Technical Specifications

Rev. B - 08/2020

Masoneilan ™

496 Series

Position Switches
and Transmitters

Baker Hughes Data Classification : Public

Numbering System
US design Series Identification 496-a

Instrument Type
1 One electromechanical switch single-pole, double-throw
2 Two electromechanical switches single-pole, double-throw
a 3 Potentiometric position transmitter
6 One electromechanical switch double-pole, double-throw
7 Two electromechanical switches double-pole, double-throw

1
2
496 - 3
6
7

2 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

Numbering System
European design Series Identification 496-ab/c

Instrument Type
1 One electromechanical switch single-pole, double-throw
2 Two electromechanical switches single-pole, double-throw
4 One proximity detector switch
a 5 Two proximity detector switches
6 One electromechanical switch double-pole, double-throw
7 Two electromechanical switches double-pole, double-throw
8 Opto-electronic position transmitter

Protection
55 Weatherproof
57 E
 xplosion-proof gas and dust (ATEX/CU TR/CCOE/KOSHA/NEPSI and
b others local certifications)
58 Intrinsically safe gas and dust (ATEX/CU TR/CCOE/KOSHA/NEPSI and
others local certifications)

Additional Switch (if any), for 496-8 Model only

1 One electromechanical switch single-pole, double-throw
2 Two electromechanical switches single-pole, double-throw
4 One proximity detector switch
5 Two proximity detector switches
c 6 One electromechanical switch double-pole, double-throw
7 Two
 electromechanical switches double-pole, double-throw
This single digit, together with the oblique stroke preceding it, is
only used in the case of transmitters provided with additional
on-off indication.

1
1
2
2
4 55
496 - 5
6
57
58
/ 4
5
6
7
7
8

Note: Among the numerous combinations mentioned above, some may not be available
or have a level of protection conforming to all the standards. Consult Baker Hughes for
confirmation.

© 2020 Baker Hughes Company. All rights reserved. Masoneilan 496 Series Position Switches and Transmitters Technical Specifications | 3
Electromechanical Switches 496-1 & 496-2
496-6 & 496-7
Material Ratings
Body and cover: Aluminum with anti-corrosion treatment, Temperature range: -55°C to +85°C (-67°F to +185°F),
epoxy or polyurethane painted. upon the type of switch. The range can be limited for used
Option: 316L type Stainless Steel with passivation. in explosible areas.
Shaft: stainless steel. Enclosure Rating: IP 66 / IP 67 according to EN 60529
0-ring seals: Buna N. ®

Approvals
No part made of copper or copper bearing alloy is
ATEX Approvals (2014/34/EU Directive)
exposed to the atmosphere.
Explosionproof:
II 2 G/D
Stroke • Ex db IIC T5 Gb Ta -55°C, +85°C
Maximum rotary travel: 90° Ex tb IIIC T100°C Db IP66/67 Ta*
Linear travel: 12 mm to 102 mm (1/2” – 4”) through a • Ex db IIC T6 Gb Ta -55°C, +75°C
linkage. Rotary or linear travel to be specified when Ex tb IIIC T85°C Db IP66/67 Ta*
ordering separate instruments. (*)The ambient temperatures range for the classification T6, T5 are linked to internal
components. See ATEX instruction manual Ref.31058.

Electrical Data Intrinsic Safety:

Microswitches: single pole, double throw, silver plated Suitable for 496-1 & 496-2 models only
contacts, individually actuated by an adjustable cam. II 1 GD
One, two or four microswitches can be used. • Ex ia IIC T6, T5 or T4* Ga Tamb*
• Ex ia IIIC T85°C or T100°C* Da Tamb*
Ratings: Suitable for explosionproof and weatherproof
 (*)The ambient and surface temperatures range for the classification T6, T5 and– T4
models only. are linked to internal components. See ATEX instruction manual Ref.31058.

