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GEM 4242 Operating Instructions Manual

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

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Summary of Contents for GEM 4242

  • Page 1 GEMÜ 4242 Combi switchbox with integrated pilot valve Operating instructions ASi-5 further information webcode: GW-4242...
  • Page 2 All rights including copyrights or industrial property rights are expressly reserved. Keep the document for future reference. © GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG 21.02.2024 GEMÜ 4242 2 / 51 www.gemu-group.com...

  • Page 3: Table Of Contents

    Function ............15.1 Cyclical process data ........LEDs ............... 15.1.1 Inputs ..........Product label ..........15.1.2 Outputs ..........4 GEMÜ CONEXO ............ 15.2 Non-cyclical parameter data ......15.3 Non-cyclical condition monitoring data ..5 Correct use ............15.4 AS-I5 events ...........

  • Page 4: General Information

    Symbol Meaning 1.3 Definition of terms Danger of explosion! Working medium The medium that flows through the GEMÜ product. Control function Danger of explosion The possible actuation functions of the GEMÜ product. Control medium The medium whose increasing or decreasing pressure causes Risk of electric shock the GEMÜ...

  • Page 5: Product Description

    In cases of uncertainty: 3.2 Description 15. Consult the nearest GEMÜ sales office. 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.

  • Page 6: Leds

    Device-specific data Item number Traceability number Serial number 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.

  • Page 7: Correct Use

    ● 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).

  • Page 8: Order Data

    Pneumatic 6 mm angled connection (code 04), No code option (code 00), 145 Nl/min flow rate, 30 mm travel sensor length (code 030) or 75 mm (code 075), Without special function (code -) or with ATEX special function (code X) GEMÜ 4242 8 / 51 www.gemu-group.com...

  • Page 9: Order Codes

    9 Flow rate Code 14 Nl/min, size 1 23 Nl/min (Booster), size 1 145 Nl/min, size 2 10 Travel sensor version Code Travel sensor 30 mm in length Travel sensor 75 mm in length www.gemu-group.com 9 / 51 GEMÜ 4242...

  • Page 10: Order Example

    M5 connection thread for size 1, G1/8 connection thread for size 2 8 Option Manual override 9 Flow rate 14 Nl/min, size 1 10 Travel sensor version Travel sensor 30 mm in length 11 Special version Without GEMÜ 4242 10 / 51 www.gemu-group.com...

  • Page 11: Technical Data

    7.4 Product conformity EMC Directive: 2014/30/EU Class: B Group: 1 Technical standards used: AS-Interface 5 Interference emission: ASi-5 Spec V1.04 Interference resistance: ASi-5 Spec V1.04 Interference emission/ EN 62026-2:2013 + A1:2019 interference resistance RoHS Directive: 2011/65/EU www.gemu-group.com 11 / 51 GEMÜ 4242...

  • Page 12: Mechanical Data

    IP 67 is achieved by piping away the exhaust air Degree of contamination: 4 (pollution degree) 7.7 Electrical data Electrical connection 1 x 5-pin M12 plug (A-coded) type: Supply voltage: 26.5 to 31.6 V DC (according to AS-Interface specifications) GEMÜ 4242 12 / 51 www.gemu-group.com...

  • Page 13: Dimensions

    8 Dimensions 8.1 Size 1 Ø57 WAF 20 for mounting kit M12x1, x = 9 mm WAF 24 for mounting kit M16x1, x = 11 mm dependent on valve used 16,6 Dimensions in mm www.gemu-group.com 13 / 51 GEMÜ 4242...

  • Page 14: Size 2

    WAF 20 for mounting kit M12x1, x = 9 mm WAF 24 for mounting kit M16x1, x = 11 mm Travel sensor 30 mm in length dependent on the valve that is used Dimensions in mm GEMÜ 4242 14 / 51 www.gemu-group.com...

  • Page 15: Assembly And Installation

    ▶ A damaged spindle surface may cause failure of the NOTICE travel sensor. ▶ 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...

  • Page 16: Mounting The Combi Switchbox On Linear Actuators

    1. Move the actuator to the closed position. 2. Place O-rings 1 and 2 into threaded adapter 3. 3. Screw threaded adapter 3 into the actuator opening as far as it will go and tighten. GEMÜ 4242 16 / 51 www.gemu-group.com...

  • Page 17: Assembling And Installing The Combi Switchbox (Linear Actuator)

    5. Connect the product electrically. assembled. 6. Connect the product pneumatically. CAUTION Incorrect installation of the product. ▶ Damage to the housing. Only tighten the product using the spanner flats provided ● for this purpose. www.gemu-group.com 17 / 51 GEMÜ 4242...

