GE Masoneilan 469 Series User manual

Masoneilan*
496 Series
Position Transmitter and Limit Switch
ATEX Instruction Manual (Rev.B)
BHGE Data Classification: Public

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,
BHGE (BAKER HUGHES, A GE 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 BHGE.
THE RIGHTS, OBLIGATIONS AND LIABILITIES OF BHGE 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 BHGE 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 WITHOUT THE WRITTEN
APPROVAL OF BHGE.
2 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.

Conversion Table
All the USCS values are converted to
metric values using the following conversion factors:
Metric values using
the following
conversion factors:
Conversion Factor
Metric Unit
in.
25.4
mm
lb.
0.4535924
kg
in2
6.4516
cm2
ft3/min
0.02831685
m3/min
gal/min
3.785412
L/min
lb/hr
0.4535924
kg/hr
psig
0.06894757
barg
ft lb
1.3558181
Nm
°F
5/9 (°F-32)
°C
Note: Multiply USCS value with conversion factor to get metric value.
NOTICE!
For valve configurations not listed in this
manual, please contact your local MARC or
BHGE sales office for assistance.
© 2018 Baker Hughes, a GE company. All rights reserved. Masoneilan 496 Series Position Transmitter ATEX Instruction Manual | 3

Contents
1. Instrument Operation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
2. Numbering System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
3. Technical Specification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .7
4. ATEX Intrinsic Safety Marking and Electrical Safety Parameters . . . . . . . . . . . . . . . . . . . . .8
5. ATEX Flameproof Marking and Electrical Safety Parameters. . . . . . . . . . . . . . . . . . . . . . . 10
6. Position Transmitter 496-8../. Electrical data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
7. Electrical Connection, Installation and Start-up. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
8. Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
9. Maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
10. Special Conditions of Work . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
11. Special Conditions of Use. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
Annex I. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
Annex II . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
Annex III. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
4 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.

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. It is certified to be used in Gas or Dust
explosive atmospheres, groups IIA, IIB, IIC and IIIC:
• Category II 1GD –zones 0, 1, 2, 20, 21 an d 22
for the protection mode “ia”
• Category II 2GD –zones 1, 2, 21 an d 22 for the
protection mode “d”and “tb”
They also comply with the essential safety
requirements of the European Directive EMC
2004/108/EC as amended, for use within an industrial
environment.
Products certified as explosion proof equipment
MUST BE:
a) Installed, put into service, used and maintained
in compliance with European and/or national
and local regulations and in accordance with
the recommendations contained in the relevant
standards concerning potentially explosive
atmospheres.
b) Used only in situations those 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 atmosphere. Such trainings
are not supported by BHGE.
It is the end user’s responsibility to:
• Verify material compatibility with the application
• Ensure proper use of fall protection when working
at heights, per Safe Site Work Practices
• Ensure use of proper Personal Protective
Equipment
• Take the appropriate actions to ensure that site
personnel who are performing installation,
commissioning and maintenance have been
trained in proper site procedures for working
with and around equipment, per Safe Site Work
Practices
BHGE reserves the right to discontinue manufacture
of any product or change product materials, design,
or specifications without notice.
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 BHGE’s Masoneilan replacement parts to
ensure that the products comply with the essential
safety requirements of the European Directives
mentioned above.
© 2018 Baker Hughes, a GE company. All rights reserved. 496 Series Masoneilan Position Transmitter ATEX Instruction Manual | 5

