GEM 4242 User manual

GEMÜ 4242
Combi switchbox with integrated pilot valve
Operating instructions
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
20.12.2021
www.gemu-group.com2 / 46GEMÜ 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 ............................................... 5
3 Product description ............................................. 5
3.1 Construction .................................................. 5
3.2 LED displays .................................................. 6
3.3 Description ..................................................... 7
3.4 Function ......................................................... 7
3.5 Product label ................................................. 7
4 GEMÜ CONEXO .................................................... 7
5 Correct use .......................................................... 7
6 Order data ........................................................... 9
7 Technical data ..................................................... 11
8 Dimensions .......................................................... 14
8.1 Size 1 .............................................................. 14
8.2 Size 2 .............................................................. 14
9 Manufacturer's information .................................. 15
9.1 Delivery .......................................................... 15
9.2 Packaging ...................................................... 15
9.3 Transport ....................................................... 15
9.4 Storage ........................................................... 15
10 Assembly and installation .................................... 15
10.1 Mounting kit assembly .................................. 15
10.2 Mounting the combi switchbox on linear ac-
tuators ............................................................ 16
10.3 Mounting the combi switchbox on quarter
turn actuators ................................................ 18
11 Pneumatic connection ......................................... 19
11.1 Size 1, standard, single acting ...................... 19
11.2 Size 1, standard, double acting .................... 19
11.3 Size 1, compact version ................................ 19
11.4 Size 2, standard, single acting ...................... 19
11.5 Size 2, standard, double acting (only avail-
able for 75 mm version) ................................ 19
12 Electrical connection ........................................... 20
12.1 Electrical connection ..................................... 20
12.2 Potential equalization – special function X
and Y .............................................................. 20
12.3 24 V, ordering option Fieldbus, code 000 .... 20
12.4 IO-Link, ordering option Fieldbus, code IOL . 21
12.5 AS-Interface, ordering option Fieldbus, code
A2, A3, A4 ....................................................... 21
12.6 DeviceNet, ordering option Fieldbus, code
DN ................................................................... 22
13 Commissioning .................................................... 22
14 Specific data - IO-Link ......................................... 25
14.1 Process data .................................................. 25
14.2 Parameter overview ...................................... 26
14.3 Description of parameter values .................. 27
14.4 Events ............................................................ 32
15 Specific data - AS-Interface ................................. 32
15.1 Inputs ............................................................. 32
15.2 Outputs .......................................................... 33
15.3 Switch point parameters ............................... 34
15.4 Error analysis ................................................. 35
16 Specific data - DeviceNet ..................................... 35
16.1 General data .................................................. 35
16.2 Net topology - DeviceNet system ................. 36
16.3 Inputs ............................................................. 36
16.4 Outputs .......................................................... 37
16.5 Parameter overview ...................................... 38
17 Manual override ................................................... 40
18 Troubleshooting .................................................. 40
18.1 LED error message ........................................ 40
18.2 Troubleshooting ............................................ 40
19 Inspection and maintenance ................................ 41
20 Disassembly ........................................................ 42
21 Disposal .............................................................. 42
22 Returns ................................................................ 42
23 Declaration of Incorporation according to
2006/42/EC (Machinery Directive) ....................... 43
24 Declaration of conformity according to 2014/30/
EU (EMC Directive) ............................................... 44
25 Declaration of Conformity in accordance with
2014/34/EU (ATEX) ............................................. 45
GEMÜ 4242www.gemu-group.com 3 / 46

www.gemu-group.com4 / 46GEMÜ 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
The following LED symbols are used in the documentation:
Symbol LED conditions
Off
Lit (on)
Flashing
1.3 Definition of terms
Speed-APfunction
Speed Assembly and Programming, a particularly user-
friendly commissioning function for fast mounting, automated
setting and initialization of GEMÜ products. Dependent on
type, activation uses an external impulse signal or existing
precautions on the device (magnetic or housing switch).
Changeover to normal operating mode takes place automatic-
ally after successful completion.
Working medium
The medium that flows through the GEMÜ product.
Control medium
The medium whose increasing or decreasing pressure causes
the GEMÜ product to be actuated and operated.
Control function
The possible actuation functions of the GEMÜ product.
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 - corrosive materials
Danger - hot surfaces

