order codes ................................................... 9
6.2 Order example ............................................... 10
7 Technical data ..................................................... 11
7.1 Medium .......................................................... 11
7.2 Temperature .................................................. 11
7.3 Pressure ......................................................... 11
7.4 Product conformity ....................................... 11
7.5 Mechanical data ............................................ 12
7.6 Operating conditions ..................................... 12
7.7 Electrical data ................................................ 12
8 Dimensions .......................................................... 13
8.1 Size 1 .............................................................. 13
8.2 Size 2 .............................................................. 14
9 Assembly and installation .................................... 15
9.1 Mounting kit assembly .................................. 15
9.2 Mounting the combi switchbox on linear ac-
tuators ............................................................ 16
9.2.1 Preparations for assembly to the
valve .................................................. 16
9.2.2 Threaded adapter assembly (linear
actuator) ........................................... 16
9.2.3 Assembling the stroke limiter (lin-
ear actuator) ..................................... 16
9.2.4 Assembling and installing the
combi switchbox (linear actuator) .. 17
9.3 Mounting the combi switchbox on quarter
turn actuators ................................................ 18
9.3.1 Contents of PTAZ mounting kit for
quarter turn actuator ........................ 18
9.3.2 Preparations for assembly to the
valve (quarter turn actuator) ............ 18
9.3.3 Assembling and installing the
combi switchbox (quarter turn actu-
ator) ................................................... 18
10 Pneumatic connection ......................................... 19
10.1 Size 1, standard, single acting ...................... 19
10.2 Size 2, standard, single acting ...................... 19
11 Electrical connection ........................................... 20
11.1 AS-Interface, fieldbus ordering option, code
A5, A5D .......................................................... 20
11.2 Potential equalization – Special function X 21
12 Commissioning .................................................... 22
12.1.1 Autonomous end position process/
end position tracking ....................... 22
12.1.2 Classic initialization process ........... 23
13 Operation ............................................................. 23
13.1 Wireless interface ......................................... 23
13.2 Basic operation of the app ........................... 24
14 App parameter list ............................................... 25
15 Specific data – AS-Interface ................................ 29
15.1 Cyclical process data .................................... 29
15.1.1 Inputs ................................................ 29
15.1.2 Outputs ............................................. 30
15.2 Non-cyclical parameter data ........................ 30
15.3 Non-cyclical condition monitoring data ....... 39
15.4 AS-I5 events ................................................... 41
16 Manual override ................................................... 42
17 Messages and troubleshooting ............................ 43
18 Disposal .............................................................. 46
19 Returns ................................................................ 46
20 EU Declaration of Incorporation according to the
EC Machinery Directive 2006/42/EC, Annex II B ... 47
21 EU Declaration of Conformity in accordance with
2014/53/EU (RED Directive) ................................. 48
22 EU Declaration of Conformity in accordance with
2014/34/EU (ATEX Directive) ............................... 49
23 EU Declaration of Conformity in accordance with
2011/65/EU (RoHS Directive) ............................... 50
GEMÜ 4242www.gemu-group.com 3 / 51

www.gemu-group.com4 / 51GEMÜ 4242
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
1.3 Definition of terms
Working medium
The medium that flows through the GEMÜ product.
Control function
The possible actuation functions of the GEMÜ product.
Control medium
The medium whose increasing or decreasing pressure causes
the GEMÜ product to be actuated and operated.
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!
Danger of explosion
Risk of electric shock
Hazardous situation
Safety notice!
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.