Circuit type Voltage Current FM Approvals

110/125 VDC Explosionproof:
0.24 A
220 VDC Class I, Div 1, Groups B, C and D
24/30 VDC 1.2 A Dust Ignition:
48 VDC Class II, III, Div 1, Groups E, F and G
Resistive load 1A
115 VAC
250 VDC 3A CSA Approvals
125 VDC 10 A Class I, Groups B, C and D
28 VDC 25 A Class II, Groups E, F and G
110/125 VDC Class III
0.018 A
220 VDC Suitable for 496-1 & 496-2 models only
24/30 VDC 0.6 A Class I, Div 2, Groups A, B, C and D
48 VDC 0.5 A
115 VAC 1A Others Local approvals available
Inductive load
28 VDC Please consult Baker Hughes
125 VAC
10 A
250 VAC
Performance
480 VAC
Differential gap (percent of full scale):
250 VAC 15 A
Motor (US model only) 28 VDC 5A Rotary valves: 1.5 percent
Lamp (US model only) 28 VDC 3A
Linear motion valves:

Connections: 3/4’’ NPT Travel Differential gap

Other connection types allowed using adaptors or 12 mm (1/2”) 4 percent
reducers. 25 mm (1”) 3 percent
In case of separate cables requested with additional 50 mm (2”) 1.5 percent

functions, a 3 outputs cable output type Y237 is available. 100 mm (4”) 1.5 percent

Repeatability: 0.2 percent

4 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

Electromechanical Switches 496-1 & 496-2
496-6 & 496-7
Part Reference

1 6 9 10 11 12 8 13

13 3

4 3

17 7 15

5 14
18
5

16

Ref. N°. Part Name Ref. N°. Part Name Ref. N°. Part Name Ref. N°. Part Name

1 Grub screw 6 Housing 11 Shaft 16 Insulator

2 Adjusting screw 7 O-Ring 12 Cover 17 Fixing screw

3 Fixing screw 8 Circlip 13 Cam 18 Washer

4 Microswitch 9 Security screw 14 Serial plate 19 Spacer (not shown)

5 Lever 10 O-Ring 15 Drive screw

Dimensions - mm (inches)

8 holes 7 (0.28) Dia. 5.2 (0.2)

99 (3.9)
78 (3) square 2.5 (0.98)

45° 45° 8 (0.31)

Drill.circles: 92 (3.6) 7.88 12.68
(0.310) (0.499) Dia.
7.85 12.65
(0.309) (0.498)
Drill.circles: 55.6 (2.2)

136 (5.35) Dia. 32.5 (1.28)

81 (5.35)

1/4"-28 UNF 2B Dia.

124 (4.88) 3/4" NPT Connection or
Deep: 13 (0.5) Integral cable gland

© 2020 Baker Hughes Company. All rights reserved. Masoneilan 496 Series Position Switches and Transmitters Technical Specifications | 5
Potentiometric Position Transmitters 496-3
Material Electrical Data
Body and cover: Anodized aluminum, epoxy or Potentiometer: E
 lectrical angle: 320°
polyurethane painted. Total resistance: 1000 Ohms ±10 percent
Shaft: stainless steel. Voltage gain: Variable depending on the type of valve
0-ring seals: Buna N.® and travel.

No part made of copper or copper bearing alloy is Maximum supply voltage: 30 VDC
exposed to the atmosphere. Connections: The standard cable inlet is integral with
the body and includes a clamping device suitable for
Stroke unarmoured cables of 6 to 15 mm diameter.
Maximum rotary travel: 133° 3/4” NPT is available on request, with the following options:
Linear travel: 12 mm to 102 mm (1/2” – 4”) through a • Threaded inlet for unarmoured cables of 15 to 17 mm
linkage. Rotary or linear travel to be specified when diameter
ordering separate instruments.
• Threaded inlet for armoured cables (Consult Baker
Direction of rotation: clockwise or counter-clockwise. Hughes giving details of the cable dimensions)