www.gemu-group.com 5 / 46 GEMÜ 4242
2 Safety information
The safety information in this document refers only to an indi-
vidual product. Potentially dangerous conditions can arise in
combination with other plant components, which need to be
considered on the basis of a risk analysis. The operator is re-
sponsible for the production of the risk analysis and for com-
pliance with the resulting precautionary measures and re-
gional safety regulations.
The document contains fundamental safety information that
must be observed during commissioning, operation and main-
tenance. Non-compliance with these instructions may cause:
•Personal hazard due to electrical, mechanical and chemical
effects.
•Hazard to nearby equipment.
•Failure of important functions.
•Hazard to the environment due to the leakage of dangerous
materials.
The safety information does not take into account:
•Unexpected incidents and events, which may occur during
installation, operation and maintenance.
•Local safety regulations which must be adhered to by the
operator and by any additional installation personnel.
Prior to commissioning:
1. Transport and store the product correctly.
2. Do not paint the bolts and plastic parts of the product.
3. Carry out installation and commissioning using trained
personnel.
4. Provide adequate training for installation and operating
personnel.
5. Ensure that the contents of the document have been fully
understood by the responsible personnel.
6. Define the areas of responsibility.
7. Observe the safety data sheets.
8. Observe the safety regulations for the media used.
During operation:
9. Keep this document available at the place of use.
10. Observe the safety information.
11. Operate the product in accordance with this document.
12. Operate the product in accordance with the specifications.
13. Maintain the product correctly.
14. Do not carry out any maintenance work and repairs not de-
scribed in this document without consulting the manufac-
turer first.
In cases of uncertainty:
15. Consult the nearest GEMÜ sales office.
3 Product description
3.1 Construction
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
Housing cover –
compact version:
PP - -
2 Housing base Anodized
aluminium
or stainless
steel
PPS PPS
3 Electrical connec-
tion
Threaded
piece:
Stainless
steel
(1.4305)
insert: PA
Threaded
piece: PPS
or stainless
steel
(1.4305)
insert: PA
Threaded
piece: PPS
or 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 NBR
3 Product description

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3 Product description
3.2 LED displays
3.2.1 Status LEDs
As well as the electrical position feedback and error analysis,
a visual signal is emitted by LEDs that can be seen from
above as well as a high visibility LED.
24 V / AS-Interface / IO-Link
version
DeviceNet version
LED Colour Function
Standard 1) Inversed 2)
CLOSED Green Orange Process valve
in CLOSED po-
sition
ERROR Red Red Error
OPEN Orange Green Process valve
in OPEN posi-
tion
High visibility
LED
Green Orange Process valve
in CLOSED po-
sition
Orange Green Process valve
in OPEN posi-
tion
Alternating
green/orange
Alternating
green/orange
Programming
mode
Flashes or-
ange
Flashes or-
ange
Error
PWR/FAULT
(24 V version,
code 000)
Green Power on
Red Supply voltage
too low
PWR/FAULT 3)
(ASi version,
code A2, A3,
A4)
Green Communica-
tion active
Red Communica-
tion error/ad-
dress 0
Flashes red Device error
PWR/FAULT
(IO-Link ver-
sion, code
IOL)
Green SIO operation
Flashes green Communica-
tion active
Red Communica-
tion error or
supply voltage
too low
LED Colour Function
Standard 1) Inversed 2)
MNS 4)
(DeviceNet
version, code
DN)
Flashes green Ready for
communica-
tion
Green Communica-
tion active
Flashes red Communica-
tion error
Red Communica-
tion error,
device has
disconnected
independently
from the bus
1) Option
Code 00: Without
Code 01: Manual override
2) Option
Code 40: Inversed LED colours
Code 41: Inversed LED colours, manual override
3) The flash codes of the PWR/FAULT LED are specified according
to AS-Interface and provide feedback about the status of AS-Inter-
face communication.
4) The flash codes of the MNS LEDs are specified according to Devi-
ceNet and give feedback about the status of the DeviceNet com-
munication.
For order codes see chapter "Order data"

