Omega mark-1, Mark-4 User guide

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Page 1

Bulletin V-30

Series Mark Position Indicator/Transmitter

Specications - Installation and Operating Instructions

INTRODUCTION

The Proximity Controls Series Mark Position Indicator/Transmitter is a line of position indicators

with a selection of various output options. Three model styles make up the Mark Series to cover almost any application. A magnetic drive that completely seals the switch compartment from the atmosphere for maximum leak protection is utilized in the Mark 1. The Mark 3 uses the same magnetic drive of the Mark 1, but it can be used for multi-turn applications with 1 to 25 revolutions, such as gate valves. A through shaft drive is incorporated in the Mark 4 making the unit a lower cost alternative to the Mark 1 for applications that are not as demanding.

Standard models in the Mark Series have visual position

indicators and are weatherproof, ameproof, and

submersible. A large variety of outputs are available to

t specic applications. There is a choice of 1 to 6 switch

outputs of 13 varieties including inductive sensors, high temperature switches, gold contact switches, hermetically sealed switches, and high current switches. Aside from switch outputs, the Mark Series offers potentiometer outputs, 4-20 mA transmitters, and HART communication.

The units are purchased for either direct drive applications, such as rotary valves, or lever drive applications, such as linear valves. For the Mark 1, 3, and 4 this instruction manual starts with installation of the unit to the device being monitored, and the set up of switch models. Separate instructions follow covering the potentiometer and transmitter set up if your unit has those options.

This product uses FreeRTOS (www.FreeRTOS.org) version 8.0.1. A copy of the original FreeRTOS source shall be provided upon request.

TABLE OF CONTENTS

Introduction. . . . . . . . . . . . . . . . . . . . . . 1

Dimensions . . . . . . . . . . . . . . . . . . . . . 2

Specications . . . . . . . . . . . . . . . . . . . 2-3

Model Number Conguration. . . . . . . . . . . . 4-5

Junction Package . . . . . . . . . . . . . . . . . . 6

Factory Sealed Leads . . . . . . . . . . . . . . . . 6

Mounting Kits for Valves . . . . . . . . . . . . . . . 6

Mark 1 and 4 Direct Drive Installation . . . . . . . . 7

Mark 1 and 4 Lever Drive Installation . . . . . . . . 8

Mark 3 Direct and Lever Drive Installation . . . . . . 9

Mark 1, 3, and 4 with Potentiometer Installation . . 10 Mark 1, 3, and 4 with Transmitter Installation . . 11-12 Mark 1, 3, and 4 Transmitter with

Communication Protocol . . . . . . . . .12-13

HART

Wiring, Intrinsic Safety and Warnings . . . . . . 14-15

Schematics: General and Intrinsic Safety . . . . 16-19

Maintenance . . . . . . . . . . . . . . . . . . . . 20

DWYER INSTRUMENTS, INC.

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46360, U.S.A.

Phone: 219-879-8000 Fax: 219-872-9057

dwyer-inst.com e-mail: [email protected]

Page 2

DIMENSIONS

CLEARANCE REQUIRED

FOR COVER REMOVAL

4-1/4

[107.95]

DIRECT

DRIVE

CONNECTION OR OPTIONAL

SPECIFICATIONS General

Product Ratings: Weatherproof and ameproof. NEMA

1, 2, 3, 3R, 3S, 4, 4X, 6, 7, 9, 12, 13.

UL rated: Class I, Div. 1 and 2, Groups B, C, D (Some units available for Group A, consult factory); Class II,

Div. 1 and 2, Groups E, F, and G.

CSA rated: Class I, Div. 1 and 2, Groups A, B, C, D;

Class II, Div. 1 and 2, Groups E, F, and G. Submersible to 15 meters (IP68); It is up to the end user to source the proper ttings to ensure a watertight seal.

ATEX Compliant:

-B sufx: Directive 2014/34/EU, KEMA 03ATEX2391 X, 2813 II 2G Ex db IIC T6 Gb for -25°C/-40°C/-50°C

≤ Tamb ≤ 63°C depending on output and switch type selected. Compliant per EN 60079-0:2012+A11:2013 and EN 60079-1:2014.

-IS sufx: Directive 2014/34/EU, KEMA 03ATEX1392 X, 2813 II 1G Ex ia IIC T4 Ga. Compliant per EN

60079-0:2012 + A11: 2013 and EN 60079-11:2012.

3 [76.20]

*4-9/16

[115.89]

5-15/16

[150.81]

1-9/16 [39.69]

1 [25.40]

3/4 NPT

CONDUIT

118°

M25 X 1.5

1-1/2

[38.10]

1/4-20 UNC THREAD

X 7/16 [11.11] DP

TYP 2 PLACES

4-7/8 [123.83]

2-3/8

[60.33]

1/2 NPT CONDUIT CONNECTION [OPTIONAL] OR OPTIONAL M20 X 1.5 2 PLACES

*FOR MODELS 11, 12, 41 & 42

LEVER DRIVE

2-3/8

[60.33]

.249 ± .001 [6.32 ± .03]

1-1/4 [31.75]

1/4

[6.35]

TYP

Ø4-7/16 [112.71]

Ø1/8 [3.18] PIN TYP 2 PLACES

IECEx Compliant:

-IE sufx:IECEx DEK 11.0056X Ex db IIC T6 Gb for

-25°C/-40°C/-50°C ≤ Tamb ≤ 63°C depending on output and switch type selected. Compliant per IEC 600790:2011 and IEC 60079-1:2014.

-II sufx: IECEx DEK 11.0061X Ex ia IIC T4 Ga. Compliant per IEC 60079-0:2011, IEC 60079-11:2011, and IEC 60079-26:2014.

Electrical Connections: Screw terminal. Optional

factory sealed leads that are 36˝ (914.4 mm) of 16 AWG. Conduit Connection: Standard: one 3/4˝ female NPT; optional one to two 1/2˝ female NPT; Optional: M25 X

1.5 or M20 X 1.5 connections may be supplied in lieu of

3/4˝ and 1/2˝ female NPT for all models.

Mounting Orientation: Not position sensitive. Weight: 4 to 6 lb (1.5 to 3.0 kg). Operational Life: Over 10,000,000 cycles. Maximum Altitude: 2000 meters. 5000 meters for

models 1, 3 & 4 followed by 1, 2, 4 or 6

followed by A, B, C, G, I, T, V or W.

