MTL MTL4500 Series User manual

ＭＴＬ合作伙伴：滨州新大新机电科技有限公司
Instruction Manual
INM4500
MTL4500 Series
isolating interface units

ii INM4500-2
Mar 2009

iii
INM4500-2
Mar 2009
CONTENTS
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 The MTL4500 concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 MTL4500 SERIES DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2.1 Standard backplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
2.2 Customised backplanes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2
2.3 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3 INSTALLATION – PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
3.2 Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4 INSTALLATION – BACKPLANES AND ENCLOSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4.1 Backplanes – mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
4.2 Backplanes – identification and tagging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
4.3 Backplanes - earth rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.4 Backplanes – connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .6
4.5 Backplanes – customised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7
5 INSTALLATION – MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.1 Modules – pre-installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
5.2 Modules - installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9
6 UNIT DESCRIPTIONS, SETTING-UP AND CONNECTIONS . . . . . . . . . . . . . . . . . . . . . . . . 10
6.1 Digital Input modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1.1 MTL4501-SR - Failsafe Switch/Proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
6.1.2 MTL4510 & MTL4510B - Switch/Proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6.1.3 MTL4511 - Switch/Proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1.4 MTL4513 - Switch/Proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.5 MTL4514 - Switch/Proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1.6 MTL4516 - Switch/Proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
6.1.7 MTL4516C - Switch/Proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20
6.1.8 MTL4517 - Switch/Proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
6.2 Digital Output modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .22
6.2.1 MTL4521 - Solenoid Alarm driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.2.3 MTL4523/MTL4523R - Solenoid Alarm driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
6.2.4 MTL4523L - Solenoid Alarm driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.2.5 MTL4524 - Solenoid Alarm driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.2.6 MTL4524S - Solenoid Alarm driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26
6.2.7 MTL4525 - Solenoid Alarm driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2.8 MTL4526 - Switch operated relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
6.3 Analogue Input modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.1 MTL4541 - Repeater Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.3.2 MTL4541B/4541P - Repeater Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.3.3 MTL4544 - Repeater Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.3.4 MTL4544B - Repeater Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.4 Analogue Output modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4.1 MTL4546/4546C/4546Y - Isolating Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.4.2 MTL4549/4549C/4549Y - Isolating Driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.5 Temperature Input module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.5.1 MTL4575 - Temperature Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.6 General modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.6.1 MTL4599 - Dummy Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.6.2 MTL4599N - General purpose feedthrough module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.7 PCS45/PCL45USB configurator for MTL temperature converters . . . . . . . . . . . . . . . . . . . . . 38
(continued on next page)

iv INM4500-2
Mar 2009
WARNING
This manual describes the use and installation of safety equipment. This
equipment must be installed, operated and maintained only by trained
competent personnel and in accordance with all appropriate international,
national and local standard codes of practice and site regulations for
intrinsically safe apparatus and in accordance with the instructions contained
here.
ATEX
If the country of installation is governed by the Essential Health and Safety Requirements
(Annex II) of the EU Directive 94/9/EC [the ATEX Directive - safety of apparatus] then MTL
document INA4500 must be consulted before installation.
CERTIFICATION DATA
The MTL web site http://www.mtl-inst.com contains product documentation regarding intrinsic
safety certification for many locations around the world. Consult this data for information
relevant to your local certifying authority.
REPAIR
These products MUST NOT be repaired. Faulty or damaged products must be replaced with
an equivalent certified product.
7 BENCH TESTING MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.1 Digital Input (DI) modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .40
7.2 Digital Output (DO) modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.3 Analogue Input (AI) Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.4 Analogue Output (AO) Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
7.5 Testing the functioning of other modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
8 APPLICATIONS INVOLVING ZONE 2 AND/OR ZONE 22 HAZARDOUS AREAS . . . . . . . 44
8.1 Enclosure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
© 2009 MTL Instruments Group. All rights reserved.

