Gem Lsc User manual

GEMÜ LSC

Limit switch box for quarter turn actuators

Operating instructions

further information

webcode: GW-LSC

All rights including copyrights or industrial property rights are expressly reserved.

Keep the document for future reference.

16.04.2020

www.gemu-group.com2 / 28GEMÜ LSC

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 Correct use ............................................................... 7

5 Order data ................................................................. 8

6 Technical data .......................................................... 9

7 Dimensions ............................................................... 11

8 Manufacturer's information ....................................... 12

8.1 Delivery ................................................................ 12

8.2 Packaging ............................................................ 12

8.3 Transport ............................................................. 12

8.4 Storage ................................................................. 12

9 Assembly and installation ......................................... 12

10 Electrical connection ................................................. 14

11 Troubleshooting ........................................................ 16

12 Inspection and maintenance ...................................... 16

13 Disassembly .............................................................. 16

14 Disposal .................................................................... 16

15 Returns ..................................................................... 16

16 Declaration of conformity according to 2006/42/EC

(Machinery Directive) ................................................ 17

17 Declaration of conformity according to 2014/30/EU

(EMC Directive) ......................................................... 18

18 EU Declaration of conformity according to 2014/34/

EU (ATEX) ................................................................. 19

19 Operating instructions for ATEX position indicators .. 20

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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

The following LED symbols are used in the documentation:

Symbol LED conditions

Off

Lit (on)

Flashing

1.3 Warning notes

Wherever possible, warning notes are organised according to the following scheme:

SIGNAL WORD

Type and source of the danger

Possible

symbol for the

specific

danger

Possible consequences of non-observance.

Measures for avoiding danger.

Warning notes are always marked with a signal word and sometimes also with a symbol for the specific danger.

The following signal words and danger levels are used:

DANGER

Imminent danger!

▶Non-observance can cause death or severe injury.

WARNING

Potentially dangerous situation!

▶Non-observance can cause death or severe injury.

CAUTION

Potentially dangerous situation!

▶Non-observance can cause moderate to light injury.

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NOTICE

Potentially dangerous situation!

▶Non-observance can cause damage to property.

The following symbols for the specific dangers can be used within a warning note:

Symbol Meaning

Danger of explosion

2 Safety information

The safety information in this document refers only to an individual product. Potentially dangerous conditions can arise in com-

bination with other plant components, which need to be considered on the basis of a risk analysis. The operator is responsible

for the production of the risk analysis and for compliance with the resulting precautionary measures and regional safety regula-

tions.

The document contains fundamental safety information that must be observed during commissioning, operation and mainten-

ance. Non-compliance with these instructions may cause:

– Personal hazard due to electrical, mechanical and chemical effects.

– Hazard to nearby equipment.

– Failure of important functions.

– Hazard to the environment due to the leakage of dangerous 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

3.1 Construction

Item Name Materials

1 Housing cover PC or Vestamid (ATEX version)

2 Housing base PA 6 or Vestamid (ATEX version)

3 Fastening elements Stainless steel

Mounting kit PA 6 or stainless steel

Seals EPDM, NBR

Item Name Materials

1 Housing cover Aluminium or Vestamid (ATEX version)

2 Housing base Aluminium

3 Fastening elements Stainless steel

Mounting kit Stainless steel

Seals EPDM, NBR

3.2 Description

The GEMÜ LSC limit switch box is suitable for installation on manually and pneumatically operated quarter turn valves. It is also

fitted with an optical position indication for visual confirmation of position.

3.3 Function

Limit switch boxes are used to feed back and verify the position of valves, whether manual or pneumatically actuated quarter

turn actuators. Depending on the version, the limit switch box GEMÜ LSC is equipped with 1 to 4 sensors or microswitches. The

shaft of the limit switch box is positively connected to the shaft of the quarter turn actuator and is turned with the rotary move-

ment of the quarter turn actuator. The trip cams fastened to the shaft then actuate the integrated sensors, which are used for

electronic signal transmission.

