GE Masoneilan 496 Series User manual

GE Oil & Gas
496 Series
Masoneilan* Rotary Electric Switch
Instruction Manual
GE Data Classification : Public

b | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
THESE INSTRUCTIONS PROVIDE THE CUSTOMER/OPERATOR WITH IMPORTANT PROJECT-SPECIFIC REFERENCE
INFORMATION IN ADDITION TO THE CUSTOMER/OPERATOR’S NORMAL OPERATION AND MAINTENANCE PROCEDURES.
SINCE OPERATION AND MAINTENANCE PHILOSOPHIES VARY, GE (GENERAL ELECTRIC COMPANY AND ITS SUBSIDIARIES
AND AFFILIATES) DOES NOT ATTEMPT TO DICTATE SPECIFIC PROCEDURES, BUT TO PROVIDE BASIC LIMITATIONS AND
REQUIREMENTS CREATED BY THE TYPE OF EQUIPMENT PROVIDED.
THESE INSTRUCTIONS ASSUME THAT OPERATORS ALREADY HAVE A GENERAL UNDERSTANDING OF THE REQUIREMENTS
FOR SAFE OPERATION OF MECHANICAL AND ELECTRICAL EQUIPMENT IN POTENTIALLY HAZARDOUS ENVIRONMENTS.
THEREFORE, THESE INSTRUCTIONS SHOULD BE INTERPRETED AND APPLIED IN CONJUNCTION WITH THE SAFETY
RULES AND REGULATIONS APPLICABLE AT THE SITE AND THE PARTICULAR REQUIREMENTS FOR OPERATION OF OTHER
EQUIPMENT AT THE SITE.
THESE INSTRUCTIONS DO NOT PURPORT TO COVER ALL DETAILS OR VARIATIONS IN EQUIPMENT NOR TO PROVIDE FOR
EVERY POSSIBLE CONTINGENCY TO BE MET IN CONNECTION WITH INSTALLATION, OPERATION OR MAINTENANCE.
SHOULD FURTHER INFORMATION BE DESIRED OR SHOULD PARTICULAR PROBLEMS ARISE WHICH ARE NOT COVERED
SUFFICIENTLY FOR THE CUSTOMER/OPERATOR'S PURPOSES THE MATTER SHOULD BE REFERRED TO GE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF GE AND THE CUSTOMER/OPERATOR ARE STRICTLY LIMITED TO
THOSE EXPRESSLY PROVIDED IN THE CONTRACT RELATING TO THE SUPPLY OF THE EQUIPMENT. NO ADDITIONAL
REPRESENTATIONS OR WARRANTIES BY GE REGARDING THE EQUIPMENT OR ITS USE ARE GIVEN OR IMPLIED BY THE
ISSUE OF THESE INSTRUCTIONS.
THESE INSTRUCTIONS ARE FURNISHED TO THE CUSTOMER/OPERATOR SOLELY TO ASSIST IN THE INSTALLATION,
TESTING, OPERATION, AND/OR MAINTENANCE OF THE EQUIPMENT DESCRIBED. THIS DOCUMENT SHALL NOT BE
REPRODUCED IN WHOLE OR IN PART TO ANY THIRD PARTY WITHOUT THE WRITTEN APPROVAL OF GE.

Masoneilan 496 Series Rotary Electric Switch Instructions Manual | c© 2015 General Electric Company. All rights reserved.
Contents
Safety Information .........................................................1
1. Introduction ............................................................2
2. Operation ..............................................................2
3. Installation .............................................................2
4. Adjustments ............................................................2
5. Mounting Arrangements .................................................4
A. 35002 Series Camflex II
30000 Series Varimax ....................................................................................4
B. 36002 Series Control Ball II
37002 Series MiniTork II
39002 Series High Performance Butterfly .................................................................6
C. 37/38 Diaphragm Actuators ..............................................................................7
D. 87/88 Spring Diaphragm Actuators .......................................................................8

