GEM 4242 Operating Instructions Manual
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GEM 4242 Operating Instructions Manual

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

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Summary of Contents for GEM 4242

  • Page 1 GEMÜ 4242 IO-Link Combi switchbox with integrated pilot valve Operating instructions 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 14.01.2021 GEMÜ 4242 2 / 40 www.gemu-group.com IO-Link...

  • Page 3: Table Of Contents

    3 Product description ........... Construction ............LED displays ............Function .............. Product label ............4 GEMÜ CONEXO ............5 Correct use ............... 10 6 Order data ..............12 7 Technical data ............14 8 Dimensions ............... 16 Size 1 ..............16 Size 2 ..............

  • Page 4: General Information

    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 automatically after successful completion.

  • Page 5: Warning Notes

    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 / 40 GEMÜ 4242 IO-Link...

  • Page 6: Safety Information

    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. GEMÜ 4242 6 / 40 www.gemu-group.com...

  • Page 7: Product Description

    Size 2 Housing cover - standard version: Housing cover - compact version: Housing base Anodised aluminium or SS Electrical connection SS, PP SS, PP Adapter piece Mounting kit, valve specific Seals EPDM and NBR www.gemu-group.com 7 / 40 GEMÜ 4242 IO-Link...

  • Page 8: Led Displays

    3.3 Description The GEMÜ 4242 combi switchbox is suitable for mounting to pneumatically operated linear actuators. The position of the valve spindle is reliably electronically detected and evaluated using play-free and non-positive mounting. Integrated pilot valves enable direct activation of the process valve connected to them. Intelligent microprocessor controlled functions make commissioning and support during operation easier.

  • Page 9: Function

    3.4 Function The GEMÜ 4242 combi switchbox shows the current position of the valve. When the valve is opened, the spindle in the combi switchbox moves upwards and indicates that the valve is OPEN using the high visibility LEDs and communication interface.

  • Page 10: Correct Use

    ● ument. The GEMÜ 4242 with integrated pilot valve is designed for linear actuators. The product has a microprocessor controlled intel- ligent position sensor as well as an analogue travel sensor system (potentiometer) which is positively connected with the ac- tuator spindle by means of a mounting kit (spring, operating bush).
  • Page 11 3. Warning label "Danger from electrostatic build-up". 4. Warning label "Do not disconnect when live". The housing must be installed protected from mechanical influences. RFID chips must not be read out in potentially explosive areas. www.gemu-group.com 11 / 40 GEMÜ 4242 IO-Link...

  • Page 12: Order Data

    (for IP67 or piped air outlet) Air supply 6 mm angled connection, exhaust air 6 mm angled connection (for IP67 or piped air outlet) Air supply 1/4" angled connection, exhaust air 1/4" angled connection GEMÜ 4242 12 / 40 www.gemu-group.com IO-Link...
  • Page 13 Connection thread M5 for size 1, connection thread G1/8 for size 2 8 Option Manual override 9 Flow rate 14 Nl/min, size 1 10 Travel sensor version Potentiometer 30 mm length, size 1 11 Special version Without www.gemu-group.com 13 / 40 GEMÜ 4242 IO-Link...

  • Page 14: Technical Data

    Class I, Division II, Groups C & D, T4 Approvals: IO-Link Fieldbus / Travel sensor version 030: IO- Communication Link specification V1.0 Travel sensor version 075: IO- Link specification V1.1 7.5 Mechanical data Installation position: Optional GEMÜ 4242 14 / 40 www.gemu-group.com IO-Link...
  • Page 15 Signal delay inactive td2: Signal delay t/ms Switching output "Closed" ta: Signal interval active inactive t/ms Switch points: The data in percent refer to the programmed stroke, before each end position www.gemu-group.com 15 / 40 GEMÜ 4242 IO-Link...

  • Page 16: Dimensions

    8.2 Size 2 Ø 90 WAF 20 for mounting kit M12x1, x = 9 mm WAF 24 for mounting kit M16x1, x = 11 mm 86,5 dependent on valve used Dimensions in mm GEMÜ 4242 16 / 40 www.gemu-group.com IO-Link...

  • Page 17: Manufacturer's Information

    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 certificate.
  • Page 18 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. GEMÜ 4242 18 / 40 www.gemu-group.com...

  • Page 19: Mounting The Combi Switchbox On Linear Actuators

    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 –...
  • Page 20 Operating bush Distance piece Spindle Actuator spindle 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. GEMÜ 4242 20 / 40 www.gemu-group.com IO-Link...
  • Page 21 ▶ In both cases, check the mounting kit parts and that they are being used correctly and in their entirety. 8. The product with mounting kit is fully assembled. www.gemu-group.com 21 / 40 GEMÜ 4242 IO-Link...

  • Page 22: Mounting The Combi Switchbox On Quarter Turn Actuators

    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). 2. Remove the screw 1 from the trigger cam 2. GEMÜ 4242 22 / 40 www.gemu-group.com IO-Link...
  • Page 23 3. Turn the housing clockwise to align the pneumatic or electrical connections. 4. Connect the product electrically, see chapter "Electrical connection". 5. Connect the product pneumatically, see chapter "Pneumatic connection". 6. Initialize the product (see “Commissioning“, page 29). www.gemu-group.com 23 / 40 GEMÜ 4242 IO-Link...