www.gemu-group.com 5 / 51 GEMÜ 4242
- 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 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
1
2
4
3
5
Size 1, 30 mm Size 2, 75 mm
1
2
5
3
4
Size 2, 30 mm
1
2
5
3
4
Ite
m
Name Materials
Size 1, 30
mm
Size 2, 75
mm
Size 2, 30
mm
1 Housing cover –
standard version:
PC PC PC
2 Housing base Anodized
aluminium
or stainless
steel
Stainless
steel
Stainless
steel
3 Electrical connec-
tion
Threaded
piece:
Stainless
steel
(1.4305)
Insert: PA
Threaded
piece:
Stainless
steel
(1.4305)
Insert: PA
Threaded
piece:
Stainless
steel
(1.4305)
Insert: PA
4 Adapter piece Stainless
steel
(1.4305)
Stainless
steel
(1.4305)
Stainless
steel
(1.4305)
5 Mounting kit,
valve-specific
Valve-spe-
cific
materials
Valve-spe-
cific
materials
Valve-spe-
cific
materials
Seals EPDM and
NBR
NBR, EPDM
and VMQ
NBR, EPDM
and VMQ
3.2 Description
The GEMÜ 4242 combi switchbox is suitable for installation
on pneumatically operated linear actuators. The position of
the valve spindle is reliably electronically detected and evalu-
ated using play-free and non-positive mounting. Integrated pi-
lot valves enable direct activation of the process valve con-
nected to them. Intelligent microprocessor-controlled func-
tions facilitate commissioning and support during operation.
The current position of the valve is displayed via high-visibility
LEDs and fed back via electrical signals.
3.3 Function
The GEMÜ 4242 combi switchbox controls the pneumatic ac-
tuator via integrated pilot valves and simultaneously indicates
the current position of the valve. Should the valve be opened,
the internally installed pilot valves control the pneumatic actu-
ator accordingly. The spindle in the combi switchbox con-
sequently moves upwards and indicates that the valve is
OPEN using the high visibility LEDs and communication inter-
face. Should the valve be closed, the internally installed pilot
valves control the pneumatic actuator accordingly. The spring
in the mounting kit simultaneously pushes the spindle in the
3 Product description

www.gemu-group.com6 / 51GEMÜ 4242
4 GEMÜ CONEXO
combi switchbox downwards and indicates that the valve is
CLOSED using the high visibility LEDs and communication in-
terface.
3.4 LEDs
As well as the electrical position indicator and error output, a
visual signal of the various operating conditions is emitted by
high-visibility LEDs integrated into the housing. The LEDs are
arranged so that the transparent cover is illuminated all round,
making the condition visible from afar. The following condi-
tions are illustrated here:
Colour of high-visibility LEDs Function
Standard Inversed
Green Orange Process valve in
OPEN position
Orange Green Process valve in
CLOSED position
Flashing green Flashing orange Movement of pro-
cess valve in OPEN
direction
Flashing orange Flashing green Movement of pro-
cess valve in
CLOSED direction
Flashing yellow/white Initialization active
Flashing white Localization active
Flashing orange/red Warning active
Flashing red Error active
Flashing yellow/turquoise Maintenance re-
quired
Flashing blue (briefly) Wireless connec-
tion established
Flashing purple/green Internal update pro-
cess active
Flashing turquoise (briefly) Device start
3.5 Product label
Device version Design in accordance with order data
Item number Traceability number Serial number
Device-specific data
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 display this informa-
tion.
Installing the RFID chip (1)
1
1
1
Size 1, 30 mm Size 2, 75 mm Size 2, 30 mm
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.

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5 Correct use
DANGER
Danger of explosion!
▶Risk of severe injury or death
●Only versions that have been approved
according to their technical data may
be used in potentially explosive envir-
onments.
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 4242 with integrated pilot valve is designed for
pneumatic actuators. The product has a microprocessor-con-
trolled intelligent position sensor as well as an analogue
travel sensor system (potentiometer). It is non-positively con-
nected with the actuator spindle by means of a mounting kit
(spring, operating bush). The valve end positions and the in-
tegrated travel sensor can be controlled via the electrical con-
nections. The pneumatic valve actuator is directly activated
by an integrated 3/2-way pilot valve. The housing cover must
not be removed.
5.1 Product without special function X
The product is not intended for use in potentially explosive
areas.
5.2 Product with special function X
The product with ordering option Special version X is intended
for use in potentially explosive areas of zone 2 with gases,
mists or vapours and zone 22 with combustible dusts in ac-
cordance with EU directive 2014/34/EU (ATEX) and IECEx.
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 T100°C Dc X
The product has been developed in compliance with the fol-
lowing harmonised standards:
- EN IEC 60079-0:2018
- EN IEC 60079-7:2015/A1:2018
- EN 60079-31:2014
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 explosion protection 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.
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, control
function and actuator size must be stated.
Information for AS-Interface 5 versions: If there are customer or system restrictions that prohibit the use of a Bluetooth wireless
interface, it is recommended to use an order variant with a deactivated BLE interface. For versions without a deactivated BLE in-
terface, the option also exists to deactivate the interface independently later.
The versions with fieldbus ASi-5 are (temporarily) only available in the following basic configuration:
Size 1:
Fieldbus AS-Interface 5, 96 slaves, BLE (code A5),
Housing material: Stainless steel base (code 07),
Single acting (code 01),
M12 plug, 5-pin (code 01),
Pneumatic 6mm angled connection (code 04),
Without manual override (code 01).
23 Nl/min flow rate (code 02),
30 mm travel sensor length (code 030),
Without special function (code -) or with ATEX special function (code X)
Size 2:
Fieldbus AS-Interface 5, 96 slaves, BLE (code A5),
Housing material: Stainless steel base (code 07),
Single acting (code 01),
M12 plug, 5-pin, stainless steel (code S1),
Pneumatic 6mm angled connection (code 04),
No code option (code 00),
145 Nl/min flow rate,
30 mm travel sensor length (code 030) or 75 mm (code 075),
Without special function (code -) or with ATEX special function (code X)
6 Order data
www.gemu-group.com8 / 51GEMÜ 4242

