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ATEX Instruction Manual

496 Position Transmitter


and Limit Switch

Instruction
N 185888
10/2004

Masoneilan

TABLE OF CONTENT

Safety warnings ................................................................................................................................... 3


Instrument operation ............................................................................................................................ 3
1. Numbering system ........................................................................................................................... 4
2. Technical data ...................................................................................................................................4
3. ATEX marking and electrical safety parameters of intrisically safe rotary limit switch 496-.58.........4
3.1. Marking .....................................................................................................................................4
3.2. Electrical safety parameters .................................................................................................... 4
4. ATEX marking and electrical safety parameters of intrisically safe postion transmitter
types 496-858 or 496-858/. ............................................................................................................. 5
4.1. Marking .....................................................................................................................................5
4.2. Electrical safety parameters .................................................................................................... 5
5. ATEX marking and electrical safety parameters of explosionproof rotary limit switch type 496-57
and position transmitters 496-857 or 496-857/. .............................................................................. 6
5.1. Marking .....................................................................................................................................6
5.2. Electrical safety parameter ...................................................................................................... 6
6. Electrical data of position transmitter 496-8../. ................................................................................. 6
7. Electrical connection, installation and start up ................................................................................. 7
7.1. Cable entry ................................................................................................................................7
7.2. Electrical connection of rotary limit switch 496-.57 or 496-.58 .................................................7
7.3. Electrical connection of position transmitter 496-857 or 496-857/. and 496-858 or 496-858/. 7
7.4. Installation and start up ............................................................................................................ 7
8. Calibration ........................................................................................................................................ 8
8.1. Calibration of rotary limit switch 496-57 and 496-58 with micro switch(es) ..............................8
8.2. Calibration of rotary limit switch 496-57 and 496-58 with proximity switch(es) ........................9
8.3. Calibration of position transmitter 496-858 or 496-858/. ........................................................10
9. Maintenance .................................................................................................................................. 12
EC declaration of conformity ...............................................................................................................13

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WARNING
BEFORE installing, using or carrying out any maintenance tasks associated with this instrument, READ THE INSTRUCTIONS
CAREFULLY.
These instruments comply with the essential safety requirements of the European Directive ATEX 94/9/CE.
They also comply with the essential safety requirements of the European Directive EMC 89/336/CE (as amended), for use within an
industrial environment.
Products certified as explosionproof equipment or for use in intrinsically safe installations MUST BE:
a) Installed, put into service, used and maintained in compliance with national and local regulations and in accordance with the
recommendations contained in the relevant standards concerning potentially explosive atmospheres.
b) Used only in situations that comply with the certification conditions shown in this document and after verification of their
compatibility with the zone of intended use and the permitted maximum ambient temperature.
c) Installed, put into service and maintained by qualified and competent professionals who have undergone suitable training for
instrumentation used in areas with potentially explosive atmospheres.
Under certain operating conditions, the use of damaged instruments could cause a degradation of the performances of the system
which may lead to personal injury or death.
Use only genuine replacement parts, which are provided by the manufacturer, to guarantee that the products comply with the
essential safety requirements of the European Directives mentioned above.

INSTRUMENT OPERATION
a) The 496-.58 limit switch allows to switch 1 or 2 electrical circuits.1 or 2 micro- switch(es) or 1 or 2 proximity switch(es)
are provided for.
b) The 496-858 or 496-858/. position transmitter gives the actual position of a valve stem or shaft.
The displacement of the stem or shaft is transmitted to the opto-electronic sensor by 2 gears.
The opto-electronic sensor has the same function than a standard potentiometer and its output voltage is proportional
to the rotation of its axis.
An electronic circuit amplifies this voltage to a 4-20 mA signal proportional to the angle of rotation.
This equipment has many advantages:

non sparkling,

frictionless,

unlimited life,

non sensitive to vibration and electrical noise,

very low operating torque: 0,02 N.m.