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3.2.2 LED conditions
Function CLOSED ERROR OPEN High vis-
ibility
LED
Valve in OPEN posi-
tion
Valve in CLOSED po-
sition
Programming mode
OPEN / CLOSED flash altern-
ately
flashes
altern-
ately
LED conditions
lit (on) ~ irrelevant flashes off
3.3 Description
The GEMÜ 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.
3.4 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
combi switchbox downwards and indicates that the valve is
CLOSED using the high visibility LEDs and communication in-
terface.
3.5 Product label
Device version Design in accordance with order data
Item number Traceability number Serial number
Device-specific data
Year of manufacture
The manufacturing month is coded under the traceability
number and can be requested from GEMÜ. The product was
manufactured in Germany.
4 GEMÜ CONEXO
Order variant
In the corresponding design with CONEXO, this product has
an RFID chip (1) for electronic identification purposes. The po-
sition of the RFID chip can be seen below. The CONEXO pen
helps read out information stored in the RFID chips. The CON-
EXO app or CONEXO portal is required to view this informa-
tion.
Installing the RFID chip (1)
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.
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 or Y
The product is not intended for use in potentially explosive
areas.
5 Correct use

www.gemu-group.com8 / 46GEMÜ 4242
5 Correct use
5.2 Product with special function Y
The product with special function Y is UL/CSA certified and
protected against explosion in accordance with ISA 12.12.01
(see "Technical data").
The product with special function Y can be connected to
switches, power supplies, PLC outputs and PLC inputs.
The energy supply must be equipped with a switch or an over-
current protective device in the system. The switch or overcur-
rent protective device must be placed in a suitable and ac-
cessible position and also labelled as an isolating device for
the product with special function Y.
The product user is responsible for providing connections that
comply with standards, a locking mechanism, cable compat-
ibility and warning signs.
Suitable locking clips must be used to secure the circular con-
nectors against becoming unintentionally loose or being
loosened without the use of tools.
Installation, operation and maintenance must only be carried
out by qualified trained personnel.
Do not repair the device yourself if it is faulty. Instead, replace
it with an equivalent new device. Repairs must only be carried
out by the manufacturer!
The device must only be used if its materials are resistant
against mechanical and/or chemical influences or corrosion
under the respective operating conditions to such a sufficient
degree that the explosion protection is not impaired or nulli-
fied.
5.3 Product with special function X
The product with 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 T 80 °C Dc X
IECEx
Gas: Ex ec nC IIC T4 Gc
Dust: Ex tc IIIC T80°C Dc
Certificate: IECEx IBE 19.0011 X
The product has been developed in compliance with the fol-
lowing harmonised standards:
•IEC 60079-0: 2011 (EN 60079-0:2012+A11:2013)
•IEC 60079-15: 2010 (EN 60079-15:2010)
•IEC 60079-31: 2013 (EN 60079-31:2014)
•IEC 60079-7: 2017 (EN 60079-7+A1:2015)
Use of the product is permissible in the following ambient
temperature ranges: 0°C to +40°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.

