ATEX du 496-185888

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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 transmittertypes 496-858 or 496-858/. ............................................................................................................. 5

4.1. Marking .....................................................................................................................................54.2. Electrical safety parameters .................................................................................................... 5

5. ATEX marking and electrical safety parameters of explosionproof rotary limit switch type 496-57and 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 ................................................................................................................................77.2. 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 INSTRUCTIONSCAREFULLY.

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 safeinstallations MUST BE:

a) Installed, put into service, used and maintained in compliance with national and local regulations and in accordance with therecommendations 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 theircompatibility 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 forinstrumentation 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 systemwhich 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 proportionalto 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 electricalcircuits. 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

496- /

TYPE PROTECTIONADDITIONAL FUNCTION

FOR A TRANSMITTERONLY

1. one mechanical switchsingle pole double throw

57- Explosionproofand dust and water

tight

1. one mechanical switchsingle pole double throw

2. two mechanicalswitchessingle pole double throw

58. Intrinsically safeand dust and watertight

2. two mechanical switchessingle pole double throw

4. one proximity switch 4. one proximity switch

5. two proximity switches 5. two proximity switches

6. one mechanical switchdouble pole double throw

6. one mechanical switchdouble pole double throw

7. two mechanicalswitchesdouble pole double throw

7. two mechanical switchesdouble pole double throw

8. Optoelectronic positiontransmitter

2. TECHNICAL SPECIFICATION

Internal components of the rotary limit switch and position transmitter are mounted inside an IP65/IP67 enclosure.

Performances o f posit ion transmi tter 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 deadbanderrors,

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 aregiven in the following sections.

3. ATEX MARKING AND ELECTRICAL SAFETY PARAMETERS OF INTRISICALLY SAFE ROTARY LIMIT SWITCH496-.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 GEEx ia IIC T6 Ta : - 55 C to + 80 C

Limit switch with proximity switch(es)

II 2 GEEx 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 itsoutput 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:

UiV

IiA

CinF

LH

DC source 30 0,5 0 0Variation withmicro-switch AC source 90 1,4 0 0

Variation with proximity switch 16 0,052 120 200

4. ATEX MARKING AND ELECTRICAL SAFETY PARAMETERS OF INTRISICALLY SAFE POSITIONTRANSMITTER 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)


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 intrinsicallysafe 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:

UiV

IiA

CinF

LiH

28 0,11 20 0

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Additional funct ion for instrument type 496-858/.

Maximum input characteristics at terminal block of additi onal function:

UiV

IiA

CinF

LiH

DCsource

30 0,5 0 0Variation withmicro-switch AC

source90 1,4 0 0

Additionalfunction

Variation with proximityswitch

16 0,052 50 150

5. ATEX MARKING OF EXPLOSIONPROOF ROTARY LIMIT SWITCH TYPE 496-.57 AND OF EXPLOSIONPROOFPOSITION 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/. (where . can be replaced by 1, 2, 4, 5, 6, 7)

INERIS 02 ATEX 0080X

(serial number)


Rotary limit switch 496-.57 :

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/DEEx 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 componentmounted inside the enclosure

5.2. Electrical safety parameter

Pmax = 5W.

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

Power supply : - Explosionproof : U min = 12.5 V and U max = 40 V.- Intrinsically safe : U min = 12.5 V and U max = 28 V.

Protected against polarity inversion,

Maximum load ( ))(Imaxi

)(5,12)(VoltageSupply

A

VVZc

=

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

SUPPLY POSITIONTRANSMITTER

Load Zc

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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 t he instrument or make sure that the localconditions 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 sealin 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 manufacturerwhose 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 dIIC for an explosionproof instrument)and suitable to the equipment operating zone(IP 6X for zones 21).

7.2. Electrical connection of the rotary limit swi tch type 496-.57 or 496-.58

The electrical cables are connected either directly on to the microswitch(es) or to the proximity switch terminalblock.Connect the device to the earth using the earth connections provided inside the housing and on the outside ofthe device.

7.3. Electrical connection of the posi tion transmi tter 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 eitherdirectly 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 ofthe device.

7.4. Installation and start-up

Installation

Explosionproof instrument can be installed in flammable gas explosive atmosphere groups IIA, IIB, IIC forthe 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 thezones 0, 1 and 2.

Start up


Check that the cable gland is certified for the intended use and that the electrical data are suitablefor the operating zone.

Before start up, proceed, if required, with instrument calibration as per paragraph 8 and/or ensure that all thesafety 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.



Before carrying out any work on the device, power off t he instrument or make sure that the localconditions in the potentially explosive atmosphere permit the safe opening o f the cover.


8.1 Calibration of ro tary lim it swi tch 496-.57 and 496-.58 equipped with micro swi tch(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 thecounterclockwise 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-switchmust 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 tochange 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 camenough to properly depress the lever (5).

Strictly follow safety instructions under 7.4 before putting into service.

PARTS LISTS

Rep. Designation Rep Designation Rep Designation1 Adjusting screw 8 Snap ring 15 Drive screw

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

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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 theproximity sensor.

The figure below shows the location of the proximity sensor and of the arm when triggering as a function of thesense of rotation.

Slowly move the arm towards the proximity sensor until it triggers. Triggering occurs when the arm overlapsapproximately 1/3 of the proximity switch.