5/16 [7.94]

#6-32 UNC THREAD X 1/4 [6.35] DEEP

1-1/16 [26.99]

Page 3

Mark 1, 3 and 4 with Switch Outputs Temperature Limits: -58 to 176°F (-50 to 80°C). Switch type C rated to 350°F (176°C) for 600 hours, Switch type T

rated to 250°F (121°C) continuous. (ATEX ameproof, -B sufx and IECEx ameproof, -IE sufx, rated -58 to 145°F (-50 to 63°C) for switch type A, G, H, T, or M, -40 to 145°F (-40 to 63°C) for switch type O, R, S, V, or W, -13 to 145°F (-25 to 63°C) for switch type B, D, I, or AS interface; ATEX intrinsically safe, -IS sufx and IECEx intrinsically safe, -II sufx, rated -13 to 104°F (-25 to 40°C) for switch type D or I, -40 to 104°F (-40 to 40°C) for switch type R, V, or W, or -58 to 104°F (-50 to 40°C) for switch type A, G, or H).

Switch Type: See model chart on pages 4 and 5.

Electrical Rating: See model chart on pages 4 and 5. Set Point Adjustment: Mark 1 and 4: 5 to 360°. Mark 3: 1 to 25 revolutions.

Mark 1, 3, and 4 with Potentiometer Accuracy: ± 0.5% of FS. Optional ± 0.25% of FS. Temperature Limits: -40 to 176°F (-40 to 80°C).(ATEX ameproof, -B sufx and IECEx ameproof, -IE sufx, rated

-40 to 145°F (-40 to 63°C) for switch types A, G, M, O, R, S, T, V, or W, -13 to 145°F (-25 to 63°C) for switch types B, D, or I.; ATEX intrinsically safe, -IS sufx and IECEx intrinsically safe, -II sufx, rated -13 to 104°F (-25 to 40°C) for switch type I, -40 to 104°F (-40 to 40°C) for switch types O, R, S, V, or W.

Power Rating: 1.5 watt maximum. Output Signal: 1000 Ω standard. Optional 2000, 5000, 10000, or 20000 Ω. Zero and Span Adjustments: Span trim pot with 2000Ω adjustment. No zero adjustment. Rotational Travel: Mark 1 and 4: Minimum: 0°, Maximum: 340°. Mark 3: 0 to 10 revolutions.

Mark 1, 3, and 4 with Transmitter Accuracy: ± 0.5% of FS. Optional ± 0.25% of FS. Temperature Limits: -40 to 176°F (-40 to 80°C). (ATEX ameproof, -B sufx and IECEx ameproof, -IE sufx, rated

Power Requirements: 5-30 VDC. Current Consumption: 50 mA. Output Signal: 4-20 mA. Zero and Span Adjustments: Trim pots for adjusting both. Mark 1 and 4: Span is adjustable from 50 to 300°. Mark

3: Span is adjustable from 1.5 to 8.5 revolutions. Conduit Connection: 3/4˝ female NPT standard. Optional one or two 1/2˝ female NPT. M25 X 1.5 and M20 X 1.5

optional.

Rotational Travel: Mark 1 and 4: Minimum: 50°, Maximum: 300°. Mark 3: Minimum: 1.5 revolutions; Maximum: 8.5

revolutions.

Mark 1 and 4 Transmitter with HART Accuracy: ± 0.5% of FS. Optional ± 0.25% of FS.

Communication

Temperature Limits: -40 to 176°F (-40 to 65°C). (ATEX ameproof, -B sufx and IECEx ameproof, -IE sufx, rated

-40 to 145°F (-40 to 63°C) for switch types A, G, M, O, R, S, V or W, -13 to 145°F (-25 to 63°C) for switch types B, D or I; ATEX intrinsically safe, -IS sufx and IECEx intrinsically safe, -II sufx, rated -40 to 104°F (-40 to 40°C) for switch types O, R, S, V or W; -13 to 104°F (-25 to 40°C) for switch type I).

Power Requirements: 8-30 VDC. Current Consumption: 21 mA. Output Signal: 4-20 mA.

Receive Impedance: Rx = 500 kΩ; Cx = 2500 pF.

HART Zero and Span Adjustments: Pushbuttons or HART

communication master for setting both. Mark 1 and 4: Span

is adjustable from 0 to 330°. Mark 3: Span is adjustable from 1.5 to 8.5 revolutions. Conduit Connection: 3/4˝ female NPT standard. Optional one or two 1/2˝ female NPT. M25 X 1.5 and M20 X 1.5

optional.

Rotational Travel: Mark 1 and 4: Maximum: 330°.

Page 4

Construction 1

3 4

Mark 1, magnetic coupling Mark 3, multi-turn Mark 4, thru-shaft

Available Options “A”

signies

available with corresponding construction style Mark

), 1/4 hp

1 3 4 A

A A A A A A A A A A

A A A

A A

A A A A

A A

Output Type 1

Switch Type and Rating

*Mark 1 and 4 potentiometer and transmitter outputs will have no switches when ordered with switch type O; 2

1 switch

2 switches

1 kΩ potentiometer 1/2%; Available with switches, see note below*

1 kΩ potentiometer 1/4%; Available with switches, see note below*

2 kΩ potentiometer; Available with switches, see note below*

5 kΩ potentiometer; Available with switches, see note below*

310

10 kΩ potentiometer; Available with switches, see note below*

320

20 kΩ potentiometer; Available with switches, see note below*

4 switches

Transmitter 1 kΩ potentiometer 1/2%; 4-20 mA; Available with switches, see note below*

Transmitter 1 kΩ potentiometer 1/4%; Available with switches, see note below*

Transmitter 2 kΩ potentiometer; Available with switches, see note below*

6 switches; Available with switch types B, C, I, R, V, W (UL and CSA

approved units only)

AS-interface and 1 switch; Available with switch types B, I, R, W

AS-interface and 2 switches; Available with switch types B, I, R, W

Transmitter with HART

note below*

SPDT snap, rated: 15 A @ 125/250/480 VAC (~); 1/8 hp @ 125 VAC (~), 1/4 hp @ 250 VAC (~), 1/2 A @ 125 VDC (