1
INM4500-2
Mar 2009
1 INTRODUCTION
1.1 General
This instruction manual describes the procedures for installing, connecting, checking and maintaining
MTL4500 Series isolating interfaces and accessories.
The individual sections cover the following topics
♦Section 2 describes the series and its accessories
♦Section 3 precautions before and during installation
♦Section 4 installing backplanes
♦Section 5 installing modules
♦Section 6 relevant technical data
♦Section 7 fault-finding and maintenance
♦Section 8 test procedures for all modules
1.2 The MTL4500 concept
The MTL4500 Series of modules and accessories is designed for use with process connected systems. It
consists of compact isolating interface modules mounted on backplanes, which carry safe-area signals
and power supplies. Hazardous-area circuits are connected to the terminals on the modules. Backplanes
can be integrated into a user’s process system architecture or mounted in separate enclosures.
2 MTL4500 SERIES DESCRIPTION
Each module has a multi-pin connector in its base that plugs into a matching connector on the backplane.
This connector carries all appropriate safe-area circuits and power supplies. Additional multiway
connectors, located at the front of the module, accept the wiring from the hazardous-area circuits. All
connectors are keyed so that connections cannot be made the ‘wrong way round’.
Status LEDs and configuration ports (where appropriate) are located on the front of the modules for easy
access and full dc isolation is provided between the input and output so that the modules are intrinsically
safe without needing an earth.
INM4500-2
Mar 2009
MTL4500 Series Interface units

2INM4500-2
Mar 2009
2.1 Standard backplanes
MTL4500 series standard backplanes, with quick-release clip connectors, accommodate 4, 8, 16 or
24 modules. The backplane carries the safe-area signals and distributes dual-redundant 24V dc power
supplies with three-point status monitoring. In applications where a number of 8- and 16-way backplanes
are installed, the power supplies can be interconnected. Optional earth-rail kits are available for 8- and
16-way backplanes and tagging-strip kits are available for all backplanes.
2.2 Customised backplanes
If the backplane is to be mounted in a safe area (which is the most common type of application) then
it does not need to be certified, because the hazardous area wiring connects to the I/O modules, not
the backplane. This means that non-hazardous area backplanes can be produced easily by MTL, or the
user, and can be designed to match exactly the size, shape, method of mounting, type of connector, pin
assignments, etc, of a particular process system. Please contact MTL for further information.
When mounting the back plane in Zone 2/Div 2 hazardous areas the MTL web site should be consulted
for documents detailing any approvals.
2.3 Accessories
Accessories are available that enable the user to mount standard MTL backplanes. These include surface-
mounting kits, T-section and G-section DIN-rail mounting kits and end stops and a horizontal plate for
mounting 24-way backplanes in 19-inch racks.
3 INSTALLATION – PRECAUTIONS
3.1 General
Please read this section before beginning to install backplanes, enclosures, modules etc.
3.2 Precautions
Make sure that all installation work is carried out in accordance with all relevant local
standards, codes of practice and site regulations.
Check that the hazardous-area equipment complies with the descriptive system document.
If in doubt, refer to the certificate/catalogue for clarification of any aspects of intrinsic safety,
or contact MTL or your local MTL representative for assistance.
Check that the interface unit(s) function(s) are correct for the application(s).
When plugging modules into backplanes and hazardous-area connectors into modules, check
the identification labels to make sure the items match correctly.
4 INSTALLATION – BACKPLANES AND ENCLOSURES
4.1 Backplanes – mounting
See Table 4.1 for listings of the mounting methods and kits and accessories applicable to MTL standard
backplanes and Figure 4.1 for dimensions and mounting centres.
4.1.1 Surface mounting – with SMS01 mounting kit
Refer to Figures 4.1 and 4.2.
Drill mounting surface at centres A (Figure 4.1) and tap, or fit retaining nuts if required.
Select the appropriate number of M4 x 20mm screws for the size of backplane
(4 for a 4-way and 8-way, 6 for a 16-way and 8 for a 24-way backplane).
Fit each M4 x 20mm screw (1) with a locking washer (2) and a plain washer (3) (Figure 4.2).
Insert the screws through the backplane at each mounting centre A.
Fit each with an M4 x 10mm spacer (5) and a retaining washer (6) (Figure 4.2).
Attach the assemblies to the prepared surface using a suitable nut if the holes are not tapped.
a)
b)
c)
d)
e)
a)
b)
c)
d)
e)
f)

