GEMÜ 1435 ePos

Intelligent electro-pneumatic positioner

EN Operating instructions

further information
webcode: GW-1435
All rights including copyrights or industrial property rights are expressly reserved.
Keep the document for future reference.
© GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
28.08.2023

GEMÜ 1435 ePos 2 / 71 www.gemu-group.com

 1 Quick commissioning

1 Quick commissioning

CAUTION
Hazardous situation
▶ Risk of injury or damage possible.
● For correct commissioning, the product must be calibrated to the process valve via
the initialization process.
● During this commissioning, the valve is automatically opened and closed several
times. It must therefore be ensured in advance that this does not lead to a dangerous
situation.

NOTICE
Incorrect initialization
● Always carry out initialization without operating medium pressure on the process valve. Carry out initialization of the pro-
cess valve in neutral position (NO/NC).

NOTICE
● For delivery of the product assembled on a valve at the factory, the complete construction is already ready for operation at
a control pressure of 5.5 to 6 bar without operating 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 ac-
tuator replacement). The initialization is retained even in the event of voltage cutoff.

NOTICE
● 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 repeated every time that the process valve is changed (e.g. seal replacement
or actuator replacement).

NOTICE
Operating errors
● Prior to commissioning, familiarize yourself with the operation of the product.

The initialization is absolutely essential for the correct operation of the positioner and must be carried out once.
For delivery of the product pre-assembled on a valve at the factory, the complete construction is already ready for operation at a
control pressure of 5.5 to 6 bar without operating pressure - the positioner is in automatic operation. A reinitialization is recom-
mended 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.

Prerequisites:
- Mounted to the valve.
- Air supply, max. 6 bar, connected.
- 24 V DC supply voltage connected.
- Set value and actual value signals need not be connected.
- For correct commissioning proceed as described in the following flow chart:

NOTICE
Tip for use
▶ During automatic initialization of actuators whose movement profiles are not continuous (i.e. with undefined stopping or
stalling, e.g. with large size butterfly valves), it may not be possible to clearly detect the end positions and unjustified error
messages may appear (for example LEAKAGE).
▶ Manual initialization with sequential movement through the menu by the operator or, if possible, acknowledging the error
message to repeat the step may help here (see “Carrying out initialization“, page 51).

www.gemu-group.com 3 / 71 GEMÜ 1435 ePos

1 Quick commissioning

Menu sequence for quick initialization of the positioner

After switching
Nach on
dem Einschalten Press foralsmore
länger than 3 seconds
3s drücken

P = 45.4 PRESS -> FOR 3s NO INIT

D: NO INIT C: CONFIG 1: SETPOINT 2: INIT ALL

Press for3smore
länger als drückenthan 3 seconds

PRESS -> FOR 3s P = XX.X

2: INIT ALL 2: INIT RUN 1

The valve travel times (up->down, down->up) are measured

and displayed. If these measure < 1 second, an error P = XX.X
2: INIT RUN 2
is displayed and the valve travel time must be set
to at least > 1 second using the throttle screw(s). This step may need to be repeated
several times until an optimal valve travel time up -> down
2: INIT RUN 3
can be achieved. Experience has shown that valve travel times
of approx. 1-2 seconds produce optimal control characteristics. The
two valve travel times should ideally not be down -> up
2: INIT RUN 3
too far apart.For further information, see chapter
14.1.1 Error causes and troubleshooting during initialization
P = XX.X
The product is 2: INIT RUN 4
ready for operation and reacts
to the externally P = XX.X
specified set value. 2: INIT RUN 5

.. .... X = 30.5 X = 55.5 PRESS -> FOR 3s INIT OK

A: AUTO. W = 30.5 B: MANUAL. W = 55.5 C: CONFIG 1: SETPOINT 2: INIT ALL

Automatic quick initialization

The positioner adapts to the valve when automatic initialization is started (via the 2: INIT ALL parameter). All parameters are in-
dependently and automatically retrieved. This procedure can take a few minutes, depending on the valve.
If the message "INIT OK" appears, the product is ready for operation and can be set to the desired operating mode.
– Operating mode A: AUTO – reacts to the externally specified set value.
– Operating mode B: MANUAL – the valve position can be specified manually using the keys.

GEMÜ 1435 ePos 4 / 71 www.gemu-group.com

Contents
1 Quick commissioning .......................................... 3 16.1 Operating modes ........................................... 31
2 General information ............................................. 6 16.2 Parameter table ............................................. 33
2.1 Information .................................................... 6 16.3 Explanation of parameters ........................... 35
2.2 Symbols used ................................................ 6 17 System mode ADVANCED .................................... 38
2.3 Definition of terms ........................................ 6 17.1 Menu level ...................................................... 38
2.4 Warning notes ............................................... 6 17.2 Configuration menu (SETUP) ....................... 39
3 Safety information ............................................... 7 17.2.1 Menu structure overview ................. 40
17.2.2 Parameter overview ......................... 41
4 Product description ............................................. 7
17.2.3 Menu 1 Service ................................. 44
5 GEMÜ CONEXO .................................................... 9 17.2.4 Menu 2 SetBasics ............................ 49
6 Intended use ........................................................ 9 17.2.5 Menu 3 SetFunction ......................... 54
7 Order data ........................................................... 10 17.2.6 Menu 4 SetCalibration ..................... 61
17.2.7 Menu 5 Communication .................. 65
8 Technical data ..................................................... 11
18 Troubleshooting .................................................. 66
9 Dimensions .......................................................... 15
9.1 Positioner dimensions .................................. 15 19 Inspection and maintenance ................................ 67
9.2 Dimensions of the travel sensor, mounting 19.1 Cleaning the product ..................................... 67
options and mounting facilities .................... 15 20 Disassembly ........................................................ 67
10 Manufacturer's information .................................. 16 21 Disposal .............................................................. 67
10.1 Delivery .......................................................... 16 22 Returns ................................................................ 67
10.2 Transport ....................................................... 16
Keyword index ..................................................... 68
10.3 Storage ........................................................... 16
23 EU Declaration of Conformity in accordance with
11 Assembly ............................................................. 16
2014/30/EU (EMC Directive) ................................ 69
11.1 Information for use in damp conditions ...... 16
11.2 Assembly on linear actuators ....................... 16 24 EU Declaration of Conformity In accordance with
11.3 Assembly on quarter turn actuators ............ 18 2011/65/EU (RoHS Directive) ............................... 70
11.3.1 Preparations for assembly to the
valve (quarter turn actuator) ............ 18
11.4 Checking the mechanical mounting ............ 22
12 Electrical connection ........................................... 23
13 Pneumatic connection ......................................... 26
13.1 Connection diagram for linear valves .......... 26
13.1.1 Connection diagram for NC valves
(Normally Closed) ............................ 26
13.1.2 Connection diagram for NO valves
(Normally Open) ............................... 26
13.1.3 Connection diagram for double act-
ing valves .......................................... 26
13.2 Connection diagram for quarter turn actuat-
ors ................................................................. 27
13.2.1 Connection diagram for NC/NO
valves (Normally Closed/Normally
Open) ................................................ 27
13.2.2 Connection diagram for double act-
ing valves .......................................... 27
13.2.3 Note for vertical pneumatic connec-
tions .................................................. 27
13.3 Replacing the filter strainers ........................ 27
14 Commissioning .................................................... 27
14.1 Without default setting (when supplied
without a valve) ............................................. 28
14.1.1 Error causes and troubleshooting
during initialization ........................... 29
14.2 With default setting (positioner supplied
mounted to the valve) ................................... 31
15 Switching the operator interface .......................... 31
16 System mode CLASSIC ........................................ 31

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2 General information

2 General information DANGER

2.1 Information Imminent danger!
▶ Non-observance can cause death or
- The descriptions and instructions apply to the standard ver- severe injury.
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
WARNING
ensure faultless operation of the product. Potentially dangerous situation!
- Should there be any doubts or misunderstandings, the Ger- ▶ Non-observance can cause death or
man version is the authoritative document. severe injury.
- Contact us at the address on the last page for staff training
information.
CAUTION
2.2 Symbols used
Potentially dangerous situation!
The following symbols are used in this document: ▶ Non-observance can cause moderate
Symbol Meaning to light injury.

Tasks to be performed
Response(s) to tasks
NOTICE
– Lists
Potentially dangerous situation!
2.3 Definition of terms ▶ Non-observance can cause damage to
property.
Working medium
The medium that flows through the GEMÜ product.
Control function The following symbols for the specific dangers can be used
within a warning note:
The possible actuation functions of the GEMÜ product.
Control medium Symbol Meaning
The medium whose increasing or decreasing pressure causes Danger of explosion
the GEMÜ product to be actuated and operated.
Speed-APfunction
Speed Assembly and Programming, a particularly Danger - high voltage!
user-friendly commissioning function for fast mounting, auto-
mated 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). Corrosive chemicals!
Changeover to normal operating mode takes place automatic-
ally after successful completion.

2.4 Warning notes Hot plant components!

Wherever possible, warning notes are organised according to
the following scheme:

SIGNAL WORD
Possible Type and source of the danger
symbol for the
Possible consequences of non-observance.
specific
danger
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:

GEMÜ 1435 ePos 6 / 71 www.gemu-group.com

 4 Product description

3 Safety information 4 Product description

The safety information in this document refers only to an indi-
4.1 Construction
vidual product. Potentially dangerous conditions can arise in
combination with other plant components, which need to be
1 2 3
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 Item Name Materials
substances. 1 Housing Base: Aluminium, epoxy
The safety information does not take into account: coated, black
- Unexpected incidents and events, which may occur during Cover: Aluminium, powder
installation, operation and maintenance. coated, silver
- Local safety regulations which must be adhered to by the 2 Display with cover PMMA
operator and by any additional installation personnel. 3 Operating elements PMMA
with cover
Prior to commissioning:
1. Transport and store the product correctly. 4.2 Description
2. Do not paint the bolts and plastic parts of the product. The GEMÜ 1435 ePos digital electro-pneumatic positioner is
3. Carry out installation and commissioning using trained used to control pneumatically operated process valves with
personnel. single acting or double acting linear or quarter turn actuators,
4. Provide adequate training for installation and operating and detects the position of the valve using an external travel
personnel. sensor. It has a robust aluminium housing with protected op-
erating keys and an LCD display which allows the product to
5. Ensure that the contents of the document have been fully
be individually adapted to the control task. The travel times
understood by the responsible personnel.
can be set using integrated throttles. Connection and mount-
6. Define the areas of responsibility. ing to NAMUR is also possible. Therefore, the GEMÜ 1435
7. Observe the safety data sheets. ePos is an optimal solution for control tasks with high require-
8. Observe the safety regulations for the media used. ments, especially in applications with harsh environmental
conditions.
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.

www.gemu-group.com 7 / 71 GEMÜ 1435 ePos

4 Product description

4.3 Function 4.5 Product label

The product is an intelligent electro-pneumatic positioner for Design in accordance with order data Max. permissible control pressure
Output signal
mounting to pneumatic linear and quarter turn actuators.
The positioner can be directly mounted to the actuator using a 1435000Z10001

D-74653 Ingelfingen
Fritz-Müller-Str- 6-8
suitable mounting kit. The mounting kit contains both the PST max 6,0bar
24V o:0-10V 0-60° C
mounting bracket and adapter and the appropriate travel single 50l/min Year of
sensor with the corresponding fixing screws. Device version 12 2017
manufacture
Remote mounting is also possible. The mounting bracket/ad- 88353619 - 01302702 | 0001
apter are not required for this.
Batch number
The travel sensor measures the current position of the valve
Item number Serial number
and reports it to the product's electronic system. The elec-
tronic system then compares the actual value of the valve
with the set value specified and readjusts the valve in the
NOTICE
event of a system deviation. Device version
The information required can be called up on the two-line dis- ▶ These instructions are valid for devices from device ver-
play of the product. Self-explanatory help texts that explain sion 10. It is possible to determine which firmware has
the meaning of the parameters called-up are also displayed. been used on the basis of the device version. For older
Operation is carried out using the four keys. devices (device version older than 10), different operating
instructions with potentially different operating specifica-
4.4 Fail safe function tions are used.
▶ A change to the device version can also be due to tech-
The product has a fail safe function which ensures that the
nical changes to the hardware, which is why several
outlets are controlled during a pneumatic and electrical power
device versions can contain the same firmware version.
supply failure. The behaviour depends on the design. A safety
reaction also ensures that the valve is controlled in the event Device Firmware version Effective Changes
of a signal error. This fail safe function is not a substitute for version from
specific plant safety requirements. The product is not a safety
10 V2.0.0.0 09/2013
control system.
11 V2.0.0.2 02/2014 Bugfix, error output
Error Output 2 Output 4
12 V2.0.0.4 03/2014 Bugfix, incorrect
Failure of the Single acting: ven- Single acting: non actual value output
electrical ted existent for normally open
power Double acting: ven- Double acting: pres- valves
supply ted surized 12 / 13 V2.0.0.5 06/2015 Optimization of ac-
Pneumatic supply Single acting: ven- Single acting: non tuation behaviour
failure ted existent of small-volume lin-
Double acting: un- Double acting: un- ear actuators with
defined, defined, low stroke

dependent on the dependent on the 14 V2.0.0.6 09/2018 Adaptation to the

operating condi- operating condi- new display con-
tions of the actu- tions of the actu- troller
ator ator
Set value < 4.0 mA* Single acting: ven- Single acting: non
ted existent
Double acting: ven- Double acting: pres-
ted surized
Set value > 20 mA / Single acting: ven- Single acting: non
10 V ted existent
Double acting: ven- Double acting: pres-
ted surized
* Only when using the 4–20 mA type of set value (parameter
setting)
This fail safe function is not a substitute for specific plant
safety requirements.

GEMÜ 1435 ePos 8 / 71 www.gemu-group.com

 6 Intended use

5 GEMÜ CONEXO 6 Intended use

Order variant
DANGER
In the corresponding design with CONEXO, this product has
an RFID chip (1) for electronic identification purposes. The po- Danger of explosion
sition of the RFID chip can be seen below. The CONEXO pen ▶ Risk of severe injury or death.
helps read out information stored in the RFID chips. The CON- ● Do not use the product in potentially
EXO app or CONEXO portal is required to display this informa- explosive zones.
tion. ● The product can control valves in po-
tentially explosive areas using special
wiring (installation of the positioner
outside the EX area).

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
1
this document.
For further information please read the operating instructions
for CONEXO products or the CONEXO datasheet. The product is not intended for use in potentially explosive
areas.
Products such as the CONEXO app, the CONEXO portal and
the CONEXO pen are not included in the scope of delivery and The product with integrated pilot valves is designed for linear
need to be ordered separately. actuators and quarter turn actuators. The product works with
microprocessor controlled intelligent position control by
means of an analogue travel sensor (potentiometer). This is
connected in a force-locking way with the actuator spindle or
shaft by means of a mounting kit (spring, operating bush).
The valve position and the integrated travel sensor can be
monitored via the electrical connections. The pneumatic actu-
ator is directly operated and controlled by means of the pilot
valves.
● Use the product in accordance with the technical data.