Protection
55. Weatherproof
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
6. One mechanical switch double
pole double throw
7. Two mechanical switches
double pole double throw
1. Instrument Operation
1.1 The 496-.58 and 496-.57 position
limit switch
Allow switching 1 or 2 electrical circuits. This function is
provided by 1 or 2 micro- switch(es) or 1 or 2 proximity
switch(es).
1.2 The 496-857 and 496-857/. and
496-858 or 496-858/. position
transmitter
The 496 Series instrument is a non-contact opto-
electronic positioner transmitter which provides a
4-20mA analog output signal proportional to the valve
position. This device can be mounted both on rotary
and reciprocating valves through a system of gears
and (for reciprocating valves only) a linkage.
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 electrical noise typical of potentiometer
with cursor
• frictionless
• unlimited life
• non sensitive to vibration and electrical noise
• very low operating torque: 0.02 N.m
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.
2. Numbering System
496 -_ _ _ / _
6 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.
Type
1. One mechanical switch single
pole double throw
2. Two mechanical switches
single pole double throw
4. One proximity switch
5. Two proximity switches
6. One mechanical switch double
pole double throw
7. Two mechanical switches
double pole double throw
8. Optoelectronic position
transmitter

3. Technical Specification
Internal components for limit switch and position transmitter are mounted inside an IP66/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)
• Acceptable span on the command axle: from 25° to 90° for rotary or reciprocating valves
• Rotation: clockwise or counter clockwise
• Linearity: ≤ ± 0.5% for a rotary angle of 25° to 90° (typically ± 0.3% for a rotary angle ≥ 60°)
• Hysteresis: ≤ 0.1%
• Dead band: ≤ 0.1%
• Repeatability: ≤ 0.1%
• Total drift in temperature: 0.02 %/°C or 200 ppm/°C (zero and span range)
• Operating temperature range: -40°C to +80°C
Electrical characteristics and temperature range of the position transmitter with micro-switch(es) or proximity
switch(es) are given in the following sections.
© 2018 Baker Hughes, a GE company. All rights reserved. 496 Series Masoneilan Position Transmitter ATEX Instruction Manual | 7

4.
ATEX Intrinsic Safety Marking and Electrical
Safety Parameters
4.1 Marking
The marking is on the serial plate stamped on the 496
cover (rep 14).
• Name and address of the manufacturer:
Dresser Produits Industriels S.A.S.
14110 CONDE SUR NOIREAU - FRANCE
• Type designation:
–496-858 for transmitter,
–496-858/• for transmitter with additional
function(s)
–496-•58 for position switches
the “•” can take the values 1, 2, 4, 5.
• Basic and complementary marking:
–Transmitter alone or with mechanical switch(es)
(additional function):
II 1 GD
Ex ia IIC T.* Ga Tamb = -..°C à +..°C *
Ex ia IIIC T..°C* Da
–Transmitter alone or with proximity switch(es)
(additional function):
II 1G* or II 2G*
Ex ia IIC T.* Ga Tamb = -..°C à +..°C *
–Position mechanical switch(es):
II 1 GD
Ex ia IIC T.* Ga Tamb = -..°C à +..°C *
Ex ia IIIC T..°C* Da
–Position proximity switch(es) (additional function):
II 1G*, II 2G*
Ex ia IIC T.* Ga Tamb = -..°C à +..°C *
* Ambient temperatures ranges and surface
temperatures for the temperature classifications T6, T5
and T4 are given in ANNEX I with:
–Tables 1, 2 and 3 for the transmitter alone, the
mechanical switch(es) alone and the proximity
switch(es) alone.
–Tables 4 and 5 for the transmitter with mechanical
switch(es) and for the transmitter with proximity
switch(es).
• Serial number
• Year of manufacturing
• Number of notified body ••••
• EC-Type examination certificate number
Warning:
AVERTISSEMENT : DANGER POTENTIEL DE CHARGES
ELECTROSTATIQUES –VOIR INSTRUCTIONS
WARNING: POTENTIAL DANGER OF ELECTROSTATIC
CHARGES. SEE INSTRUCTIONS
4.2 Electrical safety parameters
4.2.1 Type 496-.58
4.2.1.1 Option with 1 or 2 Micro-Switch(es)
• Type identification is: 496-158 and 496-258.
• Mechanical switch(es): type BZ-2R72-A2,
manufacturer: HONEYWELL
• They are supplied by a certified power source for
explosible atmospheres group IIC with the maximal
characteristics:
–Constant power supply: Ui= 30V, Ii = 0.5A, Ci = 0F
and Li = 0H
–Alternative power supply: Ui= 90V, Ii = 1.4A, Ci = 0F
and Li = 0H
• The wiring connection is done directly on mechanical
switch(es).
4.2.1.2 Option with 1 or 2 Proximity Switch(es)
• Type identification is: 496-458 and 496-558.
• These detectors from PEPPERL & FUCHS are
defined as:
–II 1G Ex ia IIC T6 Ga
–II 2G Ex ia IIC T6 Gb
• EC type examination certificate:
–PTB 00 ATEX 2048 X (II1G, II2G)
PTB 00 ATEX 2049 X (II1G, II2G)
8 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.