  • Page 18: Mounting The Combi Switchbox On Quarter Turn Actuators

    2. Use the spanner flat 8 (WAF 27) of the travel sensor to tighten the product. 3. Turn the housing clockwise to align the pneumatic or elec- trical connections. 4. Connect the product electrically. 5. Connect the product pneumatically. 6. Initialize the product. GEMÜ 4242 18 / 51 www.gemu-group.com...

  • Page 19: Pneumatic Connection

    Ensure that the ventilation line is always depressurized, that it is not operated with throttles, filters or similar components, and that it is laid in such a way that moisture cannot flow back. www.gemu-group.com 19 / 51 GEMÜ 4242...

  • Page 20: Electrical Connection

    4. Protect the product and the cables from damage. 5. Only clean the product with an anti-static or damp cloth. 6. Only operate the product when it is fully assembled. 11.1.1 Pin assignment Signal name AS-Interface + GEMÜ 4242 20 / 51 www.gemu-group.com...

  • Page 21: Potential Equalization - Special Function

    The potential equalization connection's maximum permissible resistance limit value is defined as R ≤ 100 Ω. During the plant- specific maintenance cycle, the potential equalization connection must be checked to ensure that it has been connected cor- rectly and that the maximum resistance limit value has not been exceeded. www.gemu-group.com 21 / 51 GEMÜ 4242...
  • Page 22 Initialization is only unsuc- cessful if an error message appears with LED signalling. GEMÜ 4242 22 / 51 www.gemu-group.com...
  • Page 23 In the event of deviating status indications, observe the LEDs ending the process, the app can be used again without re- and Troubleshooting chapters. strictions. While the wireless connection is active, starting the initial- ization via the magnetic trigger is deactivated. www.gemu-group.com 23 / 51 GEMÜ 4242...
  • Page 24 Using an integrated Bluetooth Low Energy interface, the fol- Caution! If one or both passwords for the reset mechanism lowing functions can be used in conjunction with the GEMÜ are enabled, anyone with access to the digital product label app: (QR code) can remove the password protection.
  • Page 25 Open Closed Safety position Defines the function of digital Deactivated Activation of pilot valve 1 Digital input 1 function input 1 Activation of pilot valve 1 Initialization input Localization Safety position www.gemu-group.com 25 / 51 GEMÜ 4242...
  • Page 26 OPEN feedback CLOSED feedback Error output Warning output Operating mode feedback Defines the function of digital Deactivated Deactivated Digital output 5 function output 5 OPEN feedback CLOSED feedback Error output Warning output Operating mode feedback GEMÜ 4242 26 / 51 www.gemu-group.com...
  • Page 27 Indicates the measured relat- 0 ... 100 % Humidity of housing ive humidity inside the hous- www.gemu-group.com 27 / 51 GEMÜ 4242...
  • Page 28 Displays the number of user  0 ... 2147483647 Cycles Valve actuations user counter valve actuations counted Defines whether a warning Deactivated Activated Time-based diagnostic mes- message needs to be issued Activated sages for time-based diagnostic functions GEMÜ 4242 28 / 51 www.gemu-group.com...
  • Page 29 Indication of CLOSED position Valve position CLOSED feedback Error output Signals an active error Warning message output Signals an active warning Indication of operating mode Feedback of the active operating mode → normal opera- tion / initialisation active www.gemu-group.com 29 / 51 GEMÜ 4242...
  • Page 30 ASI ID 7 byte 0x0191 (Vendor ID) and 5 byte (consecutive numbers) 0x0001 RO Manufacturer device 10 byte StringT - "4242 AS-I5" - name 0x000F RO Manufacturer device 14 byte StringT - "4242" family 0x0031 RO ASi-5 device Process 1 byte...
  • Page 31 -> nor- mode mal operation/initializ- ation active 0x6441 RW Digital output 3 func- 8 bit uint:8 No function tion (Indication Indication of Valve position OPEN of operating OPEN posi- feedback mode) tion www.gemu-group.com 31 / 51 GEMÜ 4242...
  • Page 32 Indication of Valve position OPEN (Defines the behaviour OPEN posi- feedback of the output process tion data bit 5) Indication of Valve position CLOSED po- CLOSED feedback sition Error output Signals an active error GEMÜ 4242 32 / 51 www.gemu-group.com...
  • Page 33 Position of the valve is (Vent valve) position held in the event of an error Open valve Valve is opened in the event of an error Close valve Valve is closed in the event of an error www.gemu-group.com 33 / 51 GEMÜ 4242...
  • Page 34 Must be at least 10.0% lower than switch point Open 0x6531 RO Absolute travel sensor 2 byte uint:16 0 0.0 to Initialized travel position OPEN end po- 100.0% sensor position OPEN sition end position GEMÜ 4242 34 / 51 www.gemu-group.com...