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7 Order data

7 Order data
The order data provide an overview of standard configurations.
Please check the availability before ordering. Other configurations available on request.
Note: Pneumatic connecting components (union and compressed air tube) for the connection between the process valve and
positioner are included with each positioner.
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 6 Option Code
Electro-pneumatic positioner 1435 Electrical connections M12, 5-pin, 5
ePos heating element
Heating element 6
2 Fieldbus Code
4 - 20 mA, actual value output, 7
Without 000 electrical connections M12, 5-pin,
heating element
3 Accessory Code
Accessory Z 7 Flow rate Code
Electro-pneumatic, 50 l/min 01
4 Action Code
Electro-pneumatic, 90 l/min (Booster) 02
Single acting 1
Double acting 3 8 Special specification Code
Without
5 Explosion-proof class Code
Dead zone presetting 2% 2442
Without explosion-proof rating 0
Dead zone presetting 5% 2443
6 Option Code Inversed direction, 6960
Without 0 for quarter turn valves control function NO (2)

Electrical connections M12, 5-pin 1 9 CONEXO Code

4–20 mA, actual value output 2
Without
4- 20 mA, actual value output, 3
Integrated RFID chip for electronic identification and C
electrical connections M12, 5-pin
traceability
4 - 20 mA, actual value output, 4
heating element

Order example
Ordering option Code Description
1 Type 1435 Electro-pneumatic positioner
ePos
2 Fieldbus 000 Without
3 Accessory Z Accessory
4 Action 1 Single acting
5 Explosion-proof class 0 Without explosion-proof rating
6 Option 0 Without
7 Flow rate 01 Electro-pneumatic, 50 l/min
8 Special specification Without
9 CONEXO Without

GEMÜ 1435 ePos 10 / 71 www.gemu-group.com

 8 Technical data

8 Technical data
8.1 Medium
Working medium: Compressed air and inert gases

Dust content: Class 3, max. particle size 5 μm, max. particle density 5 mg/m³

Pressure dew point: Class 4, max. pressure dew point +3 °C

Oil content: Class 3, max. oil concentration 1 mg/m³

Quality classes to DIN ISO 8573-1
Note: Filter strainers are installed in the pneumatic connectors of the positioner to protect against
rough dirt particles. They can be ordered as spare parts with order number 1435 SFI. Each kit con-
tains 3 filter strainers. These filter strainers are meant as an additional protection and do not re-
place the requirement to filter all site compressed air.

8.2 Temperature
Ambient temperature: 0 — 60 °C (standard, Option code 0, 1, 2, 3)
-20 — 60 °C (with heating element, Option code 4, 5, 6, 7)
≤ 5 °C (heating active)
≥ 15 °C (heating inactive)

Storage temperature: 0 — 60 °C

8.3 Product compliance

EMC Directive: 2014/30/EU

RoHS Directive: 2011/65/EU

8.4 Pressure
Operating pressure: 0 — 6 bar
The applied pressure must not exceed the maximum control pressure of the process valve.

Flow rate: 50 Nl/min (Flow rate code 01)

90 Nl/min (Flow rate code 02)

Air consumption: 0 Nl/min (when idle)

8.5 Mechanical data

Installation position: Optional

Protection class: IP 65 acc. to EN 60529

Weight: 1.7 kg

www.gemu-group.com 11 / 71 GEMÜ 1435 ePos

8 Technical data

Travel sensor:

Linear design Quarter turn

design
Detection range: 1–29 mm 1.5–48.5 mm 2.0–73 mm Angle of rotation
5–90°
Operating range: 0–30 mm 0–50 mm 0–75 mm Angle of rotation
0 - 93°
Resistance R: 3 kΩ 5 kΩ 5 kΩ 3 kΩ
Minimum travel sensor 10% (only relevant for initialization)
change:
Connection: Pre-fitted cable (max. 20 m)
Installation: external
Correlation - Travel Retracted (top) 90° ≙ 100% (valve
sensor 1) ≙ 100% (valve open) open)
spindle/valve position Extended (bottom) 0° ≙ 0% (valve
≙ 0% (valve closed) closed)
1) Type of design code 6960: Inversed mode of action compared with description
(Travel sensor signal inversed). For valves with inverted correlation.

8.6 Electrical data

8.6.1 Power supply
Supply voltage: 24 V DC (-5/+10%)

Power consumption: Single acting: ≤ 6.5 W

Double acting / Booster: ≤ 9.8 W
plus in each case: max. 36 W for active digital outputs with max. on-load current
max. 25 W for operation with heating element

Reverse battery protec- Yes

tion:

Duty cycle: Continuous duty

Electrical protection III

class:

8.6.2 Analogue input

Set value input: 0/4 - 20 mA; 0 - 10 V

Input type: passive

Input load: 0/4–20 mA:

50 Ω + approx. 0.7 V voltage drop due to reverse battery protection
0–10 V:
100 kΩ

Accuracy/linearity: ≤ ±0.3% of full flow

Temperature drift: ≤ ±0.5% of full flow

Resolution: 12 bit

Reverse battery protec- yes

tion:

Overload proof: Yes (up to ± 24 V DC)

GEMÜ 1435 ePos 12 / 71 www.gemu-group.com

 8 Technical data

8.6.3 Analogue output

Note: The analogue output 4-20 mA must be ordered using the ordering option "Option".

Actual value output: 0 - 10 V

4 - 20 mA (optional)

Output type: Active

On-load current: 0–10 V: Max. 10 mA

Load resistor: 4 – 20 mA:

max. 600 Ω (for ordering option "Option" code 2, 3, 4, 7)

Accuracy/linearity: ≤ ±1% of full flow

Temperature drift: ≤ ±0.5% of full flow

Resolution: 12 bit

Short-circuit proof: Yes

Overload proof: Yes (up to ± 24 V DC)

8.6.4 Digital output signals

Switching outputs: Alarm output 1
Alarm output 2
Error message output

Switching voltage: Supply voltage

Drop voltage: Max. 2.5 V DC at 0.5 A

Short-circuit proof: yes

Overload proof: Yes (up to ± 24 V DC)

Type of contact: PNP

Pull-Down resistance: 120 kΩ

On-load current: max. 0.5 A

8.6.5 Travel sensor input

Supply Typically 10 V DC
voltage UP+:

Resistance range of re- 1 to 10 kΩ

mote potentiometers:

Input voltage 0 to UP+

range:

Input resistance: 330 kΩ

Accuracy/linearity: ≤ ±0.3% of full flow

Temperature drift: ≤ ±0.3% of full flow

Resolution: 12 bit

www.gemu-group.com 13 / 71 GEMÜ 1435 ePos

8 Technical data

8.6.6 Positioner specifications

Note: The following diagram is valid for valves with a standard assignment of the spindle position to the
valve position.
(See section "Mechanical data, correlation between travel sensor spindle/valve position")

Control diagram: Default setting / The control characteristic is adjustable.

100

Valve opening degree [%]

75

50

25

0
0 5 10 15 20 mA
4 8 12 16 20 mA
0 2,5 5 7,5 10 V

Set value input (mA / V)

During initialization, the 1435 ePos positioner automatically detects the control function of the
valve and adjusts itself by default so that the valve is closed when the signal is 0/4 mA or 0 V.*
The assignment can be changed subsequently by means of parameters.
* with double acting actuators dependent on pneumatic actuator

System deviation 1 % default setting

(dead zone): ≥ 0.1 % (adjustable)
≤ 2.0 % (preset, K-no. 2442)
≤ 5.0 % (preset, K-no. 2443)

Initialization: automatic (manual possible in ADVANCED system mode)

Close tight function: option

GEMÜ 1435 ePos 14 / 71 www.gemu-group.com

 9 Dimensions

9 Dimensions
9.1 Positioner dimensions

M8x1.25 M5 G 1/4

90

50
M6 32
160
78
170
84
G1/4
40

Dimensions in mm

9.2 Dimensions of the travel sensor, mounting options and mounting facilities
For dimensions of travel sensors 4231 and 4232, which are used to measure the travel from the process valve, as well as the
mounting bracket for wall mounting the 1435, see the 1435 ePos datasheet.

www.gemu-group.com 15 / 71 GEMÜ 1435 ePos

10 Manufacturer's information

10 Manufacturer's information 11.2.2 Linear travel sensor mounting kit assembly for remote
mounting
10.1 Delivery
CAUTION
● Check that all parts are present and check for any damage
immediately upon receipt. Pretensioned spring!
▶ Damage to the device.
The product's performance is tested at the factory. The scope
● Slowly release the tension in the spring.
of delivery is apparent from the dispatch documents and the
design from the order number.
CAUTION
10.2 Transport Do not scratch the spindle!
1. Only transport the product by suitable means. Do not drop. ▶ A damaged spindle surface may cause failure of the
Handle carefully. travel sensor.

2. After the installation dispose of transport packaging ma- Item Name

terial according to relevant local or national disposal regu-
1 Travel sensor
lations / environmental protection laws.
2 Spindle
10.3 Storage 3 Spring
1. Store the product free from dust and moisture in its ori- 4 Operating bush
ginal packaging. 5 Guide bush*
2. Avoid UV rays and direct sunlight. 6 Threaded adapter**
3. Do not exceed the maximum storage temperature (see
*Included depending on version
chapter "Technical data").
**If a threaded adapter is included, it must be screwed into
4. Do not store solvents, chemicals, acids, fuels or similar
the actuator top of the process valve
fluids in the same room as GEMÜ products and their spare
parts. The process described below refers to the mounting kit
mounting for direct and remote mounting.

11 Assembly
11.1 Information for use in damp conditions 1
1. The product must not be used outdoors without a heating
element. The version with heating element may only be 1
used outdoors in a rain-protected area.
5
2. The product must be protected from the direct influence 1 2 5
of rain water.
3 2
11.2 Assembly on linear actuators 3
2 4
11.2.1 Preparations for assembly to the valve 4
1. Move the actuator A into zero position (actuator vented).
2. Remove optical position indicator 2 and / or protective cap 1. Pull the spindle 2 out of the travel sensor 1.
1 from the actuator top. 2. If included, push the guide bush 5 taper over the spindle 2
first.
1 2 3. Push the spring 3 over the spindle 2 and secure with the
operating bush 4.
4. Tighten the operating bush 4 by turning it clockwise.
5. Push in the spindle 2 as far as it will go on the spring 3
and then slowly release the pressure on the spring 3.

GEMÜ 1435 ePos 16 / 71 www.gemu-group.com

 11 Assembly

11.2.3 Installing the adapter 11.2.4 Direct mounting

With some mounting kits it is necessary to install an adapter
as well. These adapters are included with the required mount-
ing kits. Valves with a normally open and double acting con-
trol function (code 2+3) also include additional O-rings (1+2). 5
3
NOTICE 7 4
● The adapter only needs to be mounted if included. 6
2
● There are two variants for mounting the adapter.
1
- One adapter included with or without mounting bracket.
- Two adapters included (identical or different design) with
mounting bracket.
1
3

Item Name
1 Mounting bracket
2 Actuator
4 3 Travel sensor
4 Hexagon
5 M6 screws
6 M12 cable gland
7 M4 screws

1. Mount the travel sensor mounting kit.

2. Move the actuator to the open position.
3. Depending on the version, attach the mounting bracket 1
to the actuator 2 or adapter and guide the travel sensor 3
through the mounting bracket as far as it will go into the
actuator opening and screw in place in the clockwise dir-
1. Move the actuator to the closed position.
ection against the initial spring tension.
2. Place O-rings 1 and 2 into adapter 3.
If one adapter is included:
3. Screw the adapter 3 into the actuator opening as far as it
will go and tighten.
ð In some cases, if included, a mounting bracket may
also need to be mounted under the adapter (see
chapter 10.6, Direct mounting with mounting bracket
type 2). Otherwise, the mounting bracket included is
mounted later.
If two adapters are included with mounting bracket:
4. The mounting bracket 4 is fixed through the travel sensor
later.
5. Screw the appropriate adapter 3.1 into the actuator open-
ing as far as it will go and tighten.
ð The mounting bracket is mounted later with the
second adapter (see chapter 10.6, Direct mounting
with mounting bracket type 4).

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11 Assembly

NOTICE NOTICE
Wrong mounting kit Wrong mounting kit
▶ If no initial spring tension can be felt, it may be the case ▶ If no initial spring tension can be felt, it may be the case
that the wrong mounting kit with too short an operating that the wrong mounting kit with too short an operating
bush has been used. bush has been used.
▶ If the spring locks and the positioner cannot be correctly ▶ If the spring locks and the positioner cannot be correctly
mounted on the valve, it may be the case that the wrong mounted on the valve, it may be the case that the wrong
mounting kit with too long an operating bush has been mounting kit with too long an operating bush has been
used or that a required adapter has not been used. used or that a required adapter has not been used.
● In both cases, check that the mounting kit parts are being ● In both cases, check that the mounting kit parts are being
used correctly and in their entirety. used correctly and in their entirety.
4. Tighten the travel sensor 3 using a suitable open-end 5. Tighten the travel sensor 3 using a suitable open-end
wrench WAF 27. wrench WAF 27.
5. Attach the positioner to the mounting bracket 1 with two 6. Connect the travel sensor 3 to the positioner electrically.
M6 screws 5. 7. Loosen the M4 screws 7 on the housing cover and swing
6. Loosen the M4 screws 7 on the housing cover and swing the cover open.
the cover open. 8. Feed the connection cable of the travel sensor into the
7. Feed the connection cable of the travel sensor into the cable gland 6 of the positioner and connect to the terminal
cable gland 6 of the positioner and connect to the terminal board as shown in the wiring diagram.
board as shown in the wiring diagram. 9. Then tighten the cable gland. The cable must be held
8. Then tighten the cable gland. The cable must be held firmly on all sides.
firmly on all sides. 10. Connect the pneumatic supply to the positioner and con-
9. Connect the pneumatic supply to the positioner and con- nect to the process valve.
nect to the process valve.
11.3 Assembly on quarter turn actuators
11.2.5 Remote mounting
11.3.1 Preparations for assembly to the valve (quarter turn
GEMÜ 4232 actuator)
1. Move the actuator A into zero position (actuator vented).
1
A
2

2. Remove the screw 1 from the trigger cam 2.

1. Mount the travel sensor mounting kit.

2. Move the actuator to the open position.
3. Guide the travel sensor 3 as far as it will go into the actu-
ator opening and screw it in clockwise against the initial
spring tension.
4. Fit the positioner in a suitable location.

NOTICE
Mounting bracket
▶ The GEMÜ 1445 000 ZMP mounting bracket, which is
available separately, can be used for this.