4.
ATEX Intrinsic Safety Marking and Electrical
Variation Ui Ii Ci
(V) (A) (nF)
Li Pi
(μH) (W)
With
Micro-
switch
DC Source
30
0.5
0
0
-
AC Source
Peak Value
90
1.4
0
0
-
With Proximity Switch
16
0.052
120
200
0.169
Safety Parameters (Contd)
• They are supplied by a certified power source
* for explosible atmospheres with the maximal
characteristics:
Ui = 16V ; Ii = 0.052A ; Pi = 0.169W.
* The power source (Control circuit) must be one
manufactured by Pepperl & Fuchs below:
WE 77/EX 1 or WE 77/EX 2
• The wiring connection is done on one or two terminal
connector type:
MK 3 ; 2.5mm2 ; 380 volts ; manufacturer:
WEIDMULLER or equivalent product.
4.2.1.3 Maximum Input Characteristics
4.2.2.2 Type 496-858/. :
The additional functions of position transmitters are
identical to type 496-•58
Maximum input characteristics at terminal block of
additional function:
Variation Ui Ii Ci
(V) (A) (nF)
Li Pi
(μH) (W)
With
Micro-
switch
DC Source
30
0.5
0
0
–
AC Source
Peak Value
90
1.4
0
0
-
With Proximity Switch
16
0.052
120
200
0.169
4.2.2 Types 496-858 and 496-858/. :
4.2.2.1 Type 496-8:
The position transmitter is connected to a linear tension
source of a certified type for use in group IIC hazardous
locations and its output circuit must be intrinsically safe
approved per EN 60079-11.
Maximum input characteristics at terminal block:
Ui (V) Ii (A)
Ci (nF)
Li (μH)
Pi (W)
28
0.11
36
0
0.77
© 2018 Baker Hughes, a GE company. All rights reserved. 496 Series Masoneilan Position Transmitter ATEX Instruction Manual | 9

Type Min Max
Voltage Voltage
496-157 or
496-257 or
496-657 or
496-757
-
220V
(direct current) or
250V (alternative
current)
496-457 or
496-557
Pepperl
and Fuchs
-
16V
(direct current)
496-457 or
496-557
Télémécanique
-
58V
(direct current)
496-857/.
9.0V
(direct current)
36V
(direct current)
5. ATEX Flameproof Marking and Electrical Safety
Parameters
5.1 Marking
The marking is on the serial plate stamped on the 496
cover (rep 14).
• Name and address of the manufacturer
Dresser Produits Industriels S.A.S.
14110 CONDE SUR NOIREAU –FRANCE
• Type designation:
–496-857 for a position transmitter
–496-857/• for a position transmitter with
additional function(s), for a transmitter
–496-•57 for a position limit switch
The • can be replaced by 1, 2, 4, 5, 6 and 7.
• the specific marking:
II 2 GD
• the complementary marking:
–Ex d IIC T6 Gb Ta –55°C, +75°C (*)
Ex tb IIIC T85°C Db IP66/IP67
–Ex d IIC T5 Gb Ta –55°C, +85°C (*)
Ex tb IIIC T100°C Db IP66/IP67
• Serial number
• Year of manufacturing
• Number of notified body ••••
• EC-Type examination certificate number
Warning:
AVERTISSEMENT : NE PAS OUVRIR SOUS TENSION
WARNING : DO NOT OPEN WHEN ENERGIZED
• T cable : (**)
(*) temperature range can be reduced without
exceeding above values depending upon the type
of component mounted inside the enclosure.
(**) Mandatory mention when the ambient
temperature is higher than 70°C.
T ambient T cable
70°C
75°C
75°C
80°C
80°C
85°C
85°C
90°C
5.2 Electrical safety parameter
• Maximum dispersed power = 5W
• Voltage supply allowable:
Warning:
AVERTISSEMENT : DANGER POTENTIEL DE CHARGES
ELECTROSTATIQUES –VOIR INSTRUCTIONS
WARNING: POTENTIAL DANGER OF ELECTROSTATIC
CHARGES. SEE INSTRUCTIONS
10 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.