)

( Inductive sensor. 10-30 VDC (

SPDT high temperature snap, 350°F (176°C) for 600 hours, rated:

15.1 A @ 125/250/277 VAC (~) DPDT snap, rated: 10 A @ 125/250 VAC (~), 0.3 A @ 125 VDC (

0.15 A @ 250 VDC (

SPDT gold contact snap, rated: 1 A @ 125 VAC (~)

SPDT hermetically sealed snap, rated: 1 A @ 125 VAC (~)

NAMUR inductive sensor; 15 mA max @ 5-25 VDC (

SPDT magnetic blow-out, rated: 10 A @ 125 VAC (~)/VDC (

@ 125 VAC (~)/VDC (

No switches

SPDT hermetically sealed reed, rated: 2 A @ 125 VAC (~), 2 A @

24 VDC (

SPDT snap, rated: 4 A @ 125/250 VAC (~)

SPDT high temperature snap, 250°F (121°C) continuous, rated: 5 A @

125/250/480 VAC (~) SPDT snap, rated: 10 A @ 125/250 VAC (~), 1/3 hp @ 125/250 VAC

(~), 1/2 A @ 125 VDC (

(tungsten)

SPDT gold contact snap, rated 0.1 A @ 125 VAC (~)

)

communication; Available with switches, see

), 1/4 A @ 250 VDC

); Load: 0.1 A

)

), 1/4 A @ 250 VDC (), 4 A @ 125 VAC (~)

)

switches if ordered with switch types B, C, D, I, R, V, or W; and 4 switches if ordered with switch type S. Mark 3 potentiometer and transmitter outputs will have no switches when ordered with switch type O, and 2 switches if ordered with switch types A, G, M or T.

Page 5

Available Options “A”

signies

available with corresponding construction style Mark 1 3 4

Driving

MethodAD

Enclosure 0

Options C1

*Utilizes Asco Valve, Inc. Solenoid Operator Cat. Nos. HV298934001 and HV298934002. Solenoid Operator Certicate of Conformity numbers: IECEx UL 10.0040X Issue No. 5, ATEX Certicate number DEMKO 10 ATEX 1007782X Rev. 3. Operating Fluid Temperature Range of -20°C to +49°C. Example: 12VD0-J1. Mark 1, 2 switches both type V – SPDT, direct drive, painted aluminum enclosure with junction

package. Example: 15VD0. Mark 1, 2 switches both type V – SPDT, 4-20 mA transmitter, direct drive, painted aluminum enclosure.

L M

1 2 5

7 thru 20

A direct or yoke drive without visual indicator Direct drive (or yoke) with visual indicator Direct or yoke drive with visual indicator, single window

Lever drive (shaft projection) without visual indicator Lever (shaft projection) with visual indicator

Aluminum, painted black Aluminum, painted white epoxy with SS trim Aluminum, painted red

Aluminum, painted (color not yet specied) Cast 316 SS Aluminum, painted (color not yet specied)

Long dwell cam (not on Mark 3)

Double cam (not on Mark 3)

FKM

FKM seals

Junction package with one 1/2˝ NPT female conduit connection

and terminal strip

Junction package with two 1/2˝ NPT female conduit

Connection and terminal strip

SV1

1 attached solenoid valve (must be ordered with J1 option)*

SV2

2 attached solenoid valves (must be ordered with J2 option)*

Metric threaded conduit connection, M25 X 1.5 (M20 X 1.5 for optional J1 and J2 connections)

Directive 2014/34/EU, KEMA 03ATEX2391 X, db IIC T6 Gb -25/-40/-50°C ≤ Tamb ≤ 63°C depending on output

switch type selected

Directive 2014/34/EU, KEMA 03ATEX1392 X,

ia IIC T4 Ga

IECEx DEK 11.0056X Ex db IIC T6 Gb -25/-40/-50°C ≤ Tamb ≤ 63°C depending on output and switch type selected

IECEx DEK 11.0061X Ex ia IIC T4 Ga

Plug J1, J2 ports (ATEX and IECEx units supplied with appropriate Ex db certied plug(s) which maintain IP rating.)

SS Plug J1, J2 Ports (ATEX and IECEx units supplied with appropriate Ex db certied plug(s) which maintain IP rating)

Paper tag

STR

SS tag riveted

STW

SS tag wired

2813 II 2G Ex

2813 II 1G Ex

A A A A A A A A A A A A A A A

A A A

A A

A A A

Page 6

JUNCTION PACKAGE

Complete factory assembled packages combine visual indication, solenoids, switches and transmitter in a single

convenient UL, CSA, IECEx certied or ATEX compliant

assembly which saves labor and reduces cost. The simple package is shipped ready for installation, complete with optional custom designed mounting kit for your

specic application. Many options are available such as

painted aluminum, epoxy coated aluminum or stainless

steel housings including a standard 3/4˝ NPT conduit entrance and choice of 1 or 2 additional 1/2˝ NPT conduit

entrances. The optional conduit entrances are drilled and tapped in the base of the position indicator housing and

solenoid valves are screwed into the entrances. 22 to 16

AWG wire leads from solenoids, switches and optional transmitter are terminated in prelabeled, easy-access terminal strips protected inside the housing. Note:

UL and CSA approval and ATEX compliance requires

complete package assembly by Proximity. Consult the

factory for recommended UL and CSA approved or ATEX or IECEx compliant solenoid valve options. ATEX and IECEx solenoid valve options are approved for II 2 G Ex d IIB T6 Gb -20°C ≤ Tamb ≤ 50°C IP 66. Please consult page 2 and 3 for ATEX Safety Code.

MOUNTING KITS

Mounting kits are available for direct installation of the Proximity Controls Mark Series onto most valve and actuator brands. Proximity Controls has over 2000 kits available and can custom make kits for any application.

Each kit is specially designed for a particular actuator or valve, making eld mounting simple with standard tools.

Mounting kits can be used with any model in the Mark Series, since external features are identical. Rotary valve kits utilize direct drive couplings, while linear valve kits use a lever drive.