6 Order data
The order data provide an overview of standard configurations.
Please check the availability before ordering. Other configurations available on request.
Note: A valve specific mounting kit is required for assembly. For designing the mounting kit, the valve type, nominal size, control
function and actuator size must be stated.
Order codes
1 Type Code
Combi switchbox 4242
2 Fieldbus Code
Without, 24 V DC version 000
AS-Interface, 31 slaves, 4I/4O A2
AS-Interface, 62 slaves, 4I/3O A3
AS-Interface, 62 slaves, 8I/8O A4
DeviceNet DN
IO-Link IOL
3 Accessory Code
Accessory Z
4 Housing material Code
Stainless steel base, PC cover 07
Aluminium base, PC cover 14
PPS base, PC cover 01
5 Function Code
Combi switchbox, single acting 01
Combi switchbox, double acting 02
Combi switchbox, compact version,
single acting
K1
6 Electrical connection Code
M12 plug, 5-pin 01
M12 plug, 8-pin 02
M12 plug, 5-pin, stainless steel, size 2 S1
M12 plug, 8-pin, stainless steel, size 2 S2
7 Pneumatic connection Code
Connection thread M5 for size 1,
connection thread G1/8 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
Connection thread M5 for size 1,
connection thread G1/8 for size 2
(for IP67 or piped air outlet)
E1
7 Pneumatic connection Code
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
Inversed LED colours
deactivated high visibility position feedback
80
9 Flow rate Code
14 Nl/min, size 1 01
23 Nl/min (Booster), size 1 02
250 Nl/min, size 2 03
10 Travel sensor version Code
Potentiometer 30 mm length, size 1 and 2 030
Potentiometer 75 mm length, size 2 075
11 Special version Code
Without
ATEX (2014/34/EU), IECEx X
NEC 500 and UL/CSA approval Y
6 Order data
www.gemu-group.com 9 / 46 GEMÜ 4242

Order example
Ordering option Code Description
1 Type 4242 Combi switchbox
2 Fieldbus 000 Without, 24 V DC version
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 Connection thread M5 for size 1,
connection thread G1/8 for size 2
8 Option 01 Manual override
9 Flow rate 01 14 Nl/min, size 1
10 Travel sensor version 030 Potentiometer 30 mm length, size 1
11 Special version Without
6 Order data
www.gemu-group.com10 / 46GEMÜ 4242

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
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: Standard or with special version code Y 0–60 °C
Special version code X 0–50 °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
14 Nl/min
23 Nl/min
250 Nl/min
7.4 Product conformities
EMC Directive: 2014/30/EU
Technical standards used:
24 V
Interference emission EN 61000-6-3
Interference resistance EN 61000-6-2
IO-Link
Interference emission EN 61000-6-3
Interference resistance EN 61000-6-2
AS-Interface
Interference emission acc. to AS-Interface Spec. 3.0
Interference resistance acc. to AS-Interface Spec. 3.0
DeviceNet
Interference emission EN 61000-6-3
Interference resistance EN 61000-6-2
GEMÜ 4242www.gemu-group.com 11 / 46
7 Technical data

Explosion protection: ATEX (2014/34/EU) and IECEx, order code Special version X
NEC 500 (ISA 12.12.01), order code for special version Y
EAC according to TR CU 012/211 - ATEX
ATEX marking: Gas: II 3G Ex ec nC IIC T4 Gc X
Dust: II 3D Ex tc IIIC T 80 °C Dc X
IECEx marking: Gas: Ex ec nC IIC T4 Gc
Dust: Ex tc IIIC T80°C Dc
Certificate: IECEx IBE 19.0011 X
NEC marking: Class I, Division II, Groups C & D, T4
Approvals: 24 V AS-Interface IO-Link DeviceNet
Fieldbus/
Communication
- Travel sensor ver-
sion 030: AS-Inter-
face certificate
No. 96001
Travel sensor ver-
sion 075: AS-Inter-
face certificate
No. 125601
Travel sensor ver-
sion 030: IO-Link
specification V
1.1
Travel sensor ver-
sion 075: IO-Link
specification V
1.1
n.n.
SIL: Product description: GEMÜ electrical position indicator 4242
Device type: B
Valid software version: V1.1.X.X
Safety function: The fail-safe state is defined as a High (24 V DC) signal
at pin4 (device version 24 V IO-Link), if the current posi-
tion of the integrated travel sensor is smaller than the
switch point CLOSED (default setting 12%).
HFT (Hardware Fault Tolerance): 0
MTTR (Mean Time To Restoration): 24 hours
MTBF (Mean Time Between Failures): 232 years
Further information, see SIL safety manual
7.5 Mechanical data
Installation position: Optional
Weight: Size 1 Size 2
75 mm 30 mm
Aluminium: 320 g
Stainless steel: 600g
420 g 350 g
Protection class: IP 65
IP 67 is achieved by piping away the exhausting air
IP NEMA 4X (UL 61010-1, UL 50E), only available as special version code Y
Travel sensor: Size 1 Size 2
75 mm 30 mm
Minimum stroke: 2 mm 5 mm 2 mm
Maximum stroke: 30 mm 75 mm 30 mm
Hysteresis: 0.2 mm 0.5 mm 0.2 mm
Accuracy: 0.2% Full Scale
www.gemu-group.com12 / 46GEMÜ 4242
7 Technical data