  • Page 24: Pneumatic Connection

    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. ● 2) only relevant for exhaust air duct and/or increase of protection class GEMÜ 4242 24 / 40 www.gemu-group.com IO-Link...

  • Page 25: Size 1, Compact Version

    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. ● 2) only relevant for exhaust air duct and/or increase of protection class www.gemu-group.com 25 / 40 GEMÜ 4242 IO-Link...

  • Page 26: Size 2, Standard, Double Acting

    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 fittings are mechanically secured. GEMÜ 4242 26 / 40 www.gemu-group.com...

  • Page 27: Electrical Connection

    1. Use a screw M4x6 to attach the potential equalization device to the electrical position indicator. ð Potential equalization for metal housings in potentially explosive areas: Minimum 4 mm². 2. Secure the connection against working itself loose. www.gemu-group.com 27 / 40 GEMÜ 4242 IO-Link...

  • Page 28: Io-Link, Ordering Option Fieldbus, Code Iol

    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. GEMÜ 4242 28 / 40 www.gemu-group.com IO-Link...

  • Page 29: Commissioning

    If electrical position indicators have been fitted to the process valve at the factory, the end positions will already have been programmed. The end positions can be programmed as follows: • On-site programming • Communication interface When programming via the communication interface, automatic programming is recommended. www.gemu-group.com 29 / 40 GEMÜ 4242 IO-Link...
  • Page 30 3. Open valve until end position is reached. 4. Close valve until end position is reached. 5. Programming mode is automatically terminated if the valve does not move for 5 seconds. ð The end positions are set. GEMÜ 4242 30 / 40 www.gemu-group.com IO-Link...

  • Page 31: Specific Data - Io-Link

    Physics: Physics 2 (3-wire design) Port configuration: Port type A Vendor-ID: Device-ID: 424201 Product-ID: 4242 IO-LINK ISDU support: SIO operation: IO-Link specification: Size 1 Size 2 V1.1 V1.1 when using IODD 1.1 1) When using IODD 1.0.1 the device works in accordance with IO-Link specification V1.0 (compatibility mode) Note for IO Link: Download IODD files from www.gemu-group.com.
  • Page 32 Index Parameter Length Data type Standard value Value range [Hex] bindex cess 0x13 Product ID 8 byte StringT 4242 IO-Link 0x15 Serial number 9 byte StringT 0 – 4294967296 0x16 Hardware Revision 8 byte StringT Rev. xx 0x17 Firmware Revision 10 byte StringT V x.x.x.x...

  • Page 33: Diagnostic Messages (Event Codes)

    Appear / Disappear Stroke reduction OPEN 0x8CB5 Warning Appear / Disappear Stroke reduction CLOSED 0x8CB6 Warning Appear / Disappear Parameter value out of Range 0x8DE0 Notification Single Shot Parameter value changed 0x8DE1 Notification Single Shot www.gemu-group.com 33 / 40 GEMÜ 4242 IO-Link...

  • Page 34: Manual Override

    2. Turn the manual override 3 90° anticlockwise using a flathead screwdriver (maximum slot width of 4 mm) and release it. ð The groove is vertical. NOTICE ▶ Control air and the minimum pressure must be available to use the manual override. GEMÜ 4242 34 / 40 www.gemu-group.com IO-Link...

  • Page 35: Troubleshooting

    After sensor error OPEN / CLOSED flash alternately Sensor error OPEN position CLOSED position Pneumatic fault OPEN position CLOSED position Mid position Supply voltage too low Internal error OPEN / CLOSED flash simultaneously www.gemu-group.com 35 / 40 GEMÜ 4242 IO-Link...

  • Page 36: Troubleshooting

    Contact GEMÜ Combi switchbox does not switch to pro- Magnet is held against the housing cover Only briefly hold the magnet against the gramming mode for too long housing cover until the LEDs flash GEMÜ 4242 36 / 40 www.gemu-group.com IO-Link...

  • Page 37: Inspection And Maintenance

    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 op- erator's expense.

  • Page 38: Declaration Of Conformity According To 2014/30/Eu (Emc Directive)

    21 Declaration of conformity according to 2014/30/EU (EMC Directive) EU Declaration of Conformity in accordance with 2014/30/EU (EMC Directive) 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.
  • Page 39 22 EU Declaration of conformity in accordance with 2014/34/EU (ATEX) EU Declaration of Conformity in accordance with 2014/34/EU (ATEX) 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 requirements of directive 2014/34/EU for intended use in potentially explosive areas.
  • Page 40 GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG Subject to alteration Fritz-Müller-Straße 6–8, 74653 Ingelfingen-Criesbach, Ger- *88594436* many 01.2021 | 88594436 Phone +49 (0) 7940 1230 · info@gemue.de www.gemu-group.com...

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