Kits include a drive yoke or slotted lever arm, bracket, and fasteners made in either zinc plated steel or stainless steel. The high strength, spring tempered, stainless

steel drive yoke/coupling is tailored to t securely to a specic valve or actuator stem ensuring that there is no slippage or binding. No special alignment xtures are

required due to switch-offset design and yoke to stem engagement that makes installation a snap.

If you have purchased this unit without a mounting kit, please contact us to get the proper kit for your application.

Junction package

Note: Junction package is not available on six switch models, switch type A, D, G, H, and T models.

FACTORY SEALED LEADS

Eliminate the possibility of conduit contamination and the need for seal ttings with Proximity’s factory sealed (potted) leads. This seal has been UL tested to 6000 psi

(413 bar) and is UL and CSA listed for Class I, Groups

A, B, C, D; Class II, Groups E, F and G; Div. 1 and 2

locations. Groups may vary depending on the switch

model. Standard leads are 16 AWG and 36˝ (91.44 cm)

long.

Factory seal cutaway of Model 12ADO

SWITCH

VISUAL INDICATO

DRIVE YOKE

MOUNTING KIT

VISUAL INDICATOR

A stainless steel mechanical visual indicator is standard on direct drive units. The indicator provides visual open and closed indication and a degree scale, which can

easily be seen from 75 feet away. The scale is adjustable in 15° increments and the windows are adjustable in a 56° range with 90° xed increments. Factory options include 180° indication, ow path indication, special colors, and LED’s.

Page 7

MARK 1 AND 4 DIRECT DRIVE INSTALLATION

Installation Procedure

1. Unscrew cover. Keep threads clean and free from damage.

2. Switches are set at factory when in counterclockwise position. Index marks should appear as shown (Mark 1 only). Set screws, or holes in manual cams, (#2, 4

and 6) on Closed switches will be directly above

index marks.

2 Switch Unit #1 Open #2 Closed 4 Switch Unit #1, 3 Open #2, 4 Closed

6 Switch Unit #1, 3, 5 Open #2, 4, 6 Closed

3. Attach appropriate Drive Yoke onto two pins using a #6-32 screw provided. (Note: Coupling is a special spring temper yoke or solid metal block. Do not attempt to fabricate your own yokes.)

4. Attach mounting bracket (127-003 is shown) to

switch housing using 1/4˝ screws provided.

5. With actuator shaft rotated to its counterclockwise position, spread the drive yoke and slip it down onto the square (or rectangular) part of the actuator shaft. Attach bracket with two hex cap screws. Before tightening screws, operate control slowly with a wrench or power, and observe that drive shaft and drive yoke are concentric and perpendicular

in complete stroke. Adjust position as required, and

tighten all the mounting screws. Check concentricity

and perpendicularity. Readjust per above steps as

necessary.

Adjustment Procedure

A. Using a wrench or power, rotate the actuator shaft to extreme clockwise position. All switches should change to their opposite function. B. The cam can be relocated and repositioned by

loosening the set screw. To adjust manual cams,

grasp cam on knurled segment of cam surface. Simply rotate the cam on spline attached to the

shaft. Feeling or sound of clicks indicates 6º incremental adjustments. Stop rotating and release

pressure on cam when it is at proper actuation point. This allows cam to engage spline. Check the circuit to verify contact at proper point. Rotate shaft. Repeat steps above as necessary. Lock manual cam on spline by tightening set screw provided for additional security. C. Screw on cover and tighten against O-ring seal until cover does not turn.

See Pages 14-19 for wiring procedure, intrinsic safety parameters, relevant warnings and schematics.

Page 8

MARK 1 AND 4 LEVER DRIVE INSTALLATION

CLOCKWISE

Installation Procedure

1. Attach proper mounting bracket to switch housing using screws provided. Tubular spacers are provided for some installations.

2. Attach appropriate driving lever onto shaft. Do not tighten.

3. Attach switch and bracket to actuator, making sure that lever is free to rotate over entire range of actuator stroke.

4. Attach driving pin or bolt through lever arm if slotted, or on driving side of solid lever. (It may be necessary to loosen or remove mounting bracket to accomplish connection on some actuators.)

5. Operate actuator very slowly and observe movement of all pins and levers to be sure there are no interferences. Slide lever up or down on switch shaft to most desirable position. When all motions are made and clearances are adequate, tighten clamp screw on lever that was left loose in step 2. Tighten all mounting screws. Recheck the travel of all levers and pins for proper clearance through the entire stroke of the actuator.

6. Unscrew cover. Keep threads clean and free from

damage. Index marks are imprinted into driven magnet collar as shown (Mark 1 only). Set screws or

holes in manual cams (#2, 4 and 6) will be directly

above index marks on those switches that are Closed. Marks must be in line when making switch

cam adjustments. Cams are set at factory when in

the counterclockwise position, as shown, and listed as follows: 2 Switch Unit #1 Open #2 Closed 4 Switch Unit #1, 3 Open #2, 4 Closed

6 Switch Unit #1, 3, 5 Open #2, 4, 6 Closed 90º travel in clockwise direction will reverse all of

above switch positions.

Adjustment Procedure

A. Operate actuator to full closed position. Set screws hold cams in place on the shaft. For manual cams, grasp cam on knurled segment of cam surface and simply rotate cam to get correct actuation point. Clicks

indicate incremental adjustments. Applying pressure

on cam in direction of protruding actuation segment of cam surface, and rotating, eliminates incremental

adjustments. Stop rotating and release pressure

on cam when at proper actuation point. This allows engagement of cam to spline. Check circuit to verify

contact at proper point. Repeat the cam adjustment

steps as necessary. Lock manual cam on spline with set screw provided for additional security. B. Operate actuator to opposite extreme (full open),

and adjust cams to suit.

C. Screw on cover and tighten against O-ring seal until cover does not turn.

See Pages 14-19 for wiring procedure, intrinsic safety parameters, relevant warnings and schematics.

Page 9

MARK 3 DIRECT AND LEVER DRIVE INSTALLATION

CAM SCREWS

YOKE DRIVE

CLOCKWISE

SHAFT DRIVE

Installation Procedure

Mount the switch as necessary, concentric and perpendicular over the rotating shaft that is to be monitored. Direct drive yokes are available in many

widths and lengths to t your needs (Yokes are fabricated

from spring temper stainless steel. Do not attempt to fabricate your own yokes.) Shaft drive units require an

appropriate coupling (exible type recommended) to the

shaft being monitored.