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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 manufac-

tured in Germany.

4 Correct use

DANGER

Danger of explosion

▶Danger of death or severe injury.

●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 this docu-

ment.

The GEMÜ LSC product is suitable for use in non-explosive as well as explosive atmospheres. The permissible ambient temper-

ature is between -20 °C and +80 °C. When using suitable components, use at an ambient temperature as low as -40 °C can also

be permitted. Various sensors and microswitches can be installed in the various limit switch boxes made of aluminium, polyam-

ide or polycarbonate. The electrical data varies depending on the switch type.

4.1 Product without special function X

The product is not intended for use in potentially explosive areas.

4.2 Product with special function X

The product GEMÜ LSC is intended for use in potentially explosive areas of zones 1 and 2 with gases, mists or vapours and

zones 21 and 22 with combustible dusts in accordance with EU directive 2014/34/EU (ATEX).

The product has the following explosion protection marking:

Gas: II 2G Ex ia IIC / IIB T6 / T4 Gb

Dust: II 2D Ex ia IIIC T80°C / T110°C Db

For the operation of ATEX position indicators, please refer to chapter 18 "Operating instructions for ATEX position indicators".

4 Correct use

5 Order data

The order data provide an overview of standard configurations.

Please check the availability before ordering. Other configurations available on request.

Order codes

1 Type Code

Limit switch box for quarter turn valves LSC

2 Switch Code

Change-over contact, microswitch, 12-250V AC/DC

Cherry, D44X-SPDT

105

Change-over contact, microswitch, 12-250V AC/DC

Cherry, D44X-DPDT

109

Proximity switch, 2-wire, NAMUR, ATEX ia

IFM, NS5002

205

Proximity switch, 2-wire, break contact/make

contact, PNP/NPN, 5–36VDC

IFM, IS5026

207

Proximity switch, 2-wire, NAMUR, ATEX ia

P+F, SJ 3.5 N

208

Proximity switch, 3-wire, make contact, PNP,

10-30VDC

IFM, IS5001

305

Proximity switch, 3-wire, make contact, NPN,

10-36VDC

IFM, IS5003

320

3 Accessories Code

Accessories Z

4 Housing/mounting kit material Code

Plastic housing

Plastic mounting kit

Plastic housing

Stainless steel mounting kit

Aluminium housing

Stainless steel mounting kit

Plastic housing

for manually operated valves

5 Electrical connection Code

M20 cable gland 3101

Solenoid valve connection for 1 coil 31MA

6 Option Code

Without 00

3D display 3D

Large 3D display 4D

7 SIL Code

SIL 1–3 (IEC 61508:2010) S

8 Approval Code

ATEX, IEC X

Order example

Order option Code Description

1 Type LSC Limit switch box for quarter turn valves

2 Switch 105 Change-over contact, microswitch, 12-250V AC/DC

Cherry, D44X-SPDT

3 Accessories Z Accessories

4 Housing/mounting kit material KK Plastic housing

Plastic mounting kit

5 Electrical connection 3101 M20 cable gland

6 Option 00 Without

7 SIL S SIL 1–3 (IEC 61508:2010)

5 Order data

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6 Technical data

6.1 Temperature

Ambient temperature: Housing material

Plastic/aluminium Vestamid

-25 to 80 °C -25 to 70 °C

Storage temperature: Housing material

Plastic/aluminium Vestamid

-25 to 80 °C -25 to 70 °C

6.2 Product conformities

EMC Directive: 2014/30/EU

Explosion protection: ATEX (2014/34/EU)

ATEX marking: Gas: II 2G Ex ia IIC / IIB T6 / T4 Gb

Dust: II 2D Ex ia IIIC T80°C / T110°C Db

IECEx marking: Gas: II 2G Ex ia IIC / IIB T6 / T4 Gb

Dust: II 2D Ex ia IIIC T80°C / T110°C Db

Certificate: IECEx IBE 13.0042

Notified body: IBExU, No. 0637

SIL: SIL 1–3 (IEC 61508:2010)