Zero and span are adjusted by 2 potentiometers.
A connector is provided to reverse the signal: 4-20 mA changed to 20-4 mA.
c) Optionally 496-857/. or 496-858/. apparatus can also be used as a limit switch to switch 1 or several electrical
circuits. 1 or 2 micro- switch(es) or 1 or 2 proximity switch(es) are provided for this supplementary function.

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1. PRODUCT CODE

496TYPE
1. one mechanical switch
single pole double throw
2. two mechanical
switches
single pole double throw
4. one proximity switch

/
PROTECTION
57- Explosionproof
and dust and water
tight
58. Intrinsically safe
and dust and water
tight

ADDITIONAL FUNCTION
FOR A TRANSMITTER
ONLY
1. one mechanical switch
single pole double throw
2. two mechanical switches
single pole double throw
4. one proximity switch

5. two proximity switches

5. two proximity switches

6. one mechanical switch


double pole double throw
7. two mechanical
switches
double pole double throw
8. Optoelectronic position
transmitter

6. one mechanical switch


double pole double throw
7. two mechanical switches
double pole double throw

2. TECHNICAL SPECIFICATION
Internal components of the rotary limit switch and position transmitter are mounted inside an IP65/IP67 enclosure.
Performances of position transmitter type 496-857 or 496-857/. and 496-858 or 496-858/.
Output signal : 4-20 mA (2 wires),
Span: 50 10 % for rotary valves and reciprocating valve with stroke 25 mm,
Span: 25 10 % for reciprocating valves with stroke < 25 mm,
Rotation: clockwise or counter clockwise,
Linearity: 1 % of output signal for an input angle span of 50, inclusive of non linearity, hysteresis and deadband
errors,
Hysteresis: 0,7 %,
Temperature drift: 0,03 % of output signal by C,
Operating temperature range of opto-electronical sensor - 20C to + 70C.
Electrical characteristics and temperature range of the position transmitter with micro-switch or proximity switch are
given in the following sections.

3. ATEX MARKING AND ELECTRICAL SAFETY PARAMETERS OF INTRISICALLY SAFE ROTARY LIMIT SWITCH
496-.58
3.1. Marking
D.P.I
F - 14110 - Cond-sur-Noireau.
496-.58 where the . can be replaced by 1, 2, 4 or 5
INERIS 02 ATEX 0023
(serial number)
(year of manufacture)
Limit switch with micro-switch(es)

II 1 G
EEx ia IIC T6
Ta : - 55 C to + 80 C
Limit switch with proximity switch(es)
II 2 G
EEx ia IIC T6

Ta : - 25 C or - 40C to + 51 C or + 62 C depending upon the type of proximity switch

3.2. Electrical safety parameters


Any power supply connected to the apparatus must be certified for group IIC hazardous locations and its
output circuit must be intrinsically safe approved.
Circuits, which are to be connected to the limit switch, must be approved for hazardous locations of group IIC.

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Maximum input characteristics at terminal block:

Variation with
micro-switch

DC source
AC source

Variation with proximity switch

Ui
V
30
90

Ii
A
0,5
1,4

Ci
nF
0
0

L
H
0
0

16

0,052

120

200

4. ATEX MARKING AND ELECTRICAL SAFETY PARAMETERS OF INTRISICALLY SAFE POSITION


TRANSMITTER 496-858 or 496-858/.
4.1. Marking
D.P.I
F-14110 - Cond-sur-Noireau.
496-858 or 496-858/. For a position transmitter with additional function (the . can be replaced by 1, 2, 4, 5)
INERIS 02 ATEX 0023
(serial number)
(year of manufacture)
position transmitter or position transmitter with micro-switch(es) (496-858, 496-858/1 or 496-858/2):
II 1 G
EEx ia IIC T6 Ta : - 20 C, + 70 C
position transmitter with proximity switch(es) (496-858/4 or 496-858/5):
II 2 G
EEx ia IIC T6 Ta : - 20 C, + 51 C or Ta : - 20 C, + 62 C depending upon the type of proximity switch(es)

4.2. Electrical safety parameters


Any power supply connected to either the position transmitter terminal block or to the additional function
terminal block must be certified for group IIC hazardous locations and its output circuit must be intrinsically
safe approved.
Circuits, which are to be connected to the limit switch, must be approved for hazardous locations of group IIC.