GEMÜ 1435 ePos 18 / 71 www.gemu-group.com

 11 Assembly

11.3.2 Rotary travel sensor mounting kit assembly

NOTICE
Determining the rotational direction of the actuator
▶ When viewed from above, the rotational direction of the
actuator must be anticlockwise, when the actuator moves
from the CLOSED to the OPEN position. In cases where 4
the actuator turns in a clockwise direction, the travel
sensor's end position, contrary to given instructions,
needs to be in the opposite direction. 6

eco 4. Mount the black housing of the rotary travel sensor 4 in

OPEN parallel to the mounting bracket 6 in a longitudinal direc-
1. The shaft of the rotary travel sensor is provided with a
ERROR
tion.
marking 2. CLOSED
POWER

7
0

90

2
4

6
2. Set the marking 2 so that it is correctly aligned with the 0°
position on the underside of the travel sensor housing.
The 0° position is located on the left-hand side of the
cable exit (the electrical operating range is located in the
travel range between the 0° and 90° positions).

5. Mount the external rotary travel sensor 7 with the adapter

4 on the mounting bracket 6.
2

4
6

8
3. Place the adapter 4 onto the shaft of the rotary travel
sensor 2 without twisting the shaft.

6. Note the direction of the scale 8.

ð View from below of the travel sensor 7 with mounting
bracket 6.

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11 Assembly

11.3.3 Direct mounting

1. Positioner positioned above:
NOTICE
▶ Before mounting the travel sensor on the actuator, make
sure that the shaft height and the hole pattern in the actu-
ator match the dimensions of the mounting bracket 6.

Butterfly valve 5
closed 3
1
10

2
9
Butterfly
valve 2. b) Positioner flanged onto NAMUR control air connectors:

open 3
1 N
4
1
5
2 6
7
3 8

5
Item Name 2
1 Adapter marking
2 Pneumatic connection
3 Potentiometer shaft marking
4 Actuator shaft (from above) Item Name
5 Rotary potentiometer shaft 1 Mounting bracket
6 Adapter 2 Quarter turn actuator
7 Rotary potentiometer connection 3 Rotary travel sensor
8 Butterfly disc: Closed N NAMUR adapter
9 Actuator 5 Cable gland
10 Rotary potentiometer

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 11 Assembly

11.3.4 Remote mounting

3
NOTICE
4
▶ The travel sensor's cable exit protective coating is not UV-
1
resistant and must therefore be protected against direct
exposure to weather.
2
7

6
4

3
4
3
1
2

7
3. Mount the travel sensor mounting kit (see “Rotary travel 4
sensor mounting kit assembly“, page 19). 6
4. Place the travel sensor 3 with adapter 4 and mounting 3
bracket 1 on the actuator 2.

NOTICE
▶ The adapter lug 4 must engage in the actuator shaft
groove.

NOTICE 1. Fit the positioner 1 somewhere suitable.

Installation position
▶ Observe the correct orientation of the operating range of NOTICE
the rotary travel sensor (see “Checking the mechanical Mounting bracket
mounting“, page 22). ▶ The GEMÜ 1445 000 ZMP mounting bracket, which is
5. Mount the mounting bracket 1 on the actuator 2 using the available separately, can be used for this.
screws, washers and spring washers provided. 2. Mount the travel sensor mounting kit (see “Rotary travel
6. Depending on the mounting variant, mount the positioner sensor mounting kit assembly“, page 19).
on the mounting bracket 1 or flange it directly onto the 3. Place the travel sensor 7 with adapter 4 and mounting
control air connector of the quarter turn actuator 2 with bracket 6 on the actuator 3.
the NAMUR adapter.
7. Connect the travel sensor 3 to the positioner electrically. NOTICE
8. Loosen the screws 7 on housing cover and swing the ▶ The adapter lug 4 must engage in the actuator shaft
cover open. groove.
9. Feed the connection cable of the travel sensor into the 4. Mount the mounting bracket 6 on the actuator 3 using the
M12 cable gland 6 of the positioner and connect to the ter- screws, washers and spring washers provided.
minal board as shown in the wiring diagram.
5. Connect the travel sensor 7 to the positioner electrically.
10. Tighten the M12 cable gland.
6. Loosen the screws on the housing cover and swing the
ð The cable must be held firmly on all sides. cover open.
11. Connect the pneumatic supply to the positioner and con- 7. Feed the connection cable of the travel sensor into the
nect to the quarter turn actuator 2 (not in the case of M12 cable gland of the positioner and connect to the ter-
mounting variant b). minal board as shown in the wiring diagram.
8. Tighten the M12 cable gland.

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11 Assembly

ð The cable must be held firmly on all sides.

9. Connect the pneumatic supply to the positioner and con-
nect to the quarter turn actuator 3.

11.4 Checking the mechanical mounting

1. Connect the product to the power and air supply (see elec-
trical connection and pneumatic connection).
2. The following message is displayed:

3. By pressing the and keys, the mounted actuator

can be moved to the OPEN and CLOSED position.
4. Important: The displayed valve position must be between
2% and 98%. If the display leaves this area, check the
mechanical mounting again and, if necessary, readjust the
orientation of the rotary travel sensor. In the case of linear
travel sensors, check the mounting parts used for compat-
ibility.

NOTICE
Note for the rotary travel sensor
▶ The slotted holes should be positioned in the centre on
the screws. If the travel range is incorrect (determined by
checking the attachment), loosen the two screws slightly
and twist the travel sensor. Set the travel up correctly and
tighten the screws again.

GEMÜ 1435 ePos 22 / 71 www.gemu-group.com

 12 Electrical connection

12 Electrical connection

CAUTION
Danger - high voltage!
▶ Electric shock.
● Before performing any work on the GEMÜ product switch off power and protect cir-
cuit from being switched on again.

12.1 Version with terminals (standard)

1. Loosen the screws (7) on the housing cover and swing the cover open (see “Assembly“, page 16).
2. Feed the connection cable of the travel sensor into the M12 cable gland of the positioner and connect to the terminal board
as shown in the wiring diagram (see “Electrical connection with cable gland“, page 24).
3. Feed the connection cable for the electrical supply and signal transmission into the M16 cable gland(s) of the positioner and
connect to the terminal board as shown in the wiring diagram (see “Electrical connection“, page 23).
4. Connect the 24 V DC supply voltage and potential earth.
5. Connect analogue input 0-20 mA, 4-20 mA or 0-10 V to the appropriate terminals for the specification of set values.
6. Then tighten all cable glands.
ð The cables must be held firmly on all sides.

NOTICE
Malfunctions caused by differences in potential
▶ In order to compensate for differences in potential due to plant-specific malfunctions, a jumper can be placed between ter-
minals GND and Iw-.

12.2 Version with connector (optional)

NOTICE
▶ GEMÜ 4231 and 4232 travel sensors with the M12 plug connection can be used for this version.
1. Connect the connection cable with the appropriate travel sensor connector to the X3 M12 built-in socket on the side of the
positioner.
2. Connect the connection cable with the appropriate connector for electrical supply and signal transmission to the X1 and X2
M12 plugs of the positioner as shown in the layout (see “Electrical connection“, page 23).
3. Connect the 24 V DC supply voltage and potential earth.
4. Connect analogue input 0-20 mA, 4-20 mA or 0-10 V * as appropriate for the specification of set values.
ð * Internal rewiring required for set value signal 0-10 V

X1

T
Uw+ Iw+ Iw- Uw- X+ X- GND 24V
X2
10V X

T
A1 A2 ERR

X3

NOTICE
Set value input 0-10 V
▶ For a set value input signal of 0-10 V DC, the positioner must be opened and the two stranded wires of the set value input
must be re-wired from terminals Iw+ and Iw- to terminals Uw+ and Uw-.

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12 Electrical connection

12.3 Electrical connection with cable gland

Note: Ordering option Option code 0, 2, 4, 6
Position of the connections

X1

X2

X3
Connection X1/X2: M16 cable gland

Connection X3: M12 cable gland

Recommended cable dia- X1 / X2: 4 - 10 mm

meter: X3: 3.5 – 7 mm

Terminals: Wago 236

Cross section of wire: 0.5...2.5 mm² / AWG 20…12

Internal wiring:
T
10V X Uw+ Iw+ Iw- Uw- X+ X- GND 24V

T
A1 A2 ERR

Key
10 V green 1) Connection of external travel sensor
X brown 1)
┴ white 1)
IW+ Set value input 0 / 4-20 mA
IW-
U W+ Set value input 0 - 10 V
U W-
X+ Actual value output 0 - 10 V
X- 4-20 mA (optional) - internal supply

GND Supply voltage 24 V DC

24 V
Potential earth

A1 Alarm 1
A2 Alarm 2
ERR Error message output
┴ GND out

1) Core colours when using an external travel sensor

GEMÜ 4231 or 4232. Connect in the specified order.
Other external travel sensors may have different core colours.

GEMÜ 1435 ePos 24 / 71 www.gemu-group.com

 12 Electrical connection

12.4 Electrical connection with M12

Note: Ordering option Option code 1, 3, 5, 7
Position of the connectors

X1

X2

X3
Connection X1

3 5 1

Pin Signal name

1 Uv, 24 V DC supply voltage
2 Uo, error message output, 24 V DC
3 Uv, GND supply voltage
4 Uo, alarm output 1, 24 V DC
5 Uo, alarm output 2, 24 V DC

Connection X2

3 5 1

Pin Signal name

1 Iw+, set value input 0/4–20 mA *
2 Iw-, set value input 0/4–20 mA *
3 X+, actual value output 0 - 10 V / 4-20 mA
4 X-, actual value output 0 - 10 V / 4-20 mA
5 n.c.

* For set value input Uw = 0 - 10 V on-site rewiring is required

Connection X3 (for travel sensor connection)

1
4 5 2
3

Pin Signal name

1 UP+, actual value supply 10 V DC
2 UPsig, actual value input 0–10 V DC
3 UP-, actual value supply GND
4 n.c.
5 n.c.

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13 Pneumatic connection

13 Pneumatic connection 13.1 Connection diagram for linear valves

13.1.1 Connection diagram for NC valves (Normally Closed)
CAUTION
4
Flailing broken pneumatic lines.
▶ Risk of injury.
● Comply with the general safety measures when handling
compressed air.
2
NOTICE
Coarse dirt particles
▶ Filter strainers are installed in the pneumatic connectors
of the positioner to protect against rough dirt particles.
They can be ordered as replacement items with order
number 1435 SFI. ● Fit tubing from 2 to the lower connection of the process
valve.
1. Make the connection between the pneumatic positioner
outlet 2 (single acting) or 2 and 4 (double acting) and the 13.1.2 Connection diagram for NO valves (Normally Open)
pneumatic actuator control air inlet. 4
2. Connect the auxiliary power (air supply) to the air supply
connection 1 (max. 6 bar or 90 psi).

NOTICE
▶ In the case of valves that behave significantly differently 2

with regard to the necessary travel times (for example the

normally open control function, code 2) it may be neces-
sary to fit an additional supply air throttle to the supply
connection P. This enables the travel times to be set
evenly.
● Fit tubing from 2 to the upper connection of the process
4 valve.
1 ð The throttle only needs to be assembled if it is in-
cluded.
3
13.1.3 Connection diagram for double acting valves
2 4

V2

V1 V3 2

Connection in ac- Designation Size

cordance with DIN
ISO
1219-1
1 Air supply connection P G1/4 ● Fit tubing from 2 to the lower connection of the process
valve and 4 to the upper connection of the process valve.
3 Venting connection with silen- G1/4
cer
V1 Exhaust air throttle for 2 -
V2 Exhaust air throttle for 4* -
V3 Check valve -
2 Working connection for pro- -
cess valve
4 Working connection for pro- -
cess valve*

* Only with double acting action (code 3)

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 14 Commissioning

13.2 Connection diagram for quarter turn actuators 14 Commissioning

13.2.1 Connection diagram for NC/NO valves (Normally
Closed/Normally Open)
NOTICE
● For delivery of the product assembled on a valve at the
NOTICE factory, the complete construction is already ready for op-
eration at a control pressure of 5.5 to 6 bar without oper-
▶ The control function can be adjusted via the butterfly disc
ating pressure. A reinitialization is recommended if the
or by turning the shaft.
plant is operated with a different control pressure or if the
4
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.

2 WARNING
Corrosive chemicals!
2 4 ▶ Risk of caustic burns
● Wear appropriate protective gear.
● Completely drain the plant.

Fit tubing from 2 to connector 2 of the quarter turn actuator.

CAUTION
13.2.2 Connection diagram for double acting valves
Leakage
4
▶ Emission of dangerous materials.
● Provide precautionary measures against exceeding the
maximum permitted pressures caused by pressure
surges (water hammer).

2 CAUTION
Cleaning agent
2 4 ▶ Damage to the GEMÜ product.
● The plant operator is responsible for selecting the clean-
ing material and performing the procedure.
Fit tubing from 2 to connector 2 of the quarter turn actuator 1. Commission the product.
and 4 to connector 4 of the quarter turn actuator. 2. Use suitable connectors.
13.2.3 Note for vertical pneumatic connections 3. Connect the control medium lines tension-free and
without any bends or knots.
In the case of a vertical connection, please observe the follow-
ing pneumatic connection assignment:
Connector 4

Connector 2

13.3 Replacing the filter strainers

1. Switch off the pneumatic control air supply.
2. Remove the connection cables.
3. Carefully remove the filter strainers from holes 1, 2 and 3
(only double acting version).
4. Assemble the new filter strainers (1435 SFI).
5. Re-connect the connection cables.
6. Supply pneumatic control air.

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14 Commissioning

14.1 Without default setting (when supplied without a valve)

CAUTION
Risk of injury or damage possible
● For correct commissioning, the product must be calibrated to the process valve via the initialization process.
● During this commissioning, the valve is automatically opened and closed several times. It must therefore be ensured in ad-
vance that this does not lead to a dangerous situation.
The product has 2 control medium connectors.
1. Connect the pneumatic tubes and activate the pneumatic control air supply of max. 6 bar.
2. Connect the connection cable tension-free and without any bends or knots.
3. Switch on supply voltage.
4. Use the corresponding keys to navigate to the Init ALL parameter in the menu, use the red key to select Init ALL and press
and hold the green key for 3 seconds.
5. Initialization is carried out.

NOTICE
Valve travel times (up-down, down-up)
▶ The valve travel times are measured and displayed. If these measure < 1 second, an error is displayed and the valve travel
time must be set to at least > 1 second using the throttle screw(s). This step may need to be repeated several times until an
optimal valve travel time can be achieved. Experience has shown that valve travel times of approx. 1-2 seconds produce op-
timal control characteristics. The two valve travel times should ideally not be too far apart.

NOTICE
▶ It may be necessary to close the internal positioner throttle screws a little (D1 for single acting actuators, D1 and D2 for
double acting actuators) if the actuator volume is low in order to increase the valve travel times. The travel times must
measure > 1 second, otherwise this may result in vibration behaviour of the positioner.

