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General notes about the document's applicability and authoritative version.
Explanation of symbols for tasks, responses, LED conditions, and warning notes.
Describes the structure and levels of warning notes including DANGER, WARNING, CAUTION, and NOTICE.
List of essential safety checks and preparations before starting the product.
Safety instructions to be followed during the product's operational phase.
Guidance on seeking assistance when encountering uncertainties.
Details the components and materials of the GEMÜ 1235 electrical position indicator.
Explains the status LEDs and their meanings for different device versions.
Table showing LED states for different operational modes (OPEN, CLOSED, ERROR, etc.).
Overall description of the GEMÜ 1235, its suitability, and features.
Explains how the GEMÜ 1235 indicates valve position via LEDs and communication.
Details the information found on the product label, including device version and manufacturing data.
Information about the RFID chip in CONEXO variants for electronic identification.
Warning about explosion risk and use in explosive zones.
Warning about improper use leading to severe injury or voiding warranty.
Lists codes for various configurations of the GEMÜ 1235.
Provides an example of how to construct an order code for the product.
Specifies the ambient and storage temperature ranges for the product.
Lists EMC Directive, SIL, HFT, MTTR, MTBF, and UL listing details.
Details installation position, weight, protection class, and travel sensor specifications.
Covers supply voltage, duty cycle, reverse battery protection, fuse, and current consumption.
Specifies the electrical connection as a 1x 5-pin M12 plug (A-coded).
Illustrates switching characteristic with timing diagrams and explains switch points.
Details default and minimum switch points for different travel sensor versions.
Provides dimensional drawings and a table with measurements (A, B, C) for different sensor versions.
Instructions for checking delivery contents and for factory testing.
Describes the product's packaging material and its recyclability.
Guidelines for safe transportation and disposal of packaging material.
Recommendations for storing the product to maintain its condition.
Steps to prepare a linear actuator before installing the indicator.
Steps to prepare a quarter turn actuator for indicator installation.
Instructions and cautions for assembling the mounting kit onto the indicator.
Details on how to install an adapter for linear actuators.
Steps for assembling the mounting kit for quarter turn actuators.
Detailed steps for assembling the stroke limiter for linear actuators.
Instructions and cautions for installing the indicator on linear actuators.
Instructions and cautions for installing the indicator on quarter turn actuators.
Explains the pinout and function for IO-Link connections in specific device versions.
Lists scenarios requiring end position programming, like retrofitting or replacement.
Outlines the available methods for programming end positions: on-site, input pin, or interface.
Step-by-step guide for programming end positions directly on the device.
Procedure for initializing end positions using the IO-Link communication interface.
Steps to program end positions using the dedicated programming input pin.
Explains how LED error messages indicate specific issues with the product.
Table detailing errors, their causes, and recommended troubleshooting steps.
Guidelines for non-standard maintenance and visual examination.
Information that no spare parts are available and returns are required for repair.
Instructions on how to clean the product safely.
The GEMÜ 1235 is an electrical position indicator designed for use with pneumatically operated linear actuators and, with specific mounting parts, also suitable for pneumatically operated quarter turn actuators and other selected actuator versions. It reliably detects and evaluates the valve spindle's position using play-free and non-positive mounting. The device incorporates intelligent microprocessor-controlled functions that facilitate commissioning and support during operation. The current valve position is displayed via high-visibility LEDs and fed back via electrical signals.
The GEMÜ 1235 indicates the valve's position. When the valve is open, the spindle in the electrical position indicator moves upwards, signaling an OPEN valve position through the high-visibility LEDs and the communication interface. When the valve is closed, a spring in the mounting kit pushes the spindle downwards, indicating a CLOSED valve position via the high-visibility LEDs and communication interface.
The device offers several usage features, including visual status indication through LEDs. These LEDs provide information on various states such as FAULT (red), PWR/COM (green), CLOSED (green), ERROR (red), and OPEN (orange). A "High visibility LED" also indicates CLOSED (green) or OPEN (orange) positions. In programming mode, the LEDs flash alternately green/orange. Error conditions are indicated by flashing orange LEDs, and a location function, used for optical identification of the device in a plant, causes all high-visibility LEDs to flash green, overriding other flash codes without affecting device function.
The GEMÜ 1235 supports different device versions, including Code 3E (Open/Closed position feedback, programming input, high visibility optical position indicator, IO-Link communication) and Code 4E (Open/Closed position feedback inversed, programming input, high visibility optical position indicator, IO-Link communication). Versions 3S and 4S are similar but without programming input and IO-Link communication.
The end positions of the device must be programmed under specific conditions: when retrofitting an electrical position indicator, replacing the actuator, or replacing the diaphragm. If the electrical position indicators were factory-fitted to the process valve, the end positions would already be programmed. Programming can be done on-site, via the programming input (pin 5), or through a communication interface, with automatic programming recommended for the latter.
On-site end position programming involves pulling up the housing cover (approx. 2 mm), turning it anticlockwise until it stops to enter programming mode (indicated by OPEN and CLOSED LEDs flashing alternately, and the High visibility LED flashing alternately green/orange). The valve is then opened to its end position, closed to its end position, and finally, the housing cover is turned clockwise and pressed down to set the end positions.
Programming via IO-Link involves selecting and briefly activating the automatic programming mode (parameter data "Programming mode" and process data "Programming mode" respectively, for >100 ms). This is indicated by OPEN and CLOSED LEDs flashing alternately, and the High visibility LED flashing alternately green/orange. The valve is then opened and closed to its end positions. The programming mode automatically terminates if the valve remains unmoved for 5 seconds.
Programming via the programming input (pin 5) requires connecting the supply voltage and briefly connecting a 24 V DC signal (>100 ms) to pin 5. This also triggers the alternate flashing of OPEN and CLOSED LEDs and the High visibility LED. The valve is then opened and closed to its end positions, and the programming mode terminates automatically after 5 seconds of no valve movement.
For maintenance, regular visual examination of the product is crucial to prevent leakage and damage, considering operating conditions and potential hazards. Servicing and maintenance should be performed by trained personnel wearing appropriate protective gear. Before any work, the plant or component must be shut off, secured against recommissioning, and depressurized. Products that remain in the same position should be actuated four times a year. Any maintenance or repairs not described in the operating instructions should only be performed after consulting the manufacturer. No spare parts are available for this product; faulty units should be returned to GEMÜ for repair. Cleaning the product should be done with a damp cloth, avoiding high-pressure cleaning devices.
Disassembly involves reversing the assembly steps, unscrewing electrical wiring, and then disassembling the product, always observing warning notes and safety information. For disposal, attention must be paid to adhered residual material and gas diffusion from penetrated media. All parts must be disposed of according to disposal regulations/environmental protection laws, with electronic components disposed of separately.
For returns, a completed and signed return delivery note must be included with dispatch documents as per legal regulations for environmental and personnel protection. Without this note, GEMÜ cannot process credits or repair work and will dispose of the goods at the operator's expense. The process involves cleaning the product, requesting a return delivery note from GEMÜ, completing it, and sending the product with the note to GEMÜ.
General| Model | GEM 1235 |
|---|---|
| Category | Measuring Instruments |
| Power Supply | 9V battery |
| Display | LCD |
| Operating Temperature | 0°C to 50°C |
| Dimensions | 150mm |
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