Order codes
1 Type Code
Combi switchbox 4242
2 Fieldbus Code
AS-Interface 5, 96 slaves, BLE A5
AS-Interface 5, 96 slaves, BLE deactivated A5D
3 Accessory Code
Accessory Z
4 Housing material Code
Stainless steel base, PC cover 07
Aluminium base, PC cover 14
5 Function Code
Combi switchbox, single acting 01
6 Electrical connection Code
M12 plug, 5-pin 01
M12 plug, 5-pin, stainless steel, size 2 S1
7 Pneumatic connection Code
M5 connection thread for size 1,
G1/8 connection thread for size 2
01
Air supply 4 mm angled connection,
exhaust air 4 mm angled connection
02
Air supply 4 mm T-connection,
exhaust air 4 mm angled connection
03
Air supply 6 mm angled connection,
exhaust air 6 mm angled connection
04
Air supply 6 mm T-connection,
exhaust air 6 mm angled connection
05
M5 connection thread for size 1,
G1/8 connection thread for size 2
(for IP67 or piped air outlet)
E1
Air supply 6 mm angled connection,
exhaust air 6 mm angled connection
(for IP67 or piped air outlet)
E4
Air supply 1/4" angled connection,
exhaust air 1/4" angled connection
U8
8 Option Code
Without 00
Manual override 01
Inversed LED colours 40
Inversed LED colours,
manual override
41
9 Flow rate Code
14 Nl/min, size 1 01
23 Nl/min (Booster), size 1 02
145 Nl/min, size 2 R3
10 Travel sensor version Code
Travel sensor 30 mm in length 030
Travel sensor 75 mm in length 075
11 Special version Code
Without
ATEX (2014/34/EU), IECEx X
6 Order data
www.gemu-group.com 9 / 51 GEMÜ 4242

Order example
Ordering option Code Description
1 Type 4242 Combi switchbox
2 Fieldbus A5 AS-Interface 5, 96 slaves, BLE
3 Accessory Z Accessory
4 Housing material 07 Stainless steel base, PC cover
5 Function 01 Combi switchbox, single acting
6 Electrical connection 01 M12 plug, 5-pin
7 Pneumatic connection 01 M5 connection thread for size 1,
G1/8 connection thread for size 2
8 Option 01 Manual override
9 Flow rate 01 14 Nl/min, size 1
10 Travel sensor version 030 Travel sensor 30 mm in length
11 Special version Without
6 Order data
www.gemu-group.com10 / 51GEMÜ 4242

7 Technical data
7.1 Medium
Working medium: Compressed air and inert gases
Quality classes to DIN ISO 8573-1
Dust content: Class 3, max. particle size 5 μm, max. particle density 5 mg/m³
Pressure dew point: Size 1
Class 3, max. pressure dew point -20 °C
Size 2
Class 4, max. pressure dew point +3 °C
Oil content: Size 1
Class 3, max. oil concentration 1 mg/m³
Size 2
Class 5, max. oil concentration 25 mg/m³
7.2 Temperature
Ambient temperature: 0 — 60 °C
Control medium temper-
ature:
0 — 50 °C
Storage temperature: -10 — 70 °C
7.3 Pressure
Operating pressure: Size 1 Size 2
1 to 10 bar (at 40 °C)
1 to 8 bar (at 60 °C)
2 to 7 bar
Observe the maximum control pressure of the valve actuator.
Flow rate: Size 1 Size 2
Flow rate code 01:
14 Nl/min
Flow rate code 02 (booster):
23 Nl/min
Flow rate code R3:
145 Nl/min
7.4 Product conformity
EMC Directive: 2014/30/EU
Class: B
Group: 1
Technical standards used:
AS-Interface 5
Interference emission: ASi-5 Spec V1.04
Interference resistance: ASi-5 Spec V1.04
Interference emission/
interference resistance
EN 62026-2:2013 + A1:2019
RoHS Directive: 2011/65/EU
GEMÜ 4242www.gemu-group.com 11 / 51
7 Technical data