NOTICE
Tip for use
▶ During automatic initialization of actuators whose movement profiles are not continuous (i.e. with undefined stopping or
stalling, e.g. with large size butterfly valves), it may not be possible to clearly detect the end positions and unjustified error
messages may appear (e.g. LEAKAGE).
▶ Manual initialization with sequential movement through the menu by the operator* or, if possible, acknowledging the error
message to repeat the step may help here.
*Only possible in the Advanced system mode

GEMÜ 1435 ePos 28 / 71 www.gemu-group.com

 14 Commissioning

After switching
Nach on
dem Einschalten Press foralsmore
länger than 3 seconds
3s drücken

P = 45.4 PRESS -> FOR 3s NO INIT

D: NO INIT C: CONFIG 1: SETPOINT 2: INIT ALL

Press for3smore
länger als drückenthan 3 seconds

PRESS -> FOR 3s P = XX.X

2: INIT ALL 2: INIT RUN 1

The valve travel times (up->down, down->up) are measured

and displayed. If these measure < 1 second, an error P = XX.X
2: INIT RUN 2
is displayed and the valve travel time must be set
to at least > 1 second using the throttle screw(s). This step may need to be repeated
several times until an optimal valve travel time up -> down
2: INIT RUN 3
can be achieved. Experience has shown that valve travel times
of approx. 1-2 seconds produce optimal control characteristics. The
two valve travel times should ideally not be down -> up
2: INIT RUN 3
too far apart.For further information, see chapter
14.1.1 Error causes and troubleshooting during initialization
P = XX.X
The product is 2: INIT RUN 4
ready for operation and reacts
to the externally P = XX.X
specified set value. 2: INIT RUN 5

.. .... X = 30.5 X = 55.5 PRESS -> FOR 3s INIT OK

A: AUTO. W = 30.5 B: MANUAL. W = 55.5 C: CONFIG 1: SETPOINT 2: INIT ALL

If the message "INIT OK" appears, the product is ready for operation and can be set to the desired operating mode.
- Operating mode A: AUTO – reacts to the externally specified set value.
- Operating mode B: MANUAL – the valve position can be specified manually using the keys.
14.1.1 Error causes and troubleshooting during initialization
If an error message appears during the initialization process, proceed as described below:

Display Error cause Troubleshooting

PRESS <- Actuator's direction cannot be

established. Cause: - Press the key
ERROR RUN 1
a) No compressed air supply a) Check compressed air supply (max. 6 bar)
b) Compressed air supply too b) Check compressed air supply (max. 6 bar) and correct pneu-
low matic connection

c) Travel sensor wrongly con- c) Check connection assignment

nected d) Check valve stroke
d) Valve stroke < 3 mm
PRESS <- Zero point adjustment cannot
be carried out. Cause: - Press the key
ERROR RUN 2.1
a) Incorrect travel sensor / Adjust valve manually, display value P must be > 2.0 in CLOSED
mounting kit position.

b) Adjust quarter turn travel a) Check order no.

sensor b) Turn quarter turn travel sensor (only on quarter turn actuat-
ors) until value P > 2.0

PRESS <- Zero point adjustment cannot

be carried out. Cause: - Press the key
ERROR RUN 2.2
a) Incorrect travel sensor / Adjust valve manually, display value P must be < 98.0 in
mounting kit CLOSED position.

b) Adjust quarter turn travel a) Check order no.

sensor b) Turn quarter turn travel sensor (only on quarter turn actuat-
ors) until value P < 98.0

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14 Commissioning

Display Error cause Troubleshooting

PRESS <- Actuator does not move.

Cause: - Press the key
Stroke Error
a) No compressed air supply a+b) Check compressed air supply (max. 6 bar)

b) Compressed air supply too c) Check mechanical design

low
c) Mechanical design faulty
up -> down
2: INIT RUN 3
Travel time (CLOSED – OPEN)
of valve less than 1 second - Press the key
4 - Turn throttle D1 clockwise to increase the travel time of the
ADJUST NOZZLES (S)
THEN PRESS <- V2
valve. To reduce the travel time, throttle D1 must be turned
PRESS ->
up -> down X.X anticlockwise. (throttles D1 and D2 in the case of double act-
ing actuators)
- +

V3 V1 2

- Press the key

- Repeat if necessary until travel time > 1 second
down -> up
2: INIT RUN 3
Travel time (OPEN – CLOSED)
of valve less than 1 second - Press the key
4 - Turn throttle D1 clockwise to increase the travel time of the
ADJUST NOZZLES (S) V2
THEN PRESS <-
valve. To reduce the travel time, throttle D1 must be turned
PRESS ->
down -> up X.X anticlockwise (throttles D1 and D2 in the case of double act-
ing actuators)
- +

V3 V1 2

- Press the key

- Repeat if necessary until travel time > 1 second

2: INIT
P = XX.X
RUN 5
Leakage in the system
- Press the key
REPEAT CONTINUE
<- OK ESC - Remove leakage
REMOVE LEAKAGE
THEN PRESS <-
- Press the key
PRESS ->
LEAKAGE

- Press the key for another test

- Press the key to skip the leakage test

CAUTION! Skipping the leakage test may lead to bad control
characteristics and increased wear.

GEMÜ 1435 ePos 30 / 71 www.gemu-group.com

 16 System mode CLASSIC

14.2 With default setting (positioner supplied mounted In order to switch the operator interface from [ADVANCED] to
to the valve) [CLASSIC], proceed as follows:
5. Select parameter SYSTEMMODE in the SetBasics menu.
X = 30.5 X = 55.5 PRESS -> FOR 3s 6. Switch from [ADVANCED] to [CLASSIC] and confirm with
A: AUTO W = 30.5 B: MANUAL W = 55.5 C: CONFIG
"OK". Do not exit the parameter.
7. Switch off the supply voltage (for longer than 3 seconds).
X = 55.5
B: MANUAL [W = 55.5] 8. Switch on supply voltage.

1. If the positioner is supplied ready for operation, A: AUTO System mode CLASSIC
appears on the display and the positioner reacts to the ex-
ternally specified set value. NOTICE
Voltage cutoff
2. To manually adjust the valve, press once. B: MANUAL
appears. ▶ After a voltage cutoff, the product always starts in operat-
ing mode A: AUTO (if an initialization has already been
3. Press the key. A bracket appears around the preset carried out) and reacts directly to the external set value
value. signal.

4. Press the key until you reach the digit of the value to System mode ADVANCED

be changed and adjust using the or key. NOTICE

5. Press the key until the cursor reaches the right-hand Voltage cutoff
▶ After a voltage cutoff, the product always starts in the op-
bracket and confirm the set value by pressing the erating mode which was previously set in the Mode para-
key. meter.

15 Switching the operator interface 16 System mode CLASSIC

2-line display, 16-digit

The CLASSIC system mode offers simple basic functions and
all available parameters are arranged in the form of a chain.

NOTICE
Voltage cutoff
▶ After a voltage cutoff, the product always starts in operat-
ing mode A: AUTO (if an initialization has already been
carried out) and reacts directly to the external set value
signal.

16.1 Operating modes

Back key Forward key Plus key Minus key 16.1.1 Automatic operation (A:) AUTO)
Automatic operation is the normal operating mode. The initial-
ized product reacts independently to set value changes and
The product offers you the choice between two different oper-
ator interfaces. These can be selected in the System mode readjusts the valve. Keys and have no function here.
parameter. The current position x is shown as a percentage at the top of
In order to switch the operator interface from [CLASSIC] to the display and also as a bar chart.
[ADVANCED], proceed as follows: The lower line shows the current operating mode on the left
1. Select parameter 50: SYSTEMMODE. and the current set value w in percent on the right.
2. Switch from [CLASSIC] to [ADVANCED] and do not exit the
Press the key to switch to the B: Manual operating mode.
parameter.
3. Switch off the supply voltage (for longer than 3 seconds). 16.1.2 Manual operation (B: MANUAL)
4. Switch on supply voltage. In manual mode, the valve can be operated manually. By

pressing the key a bracket opens around the set

value.Use the key to select the digit of the value to be

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16 System mode CLASSIC

changed and adjust this using the and keys. Then

move the cursor to the right-hand bracket using the key

and confirm the set value by pressing the key.

Press the key to switch to the C: CONFIG operating

mode.
16.1.3 Configuration (C: CONFIG)
Various parameter values of the product can be changed in
the configuration menu. To switch to the configuration menu,

select parameter C: CONFIG and then press and hold the

key for longer than 3 seconds.
The parameter value is displayed in the top line, the number
and name of the parameter appear in the bottom line.
Operation is as shown in the picture below.
Parameter setting:

Press for more than 3

seconds
PRESS -> FOR 3s
C: CONFIG 1: SETPOINT
4...20 mA
2: INIT ALL
NO INIT DEFAULT
3: DEFAULT STATE
...

[ 4...20 mA] PRESS -> FOR 3s PRESS -> FOR 3s

<- OK ESC 2: INIT ALL 3: DEFAULT STATE

[ 4...20 mA]
<- -> + -

[ 0...10 V ]
<- -> + -

[ 0...10 V]
<- OK ESC

0...10 V
1: SETPOINT

GEMÜ 1435 ePos 32 / 71 www.gemu-group.com

 16 System mode CLASSIC

16.2 Parameter table

Display Function Value range Unit Default setting
1:SETPOINT Type of set value 0..10 V V 4..20 mA
0..20 mA mA
4..20 mA mA
2:INIT ALL Starting automatic initialization NO INIT - NO INIT
Init OK
3:DEFAULT STATE Return to default setting NO DEFAULT - DEFAULT
DEFAULT
11:X-DIRECTION Direction of X display and actual RISE RISE
value output FALL
12:ALARM FUNCT Defines the function of the alarm OFF OFF
outputs (ALARM1 and ALARM 2) min/max
min/min
max/max
13:LEVEL ALARM1 Switch point of alarm 1 0.0...100.0 10.0
14:LEVEL ALARM2 Switch point of alarm 2 0.0...100.0 90.0
15:ERROR FUNCTN Defines the function of the error ERROR ERROR+RANGE
message output (ERROR) ERROR+ INACTIVE
RANGE
ERROR+RANGE
ERR+RANGE+INAC
16:ERROR TIME Valve travel time monitoring auto s auto
(Error message output) 0...100
17:ERROR LEVEL Maximum system deviation auto % auto
(Error message output) 0.0...100.0
18:RANGE FUNCTN Range monitoring of set value in- < 4 mA mA < 4 mA or > 20 mA
put > 20 mA
< 4 mA or > 20 mA
21:MIN POSITION Limits the CLOSED position of the 0.0...100 % 0.0
valve min. position
22:MAX POSITION Limits the OPEN position of the 0.0...100 % 100.0
valve max. position
23:CLOSETIGHT Defines the function of the close no no
tight function min
max
min & max
1)
24:SETP DIRECTN Direction of set value NORMAL NORMAL
INVERSE
25:SETP RAMP Ramp function - set value auto s 0
0...400
26:SPLIT START Split range (set value range) start 0.0 ... 90 % 0.0
27:SPLIT END Split range (set value range) end 10 ... 100 % 100
28:SETP FUNCTN Defines the function of the control Linear Linear
characteristic 1:25
1:50
free

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16 System mode CLASSIC

Display Function Value range Unit Default setting

30:FREE 0% Definition of the freely program- 0...100 % 2
31:FREE 10% mable characteristic curve 3
32:FREE 20% 4.4
33:FREE 30% 11 calibration points 6.5
34:FREE 40% 9.6
35:FREE 50% 14.1
36:FREE 60% 20.9
37:FREE 70% 30.9
38:FREE 80% 45.7
39:FREE 90% 67.6
40:FREE 100% 100
42:DEADBAND Size of dead band auto % 1.0%,
0.0...10.0 K-no. 2442: 2.0%
K-no. 2443: 5.0%
43:PROP GAIN 1) Proportional amplification (PD Kp = 0.1...100.0 1.0
controller)
44:DERIV TIME Differential time constant (PD con- Tv = 0.00 s...10.00 s s 0.1
troller)
45:FIELDBUS SETP.ANALOG FIELDBUS SETP.ANALOG
46:RELEASE VXX Software release V X.X.X.X
50:SYSTEMMODE Defines the type of operator inter- CLASSIC CLASSIC
face ADVANCED

1) Parameter value is automatically calculated and set by the positioner during initialisation. A manual change may have to be repeated after
each initialisation process

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 16 System mode CLASSIC

16.3 Explanation of parameters Item State output State output

A1 A2
1: Set Point
Range of analogue set value input (Voltage: 0-10 V or power: Level Alarm1 < x < Level 0V 0V
0/4-20 mA). Alarm2
Level Alarm1 < Level Alarm2 < 0 V 24 V
2: Init All
x
Initialization

Press and press and hold the key (> 3 sec) to start the Min/Min:
automatic initialization. The progress of the initialization is
Item State output State output
shown with RUN 1 to RUN 5 in the display.
A1 A2
During the initialization process, the positioner optimizes its
x < Level Alarm1 < Level 24 V 24 V
control parameters for controlling the valve concerned.
Alarm2
NOTICE Level Alarm1 < x < Level 0V 24 V
Alarm2
▶ This process must be carried out in order to be able to se-
Level Alarm1 < Level Alarm2 < 0 V 0V
lect automatic or manual operation and should be re-
x
peated after every change to the mechanical end posi-
tions (e.g. seal replacement on the valve/operator re-
placement). Max/Max:

3: Default State Item State output State output

Default setting A1 A2
x < Level Alarm1 < Level 0V 0V
Return to default setting and reset initialization. Press Alarm2

and press and hold the key (> 3 sec) to set the controller Level Alarm1 < x < Level 24 V 0V
to Default. Alarm2
Level Alarm1 < Level Alarm2 < 24 V 24 V
NOTICE x
Setting to default 13: Level Alarm 1
▶ After setting to Default, the product must be reinitialized. Switch point for Alarm 1. When the switch point has been
All actuation parameters established so far are deleted. reached, digital output A1 (24 V DC output) is switched.
The parameters D.Refresh and the New Code 1-3 are not
taken into account. 14: Level Alarm 2
Switch point for Alarm 2. When the switch point has been
11: X-Direction reached, digital output A2 (24 V DC output) is switched.
Correcting variable direction
15: Error Functn
Here the display direction (rising or falling) and the position Function of the error message output (24 V DC output)
feedback can be adjusted. The table shows which functions are relevant to the setting of
X-DIRECTION Valve position Displayed Allocated ac- the output at which setting value.
value tual position x Setting Error Error Range C: Config
CLOSED RISE 0% 0% Time Level Functn
OPEN 100% 100% Error X X
CLOSED FALL 100% 100% Error+ X X X
OPEN 0% 0% Inactive
Range X
12: Alarm Functn
Activates or deactivates the alarm function Error+ X X X
Range
The reaction of the alarms (limiting contacts) relates to the
position measurement (mechanical distance). Error+ X X X X
Range+
x = current actual value
Inactive

Min/Max:

Item State output State output

A1 A2
x < Level Alarm1 < Level 24 V 0V
Alarm2

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16 System mode CLASSIC

16: Error Time 23: Closetight

Monitoring time for setting the error messages (10 x travel If parameter 23: Closetight is activated, the actuator is vented
time). The set value (s) serves as a specified value for the at a set value of < 0.5%, even if there is a set Min Position of,
time within which the positioner must have reached the idle for example, 10%. With a set value of > 1.5% the actuator is
state. The associated trigger threshold is specified with para- moved back to 10%.
meter 17. When the set time has been exceeded, the error
With a set value of > 99.5%, the actuator is opened com-
message output ERR is set at 24 V DC.
pletely, even if the Max Position is set, for example, to 90%.
17: Error Level With a set value of < 98.5%, the actuator is moved back to
Error Level: 90%.
Trigger threshold of the error message

Stroke x
Here, a value (%) can be set for the permissible size of system
deviation for triggering the error message.