3
INM4500-2
Mar 2009
Figure 4.1: Standard backplane dimensions
113
175
38
28.5 112
285
1 2 3 4 5 6 7 8 9
CPS16
CPS16
10 11 12 13 14 15 16
112
AAA
AAA
B
B
B
B
C
C
C
C
C
C
C
C
113
175
38
28.5 96
157
1 2 3 4 5 6 7 8
CPS08
CPS08
AA
AA
B
B
B
B
CPS24
100
140
23
446
CPS24
139
143
10 143
AA AA
AA AA
B
B
B
B
1 2 3 4 5 6 7 8 10 11 12 13 14 15 16 917 18 19 20 21 22 23 24
132
170
32
59
72
CPS04
1 2 3 4
AA
AA
Backplane
model no.
Number
of modules
Safe-area
connections
Mounting Kits Accessories
Surface DIN-rail
(T or G)
19-inch
rack
Earth-rail
kit
Tagging
strip kit
Spare
fuse pack
CPS04 4 Screw-clamp SMS01 DMK01 – – – FUS08
CPS08 8 Screw-clamp SMS01 DMK01 – ERK08 TSK08 FUS08
CPS16 16 Screw- clamp SMS01 DMK01 – ERK16 TSK16 FUS16
CPS24 24 Screw-clamp SMS01 DMK01 HMP24 – TSK24 FUS24
Table 4.1: Backplanes, mounting kits and accessories
Locking washer (2)
Plain washer (3)
M4 x 20mm
screw(1)
MTL4500
backplane
Mo nting hole A
Retaining Washer (6)
M4 x 10mm
spacer(5)
Figure 4.2: Surface mounting
6 x 1/2 inch screw (1)
Locking washer (2)
Plain washer (3)
MTL4500
backplane
Mo nting hole A Spacer (5)
Retaining washer (6)
DIN-rail
mo nting foot
(7)
T-section DIN rail (8)
DIN-rail
mo nting foot
(7)
G-section DIN rail (8)
Figure 4.3: Mounting a backplane onto DIN rail

4INM4500-2
Mar 2009
4.1.2 T- or G-section DIN-rail mounting – with DMK01 mounting kit
See Figures 4.1 and 4.2.
Cut two pieces of T- or G-section DIN-rail to the required length and fix them side-by-side with
centres spaced appropriately – 132mm (CPS04), 113mm (CPS08/16) or 100mm (CPS24).
With reference to Figure 4.4, clip the appropriate number of mounting feet (7) to the DIN rail
(8) at centres ‘A’ (4 for each 4/8-way, 6 for each 16-way and 8 for each 24-way backplane)
(Figure 4.3).
Select the appropriate number of No. 6 x 1/2-inch screws.
Place a locking washer (2) and a plain washer (3) onto each No. 6 x 1/2-inch screw (1)
(Figure 4.3).
Insert the assemblies through the mounting holes A on the backplane (Figures 4.1 and 4.3).
Fit spacers (5), retaining them with the washers (6) (Figure 4.3).
Locate the assemblies over the mounting feet and attach the screws (1) to the feet (Figure
4.3).
NOTE: For vertically orientated backplanes it is recommended that end stops with screw fixings are
fitted on the DIN rails immediately below the lowest backplane fixing. This will avoid the chance of
backplane slippage down the DIN rail.
4.1.3 19-inch rack mounting – CPS24 backplanes with HMP24 mounting plate
See Figure 4.4.
Place an unloaded backplane onto the HMP24 mounting plate.
Attach the backplane to the mounting plate at centres A with the eight M4 x 12mm screws
provided.
Attach the assembly to the 19-inch rack centres at D.
4.2 Backplanes – identification and tagging
Backplane labelling facilities include marked areas for identifying backplanes, specific module locations
and system connections (multiway backplanes only). Mounting holes for earth-rail and tagging-strip
attachments are similarly marked
4.21 Backplane identification labels
Attach a suitably marked label to the area marked BACKPLANE IDENT. to identify an
individual backplane (Figure 4.5).
Attach suitably marked MPL01 module position labels to the areas marked MODULE IDENT
(Figure 4.5).
a)
b)
c)
d)
e)
f)
g)
a)
b)
c)
a)
b)
19 inch
HMP24
Horizontal mo nting plate
(Screws provided to mo nt backplane)
CPS24 backplane
HMP24
480mm
132.5mm
(3U)
AA A A
D
D
D
D
A A A A
Figure 4.4:
19-inch rack
mounting

