Gemu GEMU 1242 User manual

GEMÜ 1242
DeviceNet
Electrical position indicator
Operating instructions
EN
40099514009951
further information
webcode: GW-1242

All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
12.04.2019
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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 .................................................... 6
3 Product description ................................................... 7
4 Correct use ................................................................ 9
5 Order data ................................................................. 11
6 Technical data ........................................................... 12
7 Dimensions ............................................................... 13
8 Manufacturer's information ....................................... 14
8.1 Delivery ............................................................... 14
8.2 Packaging ........................................................... 14
8.3 Transport ............................................................ 14
8.4 Storage ............................................................... 14
9 Assembly and installation ......................................... 14
9.5 Assembling and installing the electrical posi-
tion indicator ...................................................... 17
10 Electrical connection ................................................. 19
10.1 Potential equalisation – special function X and
Y .......................................................................... 19
10.2 DeviceNet, ordering option Fieldbus, code DN . 20
11 Programming the end positions ................................. 22
11.1 On-site end position programming ................... 22
11.2 End position programming via DeviceNet ........ 22
12 Specific data - DeviceNet .......................................... 23
12.1 Inputs .................................................................. 23
12.2 Outputs ............................................................... 23
12.3 Parameter ........................................................... 24
13 Error clearance .......................................................... 26
14 Inspection and servicing ............................................ 27
15 Disassembly ............................................................. 27
16 Disposal .................................................................... 27
17 Returns ..................................................................... 27
18 Declaration of conformity according to 2014/30/EU
(EMC Directive) ......................................................... 28
19 Declaration of conformity in accordance with
2014/34/EU (ATEX) ................................................... 29
GEMÜ 1242
DeviceNet
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General information
1 General information
1.1 Information
– The descriptions and instructions apply to the standard versions. For special versions not described in this document
the basic information contained herein applies in combination with any additional special documentation.
– Correct installation, operation, maintenance and repair work ensure faultless operation of the product.
– Should there be any doubts or misunderstandings, the German version is the authoritative document.
– Contact us at the address on the last page for staff training information.
1.2 Symbols used
The following symbols are used in this document:
Symbol Meaning
●Tasks to be performed
Response(s) to tasks
– Lists
The following LED symbols are used in the documentation:
Symbol LED conditions
Off
Lit (on)
Flashing
1.3 Definition of terms
Speed-AP
Speed Assembly and Programming, particularly user-friendly quick assembly, setting and initialisation of electrical position in-
dicators, combi switchboxes and controllers.
1.4 Warning notes
Wherever possible, warning notes are organised according to the following scheme:
SIGNAL WORD
Symbol for
the specific
danger
Type and source of the 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.

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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 from potentially explosive atmosphere
General information

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Safety information
2 Safety information
The safety information in this document refers only to an individual product. Potentially dangerous conditions can arise in
combination with other plant components, which need to be considered on the basis of a risk analysis. The operator is re-
sponsible for the production of the risk analysis and for compliance with the resulting precautionary measures and regional
safety regulations.
The document contains fundamental safety information that must be observed during commissioning, operation and mainten-
ance. Non-compliance with these instructions may cause:
– Personal hazard due to electrical, mechanical and chemical effects.
– Hazard to nearby equipment.
– Failure of important functions.
– Hazard to the environment due to the leakage of dangerous materials.
The safety information does not take into account:
– Unexpected incidents and events, which may occur during installation, operation and maintenance.
– Local safety regulations which must be adhered to by the operator and by any additional installation personnel.
Prior to commissioning:
1. Transport and store the product correctly.
2. Do not paint the bolts and plastic parts of the product.
3. Carry out installation and commissioning using trained personnel.
4. Provide adequate training for installation and operating personnel.
5. Ensure that the contents of the document have been fully understood by the responsible personnel.
6. Define the areas of responsibility.
7. Observe the safety data sheets.
8. Observe the safety regulations for the media used.
During operation:
9. Keep this document available at the place of use.
10. Observe the safety information.
11. Operate the product in accordance with this document.
12. Operate the product in accordance with the specifications.
13. Maintain the product correctly.
14. Do not carry out any maintenance work and repairs not described in this document without consulting the manufacturer
first.
In cases of uncertainty:
15. Consult the nearest GEMÜ sales office.