[%]
If parameters 16 and 17 are both set to AUTO, the error mes- 100
sage is set if the slow-travel zone has not been reached within
a set time. This time is 10x (parameter value AUTO) the initial- 80
ization travel time.
18: Range Function 60

Range Functn:
40
Range monitoring of the set value signal
Here, it is possible to set whether the Range error signal is 20
triggered when it falls below 4 mA (cable break monitoring) or
exceeds 20 mA (short-circuit monitoring).
0 0,5 Set value w
1,5 98,5 99,5
- 21: Min Position
100 [%]
Limits the CLOSED position of the valve
24: SetP Direction
This function is equivalent to a mechanical seal adjuster.
Set value direction
- 22: Max Position
Setting the set value direction serves to reverse the direction
Limits the OPEN position of the valve of the set value. It is mainly required for split-range operation
This function is equivalent to a mechanical stroke limiter. and for single acting actuators with the fail safe OPEN setting
(control function 2).
Stroke[%]
100
Unlimited stroke Open x
Physical stroke x [%]

80 Max. Pos

60

40 Limited stroke

20 Min. Pos

0
20 40 60 80 100 Set value w Closed
Set [%]
[%]
NOTICE value
Control function 1 Control function 2
Min/Max Position
NORMAL NORMAL
▶ The mechanical regulating distance (from limit stop to
limit stop) is limited to the set values with the parameters Control function 2 Control function 1
Min Position and Max Position. This way, the actuator's
INVERSE INVERSE
mechanical positioning range can be limited.

NOTICE
▶ The intended direction of action is that a 0% set value sig-
nal is always assigned to the closed valve position (0%
stroke). In order to achieve this, the setting is automatic-
ally adjusted if an inverted direction of action (e.g. control
function 2) is identified during initialization.

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 16 System mode CLASSIC

25: SetP Ramp Four valve characteristics are stored in the unit:
Set value ramp 1. equal-percentage 1 : 25 (in CLOSED position valve remains
The set value ramp is effective during automatic operation 4% open)
and limits the speed of change of the effective set value. 2. equal-percentage 1 : 50 (in CLOSED position valve remains
When switching over from manual to automatic operation, the 2% open)
effective set value is matched to the set value on the device 3. Linear
via the set value ramp.
4. free
In the position SetP Ramp = AUTO, the slower of the two
When free is selected at 30: a characteristic with 11 calibra-
travel times which have been established during initialization
tion points can be entered.
is used for the set value ramp.
30: FREE 0 %
26: Split Start
.
Set value split range start
.
27: Split End
.
Stroke
40: FREE 100 %

Stroke x Linear and equal-percentage characteristics

120,0
[x]
100,0 100,0
100

90

80,0 80

Linear 72,5
70
67,6

60,0 60

50
1:25 52,5
45,7
40,0 40
38,1
Set value
30 30,9
Set value range 27,6
Set value range 1:50
20,0 20 20,0 20,9

controller 1 controller 2 10,5

14,5 14,1
10 9,6
7,6 6,5
4,0 5,5 4,4
2,0 3,0
0,0 0
Set value split range end 0 20 40 60 80 100 120

Parameters 26 and 27 in conjunction with parameter 24 serve Set value w [%]

to limit the effective set value range. In this way split range
tasks with the curves At gaps of 10%, a flow characteristic value can be allocated to
- rising / falling the set value calibration point concerned. These points make
a traverse with 10 straight lines, which then provides a pattern
- falling / rising
of the valve characteristic.
- falling / falling
- rising / rising NOTICE
are resolved. Entering set value calibration points
▶ Set value calibration points can only be entered with 28:
NOTICE SetP Function = free.
Difference between Split Start/End 42: Deadband
▶ The difference between the Split Start and Split End val- Positioner's dead band
ues must be > 10%.
The dead band shows the maximum permissible system devi-
28: SetP Function ation between actual value and set value.
Set value function With DeadBand = AUTO, the dead band is matched to the re-
With this function, non-linear valve characteristics can be "lin- quirements of the control circuit during initialization. In the
earised" and, with linear valve characteristics, any flow char- other discrete settings, the fixed value for the dead band is
acteristics can be reproduced. used.

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17 System mode ADVANCED

NOTICE 17 System mode ADVANCED

Increased wear due to low value
▶ The level of the system deviation should always corres-
pond to the requirements of the valve and the control cir-
cuit. A value of < 1.0% is not recommended, since this
could cause oscillating control characteristics (e.g. for
actuators with discontinuous movement profiles). This The ADVANCED system mode offers extended diagnostic fa-
could put a great deal of stress on the internal pilot cilities. All available parameters are divided into various cat-
valves. egories and stored in various submenus. A large number of
▶ The following principle applies: The smaller the set value, additional parameters are also available, providing additional
the greater the wear and the shorter the service life. information and settings.
Therefore, the value should only be set to the exact value
required. NOTICE
43: Prop Gain Voltage cutoff
Proportional amplification ▶ After a voltage cutoff, the product always starts in the op-
Adjusting the proportional amplification Kp erating mode which was previously set in the Mode para-
meter.
Kp = 0.1...100.0
The level of amplification should always correspond to the re- 17.1 Menu level
quirements of the valve and the control circuit. The optimum
setting is determined during automatic initialization but must 17.1.1 Select operating mode (Mode)
be moved out of adjustment later if necessary. In this parameter, the AUTO or MANUAL operating mode is
The behaviour of the positioner is influenced as follows: selected.

Prop Gain Press the key to jump to the change to the set value. This
Set value > determined value Set value < determined value
is indicated by two brackets. Then use the key to move
The positioner controls faster The positioner controls the cursor below the value to be changed and adjust the value
(but tends to oscillate). slower.
The set value is achieved in The set value is achieved in using the or key. Then move the cursor below the
larger steps by increasing the smaller steps by decreasing right-hand bracket using the key. The message OK now
correcting variable. the correcting variable. appears in the bottom line of the display. This is now con-
Control is less accurate. Control is more accurate.
firmed with the key. Alternatively, the change can be dis-
44: Deriv Time
carded by pressing the (ESC) key.
Derivative action time
Adjusting the derivative action time Tv (time by which a spe- Mode Manual

cific correcting variable is reached earlier because of the D

component than with a pure P-positioner)
Mode [ Manual] Mode [ Manual]
<- -> + -
Tv = 0.00 s...10.00 s
<- OK ESC

46: Release VXX

Mode [ Auto ] Mode [ Auto ]
Status of the current software version V X.X.X.X <- -> + - <- OK ESC

Selection of operator interface:

A: W 50.0 : X 50.0 SETUP Mode Auto
- CLASSIC:
Menu configuration as described in chapter CLASSIC sys-
tem mode (see “System mode CLASSIC“, page 31). Display Function Value Default Active level
- ADVANCED: range setting Read Edit
Menu configuration as described in chapter ADVANCED 1)
Mode Select AUTO, AUTO 0 3
system mode (see “System mode ADVANCED“, page 38).
operating MAN, OFF
mode

1) Only available after initialization has been carried out

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 17 System mode ADVANCED

17.1.2 Automatic operation (AUTO) 17.2 Configuration menu (SETUP)

Automatic operation is the normal operating mode. The initial- The configuration menu consists of five submenus with the
ized positioner reacts to set value changes and adjusts the following functions:
valve accordingly.
1. Service This menu is used to read out
Keys or have no function in this operating mode. all information/diagnostics re-
garding the positioner, the
The current position (x) is shown in the top right of the display
connected signals and errors
and in the middle is the applied set value signal (w) as a per-
that occur.
centage.
In the bottom line a help text is shown describing the currently 2. SetBasics SetBasics is used to set the
selected parameter. basic settings for the posi-
tioner such as the initializa-
Press the key to switch to the SETUP menu. tion, selection of input signals
and resetting to default set-
Press the key again to switch to the Mode parameter. tings.
3. SetFunction The special positioner func-
tions are switched on or off
A: W 50.0 : X 50.0 SETUP MODE Auto
here and the control paramet-
ers are set.
4. SetCalibration SetCalibration is used to set
17.1.3 Manual operation (MANUAL) the directions of action, char-
With manual mode, the valve can be adjusted manually. Press acteristic curves, stroke lim-
iter and seal adjuster.
the and keys to set the desired set value.
5. Communication No function
Press the key to switch to the SETUP menu.
17.1.4 Pause mode (OFF)
In pause mode, the valve remains in the last position and the
positioner does not react to external signals.

Press the key to switch to the SETUP menu.

17.1.5 Configuration (SETUP)
Various parameter values of the positioner can be changed in
the configuration menu. To reach the configuration menu, the
SETUP parameter must be selected in the working level and

then the key must be pressed.

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17 System mode ADVANCED

17.2.1 Menu structure overview

Service SetBasics SetFunction SetCalibration Communication

1 2 3 4 5

Fieldbus SETP.ANALOG Return

SETP.ANALOG
SETP.BUS

X-DIR: RISE SetpDir: NORMAL Setp Ramp: 0s Split Start: 0.0 % Split End: 100.0 % Setp Fn: linear Setp Functn Return
RISE...FALL
NORMAL 0...400 s 0.0...100 % 0.0...100 % linear
INVERS 1:25
1:50
free

W 90% 67.7 %. W 100% 100.0 % ... Return W 0% 2.0 % W 10% 3.0 % W 20% 4.4 %
0.0...100.0 % 0.0...100.0 %
0.0...100.0 % 0.0...100.0 % 0.0...100.0 %

W 80% 45.7 % W 70% 30.9 % W 60% 20.9 % W 50% 14.1 % W 40% 9.6 % W 30% 6.5 %
0.0...100.0 % 0.0...100.0 %
0.0...100.0 % 0.0...100.0 % 0.0...100.0 % 0.0...100.0 %

Alarm Fn OFF Level Alarm1 10.0 % Level Alarm2 90.0 % Return

OFF 0.0...100.0 % 0.0...100.0 %

min/max
min/min
max/max

Analog Out 0-10V Out min 0.0 % Out max 100.0 % Return

0-20mA * 0.0...100.0 % 0.0...100.0 %

4-20mA *

PosCtrl Dead Band Auto Alarm Output Error Output Position Output CpyParaSet OFF Return

0.0...10.0 % P1<=W
P1=>P2
P1<=P2
P1=>P3
P1<=P3
P1=>P4
P1<=P4

Error Functn Error Error Time Auto Error Level Auto Range Functn <4mA or >20mA Return
Error+Inactive 0.0...100.0 s 0.0...100.0 % < 4mA
Range > 20mA
Error+Range <4mA or > 20mA
Err+Range+Inac

Prop Gain 1.0 Deriv Time 0.1 s Min Pos 0.0 % Max Pos 100.0 % Close Tight no Return
0.1...100.0 0.01...1 s 0.0...100.0 % 0.0...100.0 % no
min
max
min & max

Init All
Auto Man ESC

Setpoint: 4-20 mA Default: Default Init All CalPointQty 9 D. Refresh 0.5 s Systemmode
0-20 mA Default 1...19 0.1...1.0 s CLASIC
4-20 mA No Default
0-10 V ADVANCED

Return Helptext ON HelpLanguage D DLightTime 5min DLight On Key

ON...OFF D 1...60min On Key
GB On

I / O Status Login Diagnosis Gemü specific Return

1.1 1.2 1.3 1.4 1.5

V: 1.1.1.1 S/N 743984/ 1 TAG1 TAG2 Return

Seriennummer

Error List hrs. XXXXX:XX:XX Warnings ON Errors ON Clear Error List Return

ON...OFF ON...OFF OK

Code: 0 Logout? NewCode:1 0 NewCode:2 0 NewCode:3 0 Return

Active Level: 3
(0...10000) OK 0...10000 0...10000 0...10000

min - Pot - max I w: XX.X mA W. Pos X Pot Abs XX.X % Valve. 1:2:3:4 Pos Ctrl Out Relais K1 : K2 : Err Return
0,0 % 100 % XX.X % XX.X% I

U w: XX.X V

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 17 System mode ADVANCED

17.2.2 Parameter overview

Menu levels Submenu Display Function Value range Default setting

Mode Select operating mode AUTO AUTO
MAN
OFF
1 Service I/O status Submenu for displaying inputs and outputs
min-Pot-max Displays travel sensor
position in percent
Iw/Uw Value of set value signal
in mA / V
W Pos X Comparison of set value
and valve position
Pot Abs Travel sensor position
Valve Displays the current posi-
tion of the internal pilot
valves
Pos Ctrl Out Deviation between set
value and actual value
(positioner)
Relais K1:K2:Err Displays the current posi-
tion of the internal out-
puts
Login Submenu for setting access authorisations
Code Password entry 0 ... 10000 0
Logout Block access OK
New Code: 1 Release the lowest prior- 0 ... 10000 0
ity
New Code: 2 Release the medium pri- 0 ... 10000 0
ority
New Code: 3 Release the top priority 0 ... 10000 0
Diagnosis Submenu for displaying diagnostic messages
Error List Displays error messages
hrs Displays operating hours
Warnings Display warnings during ON / OFF ON
operation
Errors Display errors during op- ON / OFF ON
eration
Clear Error List Delete error list OK
1435 specific Submenu for displaying the tool identification
Release Shows the current soft-
ware release
S/N Displays current serial
number
TAG1 11-digit ID number can
be set
TAG2 11-digit ID number can
be set
2 SetBasics
Setpoint Type of set value signal 4–20 mA / 0–20 4–20 mA
mA / 0–10 V
Default Reset to default settings Yes / No Yes