5
INM4500-2
Mar 2009
4.2.2 Tagging strip mounting kit (TSK08, TSK16, TSK24)
See Figures 4.1, 4.6.
Attach the tagging strip mounting posts (1) at backplane centres B (Figure 4.1) using two M3
x 12mm mounting screws (2) and washers (3) (Figure 4.9).
Attach colour coding labels (4) to the tag label (5) (Figure 4.10). See Table 4.2 for suggested
colour codes for individual modules.
Mark the tag label (5) with the tag reference.
Slide the tag label (5) into the plastic holder (6) and retain with a plastic rivet (9) (Figure 4.6).
Attach the plastic retaining tie (7) with two plastic rivets (8) (Figure 4.6).
Clip the tag strip holder (6) onto the mounting posts (1) by pushing it downwards (Figure
4.7).
If required, swivel the tagging strip vertically (Figure 4.7)
a)
b)
c)
d)
e)
f)
g)
Colour Module no. Function
White MTL451x Digital Inputs
Red MTL452x Digital Outputs
Blue MTL4541
MTL4544 Analogue Inputs
Green MTL4546
MTL4549 Analogue Outputs
Orange MTL4575 Temperature inputs
Grey MTL4599 Dummy isolator
Table 4.2: MTL4500 front label colour coding
TSK08
TSK08E K08
E K08
BACKPLANE
IDENT
MODULE
IDENT
Figure 4.5: Locations for lables and attachments
1
2
3
95
7
8
6
4
Figure 4.6:
Mounting a
tagging-strip
post
(6)
8
81
tie
(7)
Figure 4.7:
Attaching and
swivelling a
tagging-strip