Adjusting Procedure

1. Remove cover by unscrewing. Take care to keep threads clean and free from damage.

2. Clockwise rotation of the yoke or shaft will move the bar up, counterclockwise moves it down.Switches are set at the factory for approximately one revolution of the yoke or shaft to actuate switch #1. Notice, that the

cam screw for switch #1 is in location E. By changing

that cam screw to location D, three additional revolutions of the yoke or shaft will be required to actuate #1 switch. Moving the cam screw to holes C, B or A will add three revolutions for each location moved, until 13 revolutions are required between switch #1 and 2 actuation.

3. The cam screw for switch #2 in location A. By moving

it to location B, C, D, or E, three revolutions are

added for each location change.

4. Rotate the switch slowly through the full cycle several times before tightening the bolts securely. Observe the rotation for signs of yoke or shaft misalignment or binding with the actuator shaft. Correct as necessary, then tighten the mounting bolts and recheck alignment.

5. The following chart shows the various combinations of screw positions and resulting revolutions between switch actuation.

Cam Screw Locations

Switch #1 Switch #2

D C B A A A A A

6. Switch actuation at all intermediate number of

revolutions or partial revolutions can be selected by turning the cam screws in or out when located at the nearest location shown above. Any partial number of

turns may be selected, such as 4-1/2 or 12-3/4.

See Pages 14-19 for wiring procedure, intrinsic safety parameters, relevant warnings and schematics.

A D A A A B C D

Number of Revolutions

Between Switch

Actuation

1 4 7 10 13

19 22 25

Page 10

MARK 1, 3 AND 4 WITH POTENTIOMETER INSTALLATION

TERMINAL 3 TERMINAL 2 TERMINAL 1

Potentiometer

Resistance Ω

1000 2000 5000 10000 20000

Installation and Adjustment

1. Attach the switch to the actuator or valve. Refer to

Installation and Adjustment Instructions:

p. 7 for Direct Drive Mark 1 and 4 Models p. 8 for Lever Drive Mark 1 and 4 Models p. 9 for Mark 3 Models

2. Remove cover by unscrewing. Take care to keep threads clean and free from damage.

3. On models 13XXX and 43XXX, the switches are set at the factory when in the counterclockwise position as shown. Switch #1 is open, and #2 is closed.

When cams are rotated 90º clockwise, #1 becomes closed and #2 is open. The cams may be adjusted to increase or decrease the 90° rotation. For model

33XXX refer to pages 9 and 10 for Switch

Adjustment Procedure.

4. The potentiometer is positioned at the factory with the resistance element approximately centered. The resistance readings in the chart are typical of each different potentiometer.

5. To adjust the potentiometer to a different range,

loosen the two lower set screws on the coupling. While holding the cams in the desired position, rotate the coupling and potentiometer shaft to the preferred location. Rotating clockwise reduces resistance between pins 2 and 1, and increases resistance between 2 and 3. Rotating counterclockwise increases resistance between pins 2 and 1, and reduces resistance between 2 and 3. If the

resistance “jumps” rapidly, the pot is improperly rotated and functioning in the 20º dead area. Retighten the 2 set screws. A 2 kΩ span adjustment pot is provided,

to activate move bypass shunt to the other pin.

See Pages 14-19 for wiring procedure, intrinsic safety parameters, relevant warnings and schematics.

Ω Per Degree of Rotation

2.9

5.8

14.7

29.4

58.8

Resistance Between Pins

No. 2 to No. 1 No. 2 to No. 3 CCW-SET CW-90° CCW-SET CW-90°

500 1000 2500 5000 10000

235 471 1178 2354 4708

500 1000 2500 5000 10000

765

1529 3823

7646

15294

Page 11

ROTATION

MARK 1, 3 AND 4 WITH TRANSMITTER INSTALLATION

CLOCKWISE

Potentiometer

Resistance Ω

1000 2000

Models 15XXX, 35XXX and 45XXX Rotary Position Indicating Switches contain a 4-20 mA transmitter and two Single Pole Double Throw (SPDT) switches. Models 150XX, 350XX and 450XX contain a 4-20 mA transmitter only, no switches.

• 4-20 mA output is fully adjustable for various rotations

(zero and span). See chart above for rotation ranges using various potentiometers.

• 4-20 mA circuit is supply reversal protected and thermal protected.

• Clockwise or counterclockwise rotation corresponding

to increased current output can conveniently eld

selected with plug connector.

Installation and Adjustment

1. Attach the switch to the actuator or valve. Refer to

Installation and Adjustment instructions:

p. 7 for Direct Drive Mark 1 and 4 Models p. 8 for Lever Drive Mark 1 and 4 Models p. 9 for Mark 3 Models

2. Remove cover by unscrewing. Take care to keep threads clean and free from damage.

3. On models 15XXX and 45XXX, the switches are set at the factory when in the counterclockwise position as shown. Switch #1 is open, and #2 is closed. When

cams are rotated 90º clockwise, #1 becomes closed and #2 is open. The cams may be adjusted to increase or decrease the 90º rotation. For model

35XXX refer to pages 9 and 10 for Switch

Adjustment Procedure.

4. The potentiometer is positioned at the factory with the resistance element approximately centered.

Ω Per Degree of Rotation

2.9

5.8

Rotation Range Mark 1 and 4 Mark 3 Min Max Min Max

50° 25°

300° 150°

1.5 turns .75 turns

8.5 turns

4.3 turns

Page 12

Calibration

A. Set the valve at the position where you want the meter to read 0% (that is 4 mA). It may be necessary to move the plug connector to change the direction of current output to increasing for clockwise rotation or vice versa. B. On models 15XXX, loosen the two bottom set screws on the coupling. Rotate the coupling and potentiometer shaft to the position where the meter reads 0% (4 mA). Tighten two set screws. C. Turn valve to opposite position where meter should

read 100% (20 mA). Use small screwdriver to adjust

the blue rectangular potentiometer “span” until 100% (20 mA) is on the meter. If it is not possible to reach 100%, refer to Troubleshooting instructions. D. Return valve to original position at 0% (4 mA). Use

small screwdriver to adjust “zero” turning until 0%

(4 mA) is read on meter. Repeat steps C and D until 4 and 20 mA read consistently on each end of stroke.