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3 Product description
3.1 Construction
1
2
4
3
5
Item Name Materials
1 Housing cover - standard version: PC
2 Housing base Anodised aluminium or SS
3 Electrical connection SS, PP
4 Adapter piece SS
5 Mounting kit, valve specific SS
Seals EPDM and NBR
Product description

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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.
LED Colour Function
Standard 1) Inversed 2)
CLOSED green orange Process valve in CLOSED
position
ERROR red red Error
OPEN orange green Process valve in OPEN
position
MNS green green Communication existing
red red Communication error
High visibility LED green orange Process valve in CLOSED
position
orange green Process valve in OPEN
position
green / orange green / orange Programming mode
1) Option
Code 00: Without
2) Option
Code 40: Inversed LED feedback
For order codes see chapter "Order data"
3.2.2 LED conditions
Function CLOSED ERROR OPEN High visibility LED
Valve in OPEN position
Valve in CLOSED position
Programming mode
OPEN / CLOSED flash alternately flashes alternately
LED conditions
lit (on) ~ irrelevant flashes off
3.3 Description
The GEMÜ 1242 electrical position indicator is suitable for mounting to pneumatically operated linear actuators. Secure con-
nection to valve spindle means reliable feedback signal. Intelligent microprocessor controlled functions make commissioning
and support during operation easier. The current position of the valve is displayed via high visibility LEDs and fed back via
electrical signals. The GEMÜ 1242 has been specially designed for valves with a stroke of 2 to 46 mm.
3.4 Function
The GEMÜ 1242 electrical position indicator is suitable for mounting to pneumatically operated linear actuators. Secure con-
nection to valve spindle means reliable feedback signal. Intelligent microprocessor controlled functions make commissioning
and support during operation easier. The current position of the valve is displayed via high visibility LEDs and fed back via
electrical signals. The GEMÜ 1242 has been specially designed for valves with a stroke of 2 to 46 mm.

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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 1242 is designed to be fitted to a GEMÜ valve in order to detect the position of linear actuators optically and elec-
trically. The product has a microprocessor controlled intelligent position sensor as well as an analogue travel sensor system
(potentiometer) and is connected in a force-locking way with the actuator spindle by means of a mounting kit (spring, operat-
ing bush). The valve end positions and the integrated travel sensor can be controlled via the electrical connections.
4.1 Product without special function X or Y
The product is not intended for use in potentially explosive areas.
4.2 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 overcurrent protective device in the system. The switch or overcur-
rent protective device must be placed in a suitable and accessible 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 compatibil-
ity and warning signs.
Suitable locking clips must be used to secure the circular connectors against becoming unintentionally loose or being
loosened without the use of tools
Installation, operation and servicing 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 nullified.
Correct use

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Correct use
4.3 Product with special function X
The product with the special version X order option is intended for use in potentially explosive areas of zone 2 with gases,
mists or vapours and zone 22 with combustible dusts in accordance with EU directive 2014/34/EU (ATEX).
The product has the following explosion protection marking:
Gas: II 3G Ex ec nC IIC T4 Gc X
Dust: II 3D Ex tc IIIC T 80 °C Dc X
Type examination certificate: IBExU18ATEXB008 X
The product has been developed in compliance with the following harmonised standards:
– DIN EN 60079-0:2012+A11:2013
– DIN EN 60079-7:2015
– DIN EN 60079-15:2010
– DIN 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 ATEX 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".