6.3 Mechanical data

Installation position: Optional

Protection class: IP 67

Switching range: 0° to 90°

6 Technical data

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6 Technical data

6.4 Electrical data

Electrical connection

type:

M20 x 1.5 cable gland for cables with a diameter of 6 to 12 mm (code 3101)

M20 x 1.5 cable gland for cables with a diameter of 6 to 12 mm and solenoid valve connection

(code 31MA)

6.4.1 Microswitch

Switch type: Code 105 Code 109

SPDT DPDT

Supply voltage: Code 105 Code 109

24 V DC, 250 V AC 24 V DC, 250 V AC

Current consumption: Code 105 Code 109

24 V DC: 2.5 A

250 V DC: 10 A

24 V DC: 2.5 A

250 V DC: 10 A

6.4.2 2-wire proximity switch

Switch type: Code 205 Code 207 Code 208

2-wire NAMUR 2-wire, make contact 2-wire NAMUR

Supply voltage: Code 205 Code 207 Code 208

8 V DC 5–36 V DC 8 V DC

Current consumption: Code 205 Code 207 Code 208

1–2.1 mA Max. 200 mA 1–3 mA

6.4.3 3-wire proximity switch

Switch type: Code 305 Code 320

3-wire, make contact, PNP 3-wire, make contact, NPN

Supply voltage: Code 305 Code 320

10 - 30 V DC 10 - 36 V DC

Current consumption: Code 305 Code 320

Max. 200 mA Max. 200 mA

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7 Dimensions

Housing/mounting kit material (code KK)

[30]

130

[39]

124

Housing/mounting kit material (code KE, AE)

[55]

[65]

[75]

124

130

[30]

[40]

[50]

40,5

60,5

30,5

"Option" order option, code 3D "Option" order option, code 4D

Dimensions in mm

Various borehole patterns are available for installation on the pneumatic quarter turn actuators:

Borehole pattern Housing/mounting kit material

(code KK)

Housing/mounting kit material

(code KE, AE)

80 x 30 x 20 X X

80 x 30 x 30 X X

130 x 30 x 30 X X

130 x 30 x 50 - X

An additional separate mounting kit must be ordered for installation on manually operated valves. For more information, see ac-

cessories.

7 Dimensions

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8 Manufacturer's information

8.1 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.

8.2 Packaging

The product is packed in a cardboard box which can be recycled as paper.

8.3 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 / en-

vironmental protection laws.

8.4 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.

9 Assembly and installation

9.1 Installation on manually operated valves

The products with F05 connection in the bottom of the housing can also be installed with our mounting kit "LSC S01 Z" on

manually operated valves. It is important that the manual valve has a top flange in accordance with ISO 5211 and a thread bolt

hole in the shaft.

Install the mounting kit as follows:

1. Assemble the base of the mounting kit on the manual valve.

2. Mount the lock nut supplied with the product on the actuator.

3. Screw the actuator into the central threaded hole of the manual valve.

4. Position the upper section of the mounting kit on the previously assembled base.

ðThe bolt holes allow a rough height alignment to the valve used. The mounting bracket can be set to the following

heights:

– F03-F07: 60, 70, 80, 90, 100 mm

– F10-F12: 80, 90, 100, 110, 120 mm

5. Fasten the cover to the base.

ðUse the enclosed bolts and perforated washers for this.

6. Assemble the limit switch box on the cover.

7. Adjust the height of the actuator so that the shaft of the limit switch box engages in the actuator.

8. Fix in position with the lock nut.

9. Carry out a visual inspection of the complete subassembly and a functional test of the position feedback.

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9.2 Installation on pneumatic actuators

9.2.1 Preparations for installation of the actuator

1. Unscrew the bolt from the trigger cam.

2. Pull off the trigger cam.

9.2.2 Installation of the limit switch box

The modules can be mounted quickly and easily on the intended actuator using the supplied fastening fixtures in accordance

with VDI/VDE 3845.