7.6 Electrical data
Electrical connection
type:
24 V IO-Link / AS-Interface /
DeviceNet
1 x 8-pin M12
plug
(A-coded)
1 x 5-pin M12
plug
(A-coded)
Supply voltage: 24 V DC (18 to 30 V DC) (according to IO-Link specifications)
26.5 to 31.6 V DC (according to AS-Interface specifications)
11 to 25 V DC (according to DeviceNet specifications)
Current consumption: Flow rate code 24 V IO-Link AS-Interface DeviceNet
01 typically 80 mA typically 80 mA typically 100 mA typically 65 mA
02 typically 120 mA typically 120 mA typically 150 mA typically 100 mA
03 typically 100 mA typically 100 mA typically 120 mA typically 85 mA
Duty cycle: Continuous duty
Electrical protection
class:
III
Reverse battery protec-
tion:
yes
Line fuse: 630 mA medium time lag, for order code Fieldbus 000
Switching characteristic:
100%
0%
td1 td1
td1 td2
td1
ta
t/ms
t/ms
t/ms
Stroke %
Switch point "Open"
Switching hysteresis
Switching hysteresis
Switching output "Open"
Switch point "Closed"
active
inactive
active
inactive
Switching output "Closed"
td1: Signal delay
td2: Signal delay
ta: Signal interval
Switch points: The data in percent refer to the programmed stroke, before each end position
Switch points: Size 1 Size 2
75 mm 30 mm
Default setting switch point CLOSED 12% 12% 12%
Default setting switch point OPEN 25% 25% 25%
Min. switch point CLOSED 0.8 mm 2 mm 0.8 mm
Min. switch point OPEN 0.5 mm 1.25 mm 0.5 mm
If the percentage switch points dependent on the programmed stroke are smaller than the permiss-
ible min. switch points, the min. switch points apply automatically.
GEMÜ 4242www.gemu-group.com 13 / 46
7 Technical data

8 Dimensions
8.1 Size 1
Only 30 mm potentiometer length available
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
X
□42
95
20
13,6
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
dependent on valve used
Standard Compact
Dimensions in mm
8.2 Size 2
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
dependent on valve used
Potentiometer, 75 mm length
WAF 20 for mounting kit M12x1,
x = 9 mm
WAF 24 for mounting kit M16x1,
x = 11 mm
dependent on valve used Potentiometer, 30 mm length
Dimensions in mm
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8 Dimensions