Ratings Performance
Temperature range: -15°C to +40°C (5°F to +104°F)
Accuracy: ±1 percent of output span, for a 50° nominal
Enclosure Rating: NEMA 4X input angle, including combined effects of linearity,
hysteresis and deadband.
Approvals Temperature drift: 0.04 percent of output span per degree
FM Approvals Celsius.
Explosionproof: Class I, Div 1, Groups B, C and D
Dust Ignition: Class II, III, Div 1, Groups E, F and G
CSA Approvals
Class I, Groups B, C and D
Class II, Groups E, F and G
Class III

Operational Diagram

Direction of the Voltmeter Zero is set by orientation of large gear on the rotary shaft
valve shaft rotation 1000 ohms/volt from the position of the potentiometer shaft corresponding
(minimum) to the selected zero.
Adjustable constant
voltage d.c. power supply Span is set either by adjusting the supply voltage to the
desired value or by putting an adjustable resistance into
one of the supply leads of the transmitter (or of each of
position transmitter if several devices are connected to a
single non-adjustable power supply).
Diagram for principle
and wiring Reversal of action is carried out by changing over the
output terminal from 3 to 4 and vice versa.

6 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

Potentiometric Position Transmitters 496-3
Part Reference

6 9 10 11 12 8 23 1

22

7 15

25 14

21

24
20
Ref. N°. Part Name Ref. N°. Part Name Ref. N°. Part Name Ref. N°. Part Name

1 Grub screw 9 Security screw 15 Drive screw 24 Terminal Strip

3 Fixing screw 10 O-Ring 20 Potentiometer 25 Connections

6 Housing 11 Shaft 21 Bracket

7 O-Ring 12 Cover 22 Pinion

8 Circlip 14 Serial plate 23 Pinion

Dimensions - mm (inches)

8 holes 7 (0.28) Dia. 5.2 (0.2)

99 (3.9)
78 (3) square 2.5 (0.98)

45° 45° 8 (0.31)

Drill.circles: 92 (3.6) 7.88
12.68
(0.310)
(0.499) Dia.
7.85
12.65
(0.309)
Drill.circles: 55.6 (2.2) (0.498)

136 (5.35) Dia. 32.5 (1.28)

81 (5.35)

1/4"-28 UNF 2B Dia.

124 (4.88) 3/4" NPT Connection or
Deep: 13 (0.5) Integral cable gland

© 2020 Baker Hughes Company. All rights reserved. Masoneilan 496 Series Position Switches and Transmitters Technical Specifications | 7
Proximity Switches 496-4 & 496-5
Material Electrical Data
Body and cover: Aluminum with anti-corrosion treatment, Detector: By flux variation actuating a power relay located
epoxy or polyurethane painted. outside the hazardous area, by means of an oscillator and
Option: 316L type stainless steel with passivation. an amplifier.
One or two detectors can be used.
Shaft: stainless steel.
Ratings: Determined by the power relay selected, not
0-ring seals: Buna® N.
supplied with the device.
No part made of copper or copper bearing alloy is
Connections: 3/4’’ NPT
exposed to the atmosphere.
Other connection types allowed using adaptors or reducers.
In case of separate cables requested by additional
Stroke functions, a 3 outputs cable output type Y237 is available.
Maximum rotary travel: 90°
Performance
Linear travel: 25 mm to 102 mm (1” – 4”) through a linkage.
Rotary or linear travel to be specified when ordering Differential gap (percent of full scale):
separate instruments. Rotary valves: 1.5 percent
Linear motion valves:
Ratings
Temperature range: upon the type of switch and the Travel Differential gap

approval used. 25 mm (1”) 3 percent

50 mm (2”) 1.5 percent
Enclosure Rating: IP 66 / IP 67 according to EN 60529
100 mm (4”) 1.5 percent

Repeatability: 0.3 percent

Approvals
ATEX Approvals (2014/34/EU Directive)
Explosionproof:
II 2 G/D
• Ex db IIC T5 Gb Ta -55°C, +85°C
Ex tb IIIC T100°C Db IP66/67 Ta*
• Ex db IIC T6 Gb Ta -55°C, +75°C
Ex tb IIIC T85°C Db IP66/67 Ta*
(*)The ambient temperatures range for the classification T6, T5 are linked to
internal components. See ATEX instruction manual Ref.31058.

