GEM 4240 Manuel utilisateur
GEMÜ 4240
Combi switchbox
Operating instructions
EN
further information
webcode: GW-4240
All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
27.11.2023
www.gemu-group.com2 / 23GEMÜ 4240
Contents
1 General information ............................................. 4
1.1 Information .................................................... 4
1.2 Symbols used ................................................ 4
1.3 Warning notes ............................................... 4
2 Safety information ............................................... 4
3 Product description ............................................. 5
4 GEMÜ CONEXO .................................................... 6
5 Correct use .......................................................... 6
6 Order data ........................................................... 7
7 Technical data ..................................................... 8
8 Dimensions .......................................................... 9
9 Manufacturer's information .................................. 10
9.1 Delivery .......................................................... 10
9.2 Packaging ...................................................... 10
9.3 Transport ....................................................... 10
9.4 Storage ........................................................... 10
10 Assembly and installation .................................... 10
10.1 Preparations for installing the valve (linear
actuator) ........................................................ 10
10.4 Threaded adapter assembly (linear actu-
ator) ................................................................ 11
11 Pneumatic connection ......................................... 13
12 Electrical connection ........................................... 15
13 Manual override ................................................... 17
14 Troubleshooting .................................................. 17
15 Inspection and maintenance ................................ 17
16 Disassembly ........................................................ 17
17 Disposal .............................................................. 17
18 Returns ................................................................ 17
19 EU Declaration of Incorporation according to the
EC Machinery Directive 2006/42/EC, Annex II B ... 19
20 EU Declaration of Conformity in accordance with
2014/30/EU (EMC Directive) ................................ 20
21 EU Declaration of Conformity in accordance with
2014/35/EU (Low Voltage Directive) .................... 21
22 EU Declaration of Conformity in accordance with
2011/65/EU (RoHS Directive) ............................... 22
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www.gemu-group.com4 / 23GEMÜ 4240
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
1.3 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 of explosion!
Danger of explosion
Electric shock by high voltage
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
substances.
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.
www.gemu-group.com 5 / 23 GEMÜ 4240
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
5
3
4
Item Name Materials
1 Housing cover PC
2 Housing base PPS
3 Electrical connection SS, PP
4 Adapter piece SS
5 Mounting kit, valve spe-
cific
SS, PP
Seals NBR
3.2 Description
The GEMÜ 4240 combi switchbox is suitable for mounting to
pneumatically operated linear actuators. The position of the
valve spindle is reliably detected electronically and reported
via microswitches or proximity switches, using play-free and
non-positive mounting. Integrated pilot valves enable direct
activation of the process valve connected to them. The
product has been designed specially for valves with a stroke
of 5 to 75 mm.
3.3 Function
The GEMÜ 4240 combi switchbox indicates the current posi-
tion 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 communication interface. When the valve is
closed, the spring in the mounting kit presses the spindle in
the combi switchbox downwards and indicates that the valve
is CLOSED using the communication interface.
3 Product description
www.gemu-group.com6 / 23GEMÜ 4240
4 GEMÜ CONEXO
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 display this informa-
tion.
1
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 death or severe injury
●Do not use the product in potentially
explosive zones.
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 product is not intended for use in potentially explosive
areas.
The product is designed for mounting to pneumatically oper-
ated linear actuators. The position of the valve spindle is elec-
tronically detected and reported via microswitches or proxim-
ity switches through play-free and non-positive mounting. In-
tegrated pilot valves enable direct activation of the process
valve connected to them.
●Use the product in accordance with the technical data.