  • Page 35 0x6661 RW Digital input 3 function 8 bit uint:8 No function (Initializa- (Defines the behaviour Controlling Activates the pneu- tion) of the input process pneumatic matic output data bit 2) outputs www.gemu-group.com 35 / 51 GEMÜ 4242...
  • Page 36 0x6691 RW Digital input 6 function 8 bit uint:8 No function (Off) (Defines the behaviour of the input process data bit 5) GEMÜ 4242 36 / 51 www.gemu-group.com...
  • Page 37 Digital input 8 function 8 bit uint:8 No function (Off) (Defines the behaviour Controlling Activates the pneu- of the input process pneumatic matic output data bit 7) outputs Initialization Starting initialization Localization Activates the location function www.gemu-group.com 37 / 51 GEMÜ 4242...
  • Page 38 * These parameters are not reset to default settings with the "Restore Factory Settings" AS-I system command, but instead re- tain their set values GEMÜ 4242 38 / 51 www.gemu-group.com...
  • Page 39 Travel time from OPEN 99.9 s) OPEN to CLOSED end position 0x662 Operating time 16 bit uint:16 - 0 to 999 (0.0 to Travel time from CLOSED 99.9 s) CLOSED to OPEN end position www.gemu-group.com 39 / 51 GEMÜ 4242...
  • Page 40 0 to 1000 (0.0% to Measured relative 100.0%) humidity in housing in % * These parameters are not reset to default settings with the "Restore Factory Settings" AS-I system command, but instead re- tain their set values GEMÜ 4242 40 / 51 www.gemu-group.com...
  • Page 41 Internal pressure alarm threshold exceeded * Rising / Leaving Warning 0x037C Internal pressure alarm threshold not reached Rising / Leaving Warning 0x037D Vibration alarm threshold exceeded Rising / Leaving Warning 0x0382 * Message at size 2 inactive www.gemu-group.com 41 / 51 GEMÜ 4242...
  • Page 42 Deactivating the manual override: Use a flathead screwdriver (maximum slot width of 6 mm) to unscrew the manual override screw M anticlockwise as far as it will go. GEMÜ 4242 42 / 51 www.gemu-group.com...
  • Page 43 We recommend checking the cause and, if required, eliminating it. Info: The status of a temporary function is displayed. The following warning and error messages are defined for the device, and can be read out on the GEMÜ app: Message...
  • Page 44 Warning user switching cycles" has been in the GEMÜ app under Maintenance. If the condition is reached. perfect, you can alternatively adjust the warning threshold in parameter "S02: Warning threshold user switching cycles".
  • Page 45 Please send the product to GEMÜ for repair. Please con- cessed. tact your GEMÜ representative. Further information can Error also be found on the product overview in the GEMÜ App under Maintenance. Fieldbus communication error Fieldbus communication was termin- Fieldbus communication is expected. Please check that...
  • Page 46 Returned goods can be processed only when this note is completed. If no return delivery note is included with the product, GEMÜ cannot process credits or repair work but will dispose of the goods at the operator's expense.
  • Page 47 EC Machinery Directive 2006/42/EC, Annex II B Machinery Directive introductory text We, the company GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Strasse 6–8 74653 Ingelfingen-Criesbach, Germany hereby declare under our sole responsibility that the below-mentioned product complies with the relevant essential health and safety requirements in accordance with Annex I of the above-mentioned Directive.
  • Page 48 EN 301 489-17 V3.2.4 (2020-09) • EN 61010-1:2010/A1:2019/AC:2019-04 Note regarding sole responsibility for issuance The sole responsibility for issuing this declaration of conformity lies with the company GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG. M. Barghoorn Head of Global Technics Ingelfingen, 12/12/2023 GEMÜ...
  • Page 49 EN IEC 60079-7:2015/A1:2018 • EN 60079-31:2014 Note regarding sole responsibility for issuance The sole responsibility for issuing this declaration of conformity lies with the company GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG. M. Barghoorn Head of Global Technics Ingelfingen, 12/12/2023 GEMÜ...
  • Page 50 2011/65/EU (RoHS Directive) EMC introductory text We, the company GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Strasse 6–8 74653 Ingelfingen-Criesbach, Germany hereby declare under our sole responsibility that the below-mentioned product complies with the regulations of the above-men- tioned Directive.
  • Page 51 GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Fritz-Müller-Straße 6-8, 74653 Ingelfingen-Criesbach, Germany Subject to alteration Phone +49 (0) 7940 1230 · info@gemue.de www.gemu-group.com 02.2024 | 88894897...

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