Radio Equipment Direct-
ive (RED):
2014/53/EU
Technical standards used:
Standard regarding the use
of radio frequencies:
EN 300 328 V2.2.2 (2019-07)
Electromagnetic compatibil-
ity (EMC) for radio devices
and services:
EN 301 489-1 V2.2.3 (2019-11)
EN 301 489-17 V3.2.4 (2020-09)
Electrical safety: EN 61010-1:2010 + A1:2019 + A1:2019/AC:2019
Explosion protection: ATEX (2014/34/EU), order code special version X:
ATEX marking:
Gas: II 3G Ex ec nC IIC T4 Gc X
Dust: II 3D Ex tc IIIC T100°C Dc X
Approvals: AS-Interface certificate no. TBD
7.5 Mechanical data
Installation position: Optional
Weight: Size 1 Size 2
75 mm 30 mm
Housing material code 14
(aluminium base): 320 g
Housing material code 07
(stainless steel base): 600g
Housing material code 07
(stainless steel base): 1150g
Housing material code 07
(stainless steel base): 1080g
Travel sensor: Size 1 Size 2
75 mm 30 mm
Minimum stroke: 2 mm 5 mm 2 mm
Maximum stroke: 40 mm 75 mm 30 mm
* limited to 30 mm by the mounting kit
7.6 Operating conditions
Ambient conditions: Use indoors and outdoors
Dry and wet environments
Height: Up to 2000 m (above sea level)
Relative air humidity: 0–100%
Protection class: IP 65 / IP 67 acc. to EN 60529
IP 67 is achieved by piping away the exhaust air
Degree of contamination: 4 (pollution degree)
7.7 Electrical data
Electrical connection
type:
1 x 5-pin M12 plug (A-coded)
Supply voltage: 26.5 to 31.6 V DC (according to AS-Interface specifications)
www.gemu-group.com12 / 51GEMÜ 4242
7 Technical data

Current consumption: Flow rate (code) AS-Interface
01 Max. 80mA
02 Max. 120mA
R3 Max. 90mA
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: ASi-5: The data in percent refers to the programmed stroke, with reference to the lower end position (0%)
Switch points: Size 1 Size 2
75 mm 30 mm
Default setting switch point CLOSED 12% 12% 12%
Default setting switch point OPEN 75% 75% 75%
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
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8 Dimensions

8.2 Size 2
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
dependent on the valve that is used Travel sensor 75 mm in length
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
dependent on the valve that is used
Travel sensor 30 mm in length
Dimensions in mm
www.gemu-group.com14 / 51GEMÜ 4242
8 Dimensions

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9 Assembly and installation
NOTICE
●Pay attention to the information on product labels and in
product documentation.
●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 electro-static build-up.
4. Protect M12 plugs against damage.
5. Lay cables securely and protect them from damage.
9.1 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
spindle1.
2. Align the indentation of the dis-
tance 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 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 us-
ing 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 Assembly and installation

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9 Assembly and installation
9
6
11
10
Insert the O-ring 11 (if in-
cluded) into the correspond-
ing 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.
9.2 Mounting the combi switchbox on linear actuators
9.2.1 Preparations for assembly to the valve
1. Move the actuator A into zero position (actuator vented).
2. Remove optical position indicator 2 and / or protective cap
1 from the actuator top.
A
12
9.2.2 Threaded adapter assembly (linear actuator)
With some mounting kits, it is necessary to install a threaded
adapter as well. This threaded adapter is enclosed with the re-
quired 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 threaded adapter 3.
3. Screw threaded adapter 3 into the actuator opening as far
as it will go and tighten.
9.2.3 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 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.