6. Position Transmitter 496-8../. Electrical data
• Power supply:
Voltage Supply U (V)
Mini
Maxi
Flameproof
9.0V
36V
Intrinsic Safety
9.0V
28V
• Lightning protection (in standard) : 1500W 10/1000µs
• Output current 4-20mA (two wires) Zc
• Zero range adjustment : ±0.5mA U
• Span range adjustment : ±2.5mA
• Protected against polarity inversion
Supply Voltage
(
V
)
–9.0
(
V
)
• Maximum load Zc
(Ω) =
This means for 20mA:
Imaxi
(
A
)
Zc = 950 Ohm max with for an intrinsically safe loop
and
Zc = 1350 Ohm for Flameproof.
© 2018 Baker Hughes, a GE company. All rights reserved. 496 Series Masoneilan Position Transmitter ATEX Instruction Manual | 11

Plug
Manufacturer
Certification
ATEX
Certificate
IECEx
Certificate
REDAPT
Ex d IIC
Ex tb IIIC
SIRA 99
ATEX
1115U
IECEx SIR
05.0042U
Others plugs if apparatus certified ATEX or IECEx
(type Cooper CAPRI CODEC).
Adaptor or Reducer
Manufacturer
Certification
ATEX
Certificate
IECEx
Certificate
REDAPT
Ex d IIC
Ex tb IIIC
SIRA 99
ATEX
1115U
IECEx SIR
05.0042U
Other adaptors or reducers if apparatus certifie d
ATEX or IECEx (Cooper CAPRI CODEC).
7. Electrical Connection, Installation and Start-up
• Comply with current national and local regulations for electrical installation work.
• Must be installed and put into service in conformance with EN 60079-14 and/or national and local
regulations applicable for explosible atmospheres.
• 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.
• Connect the wires to the instrument terminals, taking care of complying with polarities and maximum
voltage allowed.
• Before power up or after doing any work on the device always check the cover (12) is fully screwed,
O-ring (10) is free of any damage and security screw (9) is well locked.
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 Conduit entry in flameproof application
The connections can be done with different variations
taking into account approved manufacturer and
requested approvals:
• A cable entry of a certified type Ex d IIC / Ex tb IIIC
can be mounted directly on the single ¾" NPT (ANSI/
ASME B1.20.1) housing conduit connection.
• For an adaptor or reducer need, these component
are allowed:
• For multiple cable entries (3 maximum), the adaptor
Y237 “Masoneilan” can be used for ATEX application
only.
–If one Y237 input is not used, the conduit will be
closed by the followed plugs:
–If two Y237 inputs are not used, the Y237 must be
suppresse d .
• The cable entry with or without its adaptor/reducer
and the Y237 with its cable entry must be installed in
conformance with Annex III.
12 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.