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 4240
2 Fieldbus Code
Without 000
3 Accessory Code
Accessory Z
4 Housing material Code
PPS base, PC cover 01
5 Action Code
Single acting, with manual override 01
Double acting, with manual override 02
Single acting, without manual override E1
6 Electrical connection Code
M16 Skintop cable gland 03
7 Pneumatic connection Code
G1/8 connection thread 01
Air supply 6 mm angled connection,
exhaust air 6 mm angled connection
04
7 Pneumatic connection Code
Air supply 6 mm T-connection,
exhaust air 6 mm angled connection
05
G1/8 connection thread
(for IP67 or piped air outlet)
E1
8 Switch Code
Change-over contact, microswitch, 24 V DC, 250 V AC
Crouzet, V4S, SPDT
M1
Proximity switch, 2-wire, NAMUR
P+F, HJ1.5-6.5-15-N-Y180094
N1
Proximity switch, 3-wire, make contact, PNP, 10–30 V
DC
Balluff, BES 516-371-SA 16
P1
9 Connection diagram Code
Microswitch M1
Terminals, NAMUR N1
3-wire P1
10 Travel length Code
Potentiometer, 75 mm length 075
Order example
Ordering option Code Description
1 Type 4240 Combi switchbox
2 Fieldbus 000 Without
3 Accessory Z Accessory
4 Housing material 01 PPS base, PC cover
5 Action 01 Single acting, with manual override
6 Electrical connection 03 M16 Skintop cable gland
7 Pneumatic connection 04 Air supply 6 mm angled connection,
exhaust air 6 mm angled connection
8 Switch M1 Change-over contact, microswitch, 24 V DC, 250 V AC
Crouzet, V4S, SPDT
9 Connection diagram M1 Microswitch
10 Travel length 075 Potentiometer, 75 mm length
6 Order data
www.gemu-group.com 7 / 23 GEMÜ 4240
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: 0 to 60 °C
Media temperature: 0 — 50 °C
Storage temperature: -10 — 70 °C
7.3 Pressure
Operating pressure: 30 — 105 psi
Observe the maximum control pressure of the valve actuator.
Flow rate: 250 Nl/min
7.4 Product compliance
Machinery Directive: 2006/42/EC
EMC Directive: 2014/30/EU
(only code N1 and P1)
Low Voltage
Directive:
2014/35/EU
(only code M1)
RoHS Directive: 2011/65/EU
7.5 Mechanical data
Installation position: Optional
Weight: 420 g
Protection class: IP 65 acc. to EN 60529
IP 67 is achieved by piping away the exhausting air
Travel sensor: 5 — 75 mm
www.gemu-group.com8 / 23GEMÜ 4240
7 Technical data
7.6 Electrical data
Switch type: Code M1 Code N1 Code P1
Microswitch, change-over con-
tact, SPDT
2-wire NAMUR 3-wire, normally open contact,
PNP
Supply voltage: Switch Pilot valve
Code M1 Code N1 Code P1
24 V DC, 250 V
AC
8 V DC 10 to 30 V DC 24 V DC (± 10%)
Current consumption: Switch
Code M1 Code N1 Code P1
for DC: 5 mA to 5 A
for AC: 100 mA to 6 A
≥ 3 mA (undamped)
≤ 1 mA (damped)
0–200 mA
Power consumption: Pilot valve 1.3 W
Electrical connection
type:
Connection thread: M16 x 1.5, WAF 19
Cable diameter: 4.5 to 10mm
Recommended wire cross section: 0.75 mm² x 8 cables
8 Dimensions
142
Ø 90
14,5
86,5 26
11
SW 24
Square
Dimensions in mm
GEMÜ 4240www.gemu-group.com 9 / 23
8 Dimensions
www.gemu-group.com10 / 23GEMÜ 4240
9 Manufacturer's information
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
1. Observe the national regulations and provisions.
2. Observe the installer provisions.
3. Lay cables securely and protect them from damage.
4. Connect open wire ends in a junction box with protection
class IP20 and higher or outside the EX area
10.1 Preparations for installing the valve (linear
actuator)
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 Information on use in damp conditions
1
The following information is intended to help when installing
and operating the product in damp conditions.
1. Lay cables and pipework so that no condensate or rain
water that remains on the pipework / cables can enter the
cable glands or plugs of the product.
2. Check that all cable glands or plugs are positioned cor-
rectly
3. Check the sealing ring 1 for any damage and correct posi-
tioning before tightening the cover.
10.3 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.
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