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9 Manufacturer's information
9.1 Delivery
●Check that all parts are present and check for any damage
immediately upon receipt.
The product's performance is tested at the factory. The scope
of delivery is apparent from the dispatch documents and the
design from the order number.
9.2 Packaging
The product is packaged in a cardboard box which can be re-
cycled as paper.
9.3 Transport
1. Only transport the product by suitable means. Do not drop.
Handle carefully.
2. After the installation dispose of transport packaging ma-
terial according to relevant local or national disposal regu-
lations / environmental protection laws.
9.4 Storage
1. Store the product free from dust and moisture in its ori-
ginal packaging.
2. Avoid UV rays and direct sunlight.
3. Do not exceed the maximum storage temperature (see
chapter "Technical data").
4. Do not store solvents, chemicals, acids, fuels or similar
fluids in the same room as GEMÜ products and their spare
parts.
10 Assembly and installation
NOTICE
●Pay attention to the information on product labels, in
product documentation and EC type examination certific-
ate.
●Connect cable carefully, do not damage individual wires.
●When connecting multiwire or finewire cables, prepare
the wire ends.
●Always use suitable pinch tools for pinching wire end fer-
rules in order to achieve consistent quality.
●Tighten all clamping points, even the ones not being
used.
1. Observe the national regulations and provisions.
2. Observe the installer provisions.
3. Protect M12 plugs against electrostatic build-up.
4. Protect M12 plugs against damage.
5. Lay cables securely and protect them from damage.
6. Differential voltage for two intrinsically safe electric cir-
cuits: maximum 30 V.
7. Connect open wire ends in a junction box with protection
class IP20 and higher or outside the EX area.
10.1 Mounting kit assembly
Item Name Item Name
1 Spindle 7 Flange plate
2 Spring 8 Screws
3 Operating bush 9 Pressure disc*
4 Distance piece 10 O-ring*
5 O-ring 11 O-ring*
6 Adapter
* Included depending on version.
CAUTION
Pretensioned spring!
▶Damage to the device.
●Slowly release the tension in the spring.
CAUTION
Do not scratch the spindle!
▶A damaged spindle surface may cause failure of the
travel sensor.
1
4
1
2
3
1. Pull out the spindle
1.
2. Align the indentation of the distance
piece 4 to the spring and push it over
the spindle 1 using the spring 2 and fix
it in place using the operating bush 3.
5
6
10 Assembly and installation

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

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10.2.3 Assembling the stroke limiter (linear actuator)
5
5
4
3
2
1
6
8
9
7.1
7.2
Option1 Option2
1. Screw distance piece 5 onto/
into actuator spindle 6.
2. Move the actuator to the
closed position.
3. Insert the O-ring 7.1 in the
stroke limiter 1.
4. Insert the O-ring 7.2 in the
washer 4.
5. Screw stroke limiter 1 with
nut 2, seal 3 and washer 4
into the actuator opening.
6. Set stroke limiter 1 to the re-
quired stroke.
7. Make sure that the minimum
stroke is reached.
8. Secure stroke limiter 1 with
nut 2.
Key
1 Stroke limiter 7.1 1)
7.2 1)
O-ring
2 Nut 8 Protective cap
3 1) Seal 9 Position indicator
4 1) Washer 10 Operating bush
5 2) Distance piece 11 Spindle
6 Actuator spindle 12 Travel sensor
1) Only available for valves with the NO and DA control functions.
2) Only included in required mounting kits. The design depends on
the valve.
10.2.4 Assembling and installing the 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 “Assembling the adapter (lin-
ear actuator)“, page16) or the stroke limiter 1 (see “As-
sembling the stroke limiter (linear actuator)“, page17)
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 (see “Electrical connec-
tion“, page20).
6. Connect the product pneumatically (see “Pneumatic con-
nection“, page19).
7. Initialize the product (see “Commissioning“, page22).
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

www.gemu-group.com18 / 46GEMÜ 4242
10 Assembly and installation
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.
8. The product with mounting kit is fully assembled.
9. The product with mounting kit and adapter is fully as-
sembled.
10. The product with mounting kit and stroke limiter is fully
assembled.
10.3 Mounting the combi switchbox on quarter turn
actuators
10.3.1 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
10.3.2 Preparations for installation of the valve (quarter turn
actuator)
1. Move the actuator A into zero position (actuator vented).
1
2
A
2. Remove the screw 1 from the trigger cam 2.
10.3.3 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 (see “Electrical connec-
tion“, page20).
5. Connect the product pneumatically (see “Pneumatic con-
nection“, page19).
6. Initialize the product (see “Commissioning“, page22).