Position transmitter types 496-858 and 496-858/.

Maximum input characteristics at terminal block:


Ui
V
28

Ii
A
0,11

Ci
nF
20

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Li
H
0

Additional function for instrument type 496-858/.

Maximum input characteristics at terminal block of additional function:

Additional
function

DC
source
AC
source
Variation with proximity
switch

Variation with
micro-switch

Ui
V

Ii
A

Ci
nF

Li
H

30

0,5

90

1,4

16

0,052

50

150

5. ATEX MARKING OF EXPLOSIONPROOF ROTARY LIMIT SWITCH TYPE 496-.57 AND OF EXPLOSIONPROOF
POSITION TRANSMITTER TYPE 496-857 or 496-857/.
5.1. Marking

D.P.I

F-14110 - Cond-sur-Noireau.

496-.57 or 496-857 or 496-857/.

INERIS 02 ATEX 0080X

(serial number)

(year of manufacture)

Rotary limit switch 496-.57 :

(where . can be replaced by 1, 2, 4, 5, 6, 7)

II 2 G/D
EEx d IIC T6 Ta : - 55 C, + 70 C *
EEx d IIC T5 Ta : - 55 C, + 80 C *
IP 65/67 T100C (Ta 80C)
T cable : +80C
Position transmitter 496-857 or 496-857/.
II 2 G/D
EEx d IIC T6 Ta : - 20 C, + 70 C*
IP 65/67 T85C (Ta 75C)
T cable : +80C
Do not open while energized (Ne pas ouvrir sous tension)
* temperature range can be reduced without exceeding above values depending upon the type of component
mounted inside the enclosure
5.2. Electrical safety parameter
Pmax = 5W.

6. ELECTRICAL DATA OF POSITION TRANSMITTER 496-8../.

Power supply :

Protected against polarity inversion,

Maximum load Zc ( ) =

- Explosionproof :
- Intrinsically safe :

U min = 12.5 V and U max = 40 V.


U min = 12.5 V and U max = 28 V.

Supply Voltage (V ) 12,5(V )


Imaxi( A)

Then 775 Ohm max for 20 mA for an intrinsically safe loop.


SUPPLY

Load Zc

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POSITION
TRANSMITTER

7. ELECTRICAL CONNECTION, INSTALLATION AND START-UP


) Comply with current national and local regulations for electrical installation work.
) Comply with national and local explosive atmosphere regulations
) Before carrying out any work on the device, power off the instrument or make sure that the local
conditions in the potentially explosive atmosphere permit- the safe opening of the cover.
) Before switching on or after doing any work on the device always tighten the cover (12) with its seal
in good condition (10) and screw in the safety screw (9).

Note: Before installation, check that the device is undamaged. In the event of damage, inform the manufacturer
whose address is shown on the serial plate.

7.1. Cable entry


The electrical cable enters the housing via a 3/4 NPT thread fitted a certified cable gland (type II 2 GD, EEx d
IIC for an explosionproof instrument) and suitable to the equipment operating zone (IP 6X for zones 21).

7.2. Electrical connection of the rotary limit switch type 496-.57 or 496-.58
The electrical cables are connected either directly on to the microswitch(es) or to the proximity switch terminal
block.
Connect the device to the earth using the earth connections provided inside the housing and on the outside of
the device.

7.3. Electrical connection of the position transmitter type 496-857 or 496-857/. and 496-858 or 496-858/.
Connect the electrical cables to the position transmitter terminal block located on the printed circuit board.
Respect the polarities + and .
When a position transmitter is provided with an additional function, the electrical cables are connected either
directly on to the microswitch(es) or to the proximity switch terminal block.
Connect the device to the earth using the earth connections provided inside the housing and on the outside of
the device.