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17 System mode ADVANCED

Menu levels Submenu Display Function Value range Default setting

Init All Submenu for carrying out the initialization
GoClose Scanning the closed pos-
ition
GoOpen Scanning the open posi-
tion
AdjTime Scanning the travel times
FindCoefficent Optimization of control
characteristics
Init Pilot Setting the minimum
travel times for internal
pilot valves
CalPointQty Quantity of calibration 1 ... 19 2
points when initializing
D.Refresh Time for display refresh 0.1 ... 1.0 s 0.5 s
Systemmode Type of operator inter- Classic / Advanced Classic
face
DLight Setting the display light- OnKey / On OnKey
ing
DLightTime Time for switching off 1 ... 60 min 5 min
display lighting with the
OnKey setting
HelpLanguage Text language D / GB D
HelpText Display the help text ON / OFF ON
3 SetFunction PosCtrl Submenu for setting positioner parameters
Prop Gain P amplification of the po- 0.1 ... 100.0 X.X
sitioner
Deriv Time Decay time of the D com- 0.0 ... 10.0 s 0.1 s
ponent of the positioner
MinPos Closing limit = lower pos- 0 ... 100 % 0.0 %
ition of control range
MaxPos Stroke limitation = upper 0 ... 100 % 100 %
position of control range
CloseTight Close tight function no, Min/Max, Max, no
Min
DeadBand Permissible system devi- 0 ... 100 %, auto 1.0%, K-no.
ation 2442: 2.0%, K-
no. 2443: 5.0%
AlarmOutput Submenu for setting the alarm outputs
Alarm Fn Defines the function of OFF, min/max, min/ OFF
the alarm output min, max/man
Level Alarm 1 Switch point of alarm 1 0.0 ... 100 % 10.0 %
Level Alarm 2 Switch point of alarm 2 0.0 ... 100 % 90.0%
ErrorOutput Submenu for setting the error output
Error Functn Defines the function of Error. Error+Inactive, Error+Range
the error output (Error) Range, Error+Range,
Error+Range+Inact-
ive
Error Time Valve travel time monit- AUTO, AUTO
oring 0.0 to 100.0 s
(error output)

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 17 System mode ADVANCED

Menu levels Submenu Display Function Value range Default setting

Error Level Maximum system devi- AUTO, 0.0 ... 100,0 % AUTO
ation
(error output)
Range Functn Range monitoring of set < 4 mA < 4 mA or > 20
value input > 20 mA mA
< 4 mA or > 20 mA
Position Output Submenu for setting the actual value output
Analog Out Defines the function of 0–10 V, 0–20 mA*, 0–10 V
the actual value output 4–20 mA*
Out min Valve position on actual 0.0 ... 100.0 % 0,0 %
value output signal 0 V
(0/4 mA*)
Out max Valve position on actual 0.0 ... 100.0 % 100 %
value output signal 10 V
(20 mA*)
CpyParaSet Copies parameters to
various working memor-
ies (P1/P2/P3/P4)
4 SetCalibration X-DIR Direction of X display and RISE, FALL RISE
actual value output
Setp Dir Direction of set value NORMAL, INVERSE NORMAL
Setp Ramp Ramp function - set value AUTO, 0s
0 to 400 s
Split Start Split range (set value 0.0 ... 90.0 % 0,0 %
range) start
Split End Split range (set value 10 ... 100 % 100 %
range) end
Setp Fn Defines the function of Linear/ free / 1:25 / Linear
the control characteristic 1:50
Setp Functn Submenu for setting the set value calibration points (only possible with "Setp Fn:
free")
W0% 10 control characteristic 0 ... 100.0 % 2.0 %
W 10 % points can be pro- 0 ... 100.0 % 3.0 %
grammed as desired
W 20 % 0 ... 100.0 % 4.4 %
W 30 % 0 ... 100.0 % 6.5 %
W 40 % 0 ... 100.0 % 9.6 %
W 50 % 0 ... 100.0 % 14.1 %
W 60 % 0 ... 100.0 % 20.9 %
W 70 % 0 ... 100.0 % 30.9 %
W 80 % 0 ... 100.0 % 45.7 %
W 90 % 0 ... 100.0 % 67.6 %
W 100 % 0 ... 100.0 % 100.0 %

*Only available on version with optional current output

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17 System mode ADVANCED

17.2.3 Menu 1 Service

Service
1

I / O Status Logout Diagnosis Gemü specific Return

1.1 1.2 1.3 1.4 1.5

V: 1.1.1.1 S/N 743984/ 1 TAG1 TAG2 Return

Seriennummer

Error List hrs. XXXXX:XX:XX Warnings ON Errors ON .... Clear Error List Return

ON...OFF ON...OFF OK

Code: 0 Logout? NewCode:1 0 NewCode:2 0 NewCode:3 0 Return

Active Level: 3
(0...10000) OK 0...10000 0...10000 0...10000

min - Pot - max I w: XX.X mA W. Pos X Pot Abs XX.X % Valve. 1:2:3:4 Pos Ctrl Out. Relais K1 : K2 : Err Return
0,0 % 100 % XX.X % XX.X% I

U w: XX.X V

17.2.3.1 Parameter table for 1 Service

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the
parameters.

17.2.3.1.1 I/O status

Submenu for displaying inputs and outputs

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the
parameters.

Display Function Value range Default setting Active level

Read Edit
min-Pot-max Displays travel sensor 0 o.r.* 1)
position in percent
Iw / Uw Value of set value sig- 0 o.r.* 1)
nal in mA / V
W Pos X Comparison of set 0 o.r.* 1)
value and valve posi-
tion
Pot Abs Travel sensor position 0 o.r.* 1)
Valve Displays the current 0 o.r.* 1)
position of the in-
ternal pilot valves
Pos Ctrl Out Deviation between set 0 o.r.* 1)
value and actual value
(positioner)
Relay Displays the current 0 o.r.* 1)
K1:K2:Err position of the in-
ternal outputs

1) o.r. = only readable

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 17 System mode ADVANCED

17.2.3.1.2 LogIn

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the
parameters.
Submenu for setting access authorisations

Display Function Value range Default setting Active level

Read Edit
Code Password entry 0...10000 0 0 0
Logout Block access OK 0 0
New Code: 1 Release the lowest 0...10000 0 1 1
priority
New Code: 2 Release the medium 0...10000 0 2 2
priority
New Code: 3 Release the top prior- 0...10000 0 3 3
ity

17.2.3.1.3 Diagnosis

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the
parameters.
Submenu for displaying diagnostic messages

Display Function Value range Default setting Active level

Read Edit
Error List Displays error mes- 0 o.r.* 1)
sages
hrs Displays operating 0 o.r.* 1)
hours
Warnings Display warnings dur- ON/OFF ON 0 3
ing operation
Errors Display errors during ON/OFF ON 0 3
operation
Clear Error List Delete error list OK 0 3

1) o.r. = only readable

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17 System mode ADVANCED

17.2.3.1.4 1435 specific

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the
parameters.
Submenu for displaying the tool identification

Display Function Value range Default setting Active level

Read Edit
Release Displays current soft- V2.X.X.X 0 o.r.* 1)
ware release
S/N Displays current serial 0 o.r.* 1)
number
TAG1 A TAG number can be 0 3
entered
TAG2 A TAG number can be 0 3
entered

1) o.r. = only readable

17.2.3.2 Explanation of parameters for 1 Service

17.2.3.2.1 Scanning the input and output signals

SETUP

Service SetBasics SetFunction SetCalibration Communication

1 2 3 4 5

I / O Status
1.1

Min-Pot-Max:
Displays the minimum and maximum travel sensor position in percent. To ensure correct function, this value must lie between
2% and 98%.
Iw / Uw:
Displays the value of the current set value signal compared to the current valve position in %.
W Pos X:
Displays the current travel sensor position (Caution, this value may be different to the Pos x value as the valve does not make
full use of the full 0-100% range of the travel sensor).
Valve:

Displays the current position of the internal pilot valves (valve open = )

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 17 System mode ADVANCED

Pos Ctrl Out:

Displays the speed at which the valve should move.

NOTICE
Excessive system deviation
▶ If the deviation is too large, this is shown by a dot on the left-hand side or right-hand side of the display. In this case, the
valve must move at maximum speed.
Relay:

Displays the current position of internal relays A1, A2 and Error (relay switched = ).

17.2.3.2.2 Activating or deactivating user access

SETUP

Service SetBasics SetFunction SetCalibration Communication

1 2 3 4 5

I / O Status Login
1.1 1.2

The configuration level of the product is protected in certain areas by various codes against unauthorised changing of paramet-
ers.
The operating levels are pre-defined and intended for three different user groups:
- Level 3: All customer settings available and alterable, including the option of defining the physical (e.g. system installer, oper-
ator, manager).
- Level 2. Reduced customer settings available and alterable, specially reduced to the most important parameters for fault
clearance. Option of adaptation within the set physical (e.g. system manager or machine manager).
- Level 1. Customer settings are not available or alterable, only status information is shown.
All menu items are marked by symbols indicating their write and read protection.

Configuration Display Function Value range Default setting Active level

level Read Edit
Mode Select operating AUTO AUTO 0 3
mode MAN
1 Service New Code: 1 Lowest priority re- 0…10000 0 1 1
leased

The following Active Level codes apply:

Active No release required for reading and writing

Level 0
Active The lowest priority release, code 1, is required for reading and writing
Level 1
Active The medium priority release, code 2, is required for reading and writing
Level 2
Active The highest priority release, code 3, is required for reading and writing (default state)
Level 3

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17 System mode ADVANCED

The codes can be changed or activated in the following menu:

Service
1

I / O Status Login
1.1 1.2

Code: 0 Logout? NewCode:1 0 NewCode:2 0 NewCode:3 0 Return

Active Level: 3
(0...10000) OK 0...10000 0...10000 0...10000

Code:
Enter code for user access. The currently released user level is displayed at Active Level.
Example: In Active Level 0, the positioner is disabled in all three user levels.Only the parameters marked by the symbol r0w0
can be read and changed.
Logout:
Used for logging out of write-protected and read-protected areas in the menu. This function disables various menus depending
on the user level activated. User level 0 is displayed in parameter Active Level.
New Code 1:
Enter the new code for the lowest user level (user level 1) (default setting 0).
New Code 2:
Enter the new code for the medium user level (user level 2) (default setting 0).
New Code 3:
Enter the new code for the highest user level (user level 3) (default setting 0).

NOTICE
▶ Default setting 0 means that all three codes are assigned 0. This means that all parameter menus are released.
Example: If user level 2 is to be disabled, user level 2 and also user level 3 must be assigned a code.

17.2.3.2.3 Reading out, deleting and deactivating error messages

SETUP

Service SetBasics SetFunction SetCalibration Communication

1 2 3 4 5

I / O Status Login Diagnosis

1.1 1.2 1.3

Error List:
The positioner stores the last 100 error messages in this menu. The errors are also stored in the error memory in the operator
interface during operation.
hrs:
The operating hours of the positioner are counted here.
Warnings:
The warning messages can be masked or displayed here.The positioner continues normal operation when a warning is given.
Messages are stored in ErrorList.
Errors:
The error messages can be masked or displayed here.Messages are stored in ErrorList.

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 17 System mode ADVANCED

Clear Error List:

Press the key here to delete the error list for the positioner.

17.2.3.2.4 Displaying the serial number and software version, entering the TAG number

SETUP

Service SetBasics SetFunction SetCalibration Communication

1 2 3 4 5

I / O Status Login Diagnosis Gemü Specific

1.1 1.2 1.3 1.4

V:X.X.X.X:
Displays the current software release
S/N:
Displays the positioner serial number
TAG1:
An 11-digit TAG number can be entered for identification of the positioner.
TAG2:
An 11-digit TAG number can be entered for identification of the positioner.
17.2.4 Menu 2 SetBasics

SetBasics Init All

2 Auto . Man ESC

Setpoint: 4-20 mA Default: Default Init All CalPointQty 9 D. Refresh 0.5 s Systemmode
0-20 mA Default 1...19 0.1...1.0 s CLASSIC
4-20 mA No Default
0-10 V ADVANCED

Return Helptext. ON HelpLanguage D DLightTime 5min DLight On Key

ON...OFF D 1...60min On Key
GB On

17.2.4.1 Parameter table for 2 SetBasics

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the para-
meters.

Display Function Value range Default setting Active level

Read Edit
Setpoint Type of set value sig- 4–20 mA 4–20 mA 0 3
nal 0–20 mA
0–10 V
Default Reset to default set- Yes / No Yes 3 3
tings

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17 System mode ADVANCED

Display Function Value range Default setting Active level

Read Edit
Init All Submenu for carrying
out the initialization
(see “Init All“,
page 50)
CalPointQty Quantity of calibration 1...19 2 3 3
points when initializ-
ing
D.Refresh Time for display re- 0.1...1.0 s 0.5 s 0 1
fresh
System mode Type of operator inter- CLASSIC / AD- CLASSIC 0 3
face VANCED
DLight Setting the display OnKey / On OnKey 0 2
lighting
DLightTime Time for switching off 1...60 min 5 min 0 2
display lighting during
adjustment [OnKey]
HelpLanguage Text language D / GB D 0 1
HelpText Display the help text ON/OFF ON 0 1

17.2.4.1.1 Init All

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the para-
meters.
Submenu for carrying out the initialization

Display Function Value range Default setting Active level

Read Edit
goClose Scanning the closed 3 3
position
GoOpen Scanning the open 3 3
position
AdjTime Scanning the travel 3 3
times
findCoefficent Optimization of con- 3 3
trol characteristics
InitPilot Setting the minimum 3 3
travel times for in-
ternal pilot valves

17.2.4.2 Explanation of parameters for 2 SetBasics

17.2.4.2.1 Definition of set value input

Set Point
Range of analogue set value input (Voltage: 0-10 V or power: 0/4-20 mA).

17.2.4.2.2 Reset

NOTICE
Setting to default
▶ After setting to Default, the product must be reinitialized. All actuation parameters established so far are deleted. . The
parameters D.Refresh and the New Code 1-3 are not taken into account.

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 17 System mode ADVANCED

17.2.4.2.3 Carrying out initialization

Init All
Automatic or manual initialization (adaptation of the positioner to the valve) is started.

Setup

Service SetBasics
1 2
Starting automatic initialization
Starten der
automatische Initialisierung

Setpoint: 4-20mA Default State: YES Init All

Init Valve
Auto Man ESC

P XX.X%
= Automatic
Selbstinitialisierung 2: INIT RUN 1
initialization

P XX.X%
2: INIT RUN 2

up -> down.
2: INIT RUN 3

down -> up.

2: INIT RUN 3

P XX.X%
2: INIT RUN 4

P XX.X%
2: INIT RUN 5

Init Valve OK

Press twice
2 x betätigen

A: w XX.X: x XX.X SETUP Mode Auto

Manual
OFF

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17 System mode ADVANCED

The positioner adapts to the valve when automatic initialization is started (via the Start Init Valve parameter). Relevant paramet-
ers are independently and automatically retrieved. This procedure can take a few minutes, dependent on the valve. The initializa-
tion can alternatively be started via the Init Valve parameter in the Set Basics menu item.
If the message Init Valve Ok appears, the product is ready for operation and can be set to the desired operating mode. Further
information.
If an error message appears during the initialization process.

NOTICE
Valve travel times (up-down, down-up)
▶ The valve travel times are measured and displayed. If these measure < 1 second, an error is displayed and the valve travel
time must be set to at least > 1 second using the throttle screw(s). This step may need to be repeated several times until an
optimal valve travel time can be achieved. Experience has shown that valve travel times of approx. 1-2 seconds produce op-
timal control characteristics. The two valve travel times should ideally not be too far apart.