Rep. Designation Rep Designation33 Arm 34 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 proximitysensor 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 proximitysensor until it triggers.

Make sure the first proximity switch is still correctly adjusted.


Rep. Designation Rep DesignationA Red spot B First triggering point

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Air gap adjustment

Air gap between the proximity switch and the arm is factory adjusted. If new adjustment is required proceed asfollows:

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 soas 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 Rep Designation Rep Designation

3 Screw 12 Cover 31 Snap ring6 Housing 14 Serial plate 32 Washer

7 (1) O-ring 15 Drive screw 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

8.3. Calibration of posit ion transmi tter 496-858 or 496-858/.

ActionAs 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 THERELATION SHIPBETWEEN THEROTATION SENSE OFTHE POWER SHAFTAND THE OUTPUTSIGNAL

A ConnectorB 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 thescrew (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).


PARTS LIST

Rep. Designation Rep Designation Rep Designation1 Screw 15 screw 40 Screw

6 Housing 20 Position sensor 41 Grower washer

7 (1) O ring 21 Bracket 42 Printed circuit board

8 Snap ring 19 Spacer 43 Insulating disk

9 Safety screw 22 Sensor gear 44 Washer

10 (1) O ring 23 Main gear 45 Nut

11 Arm 37 Snap ring S Span adjustment potentiometer

12 Cover 38 Spacer Z Zero adjustment potentiometer

14 Serial plate 39 Threaded rod(1) Recommended spare parts

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9. MAINTENANCE



Before carrying out any work on the device, power off t he instrument or make sure that the localconditions 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 i ts 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 Industriels3 rue Saint Pierre

F-14110 CONDE SUR NOIREAUFrance

Dclare que les transmetteurs de position de type :

496-858496-858/1, 496-858/2496-858/4, 496-858/5

496-857496-857/1, 496-857/2496-857/4, 496-857/5496-857/6, 496-857/7

et contacteurs rotatifs de type :

496-158, 496-258, 496-458, 496-558496-157, 496-257, 496-457, 496-557

496-657, 496-757

destins tre utiliss en atmosphres explosibles sont conformes:

aux exigences essentielles de la directive ATEX 94/9/CE concernant le rapprochement des lgislations des EtatsMembres pour les appareils and systmes de protection destins tre utiliss en atmosphres explosibles

Appareils 496-158, 496-258, 496-458, 496-558, 496-858, 496-858/1, 496-858/2, 496-858/4 and 496-858/5

aux normes suivantes:EN 50014:1997 and amendements 1 and 2EN 50020:1994EN 50284:1999

EN 50281-1-1:1998

au type ayant fait l'objet de l'attestation d'examenCE de type INERIS 02 ATEX 0023.

Appareils 496-157, 496-257, 496-457, 496-557, 496-657, 496-757, 496-857, 496-857/1, 496-857/2, 496-857/4, 496-857/5, 496-857/6, 496-857/7

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

au type ayant fait l'objet de l'attestation d'examenCE de type INERIS 02 ATEX 0080X

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

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

aux normes EN 50081-2 et EN 50082-2

Cond sur Noireau C. VLASSOFFLe 2 janvier 2003 Directeur Qualit/Technique

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Factory and Customer Service (Spare Parts and After Sales)

DRESSER PRODUITS INDUSTRIELS3, rue Saint Pierre

BP 8714110 Cond sur Noireau, France

Tl. +33(0)2 31 59 59 59Fax +33(0)2 31 59 59 60

www.masoneilan.com

Sales offices

BELGIUM

Masoneilan Division of Dresser Europe S.A.281-283, Chausse de Bruxelles1190 BRUSSELS - BelgiumTelephone : 32-2-344-0970Fax : 32-2-344-1123

FRANCEDresser Produits IndustrielsDivision Masoneilan4 Place de Saverne92971 Paris La Dfense CedexFranceTelephone : 33-1- 49 04 90 00

Fax : 33-1-49 04 90 10

GERMANYDRESSER VALVES EUROPEGmbH, Heiligenstrae 75,41751 Viersen Germany,Telephone : 49-2162-81700Fax : 40-2162 81 70 200

ITALYMASONEILANDivision of DRESSER ITALIA S.r.l,Via Cassano, 77,

80020 Casavatore, Napoli- ItalyTelephone : 39-081-7892-111Fax : 39-081 7892 208

THE NETHERLANDS

DRESSER VALVES EUROPESteenhouwerstraat 113194 AG HoogvlietTelephone : 31-10-438-4122Fax : 31-10-438-4443Mailing adress :P.O. Box 640NL-3190 AN Hoogvliet RTThe Netherlands

SPAINMasoneilan S.A.C/Murcia 39 C08830 Sant Boi de LLobregatBarcelona- Spain

Telephone : 34-93-6526430Fax : 34-93 652 6444

UNITED KINGDOMDI U.K. LimitedEast Gillibrands Estate, SkelmersdaleLancashire WN8 9TU - EnglandTelephone : 44-1695-52600Fax : 44-1695-52662

DRESSER FLOW CONTROL, DI U.K. Ltd.Unit 4, Suite 1.1, Nobel HouseGrand Union Office Park, Packet Boat Lane, Uxbridge

Middlesex UB8 2GH - EnglandTelephone : 44-1895-454900Fax : 44-1895-454919

ATEX du 496-185888

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