5 Order data
The order data provide an overview of standard configurations.
Please check the availability before ordering. Other configurations available on request.
Note: A valve specific mounting kit is required for assembly. For designing the mounting kit, the valve type, nominal size, con-
trol function and actuator size must be stated.
Order codes
1 Type Code
Electrical position indicator 1242
2 Fieldbus Code
Without, 24 V version, with IO-Link 000
AS-Interface, 31 slaves, 4I/4O A2
AS-Interface, 62 slaves, 4I/3O A3
AS-Interface, 62 slaves, 8I/8O A4
DeviceNet DN
3 Accessory Code
Accessory Z
4 Housing material Code
Stainless steel base, PC cover 07
Aluminium base, PC cover 14
5 Function Code
Position feedback Open / Closed 00
6 Electrical connection Code
M12 plug, 5-pin 01
M12 plug, 8-pin 02
7 Option Code
Without 00
Inversed LED feedback 40
8 Switch Code
Electronics E0
9 Connection diagram Code
M12 plug, 5-pin 01
M12 plug, 8-pin 02
10 Special version Code
Without
NEC 500 and UL/CSA approval Y
ATEX (2014/34/EU) X
Order example
Order option Code Description
1 Type 1242 Electrical position indicator
2 Fieldbus DN DeviceNet
3 Accessory Z Accessory
4 Housing material 14 Aluminium base, PC cover
5 Function 00 Position feedback Open / Closed
6 Electrical connection 01 M12 plug, 5-pin
7 Option 00 Without
8 Switch E0 Electronics
9 Connection diagram 01 M12 plug, 5-pin
10 Special version Without
Order data
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Technical data
6 Technical data
6.1 Temperature
Ambient temperature: 0 to 60 °C
Storage temperature: 0 to 40 °C
6.2 Product compliance
EMC Directive: 2014/30/EU
DeviceNet
Interference emission EN 61000-6-3
Interference resistance EN 61000-6-2
Explosion protection: ATEX (2014/34/EU), order code special version X
NEC 500 (ISA 12.12.01), order code for special version Y
ATEX marking: Gas: II 3G Ex ec nC IIC T4 Gc X
Dust: II 3D Ex tc IIIC T 80 °C Dc X
Type examination certificate: IBExU18ATEXB008 X
NEC marking: Class I, Division II, Groups C & D, T4
6.3 Mechanical data
Installation position: Optional
Weight: 320g (aluminium version)
600g (stainless steel version)
Protection class: IP 67
IP NEMA 4X (UL 61010-1, UL 50E), only available as special version code Y
IP64, only as special version code X
Travel sensor: Minimum stroke: 2 mm
Maximum stroke: 46 mm
Hysteresis: 0.2 mm
Accuracy: 0.2 Full Scale
6.4 Electrical data
Supply voltage Uv: 11 to 25 V DC
Duty cycle: Continuous duty
Reverse battery
protection:
yes
Current consumption: typically 30 mA
Electrical connection
type:
1 x 5-pin M12 plug (A-coded)

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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: Default setting switch point CLOSED 12 %
Default setting switch point OPEN 25 %
Min. switch point CLOSED 0.8 mm
Min. switch point OPEN 0.5 mm
If the percentage switch points dependent on the programmed stroke are smaller than the per-
missible min. switch points, the min. switch points apply automatically.
Electrical protection
class:
III
7 Dimensions
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
Dimensions

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Manufacturer's information
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 /
environmental 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
NOTICE
●Observe the data on the product labels, product documentation and the EC type examination certificate.
●Connect cable carefully, do not damage individual wires.
●Prepare the wire ends when connecting several cables or fine-wired cables.
●Always attach wire end ferrule stops using pinch tools 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 circuits: Maximum 30 V.
7. Connect open wire ends in a junction box with protection class IP20 and higher or outside the EX area.