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11 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.
11.1 Size 1, standard, single acting
EE
Connec-
tion
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 1)
1) only relevant for exhaust air duct and/or increase of protection
class
11.2 Size 1, standard, double acting
E
Connec-
tion
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)
4 Working connection for process
valve
M5
E Housing ventilation with integrated
check valve
M6 x 0.75 1)
1) only relevant for exhaust air duct and/or increase of protection
class
11.3 Size 1, compact version
E1
Connec-
tion
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)
E1 Housing ventilation with integrated
check valve
M6 x 0.75 1)
1) only relevant for exhaust air duct and/or increase of protection
class
11.4 Size 2, standard, single acting
Connec-
tion
Designation Connection
size
1 Air supply connection G 1/8
2 Working connection for process
valve
G 1/8
3 Venting connection with silencer (in-
tegrated housing ventilation)
G 1/8 1)
1) only relevant for exhaust air duct and/or increase of protection
class
11.5 Size 2, standard, double acting (only available for
75 mm version)
Connec-
tion
Designation Connection
size
1 Air supply connection G 1/8
2 Working connection for process
valve
G 1/8
3 Venting connection with silencer (in-
tegrated housing ventilation)
G 1/8 1)
11 Pneumatic connection

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12 Electrical connection
Connec-
tion
Designation Connection
size
4 Working connection for process
valve
G 1/8
1) only relevant for exhaust air duct and/or increase of protection
class
11.6 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 fit-
tings are mechanically secured.
12 Electrical connection
NOTICE
Risk: Electrostatic discharge
▶Destruction of electronic components
●When mounting the potentiometer, take the necessary
ESD safety precautions.
DANGER
Danger of explosion
▶Risk of severe injury or death.
●Do not connect or disconnect the
device until the power has been
switched off or the area has been clas-
sified as non-hazardous.
●The standard version of the product
(without special function X or Y) must
not be used in potentially explosive
zones.
●Danger from sparking. Never discon-
nect the connection cables when live.
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
12.1 Electrical connection
1. Connect the product in accordance with the pin assign-
ment.
For electrical connection, we recommend the M12 connectors
for EX areas from IFM, series EVCxxA.
The M12 plugs may only be assembled, connected and com-
missioned by trained personnel. The trained personnel must
have expertise in types of ignition protection, and regulations
and provisions for operating media in EX areas.
2. Securely lay the connection cables or ensure sufficient
tension relief.
3. Refer to the technical data and cable gland documentation
for details of the wire cross sections.
4. Protect the product and the cables from damage.
5. Only clean the product with an anti-static or damp cloth.
6. Only operate the product when it is fully assembled.
12.2 Potential equalization – special function X and Y
Connecting the potential equalization device
1. Use a screw M4x6 to attach the potential equalization
device to the electrical position indicator.
ðPotential equalization for metal housings in potentially
explosive areas: Minimum 4 mm².
2. Secure the connection against working itself loose.
12.3 24 V, ordering option Fieldbus, code 000
12.3.1 Pin assignment
6
5
3
2
47
8
1
Pin Signal name
1 U, 24 V DC, supply voltage
2 24 V DC, Open end position output
3 U, GND
4 24 V DC, Closed end position output
5 24 V DC, programming input
6 24 V DC, control input
7 24 V DC, error output
8 n.c.
Pin 5 and pin 6 are highly active. If not used, connect to GND
or leave open.
The following errors are indicated via pin 7 (error output):
Sensor error, pneumatic error, programming error, internal er-
ror
12.3.2 Inputs (pin 5, 6)
Input impedance