GEM 4242 Operating Instructions Manual page 22

12 Commissioning
12 Commissioning
Hazardous situation
▶ Risk of injury or damage possible.
For correct commissioning, the
●
product must be calibrated to the pro-
cess valve via the initialization pro-
cess.
During this commissioning, the valve is
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automatically opened and closed sev-
eral times. It must therefore be en-
sured in advance that this does not
lead to a dangerous situation.
Incorrect initialization
Always carry out initialization without operating medium
●
pressure on the process valve. Carry out initialization of
the process valve in neutral position (NO/NC).
For delivery of the product assembled on a valve at the
●
factory, the complete construction is already ready for op-
eration at a control pressure of 5.5 to 6 bar without oper-
ating pressure. A reinitialization is recommended if the
plant is operated with a different control pressure or if the
mechanical end positions have been changed (e.g. seal
replacement on the valve or actuator replacement). The
initialization is retained even in the event of voltage
cutoff.
For delivery of the product without default setting (e.g. for
●
delivery without valve) initialization must be carried out
once for correct operation. This initialization must be re-
peated every time that the process valve is changed (e.g.
seal replacement or actuator replacement).
1. Connect the connection cable tension-free and without
any bends or knots.
2. Switch on supply voltage.
3. Use suitable connectors.
4. Connect the control medium lines tension-free and
without any bends or knots.
5. Connect the product pneumatically to the process valve.
6. Connect the pneumatic tubes and activate the pneumatic
control air supply of max. 7 or 9 bar.
Initialization is active for an unusually long time
▶ For actuators with a large air volume (filling volume), in
some circumstances it can take several minutes until ini-
tialization can be completed. Initialization is only unsuc-
cessful if an error message appears with LED signalling.
GEMÜ 4242
CAUTION
NOTICE
NOTICE
NOTICE
NOTICE
12.1 Initialization of end positions
The initialization of the end positions is dependent on the set-
ting of the operating parameter (operating mode). A distinc-
tion is made between the autonomous and classic modes for
detection of end positions.
In the autonomous detection of end positions mode (default
setting), the end positions are determined independently as
soon as the valve moves (triggered by the corresponding con-
trol command). The valve is therefore ready for operation dir-
ectly, reports the end positions back after an initial movement
cycle, and shows these via the LED display.
In classic mode, the end positions must be calibrated via the
active triggering of the initialization process, via the commu-
nication interface or the on-site option. If correct initialization
has not been carried out, then the device is in a warning state
(signalling via the corresponding high visibility LEDs).
12.1.1 Autonomous end position process/end position
tracking
The autonomous end position process or end position track-
ing is an intelligent function, with the help of which the end
positions of a valve are independently determined (without ex-
ternal triggering). If this function is active, the end positions
are automatically determined the first time the valve moves,
and the product is ready for operation directly. The end posi-
tions are continuously monitored and responded to accord-
ingly in case of deviations.
Explanation of the functional principle:
In the autonomous end position tracking mode, a distinction
is made between two different conditions, which have an in-
fluence on the behaviour of the function.
No initialization: The device monitors whether two different
end positions have been approached at a certain distance.
The first two end positions that comply with this condition are
calibrated as newly initialized end positions.
Existing initialization: The function determines whether there
is a displacement of the end positions over the operating
time. If these displacements are outside a certain tolerance
range and display a certain consistency, the initialized end po-
sitions are overwritten by the adjusted initialization values. If
this process is triggered, this is indicated by a corresponding
message. The deviations are evaluated alongside here, and al-
low conclusions to be drawn as to the cause.
A classic initialization can also be carried out in the operating
mode of autonomous end position tracking. This is recom-
mended after a seal replacement or the like, in order to pre-
vent faulty messages regarding end position changes. If the
initialization is successful here, then the currently calibrated
end positions are overwritten and the tracking operates
against these updated end positions. If the actively triggered
initialization process is not successful here, then the most re-
cently calibrated initialization positions are deleted.
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