GE Masoneilan 469 Series, Masoneilan 496-857, Masoneilan 496-858, Masoneilan 496- Series 58, Masoneilan 496- Series 57 Instruction 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.

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 in

6.4516

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.

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

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 and 22 for the protection mode “ia”

• Category II 2GD – zones 1, 2, 21 and 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.

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 optoelectronic 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 - _ _ _ / _

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.

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)

4. ATEX Intrinsic Safety Marking and Electrical

Variation

Ui Ii Ci

(V) (A) (nF)

Li Pi

(μH) (W)

With Microswitch

DC Source

30 0.5 0 0 -

AC Source

Peak Value

1.4

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 Microswitch

DC Source

30 0.5 0 0 –

AC Source

Peak Value

1.4

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)

0.11

36 0 0.77

+ 19 hidden pages

GE Masoneilan 469 Series, Masoneilan 496-857, Masoneilan 496-858, Masoneilan 496- Series 58, Masoneilan 496- Series 57 Instruction Manual

Specifications and Main Features

Frequently Asked Questions

User Manual