1 | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
Safety Information
Important - Please Read Before Installation
Masoneilan model 496 Series Rotary Electric Switch
instructions contain DANGER, WARNING, and CAUTION
labels, where necessary, to alert you to safety related or other
important information. Read the instructions carefully before
installing and maintaining your control valve. DANGER and
WARNING hazards are related to personal injury. CAUTION
hazards involve equipment or property damage. Operation of
damaged equipment can, under certain operational conditions,
result in degraded process system performance that can
lead to injury or death. Total compliance with all DANGER,
WARNING, and CAUTION notices is required for safe operation.
This is the safety alert symbol. It alerts you to potential
personal injury hazards. Obey all safety messages that follow
this symbol to avoid possible injury or death.
Indicates a potentially hazardous situation which, if not
avoided, could result in death or serious injury.
Indicates a potentially hazardous situation which, if not
avoided, could result in serious injury.
Indicates a potentially hazardous situation which, if not
avoided, could result in minor or moderate injury.
When used without the safety alert symbol indicates a
potentially hazardous situation which, if not avoided, could
result in property damage.
Note: Indicates important facts and conditions.
About this Manual
• The information in this manual is subject to change without
prior notice.
• The information contained in this manual, in whole or part,
shall not be transcribed or copied without Masoneilan’s
written permission.
• Please report any errors or questions about the
information in this manual to your local supplier.
• These instructions are written specifically for the
496 Series Rotary Electric Switch, and do not apply for
other valves outside of this product line.
Warranty
Items sold by GE are warranted to be free from defects in
materials and workmanship for a period of one year from
the date of shipment provided said items are used according
to GE recommended usages. GE reserves the right to
discontinue manufacture of any product or change product
materials, design or specifications without notice.
This instruction manual applies to the Masoneilan
496 Series Rotary Electric Switch.
The rotary electric switch MUST BE:
• Installed, put into service and maintained by qualified and
competent professionals who have undergone suitable
training.
• Under certain operating conditions, the use of damaged
equipment could cause a degradation of the performance of
the system which may lead to personal injury or death.
• Changes to specifications, structure, and components
used may not lead to the revision of this manual unless
such changes affect the function and performance of the
product.
• All surrounding pipe lines must be thoroughly flushed
to ensure all entrained debris has been removed from the
system.

Masoneilan 496 Series Rotary Electric Switch Instructions Manual | 2© 2015 General Electric Company. All rights reserved.
1. Introduction
Series 496 rotary switches are used for electrically indicating
one or two predetermined positions in the stroke of a control
valve. They may be connected to audible alarms or signal
lights for warning of valve or system malfunction. These
switches may also be used to actuate solenoids, relays and
other electrical devices.
Basic switches (4) in the unit are single pole, double throw
snap acting and are individually adjusted by cams (13) on
the rotating shaft (11). Vernier adjustment is made by means
of locking type set screws (Nylock) (2) in the cams and these
screws actuate the switches by contacting the switch spring
levers. The spring levers provide overtravel protection and
allow maintained contact when required. The Series 496
is available with either one or two switches, each with an
adjustable cam to actuate it.
The housing and cover are made of anodized aluminum and
are explosion proof. In addition, O-ring seals
(7 and 10) in the cover and rotary shaft, make the
switch waterproof.
Series 496 switches may be mounted on the 35002
Series Camflex, 30000 Series Varimax, 36002 Series Control
Ball and 37002 Series MiniTork Butterfly valves. Also, the
addition of a standard back lever and linkage permits its use
with the 10000 and 21000 Series and linear motion valves.
For complete parts list for the Series 496 switch refer to Parts
Supplement FS7000.
2. Operation
The motion of the control valve turns by means of a back lever
(or coupling) the switch shaft (11). Cams (13), fastened to the
shaft by screws (1), actuate microswitches (4) by pushing levers
(5). Each switch may be wired to either open or close the circuit
when the lever is depressed.
3. Installation
Only two couplings are used to connect the switch shaft (11)
to the valve; a strip type coupling (Ref. 9, Figure 3) for rotating
shaft valves and a back lever (Ref. 9, Figure 6)
for linear motion valves. Each is fastened to the switch shaft
(11) with a spring washer and cap screw. Refer to Figures 3
through 7 for mounting details.
Microswitches are rated at 10, 15 or 20 amps at 115 or 230
volts dc. Check the rating printed on each switch. Each
microswitch has three terminals. The lower one is common,
the middle terminal is for normally open circuit; the top
terminal is for normally closed circuit. Pass wiring through the
3/4" NPT port in the bottom of the case.
4. Adjustments
The Series 496 switch is normally mounted and adjusted on
a control valve at the factory. To adjust the instrument in the
field, proceed as follows:
A. The concave part of the levers (5) should be exactly
concentric with the cams (13) with the switch actuated.
This is an important step to assure that once the lever is
depressed, it stays depressed during overtravel (if any).
If not, loosen screws (3 and 17) and slide the levers up or
down slightly. Tighten screws (3).
B. Unscrew slightly the cam locking screws (1) using a 3/32"
Allen wrench.
C. Actuate the valve to the desired position (usually the full
opened or full closed position).
D. It is important to note that the cam operating the right-
hand switch should make contact with lever (5) only at
the end of a counterclockwise rotation.
This assures that when the valve is throttling, the screw
(2) is completely free of the lever. The concave part of the
lever is only to maintain contact during
over-travel (if any). Similarly, the cam operating
the left-hand switch should make contact with
lever (5) only at the end of a clockwise rotation. If there
is only one switch (Model 496-1) it may be necessary to
reverse the position of the switch from left to right or vice
versa depending on the rotation and stroke position.
E. Turn the cam (13) on the shaft until the switch is a
voltmeter.) Lock the cam (13) with screw (1).
F. Make a fine adjustment with screw (2) using a
1/16" Allen wrench. The screw (2) must extend out from
the cam far enough to assure sufficient depression of
lever (5).