7.4. Installation and start-up


Installation
Explosionproof instrument can be installed in flammable gas explosive atmosphere groups IIA, IIB, IIC for
the zones 1 and 2 or in flammable dust explosive atmosphere zones 21 and 22.
Intrinsically safe instrument can be installed in flammable gas explosive atmospheres groups IIA, IIB, IIC for the
zones 0, 1 and 2.
Start up
) Before switching on or after doing any work on the device always tighten the cover (12) with its seal
in good condition (10) and screw in the safety screw (9).
) Check that the cable gland is certified for the intended use and that the electrical data are suitable
for the operating zone.

Before start up, proceed, if required, with instrument calibration as per paragraph 8 and/or ensure that all the
safety instructions in the preceding paragraphs have been strictly followed.

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8. CALIBRATION
Before switching on the device to proceed with calibration carefully read the following safety warnings.
) Comply with current national and local regulations for electrical installation work.
) Comply with national and local explosive atmosphere regulations
) Before carrying out any work on the device, power off the instrument or make sure that the local
conditions in the potentially explosive atmosphere permit the safe opening of the cover.
) Before switching on or after doing any work on the device always tighten the cover (12) with its seal
in good condition (10) and screw in the safety screw (9).
8.1 Calibration of rotary limit switch 496-.57 and 496-.58 equipped with micro switch(es)

The concave portion of the lever (5) must be strictly concentric to the cam (13) when the micro-switch is actuated.
This is an important caution to make sure the lever is properly depressed when not actuated.
If not, loosen the screws (3 & 17) and slightly move the lever upwards or downwards. Tighten the screws.
Slightly loosen the cam locking screw (1) using a 3/32 socket hex head wrench.
Move the plug stem to the position required to actuate the switch.
It is important to note that the cam operating the right hand micro-switch must actuate the lever (5) at the end of the
counterclockwise rotation. (See detail Figure 2).
This makes sure the screw (2) has free the lever (5) when the valve is throttling. The remaining concave portion
only ensures micro-switch actuation in case of overtravel. Conversely, the cam operating the left hand micro-switch
must actuate the lever (5) at the end of the clockwise rotation. (See detail Figure 2).
To meet the above requirement when only one micro-switch is provided (type 496-158) it may be necessary to
change the location of the micro-switch.
Rotate the cam (13) until the micro-switch is actuated. Lock the cam (13) tightening the screw (1).
Fine tune adjustment with screw (2). Use a 1/16 socket hex head wrench. The screw (2) must come out the cam
enough to properly depress the lever (5).
Strictly follow safety instructions under 7.4 before putting into service.

PARTS LISTS
Rep.

Designation

1
Adjusting screw
2
Adjusting screw
3
Screw (1 micro switch)
4
Micro switch
5
Lever
6
Housing
7 (1) O ring
(1) Recommended spare parts

Rep

Designation

Rep

8
9
10 (1)
11
12
13
14

Snap ring
Safety screw
Oring
Axis
Cover
Cam
Serial plate
(2) Only for 496-2 model

15
16
17
18
19 (2)
A
B

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Designation
Drive screw
Insulating
Screw (second micro switch)
Washer
Spacer (Not shown)
Contact point for the left micro switch
Contact point for the right micro switch

8.2 Calibration of rotary limit switch 496-.57 and 496-.58 equipped with proximity switch(es)
) Type 496-4
Actuate the valve to the desired triggering position and check the sense of rotation when the arm leaves the
proximity sensor.
The figure below shows the location of the proximity sensor and of the arm when triggering as a function of the
sense of rotation.
Slowly move the arm towards the proximity sensor until it triggers. Triggering occurs when the arm overlaps
approximately 1/3 of the proximity switch.
Strictly follow safety instructions under 7.4 before putting into service.