7.
Electrical Connection, Installation and Start-up (Contd)
7.2 Electrical connection for type
496-.57 or 496-.58
• The electrical cables are connected either directly
on to the micro switch(es) or to the proximity switch
terminal block.
• Connect the device to the earth using the earth
connections provided inside and outside the housing
of the device.
• Basic rule for wiring:
–Must be used in addition to local regulation for
electrical installation
–Connector slot approval:
–Insulation must be free of any damage along the
wires inside the housing
–Tightening must be sufficient to bring constant
contact in time without being excessive to cut or
damage connection.
7.3 Electrical connection for 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 –and the maximum
voltage allowed.
When a position transmitter is provided with an
additional function, the electrical cables are connected
either directly on to the micro switch(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.
• Basic rule for wiring:
–Must be used in addition to local regulation for
electrical installation
–Connector slot approval:
–Insulation must be free of any damage along the
wires inside the housing
–Tightening must be sufficient to bring constant
contact in time without being excessive to cut or
damage connection.
© 2018 Baker Hughes, a GE company. All rights reserved. 496 Series Masoneilan Position Transmitter ATEX Instruction Manual | 13

7.
Electrical Connection, Installation and Start-up (Contd)
7.4 Installation and start-up
7.4.1 Installation
Flameproof instrument may be installed in gas and
dust explosive atmosphere of groups IIA, IIB, IIC and
IIIC for the zones 1, 2, 21 and 22 with “d”and “tb”
protection mode.
Intrinsically safe instrument may be installed in gas
and dust explosive atmosphere of groups IIA, IIB,
IIC and IIIC for zones 0, 1, 2, 20, 21 and 22 with “ia”
protection mode.
Nota:
It is under the user responsibility to check the installation against Intrinsic safety rules taking into account
entity parameters of all devices in the loop in addition of temporary one like measurement devices.
7.4.2 Start-up
–Before power up or after doing any work on the device always check the cover (12) is fully screwed,
O-ring (10) is free of any damage and security screw (9) is well locked.
–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 §8 and/or ensure that all the safety
instructions in the preceding paragraphs have been strictly followed.
14 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.

8. Calibration
Before power up the device to proceed with calibration
carefully read the following safety warnings.
–Comply with current national and local
regulations for electrical installation work.
–Must be installed and put into service in
conformance with EN 60079-14 and / or
national and local regulations applicable for
explosible atmospheres.
–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.
–Connect the wires to the instrument’s
terminals, taking care of complying with
polarities and maximum voltage allowed.
–Before power up or after doing any work on
the device always check the cover (12) is fully
screwed, O-ring (10) is free of any damage
and security screw (9) is well locked.
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 below).
• 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 over travel. Conversely, the cam operating the left
hand micro-switch must actuate the lever (5) at the
end of the clockwise rotation. (See front view below).
• 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.
© 2018 Baker Hughes, a GE company. All rights reserved. 496 Series Masoneilan Position Transmitter ATEX Instruction Manual | 15

8.
Calibration (Contd)
1 6 9 10 11 12 8 13
A
8
2
13
3
4 3
17
7
15
5
14
18
5
16
B
Parts List
Rep.
Designation
Rep.
Designation
Rep.
Designation
1
Adjusting screw
8
Snap ring
2
Adjusting screw
9
Safety screw
16
Insulating
3
Screw (1 micro switch)
10 (1)
Oring
17
Screw (second micro switch)
4
Micro switch
11
Axis
18
Washer
5
Lever
12
Cover
19 (2)
Spacer (Not shown)
6
Housing
13
Cam
A
Contact point for the left micro switch
7 (1)
O ring
14
Serial plate
B
Contact point for the right micro switch
(1) Recommended spare parts
(2) Only for 496-2 model
16 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.