3 | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
3 1/16
2 11/16
3 15/16
5/16
15/16
2 13/16
2 3/4
5 3/8
3/4NPT
2 9/16
1 9/16
8 Mounting
Holes 17/64 D A Cover
Removal
Clearance
Figure 1
Dimensions
Contact Points
17
13
1
2
4
5
6910 12 13
14
15
16
11
8
7
18
3
Ref.
No. Description Ref. No. Description Ref. No. Description
1Screw 8Snap Ring 14 Serial Plate
2Screw 9Screw 15 Drive Screw
3Screw 10 O-Ring 16 Insulator
4Microswitch 11 Shaft 17 Screw
5Lever 12 Cover 18 Washer
6Body 13 Cam 19 Spacer (not shown)
7O-Ring
Figure 1
Dimensions
Figure 2
Cutaway Views

Masoneilan 496 Series Rotary Electric Switch Instructions Manual | 4© 2015 General Electric Company. All rights reserved.
5. Mounting Arrangements
A. 35002 Series Camflex II
30000 Series Varimax
When mounting a Series 496 Switch on a Camflex II or
Varimax valve:
1. Remove shaft cover, or if equipped with a positioner,
remove positioner and mounting plate.
2. Remove bottom cover.
3. Install mounting bracket (3) using two flat head screws
(7).
4. Screw pin (12) to switch lever (10) [Varimax lever (10a)].
5. Remove cap screw (11) [Varimax set screw (11a)] from
switch lever (10) [Varimax lever (10a)] slide switch lever
onto shaft behind the main lever. Position switch lever in
line with main lever. Replace and tighten cap screw (11)
[Varimax set screw (11a)].
6. Mount switch (1) on bracket (3) using cap screws (4) and
hex nuts (8).
7. Place slotted end of the back lever (9) over pin (12) on the
switch lever. Secure with washer (13) and clip (14).
8. For 3" valve and larger slip bottom cover over the linkage
and push in place.
9. Attach the back lever to the switch using lock washer (5)
and cap screw (6).
10. Refer to adjustments (Page 2) to adjust switches.
Figure 3
35002 Series Camflex II

5 | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
Figure 4
35002 Series Camflex II
30000 Series Varimax
Ref.
No. Description Ref. No. Description Ref. No. Description
1496 Rotary Switch 7 Flat Head Screw 11 Cap Screw
2Bottom Cover* 8Hex Nut 11a Set Screw
3Mounting Bracket 9Back Lever 12 Lever Pin
4Cap Screw 10 Lever 13 Washer
5Lock Washer 10a Lever 14 Retaining Clip
6Cap Screw
*Used with 7" Actuator only