Troubleshooting

I. If no current ows, check polarity of current loop (plus

and minus screws on terminal strip). Also check loop resistance for open line. II. If full output current cannot be achieved by

adjustment, voltage at transmitter may be too low. If

so, increase power supply voltage until a minimum of 15 V is registered or move voltage shunt to 12 VDC. III. If current increases and decreases in the wrong direction, move the plug connector from CW to CCW or vice versa. IV. Check specs to make sure you are in range of

adjustment, (See chart on previous page). V. If the zero adjustment does not have enough range,

the zero must be mechanically realigned as follows:

Set the “zero” (ne 4 mA) adjustment to the middle of

its range. (Full multi-turn range is 25 revolutions; set

at 12-1/2 revolutions.) Repeat calibration steps B, C

and D.

4-20 mA METER

24 VDC

POWER

SUPPLY

OPTIONAL

2-wire connections

See Pages 14-19 for wiring procedure, intrinsic safety

parameters, relevant warnings and schematics.

MARK 1 AND 4 TRANSMITTER WITH HART COMMUNICATION INSTALLATION

Models 19XXX, 39XXX and 49XXX Rotary Position Indicating Switches contain a 4-20 mA transmitter with

communication and two Single Pole Double

HART Throw (SPDT) switches. Models 190XX, 390XX and 490XX contain a 4-20 mA transmitter with HART communication only, no switches.

• 4-20 mA output is fully adjustable for various

rotations (zero and span) using pushbuttons or a

HART

• 4-20 mA circuit is polarity insensitive and thermal

communication master.

protected. Though the output terminals are labeled

(+) and (-) the transmitter will function if the terminals

are reversed.

• Clockwise or counterclockwise rotation corresponding to increased current output can be selected by use of zero and span pushbuttons or a HART communication master.

Installation and Adjustment

1. Attach the switch to the actuator or valve. Refer to

Installation and Adjustment instructions:

p. 7 for Direct Drive Mark 1 and 4 Models p. 8 for Lever Drive Mark 1 and 4 Models

2. Remove cover by unscrewing. Take care to keep threads clean and free from damage.

3. On models 19XXX and 49XXX, the switches are set at the factory when in the counterclockwise position as shown. Switch #1 is open, and #2 is closed. When

cams are rotated 90º clockwise, #1 becomes closed and #2 is open. The cams may be adjusted to increase or decrease the 90º rotation. For model

39XXX refer to pages 9 and 10 for Switch

Adjustment Procedure.

4. The potentiometer is positioned at the factory with the resistance element approximately centered.

Page 13

Circuit Board Features

OPTIONAL OTHERWISE

WP SHUNT

SQUA LED

• Two test points are provided as a convenience for attaching HART

• The WP (write project) shunt enables and disables

communication master.

the ability to change conguration settings. It can prevent unintended conguration changes from an accidental press of the ZERO or SPAN button and

from communications with a HART

master. Set this shunt to ON to prevent conguration

communication

changes. Set this shunt to OFF to allow conguration

changes.

• The FAULT shunt determines whether the transmitter fails high or low in a fault condition. When set to high, the transmitter will output 21.0 mA in a fault condition.

When set to low, the transmitter will output 3.6 mA in

a fault condition. The transmitter will output 3.8 mA and 20.5 mA when operating normally.

• The FIND shunt determines if the transmitter will respond to a FIND command. When set to ON, the transmitter will respond to HART

master’s Find Command. When set to OFF, the

transmitter will ignore FIND commands. This is useful for allowing a HART discover the transmitter

• The LED will ash in response to a HART communication master’s Squawk Command. This is

useful for identifying a transmitter attached to a HART communication master.

communication master to

communication

Calibration

A. Place the WP shunt in the OFF position in necessary to allow calibration to be performed. B. Set the valve at the position where you want the meter to read 0% (that is 4 mA). Press and hold the

ZERO pushbutton for two seconds or use a HART communication master to set the ZERO point

C. Turn the valve to opposite position where meter should read 100% (20 mA). Press and hold the SPAN pushbutton for two seconds or use a HART communication master to set the SPAN point.

D. Reposition the WP shunt if desired.

FAULT SHUNT

FIND SHUNT

HART COMMUNICATION MASTER*

4-20 mA METER

**250Q

TEST POINT

*OPTIONAL, MAYBE CONNECTED TO TEST POINT AS SHOWN OR TO SCREW TERMINALS **REQUIRED FOR HART® COMMUNICATIONS,

See Pages 14-19 for wiring procedure, intrinsic safety parameters, relevant warnings and schematics.

24 VDC POWER

SUPPL

Page 14

WIRING PROCEDURE: GENERAL

ASHER

• Complete all electrical wiring in accordance with local

and national electrical codes by qualied personnel

• It may be necessary to segregate power and signal circuits in separate conduit entries.

• For units supplied with both internal ground and external bonding terminals, the ground screw inside the housing must be used to ground the control. The external bonding screw is for supplementary bonding when allowed or required by local code. When external bonding conductor is required, conductor must be

wrapped a minimum of 180° about the external bonding

screw. See below.

• Products with ying leads shall be terminated in an approved junction box.

CONDUCTOR

SCREW

LOCKW

CLAMP

WIRING PROCEDURE: HAZARDOUS LOCATIONS, FLAMEPROOF CABLE CONNECTION:

• The cable entry device shall be Ex certied ameproof

suitable for the conditions of use and installed per

manufacturer’s instructions.

• For ambient temperatures above 58°C, cables and cable glands suitable for at least 95°C shall be used.

CONDUIT CONNECTION:

• An Ex, UL, or CSA (with appropriate classes and groups) certied ameproof sealing device such as a

conduit seal with setting compound shall be provided immediately following the conduit entrance to the enclosure. UL and CSA listed factory sealed leads are provided from the factory on request.

• For ambient temperatures above 58°C, the wiring and

setting compound in the conduit seal shall be suitable

for at least 95°C.

• Degree of protection IP66/68W is maintained when suitable glands/plugs are used for all options.

WIRING PROCEDURE: HAZARDOUS LOCATIONS, INTRINSIC SAFETY

• Potentiometer, Transmitter and each Switch and/or

NAMUR Sensor must be treated as separate intrinsically safe circuits.