Intrinsic Safety:
II 1 GD or II 1 G or II 2 G
• Ex ia IIC T6, T5 or T4* Ga Tamb*
• Ex ia IIIC T85°C or T100°C* Da Tamb*
(*)The ambient and surface temperatures range for the classification T6,
T5 and T4 are linked to internal components. See ATEX instruction manual
Ref.31058.

Others Local approvals available

Please consult Baker Hughes.

8 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

Proximity Switches 496-4 & 496-5
Part Reference

6 9 10 11 12 8 30 37A
8

31

32

33

3 36

7 15

25 14

3
24

34 37B 19

Ref. N°. Part Name Ref. N°. Part Name Ref. N°. Part Name Ref. N°. Part Name

3 Fixing screw 11 Shaft 25 Connections 34 Detector

6 Housing 12 Cover 29 Circlip 35 Spacer (not shown)

7 O-Ring 14 Serial plate 30 Spacer 36 Detector bracket

8 Circlip 15 Drive screw 31 Circlip

9 Security screw 19 Spacer 32 Washer

10 O-Ring 24 Terminal strip 33 Arm

Dimensions - mm (inches)

8 holes 7 (0.28) Dia. 5.2 (0.2)

99 (3.9)
78 (3) square 2.5 (0.98)

45° 45° 8 (0.31)

Drill.circles: 92 (3.6) 7.88
12.68
(0.310)
(0.499) Dia.
7.85
12.65
(0.309)
Drill.circles: 55.6 (2.2) (0.498)

136 (5.35) Dia. 32.5 (1.28)

81 (5.35)

1/4"-28 UNF 2B Dia. 3/4" NPT Connection or

Deep: 13 (0.5) 124 (4.88) Integral cable gland

© 2020 Baker Hughes Company. All rights reserved. Masoneilan 496 Series Position Switches and Transmitters Technical Specifications | 9
Opto-electronic Position Transmitters 496-8
Material Performance
Body and cover: Aluminum with anti-corrosion treatment, Linearity:
epoxy or polyurethane painted.
• ≤ 0.5 percent (rotary angle from 25° to 60°)
Option: 316L type stainless steel with passivation.
• ≤ 0.3 percent (rotary angle from 60° to 90°)
Shaft: stainless steel.
Hysteresis: ≤ 0.1 percent
0-ring seals: Buna® N.
Dead band: ≤ 0.1 percent
No part made of copper or copper bearing alloy is
Repeatability: ≤ 0.1 percent
exposed to the atmosphere.
Accuracy: ≤ 0.5 percent