Rep.
33

Designation

Rep

Arm

34

Designation
Proximity switch

) Type 496-5
During adjustment make sure that the proximity switch with the red spot is triggered by the arm with the red spot.
Adjustment of the first proximity switch
The first switch is adjusted at the beginning of the stroke.
Check what will be the sense of rotation when the valve is actuated. Figure (b, c) below shows the proximity
sensor and the arm assigned to the first triggering point for a given the sense of rotation.
Slowly move the arm towards the proximity switch until it triggers.
Adjustment of the second proximity switch
The second switch is adjusted at the end of the stroke.
Immobilise the first arm previously adjusted and slowly move the second arm towards the second proximity
sensor until it triggers.
Make sure the first proximity switch is still correctly adjusted.
Strictly follow safety instructions under 7.4 before putting into service.

Rep.
A

Designation
Red spot

Rep
B

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Designation
First triggering point

) Air gap adjustment


Air gap between the proximity switch and the arm is factory adjusted. If new adjustment is required proceed as
follows:
Loosen the proximity sensor nut (37A), located on the front of the bracket (36).
Unscrew a few turns the locknut (37B) located on the back of the bracket.
Position the arm above the proximity sensor and push the shaft end (11) towards the outside of the housing so
as to eliminate the longitudinal play.
Hold in position the proximity sensor and screw the nut (37A). Adjust air gap to 0,3 mm using a shim
Tighten the lock nut (37B).

NOMENCLATURE
Rep.
Designation
3
Screw
6
Housing
7 (1) O-ring
8
Snap ring
9
Safety screw
10 (1) O ring
11
Axis
(1) Recommended spare parts

Rep
12
14
15
19
24
25
30

Designation
Cover
Serial plate
Drive screw
Spacer
Terminal block
Terminal block
Spacer
(2) Only for 496-4 model

Rep
31
32
33
34
35 (2)
36
37

Designation
Snap ring
Washer
Arm
Proximity sensor
Spacer (Not shown)
Sensor bracket
Nut

8.3. Calibration of position transmitter 496-858 or 496-858/.


Action
As shown below action can be set with the connector A (relationship between output signal and shaft rotation).
Note: the amplifier board B is shown 90 out of its actual position in the housing.

USING CONNECTOR (A)


TO ESTABLISH THE
RELATION SHIP
BETWEEN THE
ROTATION SENSE OF
THE POWER SHAFT
AND THE OUTPUT
SIGNAL
A Connector
B Amplifier board

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Linkage adjustment
When mounted on reciprocating valves, adjust the turnbuckle to get the instrument lever horizontal at mid-travel.
Position transmitter adjustment
(a) Adjust the connector A
(b) Set span potentiometer at midtravel (S).
(c) Set zero potentiometer at midtravel (Z).
(d) Move the valve stem to the position that should correspond to the minimum output signal of the
transmitter (4 mA).
(e) Install a milliammeter in the loop and power up the instrument.
(f) Loosen the screw (1) of main gear (23) and rotate it to get an output signal around 4 mA. Tighten the
screw (1).
(g) Fine tune the 4 mA output signal with the zero potentiometer (Z).
(h) Full stroke the valve to the rated travel and adjust the output signal to 20 mA with the span potentiometer (S).
(i) Repeat steps d-g and h if necessary.
(j) Power down the instrument to remove the milliammeter.
Adjustment of micro-switch(es) or proximity switch(es)
Refer to paragraph 8.1 or 8.2 to adjust micro-switches or proximity switch(es).

Strictly follow safety instructions under 7.4 before putting into service.

PARTS LIST
Rep.

Designation

1
Screw
6
Housing
7 (1) O ring
8
Snap ring
9
Safety screw
10 (1) O ring
11
Arm
12
Cover
14
Serial plate
(1) Recommended spare parts

Rep
15
20
21
19
22
23
37
38
39

Designation
screw
Position sensor
Bracket
Spacer
Sensor gear
Main gear
Snap ring
Spacer
Threaded rod

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Rep
40
41
42
43
44
45
S
Z

Designation
Screw
Grower washer
Printed circuit board
Insulating disk
Washer
Nut
Span adjustment potentiometer
Zero adjustment potentiometer

9. MAINTENANCE

) Comply with current national and local regulations for electrical installation work.
) Comply with national and local explosive atmosphere regulations
) Before carrying out any work on the device, power off the instrument or make sure that the local
conditions in the potentially explosive atmosphere permit- the safe opening of the cover.
) Before switching on or after doing any work on the device always tighten the cover (12)
with its seal in good condition (10) and screw in the safety screw (9).