ELECTRICAL RATINGS:

• Potentiometer, see page 3.

• Transmitter, see page 3.

• Switches, see model chart on page 4.

INTRINSIC SAFETY INPUT PARAMETERS: (SUFFIX

IS and II)

• Potentiometer, Ui = 30 V; Ii = 50 mA; Pi = 0.65 W.; Li =

0 µH; Ci = 0 nF.

• Transmitter, Ui = 30 V; Ii = 100 mA; Pi = 1.3 W; Li = 0 µH; Ci = 0 nF.

• Switches, Ui = 30 V; Ii = 100 mA; Pi = 1.3 W; Li = 0 µH; Ci = 0 nF.

• Namur Sensor, Ui = 16 V; Ii = 76 mA; Pi = 242 mW; Li

= 50 µH; Ci = 40 nF.

• Transmitter with HART 100 mA; Pi = 1.3 W; Li = 0 µH; Ci = 4 nF.

communication, Ui = 30 V; Ii =

Page 15

CAUTION

equipment may be impaired if the equipment is used in

a manner not specied by the manufacturer.

• Risk of electric shock - disconnect supply circuit before opening. Keep unit tightly closed while circuits are alive.

• Suitable insulation between signal wiring and hazardous voltage wiring must be provided.

WARNING

• Keep cover tightly closed when in operation.

• De-energize supply circuit before opening.

• To prevent ignition of hazardous locations, replace cover before energizing the electrical circuits.

• After de-energizing delay 3 minutes before opening.

• Do not open or AS-interface equipped units when an explosive atmosphere may be present.

WARNING

• Repairs only to be conducted by Dwyer Instruments, Inc.

• Inspect through shaft/bushing joint, of Mark 4, periodically for wear, if gap exceeds .0033˝ (.0 84 mm) for a length of 1˝ (25.4 mm) return to Dwyer

Instruments, Inc. for repair or replace unit. The thread of

the cover with 4.000-16UN 2A/B must have a minimum

of 7 threads engaged.

WARNING

• Enclosure must be protected from mechanical friction and impact with iron/steel to prevent ignition capable

sparks.

NOTICE

compliant. These units are not intended for use in

potentially hazardous atmospheres in the EU. These units may be CE marked for other Directives of the EU.

GENERAL

• Protection provided by the

HAZARDOUS LOCATIONS, FLAMEPROOF

MARK 1, 3, and FLAMEPROOF ENCLOSURE OPTION B and IE

HAZARDOUS LOCATIONS, INTRINSIC SAFETY

Units without sufx B or IS are not Directive 2014/34/EU (ATEX)

MISE EN GARDE

assurée par l’équipement peut être réduite si celui-ci n’est pas utilisé conformément aux spécications du

fabricant.

• Risque d’électrocution - débrancher le circuit d’alimentation avant d’ouvrir. Laisser l’unité bien fermée

lorsque les circuits sont sous tension.

• Une isolation appropriée entre le câblage de signalisation et le câblage de tension dangereuse doit

être prévue.

AVERTISSEMENT

• Laisser le couvercle bien fermé lorsque l’unité est en

service.

• Couper le circuit d’alimentation avant d’ouvrir.

• An d’empêcher toute ignition dans des zones

dangereuses, replacer le couvercle avant de mettre les circuits électriques sous tension.

• Laisser passer 3 minutes avant d’ouvrir lors de la mise

hors tension.

• Ne pas ouvrir le ni une unité avec interface AS en

présence d’une atmosphère potentiellement explosive.

AVERTISSEMENT

MARK 1, 3 y 4, OPCIÓN B y IE

• Les réparations ne doivent être effectuées que par

Dwyer Instruments, inc.

• Inspecter périodiquement l’axe/joint de garniture du Mark 4 an de détecter tout signe d’usure ; si le jeu excède 0,084 mm (0,0033 po) de largeur pour

une longueur de 25,4 mm (1 po), renvoyer à Dwyer

Instruments, inc. pour faire réparer ou remplacer l’unité. Un minimum de 7 lets du couvercle doivent être engagés, avec 4.000-16UN 2A/B.

AVERTISSEMENT

• L’enceinte doit être protégée de la friction mécanique et de tout impact avec du fer/acier an de prévenir la création d’étincelles pouvant s’enammer.

GÉNÉRAL

• La protection normalement

ZONES DANGEREUSES, IGNIFUGE

OPCIÓN DE GABINETE A PRUEBA DE LLAMAS

ZONES DANGEREUSES, SÉCURITÉ INTRINSÈQUE

AVIS

de la Directive 2014/34/EU (ATEX). Ces unités ne

sont pas conçues pour une utilisation en atmosphère

potentiellement dangereuses au sein de l’Union Européenne. Ces unités peuvent être estampillées CE pour d’autres Directives de l’Union Européenne.

Les unités sans sufxe B ou IS ne

sont pas conformes aux exigences

Page 16

SCHEMATICS: GENERAL AND INTRINSIC SAFETY

SWITCH

1. Units supplied with switch option A, G, H, M or T have screw terminals on the back side of the switch for terminating wires.

2. UL and CSA units supplied with switch option D are

supplied with 36” minimum (0.91 meters) ying leads.

3. Units supplied with switch option B, C, I, R, S, V or

W are supplied with terminal strips or 36˝ minimum (.091 meters) ying leads.

4. Units with J1 or J2 sufx are supplied with additional

2 or 4 termination points.

GREEN WIRE

- GROUND

SW 3

ABOVE

2ND

1, 2, or 4 switches

SW 2

ABOVE 1ST

SWITCH

SW 2

1ST

BOTTOM

SWITCH

SW 1

BOTTOM

INTRINSICALLY

SAFE BARRIERS

SW 4

TOP

Figure 1: Wiring for switch types A, G, H, M, and T.