1. Place the actuator in the end position in which the groove of the actuator shaft is parallel to the actuator housing.

2. Place the box on the actuator using the appropriate mounting kit.

3. Mount the mounting kit with the supplied locking screws (x4) on the actuator.

4. Loosen the cover screws (x4) and open the housing.

ðDo not unscrew the bolts too far; leave them connected to the cover.

5. Guide the disconnected system cable through the cable gland into the housing and connect the wires to the terminal block.

ðObserve the wiring diagram on the corresponding datasheet or in the housing cover and connect the housing to the po-

tential equalisation.

6. Close off the housing with the cover.

ðWhen fitting the cover, make sure that the gasket is in the correct position.

7. Tighten the cover screws.

9.3 Adjusting the switch/travel range

The actuators are set by GEMÜ to a travel range of 0-90°. If another travel range is required for the application, please follow the

following steps:

1. Place the actuator in the desired end position 1 and adjust the lower actuator.

ðPress down the actuator on the outer ring and turn into the position in which the switch is actuated.

2. Allow the actuator to engage in the teeth above.

3. Place the actuator in the desired end position 2 and adjust the upper actuator.

ðPress down the actuator on the outer ring and turn into the position in which the switch is actuated.

4. Allow the actuator to engage in the teeth above.

5. Check the presetting by repeatedly switching the quarter turn actuator.

9 Assembly and installation

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10 Electrical connection

10.1 Microswitch, switch ordering option, code 105

23 4

1567 8 9 10 11 12

Coil Coil

Optional

10.2 Microswitch, switch ordering option, code 109

23 4

1567 8 9 10 11 12

Bottom

switch

Top

switch

10.3 2-wire proximity switch, NAMUR, PNP, switch ordering option, code 205

123 4 7 8 9 10 11 12

Bottom

switch

Top

switch Optional

Coil Coil

10.4 2-wire proximity switch, make contact, PNP, switch ordering option, code 207

123456123456

89 10 11 12

7 8 9 10 11 12

Bottom

switch Top

switch Bottom

switch Top

switch

Optional Optional

Coil Coil Coil Coil

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10.5 2-wire proximity switch, NAMUR, PNP, switch ordering option, code 208

123 4 7 8 9 10 11 12

Coil Coil

Optional

10.6 3-wire proximity switch, make contact, PNP, switch ordering option, code 305

124

35 6

7 8 9 10 11 12

Bottom

switch

Top

switch

Coil Coil

10.7 3-wire proximity switch, make contact, NPN, switch ordering option, code 320

124

35 6

7 8 9 10 11 12

Bottom

switch Top

switch Optional

Coil Coil

10 Electrical connection

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11 Troubleshooting

In case of faults, check the cables, cable connections and cam position. Check whether condensation water has collected in the

housing and whether the valve/quarter turn actuator is functioning correctly. If the fault is not remedied by this, disconnect the

housing from the supply voltage and contact authorized and trained personnel from the manufacturer.

12 Inspection and maintenance

CAUTION

Use of incorrect spare parts!

▶Damage to the product.

▶Manufacturer liability and guarantee will be void.

●Only use genuine parts.

NOTICE

Unauthorized maintenance work!

▶Damage to the product.

●Any maintenance work and repairs not described in these operating instructions must not be performed without consulting

the manufacturer first.