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9.2.4 Assembling and installing the combi switchbox (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.
6
M16 x 1 - WAF 24
M12 x 1 - WAF 20
The thread size depends
on the valve to which
the combi switchbox
is mounted.
1. Move the actuator into the OPEN position.
2. Guide the product as far as it will go into the actuator
opening, the adapter 3 (see “Threaded adapter assembly
(linear actuator)“, page16) or the stroke limiter 1 (see “As-
sembling the stroke limiter (linear actuator)“, page16) 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 elec-
trical connections.
5. Connect the product electrically.
6. Connect the product pneumatically.
CAUTION
Incorrect installation of the product.
▶Damage to the housing.
●Only tighten the product using the spanner flats provided
for this purpose.
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.
7. The product with mounting kit is fully assembled.
8. The product with mounting kit and adapter is fully as-
sembled.
9. The product with mounting kit and stroke limiter is fully
assembled.
9 Assembly and installation

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9 Assembly and installation
9.3 Mounting the combi switchbox on quarter turn
actuators
9.3.1 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
9.3.2 Preparations for assembly to 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.
9.3.3 Assembling and installing the combi switchbox (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 product 6 onto the adapter 7.
2. Use the spanner flat 8 (WAF 27) of the travel sensor to
tighten the product.
3. Turn the housing clockwise to align the pneumatic or elec-
trical connections.
4. Connect the product electrically.
5. Connect the product pneumatically.
6. Initialize the product.

10 Pneumatic connection
CAUTION
Reduction of the flow at the vent connection 3
▶Increased overpressure in the upper part of the housing
●Do not operate vent connection 3 with chokes, filters or similar.
●Ensure that vent lines are always depressurised.
●Install vent lines free of tension and kinks.
10.1 Size 1, standard, single acting
EE
M
Connection Designation Connection size
1 Air supply connection M5
2 Working connection for process valve M5
3 Venting connection with integrated check valve M6 x 0.75 1)
E Housing ventilation with integrated check valve M6 x 0.75
M Manual override -
1) only relevant for exhaust air duct and/or increase of protection class
10.2 Size 2, standard, single acting
M
E
Connection Designation Connection size
1 Air supply connection G 1/8
2 Working connection for process valve G 1/8
3 Venting connection with silencer G 1/8 1)
E Housing ventilation with integrated check valve M6 x 0.75
M Manual override -
1) only relevant for exhaust air duct and/or increase of protection class
10.3 Information for use in damp conditions
The following information is intended to help when installing and operating the product in damp conditions.
1. Cables and pipework must be laid so that condensate or rain water that remains on the pipework/cables cannot enter the
screw fittings of the product's M12 plugs.
2. Check that all cable glands of the M12 plugs and the fittings are mechanically secured.
3. In case of doubt, the housing protection class should be increased with an exhaust air duct to areas free from moisture. To
accomplish this, equip the provided venting connection with suitable pneumatic connections to discharge the exhaust air in
a targeted manner via a pneumatic line. Ensure that the ventilation line is always depressurized, that it is not operated with
throttles, filters or similar components, and that it is laid in such a way that moisture cannot flow back.
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10 Pneumatic connection

11 Electrical connection
DANGER
Risk of electric shock
▶Risk of injury or death (if operating voltage is higher than safe extra low voltage).
▶Electric shock can cause severe burns and fatal injury.
●Work on electrical connections only by qualified trained personnel.
●Disconnect the cable from the power supply before making the electrical connection.
●Connect the protective earth conductor.
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 classified 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 disconnect the connection cables when live.
NOTICE
Danger: Electrostatic discharge
▶Destruction of electronic components
●Take the necessary ESD safety precautions during installation of the product.
NOTICE
Risk of cable break
▶Overtightening can result in damage to the internal cables.
●Turn electrical connections once by max. 360°.
1
4
3
2
5
11.1 AS-Interface, fieldbus ordering option, code A5, A5D
1. Connect the product in accordance with the pin assignment.
For electrical connection special version X, we recommend the M12 connectors for EX areas supplied by IFM, series EVCxxA.
The M12 plugs may only be assembled, connected and commissioned by trained personnel. The trained personnel must have
expertise in types of ignition protection, and regulations and provisions for operating media in EX areas.
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.
11.1.1 Pin assignment
1
4
3
Pin Signal name
1 AS-Interface +
2 -
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11 Electrical connection