Masoneilan 496 Series Rotary Electric Switch Instructions Manual | 6© 2015 General Electric Company. All rights reserved.
B. 36002 Series Control Ball II
37002 Series MiniTork II
39002 Series High Performance Butterfly
496 Series Rotary Switch mounted on 36002, 37002 and
39002 valves:
1. Remove shaft cover or if equipped with a positioner
remove positioner and mounting plate.
2. Remove plastic panels for access, bottom front
and side.
3. Remove pivot pin (8) stroke air to open valve to remove
the load from the pin.
4. Replace pin (8) with switch mounting pivot pin.
5. Assemble take off link (6), locknut (9) and turnbuckle (10),
slide assembly over pivot pin (8) and push on retaining
clip (7).
6. Install front cover.
7. Install mounting plate (3) using flat head screws (1).
8. Mount switch (2) to plate (3) using cap screws (5) and nuts
(12).
9. Assemble back lever (14) to the switch using cap screw
(15) and lock washer (16).
10. Assemble clevis (11) to back lever (14) using clevis pin (13)
and retaining clip (7).
11. Replace bottom cover (4).
12. Connect the turnbuckle (10) and clevis (11). Rotate the
turnbuckle to equalize threaded ends and lock the
locknut.
13. Refer to adjustments (Page 2) to adjust switches.
Figure 5
36002 Series Control Ball II, 37002 Series MiniTork II, 39002 Series HPBV
Ref.
No. Description Ref. No. Description Ref. No. Description
1Flat Head Screw 7Retaining Clip 12 Hex Nut
2496 Rotary Switch 8Pivot Pin 13 Clevis Pin
3Mounting Plate 9 Hex Jam Nut 14 Back Lever
4Bottom Cover 10 Turnbuckle 15 Cap Screw
5Cap Screw 11 Clevis 16 Lock Washer
6 Take Off Link
*Used with 7" Actuator only

7 | GE Oil & Gas © 2015 General Electric Company. All rights reserved.
Ref.
No. Description Ref. No. Description Ref. No. Description
*1 Clamp 7Mounting Bracket 14 Cap Screw
*2 Clamp 8Cap Screw 15 Spring Washer
*3 Machine Screw 9Back Lever 16 Washer
4Turnbuckle Screw 10 Clevis 17 Cap Screw
5Locknut 11 Clip 18 Clamp Rod
6Turnbuckle 12 Pin
*Used with size 9, 11 and 13 actuators only.
Figure 6
37/38 Spring Diaphragm Actuator
C. 37/38 Diaphragm Actuators
The 496 switch is rigidly mounted on the spring barrel of the
diaphragm actuator by means of a bracket (7) fastened to
the mounting pad with cap screws (8). The back lever (9) is
fastened to the end of the switch shaft with spring washer
(15) and cap screw (17).
The take off linkage must be adjusted before adjusting the
switches. Apply air pressure to the actuator until the actuator
stem has traveled exactly half the rated stroke. Loosen
locknut (5) and turn the turnbuckle (6) until the back lever (9)
is level. Tighten locknut (5) and adjust switches according to
instructions on Page 2.

Masoneilan 496 Series Rotary Electric Switch Instructions Manual | 8© 2015 General Electric Company. All rights reserved.
Clevis Assembly
Model 88 Actuator
(Air-to-Open)
Model 87 Actuator
(Air-to-Close)
5. Attach clevis (6) to back lever (7) using clevis pin (9)
washer (10) and retaining clip (8).
6. Screw turnbuckle screw (1) onto clamp rod (2) until it lines
up with clevis (6).
7. Apply air pressure to the actuator until the actuator
stem has traveled exactly half the rated stroke.
8. Install and adjust the turnbuckle until the back lever is
horizontal. Tighten locknut.
9. Refer to adjustments (Page 2) to adjust the switches.
D. 87/88 Spring Diaphragm Actuators
Series 87/88 Actuators 496 Switch installation
1. Mount bracket (13) to yoke using cap screws (17) and lock
washers (18).
2. Attach the back lever (7) to the switch using cap screw
(11) and spring washer (12).
3. Mount switch on bracket (13) using cap screws (15) and
lock washers (16).
4. Screw locknut (3) onto clamp rod (2) install clamp rod into
split clamp and tighten locknut.
Figure 7
87/88 Spring Diaphragm Actuator
Ref.
No. Description Ref. No. Description Ref. No. Description
1Turnbuckle Screw 7Back Lever 13 Mounting Bracket
2 Clamp Rod 8 Retaining Clip 14 496 Rotary Switch
3Locknut 9 Clevis Pin 15 Cap Screw
4Locknut 10 Washer 16 Lock Washer
5Turnbuckle 11 Cap Screw 17 Cap Screw
6Clevis 12 Spring Washer 18 Lock Washer

DISTRIBUTOR
* Trademark of the General Electric Company.
Other company names and product names used in this document are
the registered trademarks or trademarks of their respective owners.
© General Electric Company. All rights reserved.
Visit our web-site:
www.fr-eps.com
E.P. & S. - FRANCE
24 bis rue de Picpus
75012 PARIS
Tel: [phone]
[e-mail]
E.P. & S. - CAMEROON
Immeuble Carré d'Or, Rue Njo-Njo
Bonapriso, DOUALA
Tel: [phone]
[e-mail]