Check that no part of the 496 is damaged.


In the event of damage replace the defective parts with genuine manufacturer's replacement part.
Pay particular attention to the following:

General condition of the housing.


Check the cable gland and the electrical connections.
Check the condition of the seal (10) of cover (12) and seal (7) of axis (11).
Make sure that axis (11) is not worn out or damaged.
If axis (11) must be removed, make sure the original snap on ring (8) is put back in place, Check that
neither the housing nor the axis are damaged.

Instruments installed in zones 20, 21 and 22 must be cleaned to prevent any dust build up on the walls.

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EC DECLARATION OF CONFORMITY

Le fabricant:
Dresser Produits Industriels
3 rue Saint Pierre
F-14110 CONDE SUR NOIREAU
France
Dclare que les transmetteurs de position de type :
496-858
496-858/1, 496-858/2
496-858/4, 496-858/5

496-857
496-857/1, 496-857/2
496-857/4, 496-857/5
496-857/6, 496-857/7

et contacteurs rotatifs de type :


496-157, 496-257, 496-457, 496-557
496-657, 496-757

496-158, 496-258, 496-458, 496-558

destins tre utiliss en atmosphres explosibles sont conformes:

aux exigences essentielles de la directive ATEX 94/9/CE concernant le rapprochement des lgislations des Etats
Membres pour les appareils and systmes de protection destins tre utiliss en atmosphres explosibles
Appareils 496-158, 496-258, 496-458, 496-558, 496858, 496-858/1, 496-858/2, 496-858/4 and 496-858/5

aux normes suivantes:


EN 50014:1997 and amendements 1 and 2
EN 50020:1994
EN 50284:1999
EN 50281-1-1:1998

Appareils 496-157, 496-257, 496-457, 496-557, 496657, 496-757, 496-857, 496-857/1, 496-857/2, 496857/4, 496-857/5, 496-857/6, 496-857/7

aux normes suivantes:


EN 50014:1997 and amendements 1 and 2
EN 50018:2000
EN 50281-1-1:1998

au type ayant fait l'objet de l'attestation d'examen


CE de type INERIS 02 ATEX 0023.

Le systme qualit est certifi selon l'annexe IV de la directive 94/9/CE par le LCIE (0081) sous le
N LCIE 02 ATEX Q8029.

au type ayant fait l'objet de l'attestation d'examen


CE de type INERIS 02 ATEX 0080X

aux exigences essentielles de la directive CEM 89/336/CE modifie concernant le rapprochement des lgislations
des Etats Membres relatives la compatibilit lectromagntique

aux normes EN 50081-2 et EN 50082-2

Cond sur Noireau


Le 2 janvier 2003

C. VLASSOFF
Directeur Qualit/Technique

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Factory and Customer Service (Spare Parts and After Sales)


DRESSER PRODUITS INDUSTRIELS
3, rue Saint Pierre
BP 87
14110 Cond sur Noireau, France
Tl. +33(0)2 31 59 59 59
Fax +33(0)2 31 59 59 60
www.masoneilan.com

Sales offices
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Telephone : 32-2-344-0970
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France
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DI U.K. Limited
East Gillibrands Estate, Skelmersdale
Lancashire WN8 9TU - England
Telephone : 44-1695-52600
Fax : 44-1695-52662
DRESSER FLOW CONTROL, DI U.K. Ltd.
Unit 4, Suite 1.1, Nobel House
Grand Union Office Park, Packet Boat Lane, Uxbridge

Middlesex UB8 2GH - England


Telephone : 44-1895-454900
Fax : 44-1895-454919