13 Disassembly

1. Disassemble in reverse order to assembly.

2. Unscrew the electrical wiring.

3. Disassemble the product. Observe warning notes and safety information.

14 Disposal

1. Pay attention to adhered residual material and gas diffusion from penetrated media.

2. Dispose of all parts in accordance with the disposal regulations/environmental protection laws.

15 Returns

Legal regulations for the protection of the environment and personnel require that the completed and signed return delivery note

is included with the dispatch documents. Returned goods can be processed only when this note is completed. If no return deliv-

ery note is included with the product, GEMÜ cannot process credits or repair work but will dispose of the goods at the operator's

expense.

1. Clean the product.

2. Request a return delivery note from GEMÜ.

3. Complete the return delivery note.

4. Send the product with a completed return delivery note to GEMÜ.

16 Declaration of conformity according to 2006/42/EC (Machinery Directive)

Declaration of Incorporation

according to the EC Machinery Directive 2006/42/EC, Annex II, 1.B for partly

completed machinery

We,

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG

Fritz-Müller-Straße 6-8

74653 Ingelfingen-Criesbach, Germany

declare that the following product

Make: GEMÜ

Commercial name: GEMÜ LSC

meets the Essential Safety and Health Requirements of the Machinery Directive 2006/42/EC.

We also declare that the specific technical documentation has been compiled in accordance with part B of Annex VII.

The manufacturer or his authorised representative undertake to transmit, in response to a reasoned request by the national au-

thorities, relevant information on the partly completed machinery. This transmission takes place:

Electronically

Authorised documentation officer

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG

Fritz-Müller-Straße 6-8

74653 Ingelfingen, Germany

This does not affect the industrial property rights!

Important note! The partly completed machinery may be put into service only if it was determined, where appropriate, that the

machinery into which the partly completed machinery is to be installed meets the provisions of this Directive.

Compliance with the following directives which also apply to the product is declared:

– EMC Directive 2014/30/EU

– Low Voltage Directive 2014/35/EU

Harmonized standards used:

DIN EN ISO 12100

Safety of machinery – General principles for design

- Risk assessment and risk reduction ISO 12100:2010

- German version EN ISO 12100:2010

Ingelfingen-Criesbach 2019-09-09

Joachim Brien

Head of Technical Department

GEMÜ LSCwww.gemu-group.com 17 / 28

16 Declaration of conformity according to 2006/42/EC (Machinery Directive)

17 Declaration of conformity according to 2014/30/EU (EMC Directive)

EU Declaration of Conformity

according to 2014/30/EU (EMC Directive)

We,

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG

Fritz-Müller-Straße 6-8

74653 Ingelfingen-Criesbach, Germany

declare that the product listed below complies with the safety requirements of the EMC Directive 2014/30/EU.

Description of the product: Electrical position indicator GEMÜ LSC

Ingelfingen-Criesbach 2019-09-09

Joachim Brien

Head of Technical Department

www.gemu-group.com

18 / 28

GEMÜ LSC

17 Declaration of conformity according to 2014/30/EU (EMC Directive)

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18 EU Declaration of conformity according to 2014/34/EU (ATEX)

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19 Operating instructions for ATEX position indicators

BA_X001

Operating instructions

Product group:

Limit switch box wave

Product type:

EV...-IA / EA...-IA

Certifications:

EVP-IA

EVE-IA

EAE-IA

Table of Contents

1. Device description .........................................................................................................................................................................2

2. Intended use ..................................................................................................................................................................................2

3. Labeling..........................................................................................................................................................................................2

4. Safe activation................................................................................................................................................................................3

5. Assembly on actuators..................................................................................................................................................................3

6. Mounting on manual valves...........................................................................................................................................................3

7. Electrical connection.....................................................................................................................................................................3

8. Disassembly...................................................................................................................................................................................4

9. Adjusting the swivel range ............................................................................................................................................................4

10. Connecting magnetic coils ..........................................................................................................................................................5

11. Outdoor use..................................................................................................................................................................................5

12. Maintenance.................................................................................................................................................................................5

13. Malfunctions ................................................................................................................................................................................5

14. Item number ................................................................................................................................................................................6