NOTICE
Tip for use
▶ During automatic initialization of actuators whose movement profiles are not continuous (i.e. with undefined stopping or
stalling, e.g. with large size butterfly valves), it may not be possible to clearly detect the end positions and unjustified error
messages may appear (for example LEAKAGE).
▶ Manual initialization with sequential movement through the menu by the operator or, if possible, acknowledging the error
message to repeat the step may help here.

Setup

Service SetBasics
1 2
Starting manual
Starten der
manuellen Initialisierung
initialization
Setpoint: 4-20mA Default State: YES Init All

Init Valve goClose XX.X% goOpen XX.X%

Auto.. Man ESC

goClose XX.X% goOpen XX.X%

Valid? OK ESC Valid? OK ESC

Return InitPilot findCoefficient adjTime 0,0: 0,0

Init Valve OK InitPilot XX.X% findCoeff XX.X% adjTime 0,0: 0,0

ESC ESC ESC

Press twice
2 x betätigen

A: w XX.X: x XX.X SETUP Mode Auto

Manual
OFF

Init All = Man: Manual initialization

When manual initialization is started, the positioner runs through an initialization program that is similar to the automatic initial-

ization. The various program steps must, however, be started and confirmed during manual initialization by pressing the
key.
- Manual initialization should only be used if automatic initialization does not achieve satisfactory positioning.
- The menu items goClose and goOpen should be executed several times for very small valve strokes in order to ensure an op-
timum adaptation of the positioner to the valve.

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 17 System mode ADVANCED

- In order to prevent incorrect operation, the parameters from manual initialization are only accepted when they comply with the
requirements for correct function.

Go Close:
The closed valve position is scanned during initialization.

In the case of manual initialization, this must be confirmed with the key .

Go Open:
The open valve position is scanned during initialization.

In the case of manual initialization, this must be confirmed with the key .
AdjTime:
Wird nur angezeigt, wenn goOpen und goClose durchgeführt wurden.
Die minimalen Stellzeiten des Ventils werden während der Initialisierung abgefragt.

Bei der manuellen Initialisierung muss diese mit der Taste bestätigt werden.

Find Coefficient:
Only displayed if adjTime was carried out.
The valve is checked for control features at various positions between the end positions.

Init Pilot:
The minimum travel times for the internal pilot valves are adjusted to the process valve.

In the case of manual initialization, this function must be started by pressing the key .

Call Point Qty:

The quantity of calibration points when initializing can be changed.
Example: QtyCalPoint=9 means: The valve will be examined for control features between the end position stops in 9 positions
(10% steps here).

17.2.4.2.4 Making the display settings

D.Refresh:
The time for display refresh can be changed.
System mode:
Selection of operator interface:
- CLASSIC:
Menu configuration as described in chapter CLASSIC system mode (see “System mode CLASSIC“, page 31).
- ADVANCED:
Menu configuration as described in chapter ADVANCED system mode (see “System mode ADVANCED“, page 38).
DLight:
The features of the display lighting can be switched between the following settings:
- OnKey – Display lighting is activated by pressing a key. The display lighting remains activated after the last key is pressed for
the period set using DLightTime.
- On – The display lighting is permanently activated.
DLightTime:
Time for automatically shutting off the display lighting when the parameter DLight is set to OnKey
HelpLanguage:
The help text language can be selected between D-German and GB-English.
HelpText:
The help texts that appear as a default in the second line of the display can be masked.
If the help texts are masked, the key assignment is displayed.

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17 System mode ADVANCED

17.2.4.3 Changing the default setting for 2 SetBasics

Display Function Default setting

SetPoint Type of set value signal 4–20 mA
D.Refresh Time for display refresh 0.5 s
System mode Type of operator interface Classic
DLight Setting the display lighting OnKey
DLightTime Time for switching off display 5 min
lighting during adjustment [On-
Key]
HelpLanguage Text language D
HelpText Display the help text ON

17.2.5 Menu 3 SetFunction

Alarm Fn OFF Level Alarm1 10.0 % Level Alarm2 90.0 % Return

OFF 0.0...100.0 % 0.0...100.0 %

min/max
min/min
max/max

Analog Out 0-10V Out min 0.0 % Out max 100.0 % Return

0-20mA * 0.0...100.0 % 0.0...100.0 %

SetFunction 4-20mA *
3

PosCtrl Dead Band Auto Alarm Output Error Output Position Output CpyParaSet OFF Return

0.0...10.0 % P1<=W
P1=>P2
P1<=P2
P1=>P3
P1<=P3
P1=>P4
P1<=P4

Error Functn Error Error Time Auto Error Level... Auto Range Functn <4mA or >20mA Return

Error+Inactive 0.0...100.0 s 0.0...100.0 % < 4mA

Range > 20mA
Error+Range <4mA or > 20mA
Err+Range+Inac

Prop Gain 1.0 Deriv Time 0.1 s Min Pos 0.0 % Max Pos 100.0 % Close Tight no Return
0.1...100.0 0.01...1 s 0.0...100.0 % 0.0...100.0 % no
min
max
min & max

17.2.5.1 Parameter table for 3 SetFunction

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the para-
meters.

Display Function Value range Default setting Active level

Read Edit
PosCtrl Submenu for setting
positioner paramet-
ers (see “PosCtrl“,
page 55)
DeadBand Permissible system 0.0...10% 1.0%, 0 2
deviation auto K-no. 2442: 2.0%
K-no. 2443: 5.0%
AlarmOutput Submenu for setting
the alarm outputs
(see “AlarmOutput“,
page 56)

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 17 System mode ADVANCED

Display Function Value range Default setting Active level

Read Edit
ErrorOutput Submenu for setting
the error output (see
“ErrorOutput“,
page 56)
PositionOutput Submenu for setting
the actual value out-
put (see “Position-
Output“, page 56)
CpyParaSet Copies parameters to 3 3
the working memor-
ies (P1/P2/P3/P4)

17.2.5.1.1 PosCtrl

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the para-
meters.
Submenu for setting positioner parameters

Display Function Value range Default setting Active level

Read Edit
1)
Prop Gain P amplification of the 0.1...100.0 X.X 0 3
positioner
DerivTime Decay time of the D 0.00...10.00 s 0.1 s 0 3
component of the po-
sitioner
MinPos Seal adjuster = lower 0...100% 0.0% 0 3
pos. control ranges
MaxPos Stroke limiter = upper 0...100% 100% 0 3
pos. control ranges
CloseTight Close tight function no no 0 3
Min / Max
Max.
Min.

1) Parameter value is automatically calculated and set by the positioner during initialisation. A manual change may have to be repeated after
each initialisation process

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17 System mode ADVANCED

17.2.5.1.2 AlarmOutput

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the para-
meters.
Submenu for setting the alarm outputs

Display Function Value range Default setting Active level

Read Edit
Alarm Fn Defines the function OFF OFF 0 2
of the alarm output Min / max
Min / min
Max / max
Level Alarm 1 Switch point of alarm 0.0...100.0% 10.0% 0 1
1
Level Alarm 2 Switch point of alarm 0.0...100.0% 90.0% 0 1
2

17.2.5.1.3 ErrorOutput

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the para-
meters.
Submenu for setting the error output

Display Function Value range Default setting Active level

Read Edit
Error Functn Defines the function of Error ERROR + RANGE 0 3
the Error+Inactive
error message output
Range
ERROR + RANGE
Err+Range+Inac
Error Time Valve travel time AUTO AUTO 0 3
monitoring 0.0...100.0 s
Error Level Maximum AUTO AUTO 0 3
system deviation 0.0...100.0%
Range Functn Range monitoring of set < 4 mA < 4 mA or > 20 mA 0 3
value input > 20 mA
< 4 mA or > 20 mA

17.2.5.1.4 PositionOutput

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the para-
meters.
Submenu for setting the actual value output

Display Function Value range Default setting Active level

Read Edit
Analog Out Defines the function of the 0–10 V 0–10 V 0 2
actual value output 0–20 mA 1)
4–20 mA 1)

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 17 System mode ADVANCED

Display Function Value range Default setting Active level

Read Edit
Out min Valve position on 0.0...100.0% 0.0% 0 2
actual value output signal 0 V
(0/4 mA) 1)
Out max Valve position on 0.0...100.0% 100.0% 0 2
actual value output signal 10
V (20 mA) 1)

1) Only available on version with optional current output

17.2.5.2 Explanation of parameters for 3 SetFunction

17.2.5.2.1 Setting the positioner parameters

Proportional amplification
Adjusting the proportional amplification Kp
Kp = 0.1...100.0
The level of amplification should always correspond to the requirements of the valve and the control circuit. The optimum set-
ting is determined during automatic initialization but must be moved out of adjustment later if necessary.
The behaviour of the positioner is influenced as follows:

Prop Gain
Set value > determined value Set value < determined value
The positioner controls faster (but tends to oscillate). The positioner controls slower.
The set value is achieved in larger steps by increasing the cor- The set value is achieved in smaller steps by decreasing the
recting variable. correcting variable.
Control is less accurate. Control is more accurate.

Deriv Time
Derivative action time
Adjusting the derivative action time Tv (time by which a specific correcting variable is reached earlier because of the D compon-
ent than with a pure P-positioner)
Tv = 0.00 s...10.00 s
Min/Max Position
- 21: Min Position
Limits the CLOSED position of the valve
This function is equivalent to a mechanical seal adjuster.
- 22: Max Position
Limits the OPEN position of the valve
This function is equivalent to a mechanical stroke limiter.

100
Unlimited stroke
Physical stroke x [%]

80 Max. Pos

60

40 Limited stroke

20 Min. Pos

0
20 40 60 80 100 Set value w
[%]

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17 System mode ADVANCED

NOTICE
Min/Max Position
▶ The mechanical regulating distance (from limit stop to limit stop) is limited to the set values with the parameters Min Posi-
tion and Max Position. This way, the actuator's mechanical positioning range can be limited.
Closetight:
If parameter 23: Closetight is activated, the actuator is vented at a set value of < 0.5%, even if there is a set Min Position of, for
example, 10%. With a set value of > 1.5% the actuator is moved back to 10%.
With a set value of > 99.5%, the actuator is opened completely, even if the Max Position is set, for example, to 90%. With a set
value of < 98.5%, the actuator is moved back to 90%.
Stroke x
[%]

100

80

60

40

20

0 0,5 Set value w

1,5 98,5 99,5
100 [%]

17.2.5.2.2 Setting the dead zone

DeadBand
Positioner's dead band
The dead band shows the maximum permissible system deviation between actual value and set value.
With DeadBand = AUTO, the dead band is matched to the requirements of the control circuit during initialization. In the other
discrete settings, the fixed value for the dead band is used.

NOTICE
Increased wear due to low value
▶ The level of the system deviation should always correspond to the requirements of the valve and the control circuit. A value
of < 1.0% is not recommended, since this could cause oscillating control characteristics (e.g. for actuators with discontinu-
ous movement profiles). This could put a great deal of stress on the internal pilot valves.
▶ The following principle applies: The smaller the set value, the greater the wear and the shorter the service life. Therefore,
the value should only be set to the exact value required.

17.2.5.2.3 Setting alarm output functions and switch points

Alarm Output:
Submenu for setting the alarm outputs.
Activates or deactivates the alarm function
The reaction of the alarms (limiting contacts) relates to the position measurement (mechanical distance).
x = current actual value

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 17 System mode ADVANCED

Min/Max:

Item State output A1 State output A2

x < Level Alarm1 < Level Alarm2 24 V 0V
Level Alarm1 < x < Level Alarm2 0V 0V
Level Alarm1 < Level Alarm2 < x 0V 24 V

Min/Min:

Item State output A1 State output A2

x < Level Alarm1 < Level Alarm2 24 V 24 V
Level Alarm1 < x < Level Alarm2 0V 24 V
Level Alarm1 < Level Alarm2 < x 0V 0V

Max/Max:

Item State output A1 State output A2

x < Level Alarm1 < Level Alarm2 0V 0V
Level Alarm1 < x < Level Alarm2 24 V 0V
Level Alarm1 < Level Alarm2 < x 24 V 24 V

Switch point for Alarm 1. When the switch point has been reached, digital output A1 (24 V DC output) is switched.
Switch point for Alarm 2. When the switch point has been reached, digital output A2 (24 V DC output) is switched.

17.2.5.2.4 Setting error output functions

Error Output:
Submenu for setting the error output.
Function of the error message output (24 V DC output).
The table shows which functions are relevant to the setting of the output at which setting value.

Setting Error Time Error Level Range Functn Mode [OFF]

Error fn X X
Error+ X X X
Inactive
Range X
Error+ X X X
Range
Error+ X X X X
Range+
Inactive

Error Time:
Monitoring time for setting the error messages (10 x travel time). The set value (s) serves as a specified value for the time
within which the positioner must have reached the idle state. The associated trigger threshold is specified with parameter 17.
When the set time has been exceeded, error message output ERR is set to 24 V DC.
Error Level:
Trigger threshold of the error message
Here, a value (%) can be set for the permissible size of system deviation for triggering the error message.
If parameters 16 and 17 are both set to AUTO, the error message is set if the slow-travel zone has not been reached within a set
time. This time is 10x (parameter value AUTO) the initialization travel time.
Range Functn:
Range monitoring of the set value signal
Here, it is possible to set whether the Range error signal is triggered when it falls below 4 mA (cable break monitoring) or ex-
ceeds 20 mA (short-circuit monitoring).

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17 System mode ADVANCED

17.2.5.2.5 Setting position feedback function and limiting values

Position Output:
Submenu for setting the actual value output.
Analog Out:
Defines the function of the actual value output.
- 0–10 V
- 0–20 mA, only on version with optional current output
- 4–20 mA, only on version with optional current output
Out Min:
Defines the valve position at which an output signal of 0 V / 0 mA / 4 mA is emitted.
Out Max:
Defines the valve position at which an output signal of 10 V / 20 mA is emitted

17.2.5.3 Changing the default setting for 3 SetFunction

Display Function Default setting

Prop Gain P amplification of the posi- X.X
tioner
Deriv Time Decay time of the D compon- 1.00 s
ent of the positioner
Min Pos Closing limit = lower position 0.0%
of control range
Max Pos Stroke limitation = upper posi- 100%
tion of control range
CloseTight Lower close tight function no
DeadBand Permissible system deviation 1.0%
K-no. 2442: 2.0%
K-no. 2443: 5.0%
Alarm Functn Defines the function of the OFF
alarm output
Level Alarm 1 Switch point of alarm 1 10.0%
Level Alarm 2 Switch point of alarm 2 90.0%
Error Functn Defines the function of the er- ERROR + RANGE
ror message output (ERROR)
Error Time Valve travel time monitoring AUTO
(error message output)
Error Level Maximum system deviation AUTO
(error message output)
Range Functn Range monitoring of set value < 4 mA or > 20 mA
input
Analog Out Defines the function of the ac- 0–10 V (4–20 mA)
tual value output
Out min Valve position on actual value 0.0%
output signal 0 V (0/4 mA)
Out max Valve position on actual value 100.0%
output signal 10 V (20 mA)

GEMÜ 1435 ePos 60 / 71 www.gemu-group.com

 17 System mode ADVANCED

17.2.6 Menu 4 SetCalibration

SetCalibration
4

X-DIR: RISE SetpDir: NORMAL Setp Ramp: 0s Split Start: 0.0 % Split End: 100.0 % Setp Fn: linear Setp Fn Return
RISE...FALL
NORMAL 0...400 s 0.0...100 % 0.0...100 % linear
INVERS 1:25
1:50
free

W 90% 67.7 %. W 100% 100.0 % ... Return W 0% 2.0 % W 10% 3.0 % W 20% 4.4 %
0.0...100.0 % 0.0...100.0 %
0.0...100.0 % 0.0...100.0 % 0.0...100.0 %

W 80% 45.7 %... W 70% 30.9 %... W 60% 20.9 %... W 50% 14.1 % W 40% 9.6 % W 30% 6.5 %
0.0...100.0 % 0.0...100.0 %
0.0...100.0 % 0.0...100.0 % 0.0...100.0 % 0.0...100.0 %

17.2.6.1 Parameter table for 4 SetCalibration

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the para-
meters.