8.
Calibration (Contd)
Rep.
Designation
Rep.
Designation
33
Arm
34
Proximity switch
8.2 Calibration of rotary limit switch
496-.57 and 496-.58 equipped with
proximity switch(es)
8.2.1 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.
34 34
33
8.2.2 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
actuator stroke.
–Immobilize 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.
a
A
B
b B c
Rep.
Designation
Rep.
Designation
A
Red spot
B
First triggering point
© 2018 Baker Hughes, a GE company. All rights reserved. 496 Series Masoneilan Position Transmitter ATEX Instruction Manual | 17

8.
Calibration (Contd)
8.2.3 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).
6 9 10 11 12 8 30 37A
8
31
32
33
3 36
7 15
25 14
3
24
34 37B 19
Parts List
Rep.
Designation
Rep.
Designation
Rep.
Designation
3
Screw
12
Cover
31
Snap ring
6
Housing
14
Serial plate
32
Washer
7 (1)
O-ring
33
Arm
8
Snap ring
19
Spacer
34
Proximity sensor
9
Safety screw
24
Terminal block
35 (2)
Spacer (Not shown)
10 (1)
O-ring
25
Terminal block
36
Sensor bracket
11
Axis
30
Spacer
37
Nut
(1) Recommended spare parts (2) Only for 496-4 model
18 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.

8.
Calibration (Contd)
Masoneilan
8.3 Calibration of position transmitter
496-858 or 496-858/
• Action
The action sense of the valve (open or closed valve,
compared to the 4 - 20 mA of the loop signal),
determines the position of the connector 3 points
of the optoelectronic sensor on one of the two
connectors of electronic circuit A or B.
The operation rule is: for a clockwise rotation of
the pinion of the control shaft (view cover side),
the output current increases (4→20 mA) when the
connector of the optoelectronic sensor is connected
in A and decreases when connected in B.
A B
C
Z S
-
PN:
+
• Linkage adjustment
When mounted on reciprocating valves, adjust the
turnbuckle to get the instrument lever perpendicular
to the plug stem at mid-travel.
• Position transmitter adjustment
–Position the connector 3 points on connector A
or B in function of the chosen action.
–Preset mid travel the zero adjustment (Z)
if necessary *.
–Preset mid travel the span adjustment (S) if
necessary **.
–Configure the switch C (see annex II) on the
rotation angle of the control axle.
–Position the valve to the origin of travel that should
correspond to the minimum of the signal (4 mA).
–Install a milliamp meter in series in the loop and
power up the instrument.
–Rotate the primary pinion on the control axle to
get an output signal around 4 mA
–Fine tune-up of the 4 mA signal with the zero
potentiometer (Z).
–Full stroke the valve to the rated travel and
adjust the output signal to 20 mA with the span
potentiometer (S).
–Check the zero and span calibration compared
to the valve stroke. Repeat the zero and span
calibration operations if necessary.
* In case of problem of Zero adjustment due to
the physical limits of the potentiometer, turn
of 5 turns in the reverse direction that desired
and turn the primary pinion to obtain an output
current nearest to 4 mA.
** In case of problem of span adjustment due to
the physical limits of the potentiometer, turn of
5 turns in the reverse direction that desired and
configure the switch C (see annex II) for a higher
or lower angle than that basis.
• 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.
© 2018 Baker Hughes, a GE company. All rights reserved. 496 Series Masoneilan Position Transmitter ATEX Instruction Manual | 19

8.
Calibration (Contd)
9 10 11 8 12 23 111 44 110
7
8 220
22144 6
114
46
222
114
14
F
View F
Vue
108
106
105
101 102 103 104 38 42
107
Parts List
Rep. Designation Rep. Designation Rep. Designation
6
housing
38
spacer
106
Grower washer
7
O-ring
42
electronic card
107
stirrup
8
circlips
44
washer
108
washer
9
CHC screw
46
card support
110
screw
10
O-ring
101
ground screw (inside)
111
spring washer
11
shaft
102
Grower washer
114
CHC screw
12
cover
103
stirrup
220
detector set
14
serial plate
104
washer
221
detector support
23
pinion
105
ground screw (outside)
222
screw
20 | BHGE © 2018 Baker Hughes, a GE company. All rights reserved.