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9.1 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 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.
Assembly and installation

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Assembly and installation
5
6
3. Tighten the operating bush 3 by turning it
clockwise.
4. Affix the O-ring 5 and the adapter 6.
7
8
5. Attach the flange plate 76. Screw the flange plate on tight using screws 8.
– Push in the spindle until it pushes against the spring and then slowly release the pressure on the spring.
NOTICE
▶For some valves (e.g. GEMÜ 650 and GEMÜ 687) it is necessary to fit a pressure disc between the threaded adapter and
the actuator head. This is included in the required mounting kits, sometimes with an additional O-ring (only GEMÜ 650
with normally open and double-acting control function – code 2+3).
▶If the pressure disc does not have a groove for a seal, this will already be inserted in the groove provided at the adapter
opening of the actuator head (e.g. GEMÜ 687 with normally open control function – code 2).
9
6
11
10
Insert the O-ring 11 (if included) into the corresponding groove
on the adapter 6.
If included: Push the pressure disc 9 over the adapter 6 and
insert the O-ring 10 in the intended groove of the pressure
disc.

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9.3 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.
9.4 Assembling the stroke limiter (linear actuator)
5
5
4
3
2
1
6
8
9
7.1
7.2
Option1 Option2
1. Screw distance piece 5 onto/into actuator spindle
6.
2. Move the actuator to the closed position.
3. Insert the O-ring 7.1 in the stroke limiter 1.
4. Insert the O-ring 7.2 in the washer 4.
5. Screw stroke limiter 1 with nut 2, seal 3 and washer
4 into the actuator opening.
6. Set stroke limiter 1 to the required stroke.
7. Make sure that the minimum stroke is reached.
8. Secure stroke limiter 1 with nut 2.
Key
1 Stroke limiter 7.1 1)
7.2 1)
O-ring
2 Nut 8 Protective cap
3 1) Seal 9 Position indicator
4 1) Disc 10 Operating bush
5 2) Distance piece 11 Spindle
6 Actuator spindle 12 Travel sensor
1) Only available for valves with the NO and DA control functions.
2) Only included in required mounting kits. The design depends on the valve.
9.5 Assembling and installing the electrical position indicator
DANGER
Danger of explosion
▶Danger of death or severe injury.
●Do not use the product as a step or foothold.
●Prior to commissioning, ensure that the cover is fully closed and that the housing and the O-ring are not
damaged.
Assembly and installation

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Assembly and installation
1. Move the actuator to the open position.
2. Place the product as far as it will go into the actuator opening, insert adapter 3 (see chapter 9.3) or stroke limiter 1 (see
chapter 9.4) and screw in clockwise against the initial spring tension.
3. Use the spanner flat of the travel sensor to tighten the product.
4. Turn the housing clockwise to align the pneumatic or electrical connections.
CAUTION
Incorrect installation of the product.
▶Damage to the housing.
●Only tighten the product using the spanner flats provided for this purpose.
5. The product with mounting kit is fully assembled.
6. The product with mounting kit and adapter is fully assembled.

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7. The product with mounting kit and stroke limiter is fully assembled.
10 Electrical connection
10.1 Potential equalisation – special function X and Y
Connecting the potential equalisation device
1. Use a screw M4x6 to attach the potential equalisation device to the electrical position indicator.
ðPotential equalisation for metal housings in potentially explosive areas: Minimum 4 mm².
2. Secure the connection against working itself loose.
Electrical connection

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Electrical connection
10.2 DeviceNet, ordering option Fieldbus, code DN
DANGER
Danger of explosion!
▶Risk of injury or death!
●Do not connect or disconnect the device until the power has been switched off or the area has been classi-
fied as non-hazardous.
●The standard version of the product (without special function X or Y) must not be used in potentially explos-
ive zones.
DANGER
Danger of explosion due to sparking
▶Risk of severe injury or death.
●Never disconnect the connection cables when live.
10.2.1 Net topology - DeviceNet system
To avoid malfunction the trunk cable is fitted with resistors on both sides. The drop cables do not require bus ends.
V+
V-
CAN_H 120 Ω
1/4 W
CAN_L
Shield
Protective
earth
Protective
earth
Drop cable
120 Ω
1/4 W
Trunk cable
Maximum cable length
Baud rate [kBaud] Trunk cable Drop cable
Thick cable Thin cable Max. cable length per
drop cable
Max. drop cable accu-
mulated length
125 500 m 100 m 6 m 156 m
250 250 m 100 m 6 m 78 m
500 100 m 100 m 6 m 39 m