Display Function Value range Default setting Active level

Read Edit
X-DIR Direction of X display RISE RISE 0 3
and actual value out- FALL
put
Setp Dir 1) Direction of set value NORMAL NORMAL 0 3
INVERSE
Setp Ramp Ramp function - set AUTO 0s 0 3
value 0...400 s
Split Start Split range (set value 0.0...90% 0.0% 0 3
range) start
Setp Fn Defines the function Linear / free / Linear 0 3
of the control charac- 1:25 / 1:50
teristic
Setp Functn Submenu for setting
the set value calibra-
tion points (only pos-
sible with Setp Fn:
free) (see “Setp
Functn“, page 61)

1) Parameter value is automatically calculated and set by the positioner during initialisation. A manual change may have to be repeated after
each initialisation process

17.2.6.1.1 Setp Functn

NOTICE
▶ Certain Active Levels are required (see “Activating or deactivating user access“, page 47) in order to read and edit the para-
meters.
Submenu for setting the set value calibration points (only possible with Setp Fn: free)

Display Value range Default setting Active level

Read Edit
W 0% 0...100% 2.0% 0 3
W 10% 0...100% 3.0% 0 3
W 20% 0...100% 4.4% 0 3
W 30% 0...100% 6.5% 0 3

www.gemu-group.com 61 / 71 GEMÜ 1435 ePos

17 System mode ADVANCED

Display Value range Default setting Active level

Read Edit
W 40% 0...100% 9.6% 0 3
W 50% 0...100% 14.1% 0 3
W 60% 0...100% 20.9% 0 3
W 70% 0...100% 30.9% 0 3
W 80% 0...100% 45.7% 0 3
W 90% 0...100% 67.6% 0 3
W 100% 0...100% 100.0% 0 3

17.2.6.2 Explanation of parameters for 4 SetCalibration

17.2.6.2.1 Setting the direction of action of actual values

X-Direction
Correcting variable direction
Here the display direction (rising or falling) and the position feedback can be adjusted.

X-DIRECTION Valve position Displayed value Allocated actual posi-

tion x
CLOSED RISE 0% 0%
OPEN 100% 100%
CLOSED FALL 100% 100%
OPEN 0% 0%

SetP Direction
Set value direction
Setting the set value direction serves to reverse the direction of the set value. It is mainly required for split-range operation and
for single acting actuators with the fail safe OPEN setting (control function 2).
Stroke[%]
Open x

Closed
Set [%]

value
Control function 1 Control function 2
NORMAL NORMAL

Control function 2 Control function 1

INVERSE INVERSE

NOTICE
▶ The intended direction of action is that a 0% set value signal is always assigned to the closed valve position (0% stroke). In
order to achieve this, the setting is automatically adjusted if an inverted direction of action (e.g. control function 2) is identi-
fied during initialization.

GEMÜ 1435 ePos 62 / 71 www.gemu-group.com

 17 System mode ADVANCED

SetP Ramp
Set value ramp
The set value ramp is effective during automatic operation and limits the speed of change of the effective set value. When
switching over from manual to automatic operation, the effective set value is matched to the set value on the device via the set
value ramp.
In the position SetP Ramp = AUTO, the slower of the two travel times which have been established during initialization is used
for the set value ramp.
Split Start
Set value split range start
Split End

Stroke

Set value
Set value range Set value range
controller 1 controller 2

Set value split range end

Parameters 26 and 27 in conjunction with parameter 24 serve to limit the effective set value range. In this way split range tasks
with the curves
- rising / falling
- falling / rising
- falling / falling
- rising / rising
are resolved.

NOTICE
Difference between Split Start/End
▶ The difference between the Split Start and Split End values must be > 10%.

www.gemu-group.com 63 / 71 GEMÜ 1435 ePos

17 System mode ADVANCED

SetP Function

NOTICE
Entering set value calibration points
▶ Set value calibration points can only be entered with 28: SetP Function = free.
Set value function
With this function, non-linear valve characteristics can be "linearised" and, with linear valve characteristics, any flow character-
istics can be reproduced.
Four valve characteristics are stored in the unit:
1. equal-percentage 1 : 25 (in CLOSED position valve remains 4% open)
2. equal-percentage 1 : 50 (in CLOSED position valve remains 2% open)
3. Linear
4. free
When free is selected at 30: a characteristic with 11 calibration points can be entered.
30: FREE 0 %
.
.
.
40: FREE 100 %

Stroke x Linear and equal-percentage characteristics

120,0
[x]
100,0 100,0
100

90

80,0 80

Linear 72,5
70
67,6

60,0 60

50
1:25 52,5
45,7
40,0 40
38,1

30 30,9
27,6
1:50
20,0 20 20,0 20,9
14,5 14,1
10 10,5 9,6
7,6 6,5
4,0 5,5 4,4
2,0 3,0
0,0 0
0 20 40 60 80 100 120

Set value w [%]

At gaps of 10%, a flow characteristic value can be allocated to the set value calibration point concerned. These points make a
traverse with 10 straight lines, which then provides a pattern of the valve characteristic.

GEMÜ 1435 ePos 64 / 71 www.gemu-group.com

 17 System mode ADVANCED

17.2.6.3 Changing the default setting for 4 SetCalibration

Display Function Default setting

X-Direction Direction of X display and ac- RISE
tual value output
Setp Direction Direction of set value NORMAL
Setp Ramp Ramp function - set value 0s
Split Start Split range (set value range) 0.0%
start
Split End Split range (set value range) 100%
end
Setp Function Defines the function of the Linear
control characteristic
W 0% 2.0
W 10% 3.0
W 20% 4.4
W 30% 6.5
W 40% 9.6
W 50% 14.1
W 60% 20.9
W 70% 30.9
W 80% 45.7
W 90% 67.6
W 100% 100

17.2.7 Menu 5 Communication

The Communication menu has no function.
Communication
5

Fieldbus SETP.ANALOG Return

SETP.ANALOG
SETP.BUS

www.gemu-group.com 65 / 71 GEMÜ 1435 ePos

18 Troubleshooting

18 Troubleshooting
Display Causes of errors Troubleshooting
SetP.Range The set value signal is outside the defined Check set value signal
range.
Error Run 1 No compressed air supply Check and connect the compressed air supply
Control pressure too low (max. 6 bar) and make sure the pneumatic
connection is correct
Travel sensor wrongly connected Check the connection assignment
Valve stroke < 3 mm Check the valve stroke
Error Run 2.1 Zero point adjustment could not be carried out. Move the valve to the CLOSED position by
hand, display value must be > 2.0.
Incorrect travel sensor/mounting kit Check the order number
Quarter turn travel sensor incorrectly adjusted Twist the quarter turn travel sensor until P >
2.0
Error Run 2.2 Zero point adjustment could not be carried out. Move the valve to the OPEN position by hand,
display value must be < 98.0.
Incorrect travel sensor/mounting kit Check the order number
Quarter turn travel sensor incorrectly adjusted Twist the quarter turn travel sensor until P <
98.0
AD Nozzle (s) Valve travel time less than 1 second. Adjust throttles D1 and D2 depending on the
control function of the actuator until the travel
time is > 1 second.
Clockwise = travel time longer.
Then press the yellow key.
Leakage Run 4 Leakage in the pneumatic system. Check the external pneumatic system connec-
tions for leakage (tighten the fittings).
Error Drive Actuator does not move. Check the pneumatic system.
Check the mechanical design.
Stroke Error Actuator does not move. Check the pneumatic system.
Check the mechanical design

GEMÜ 1435 ePos 66 / 71 www.gemu-group.com

 22 Returns

19 Inspection and maintenance no return delivery note is included with the product, GEMÜ
cannot process credits or repair work but will dispose of the
WARNING goods at the operator's expense.
The equipment is subject to pressure! 1. Clean the product.
▶ Risk of severe injury or death 2. Request a return delivery note from GEMÜ.
● Depressurize the plant. 3. Complete the return delivery note.
● Completely drain the plant.
4. Send the product with a completed return delivery note to
GEMÜ.
CAUTION
Use of incorrect spare parts!
▶ Damage to the GEMÜ product
▶ Manufacturer liability and guarantee will be void
● Use only genuine parts from GEMÜ.

CAUTION
Hot plant components!
▶ Risk of burns
● Only work on plant that has cooled
down.

NOTICE
Exceptional maintenance work!
▶ Damage to the GEMÜ product
● Any maintenance work and repairs not described in these
operating instructions must not be performed without
consulting the manufacturer first.

19.1 Cleaning the product

- Clean the product with a damp cloth.
- Do not clean the product with a high pressure cleaning
device.

20 Disassembly
1. Disassemble in reverse order to assembly.
2. Unscrew the electrical wiring.
3. Deactivate the control medium.
4. Disconnect the control medium line(s).
5. Disassemble the product. Observe warning notes and
safety information.

21 Disposal
1. Pay attention to adhered residual material and gas diffu-
sion from penetrated media.
2. Dispose of all parts in accordance with the disposal regu-
lations/environmental protection laws.

22 Returns
Legal regulations for the protection of the environment and
personnel require that the completed and signed return deliv-
ery note is included with the dispatch documents. Returned
goods can be processed only when this note is completed. If

www.gemu-group.com 67 / 71 GEMÜ 1435 ePos

22 Returns

Keyword index
Numerical LogIn ......................................................................................... 45
Logout....................................................................................... 48
1436 specific............................................................................ 46
M
A
Max Position ...................................................................... 36, 57
Active level ............................................................................... 47
Min Position ....................................................................... 36, 57
AdjTime .................................................................................... 53
Min/Max Position..................................................................... 57
Alarm Functn ............................................................................ 35
Min-Pot-Max ............................................................................. 46
Alarm Output ............................................................................ 58
Analog Out................................................................................ 60 N
C New Code 1 .............................................................................. 48
New Code 2 .............................................................................. 48
Call Point Qty............................................................................ 53
New Code 3 .............................................................................. 48
Clear Error List.......................................................................... 49
Closetight ........................................................................... 36, 58 O
Code.......................................................................................... 48
Out Max .................................................................................... 60
Communication........................................................................ 39
Out Min ..................................................................................... 60
D P
D Light....................................................................................... 53
Pos Ctrl Out .............................................................................. 47
D Light Time ............................................................................. 53
Position Output ........................................................................ 60
D.Refresh .................................................................................. 53
Prop Gain .................................................................................. 38
Deadband ........................................................................... 37, 58
Default ................................................................................ 35, 50 R
Default State............................................................................. 35
Range Function ........................................................................ 36
Deriv Time .......................................................................... 38, 57
Relay ......................................................................................... 47
Diagnosis.................................................................................. 45
Release ..................................................................................... 38
E
S
Error Functn.............................................................................. 35
S/N ............................................................................................ 49
Error Level................................................................................. 36
Service ...................................................................................... 39
Error List ................................................................................... 48
Set Point ............................................................................. 35, 50
Error Output .............................................................................. 59
SetBasics.................................................................................. 39
Error Time................................................................................. 36
SetCalibration........................................................................... 39
Errors ........................................................................................ 48
SetFunction .............................................................................. 39
F SetP Direction..................................................................... 36, 62
SetP Function ..................................................................... 37, 64
Find Coefficient........................................................................ 53
SetP Ramp.......................................................................... 37, 63
G Split End.............................................................................. 37, 63
Split Start ............................................................................ 37, 63
Go Close ................................................................................... 53
System mode ........................................................................... 53
Go Open .................................................................................... 53
T
H
TAG1 ......................................................................................... 49
Help Language ......................................................................... 53
TAG2 ......................................................................................... 49
Help Text .................................................................................. 53
hrs ............................................................................................. 48 V
I V.X.X.X.X................................................................................... 49
Valve ......................................................................................... 46
I/O status.................................................................................. 44
Init All .................................................................................. 35, 51 W
Init All Man................................................................................ 52
W Pos X .................................................................................... 46
Init Pilot..................................................................................... 53
Warnings................................................................................... 48
Iw / Uw...................................................................................... 46
X
L
X-Direction .......................................................................... 35, 62
Level Alarm 1............................................................................ 35
Level Alarm 2............................................................................ 35

GEMÜ 1435 ePos 68 / 71 www.gemu-group.com

 23 EU Declaration of Conformity in accordance with 2014/30/EU (EMC Directive)

23 EU Declaration of Conformity in accordance with 2014/30/EU (EMC Directive)

1435

EU Declaration of Conformity
in accordance with 2014/30/EU (EMC 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.
EMC texts

Product: GEMÜ 1435

Product name: Intelligent electro-pneumatic positioner
The following harmonized standards (or EN 61800-3:2004/A1:2012; EN 61326-1:2013; EN 61000-6-2:2005/AC:2005
parts thereof) have been applied:

M. Barghoorn
Head of Global Technics

Ingelfingen, 29/06/2023

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG www.gemu-group.com

Fritz-Müller-Straße 6-8 D-74653 Ingelfingen-Criesbach [email protected]

www.gemu-group.com 69 / 71 GEMÜ 1435 ePos

24 EU Declaration of Conformity In accordance with 2011/65/EU (RoHS Directive)

24 EU Declaration of Conformity In accordance with 2011/65/EU (RoHS Directive)

1435

EU Declaration of Conformity
In accordance with 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.
EMC texts

Product: GEMÜ 1435

Product name: Intelligent electro-pneumatic positioner
The following harmonized standards (or EN IEC 63000:2018
parts thereof) have been applied:

M. Barghoorn
Head of Global Technics

Ingelfingen, 29/06/2023

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG www.gemu-group.com

Fritz-Müller-Straße 6-8 D-74653 Ingelfingen-Criesbach [email protected]

GEMÜ 1435 ePos 70 / 71 www.gemu-group.com

GEMÜ Gebr. Müller Apparatebau GmbH & Co. KG
Fritz-Müller-Straße 6-8, 74653 Ingelfingen-Criesbach, Germany Subject to alteration
Phone +49 (0) 7940 1230 · [email protected]
www.gemu-group.com 08.2023 | 88306070