Stroke
Rotary travel: 25° to 90° Accessories
The body can optionally be equipped either with one or
Linear travel: 12 mm to 102 mm (1/2” – 4”) through a
two micro-switches or with one or two proximity detectors
linkage. Rotary or linear travel to be specified when
as described on pages 2 & 3.
ordering separate instruments.
Direction of rotation: clockwise or counterclockwise. Electrical Data
2-wire instrument
Ratings Output signal: 4-20 mA
Temperature range: -40°C to +80°C (-40°F to +176°F).
Supply voltage: 9 to 36 VDC (explosion-proof)
The range can be limited for used in explosible areas.
9 to 28 VDC (intrinsic safety)
Enclosure Rating: IP 66 / IP 67 according to EN 60529
Maximum load impedance:
1350 Ω for supply under 36 V
Approvals 950 Ω for supply under 28 V
ATEX Approvals (2014/34/EU Directive)
Zero and span settings:
Explosionproof:
By auxiliary internal potentiometers.
II 2 G/D
• Ex db IIC T5 Gb Ta -40°C, +80°C Connections: 3/4’’ NPT
Ex tb IIIC T100°C Db IP66/67 Ta -40°C, +80°C Other connection types allowed using
• Ex db IIC T6 Gb Ta -40°C, +75°C adaptors or reducers.
Ex tb IIIC T85°C Db IP66/67 Ta -40°C, +75°C
In case of separate cables requested by
Intrinsic Safety:
additional functions, a 3 outputs cable
II 1 GD or II 1 G or II 2 G
output type Y237 is available.
• Ex ia IIC T6, T5 or T4 * Ga Tamb*
• Ex ia IIIC T85°C or T100°C* Da Tamb*
(*)The ambient and surface temperatures range for the classification T6,
T5 and T4 are linked to internal components. See ATEX instruction manual
Ref.31058.

Others Local approvals available

Please consult Baker Hughes.

10 | Baker Hughes © 2020 Baker Hughes Company. All rights reserved.

Opto-electronic Position Transmitters 496-8
Operational Diagram

A prism, mechanically driven by the valve plug, follows the plug displacement
through a system of gears and (for a reciprocating valve) a linkage. A light beam,
emitted by a LED, which is fixed to the housing, is reflected by the prism and impacts
on a stationary disc. This disc is equipped with three tracks. One is resistive, another
conductive, and in between is a photo-sensitive track. The light beam reflected
onto the photo-sensitive track creates a bridge between the other two tracks and
serves as a potentiometer slide by modulating the voltage at the point C for a supply
voltage VA-VB. The variable voltage thus generated VA-VC is converted electronically
to give a 4-20 mA signal. This type of detector is frictionless, non-sparking- and free
from electrical noise. It is inherently intrinsically safe, insensitive to vibrations- and
has an unequalled life span.

Housing Shaft Pinion Grub Screw

Pinion Opto-electronic sensor

Span Potentiometer "E"

Zero Potentiometer "Z"
Spacer Bracket Circuit board

Dimensions - mm (inches)

8 holes 7 (0.28) Dia. 5.2 (0.2)

167 (6.57)
78 (3) square 2.5 (0.98)

45° 45° 8 (0.31)

Drill.circles: 92 (3.6) 7.88 12.68
(0.310) (0.499)
7.85 12.65 Dia.
Drill.circles: 55.6 (2.2) (0.309) (0.498)

136 (5.35) Dia. 32.5 (1.28)

81 (5.35)

1/4"-28 UNF 2B Dia. 3/4" NPT Connection or

192 (7.56)
Deep: 13 (0.5) Integral cable gland

© 2020 Baker Hughes Company. All rights reserved. Masoneilan 496 Series Position Switches and Transmitters Technical Specifications | 11
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Copyright 2020 Baker Hughes Company. All rights reserved. Baker Hughes provides this
information on an “as is” basis for general information purposes. Baker Hughes does not
make any representation as to the accuracy or completeness of the information and makes
no warranties of any kind, specific, implied or oral, to the fullest extent permissible by law,
including those of merchantability and fitness for a particular purpose or use. Baker Hughes
hereby disclaims any and all liability for any direct, indirect, consequential or special damages,
claims for lost profits, or third party claims arising from the use of the information, whether
a claim is asserted in contract, tort, or otherwise. Baker Hughes reserves the right to make
changes in specifications and features shown herein, or discontinue the product described at
any time without notice or obligation. Contact your Baker Hughes representative for the most
current information. The Baker Hughes logo and Masoneilan are trademarks of Baker Hughes
Company. Other company names and product names used in this document are the registered
trademarks or trademarks of their respective owners.

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BHMN-496-TS-19710B-0820 08/2020