SW 4

TOP

SWITCH

SW 3

ABOVE 2ND

SW 1

SW 4

BOVE 3RD

SWITCH

Figure 3: Wiring for factory sealed leads option. 1,

2, or 4 switches. Switch 1 wires are red, switch 2

wires are black, switch 3 wires are white, and switch

4 wires are brown. Wires are labeled C, NO, NC

SWITCH 4

TOP

Figure 4: Wiring for switch type D. 1, 2, or 4

ABOVE 1ST

SW 3

ABOVE 2ND

SW 2

SWITCH

BOTTOM

SWITCH 3

ABOVE 2ND

SW 1

SWITCH 2

ABOVE 1ST

switches

SWITCH 1

BOTTOM

Figure 2: Intrinsically safe wiring for switch types A,

G, H, M and T. 1, 2, or 4 switches

Page 17

ABOVE 2ND SWITCH

BOTTOM SWITCH

INTRINSICALLY

SAFE BARRIERS

SWITCH

SAFE BARRIERS

INTRINSICALLY

SWITCH 4

TOP SWITCH

Figure 5: Intrinsically safe wiring for switch type D.

SWITCH 3

1, 2, or 4 switches

SWITCH 2

ABOVE 1ST SWITCH

SW 4

TOP

SWITCH

ABOVE 1ST

SWITCH

SW 3

ABOVE 2ND

SWITCH

SWITCH 1

SW 2

BOTT

SW 1

ABOVE 1ST

SWITCH

SW 3

ABOVE 2ND

SWITCH

SW 2

SW 1 BOTTOM SWITCH

SW 4

TOP

SWITCH

Figure 7: Intrinsically safe wiring for switch types C,

R, V, and W. 1, 2, or 4 switches

Figure 6: Wiring for switch types C, R, V and W. 1, 2,

or 4 switches

Page 18

POTENTIOMETER

TRANSMITTER

SWITCH

USE CONNECTOR SUPPLIED

WITH SWITCH ONLY. MAKE SURE CONNECTOR IS PUSHED ON ALL

THE WAY TO ASSURE A

TIGHT CONNECTION.

SW 6

BOVE 5TH

SWITCH

Figure 8: Wiring for switch types B, C, I, R, V, and W.

1, 2, 4, or 6 switches. Switch types B and I have “+”

ABOVE 3RD

SWITCH

SW 5

ABOVE 4TH

SW 4

SW 2

ABOVE 1ST

SWITCH

SW 3

ABOVE 2ND

and “-” terminals

SW 1

BOTTOM

SW 4

TOP

SWITCH

ABOVE 2ND

Figure 9: Wiring for potentiometer and transmitter

outputs with switches. Refer to note at bottom of

SW 2

ABOVE 1ST

SWITCH

SW 3

SW 1

BOTTOM

page 3 for switch details

Page 19

TERMINAL 3 SEE WIRING SCHEMATIC

TERMINAL 2 SEE WIRING SCHEMATIC

WIRING SCHEMATIC

TERMINAL 2

SWITCH

TERMINAL 1

SEE WIRING

SCHEMATIC

SPAN ADJUSTMENT

POTENTIOMETER

J2 BYPASS

BY OTHERS

VDC

Figure 10: Intrinsically Safe wiring for potentiometer output. Refer to proper switch gure if unit has

switches as well

SEE WIRING

SCHEMATIC

TERMINAL 1 SEE WIRING SCHEMATIC

WIRING SCHEMATIC

12 VDC

24 VDC

BY OTHERS

Figure 11: Intrinsically Safe wiring for transmitter output. Refer to proper switch gure if unit has switches

as well

SEE WIRING SCHEMATIC

WIRING SCHEMATIC

12 VDC

24 VDC

BY OTHERS

SEE WIRING SCHEMATIC

TOP

SW 3

ABOVE 2ND

SW 2

ABOVE 1ST

SWITCH

BOTTOM

SW 1

SW 4

SWITCH

Figure 12: Intrinsically Safe wiring for transmitter with HART

gure if unit has switches as well

communication output. Refer to proper switch

Page 20

MAINTENANCE AND REPAIR

The moving parts of these units need no maintenance

or lubrication. Some parts are replaceable by qualied

personnel, contact the factory for details.

WARNING

IS, II or IM sufxes. Use a damp cloth with soap and

water for cleaning and decontamination. Solvents may damage O-ring seals. Units in need of repair should be returned to the following address, freight prepaid. Be sure to include a brief explanation of the problem and any relevant application information.

Proximity Controls Attn: Repair Department

1431 State Highway 210E Fergus Falls, MN 56537

LIMITED WARRANTY Limited Warranty: The Seller warrants all Dwyer

instruments and equipment to be free from defects in workmanship or material under normal use and service for a period of one year from date of shipment. Liability under this warranty is limited to repair or replacement

EXW Ex Works Dwyer Instruments, Inc of any parts

which prove to be defective within that time or repayment

of the purchase price at the Seller’s option provided the

instruments have been returned, transportation prepaid, within one year from date of purchase. All technical advice, recommendations and services are based on technical data and information which the Seller believes to be reliable and are intended for use by persons having skill and knowledge of the business, at their own discretion. In no case is Seller liable beyond replacement

of equipment EXW Ex Works Dwyer Instruments, Inc or

the full purchase price. This warranty does not apply if the maximum ratings label is removed or if the instrument or equipment is abused, altered, used at ratings above the

maximum specied, or otherwise misused in any way.

Substitution of components may impair intrinsic safety of models with

THIS EXPRESS LIMITED WARRANTY IS IN LIEU OF AND EXCLUDES ALL OTHER REPRESENTATIONS MADE BY ADVERTISEMENTS OR BY AGENTS AND ALL OTHER WARRANTIES, BOTH EXPRESS AND IMPLIED. THERE ARE NO IMPLIED WARRANTIES OF MERCHANTABILITY OR OF FITNESS FOR A PARTICULAR PURPOSE FOR GOODS COVERED HEREUNDER.

BUYER’S REMEDIES

The buyer’s exclusive and sole remedy on account

of or in respect to the furnishing of non-conforming or defective material shall be to secure replacement thereof as aforesaid. The Seller shall not in any event be liable for the cost of any labor expended on any such material or from any special, direct, indirect, consequential or incidental damages to anyone by reason of the fact that it shall have been non-conforming or defective.

HART® is a registered trademark of Hart Communication Foundation

DWYER INSTRUMENTS, INC.

P.O. BOX 373 • MICHIGAN CITY, INDIANA 46360, U.S.A.

Phone: 219-879-8000 Fax: 219-872-9057

dwyer-inst.com e-mail: [email protected]