6INM4500-2
Mar 2009
4.3 Backplanes - earth rails
Optional earth rails are available for 8- and 16-way backplanes (kits ERK08 and ERK16 respectively).
Cable screens from hazardous-area circuits, or spare pairs from a multicore cable, can be connected
to the terminals on the earth rails, which are mounted on the backplane at about the same height as the
front of the modules, close to the hazardous-area connectors. Earth rails are attached using the following
procedure:–
4.3.1 Earth rail kit (ERK08 and ERK16)
See Figures 4.1 and 4.8.
Locate the earth rail mounting posts (1) at backplane centres C (Figures 4.1 and 4.8).
Attach the mounting posts (1) with M3 x 12 screws (3) and washers (4).
Slide the earth rail (5) through the slots in the of the mounting posts (1).
Fit the earth terminal(s) (6) on the rail (5).
Attach plastic retaining rivets (7) to each end of the earth rail (5).
4.4 Backplanes – connections
Safe-area circuit connections are made to the backplane by fixed screw-clamp terminals.
Power supply connections are also made to the backplanes via pluggable screw-terminal connectors.
See section 4.4.2 for details, section 4.4.3 for a procedure used to interconnect power supplies on
multiple 8- and 16-way backplanes and section 4.4.4 for details of connecting power supplies on 24-
way backplanes.
4.4.1 Safe-area - signal connections
Each module position is provided with a 6-way split-level terminal block for safe-area signals. The six
terminals reproduce the module terminals numbered 7 to 12 as shown in Figure 4.9.
Make the appropriate connections to the terminal block in accordance with the pin
assignment numbers reproduced in Figure 4.9.
Wire entry for each terminal is from the side of the block.
The maximum permissible wire gauge is 2.5mm2(14 AWG).
4.4.2 Safe area – discrete power supply connections
(8- and 16-way backplanes)
Dual-redundant 24V DC power supplies can be connected to each backplane using plug-in connectors.
The supplies are connected in parallel, through diodes, and bussed by the backplanes to individual
isolators. LEDs on the backplane will light if the two independent supplies are operational. The diodes
between the two ensures that the highest voltage supply is the one in use at any given moment, and
providing automatic switchover of supplies if one source fails.
Connect each of the two 21V to 35V dc power supply connectors to the independent
supply sources according to the terminal assignments shown in Figure 4.10. The maximum
permissible wire size is 2.5mm2(14 AWG).
Plug the power supply connectors into the base connectors on the backplanes.
Ratings for the fuses located between the two supply connectors on the backplanes are:-
8-way: 1A (FUS08) 16-way: 2A (FUS16)
a)
b)
c)
d)
e)
a)
b)
c)
a)
b)
c)
Earth rail
post (1)
Plastic
retaining
rivets (7) Earth
terminals (6)
Earth
rail (5)
Backplane
(2)
M3x12mm
screw (3)
Washer
(4)
ERK locating holes C
1 2 3
Earth rail
post (1)
CC
Figure 4.8:
Earth rail post
kit details

7
INM4500-2
Mar 2009
4.4.3 Interconnecting power supplies for multiple 8- and 16-way backplanes
Power supplies for 8- and 16-way backplanes can be interconnected in the form of a ring. This will reduce
wiring and also permit individual backplanes to be taken out of service without affecting supplies to other
backplanes. More than one backplane can be removed, provided that they are neighbours and do not
leave any other backplanes without an active supply. The connections are shown in Figure 4.11.
Note: a mixture of 8- and 16-way backplanes can be interconnected, provided that the maximum
circuit current does not exceed 12A. Wire sizes up to 2.5mm2(14 AWG) can be used and should
be chosen according to calculated current load and voltage drop.
4.4.4 Safe area – discrete power supply connections (24-way backplanes)
Dual-redundant 24V DC power supplies can be connected to each backplane using plug-in connectors.
The supplies are connected in parallel, through diodes, and bussed by the backplanes to individual
isolators. LEDs on the backplane will light if the two independent supplies are operational. The diodes
between the two ensures that the highest voltage supply is the one in use at any given moment, and
providing automatic switchover of supplies if one source fails
Connect the power supply cables to the connector according to the pin assignments shown in
Figure 4.12. The maximum permissible wire size is 2.5mm2(14 AWG).
Plug the power supply connector into the base connector on the backplane.
The rating of the fuse is:– 24-way: 3.15A (FUS24 fuse kit)
4.5 Backplanes – customised
For information about installing customised backplanes (whether supplied by MTL or by a third party),
see the separate instructions provided with the units.
a)
b)
c)
12 10 8
11 9 7
21
Top
view
Edge
view
12 10 8
11 9 7
12 10 8
11 9 7
0V PWR1 0V PWR2
Primary
Power
S pply
+

Secondary
Power
S pply
SKT 1 SKT 2
PWR  1 PWR  2 
+
0V
Primary
Power
S pply
+

Secondary
Power
S pply
+

PWR2
PWR1
23 24
Figure 4.9:
Terminal pin
assignments
Figure 4.10:
PSU connections
8- & 16-way
Figure 4.12:
PSU connections
24-way
1 2 3 4 5 6 7 8
BPS4508
1 2 3 4 5 6 7 8
BPS4508
+

PSU
This ring wiring
config ration can
be repeated for
the PWR2 s pply
0V
0V +
+
1 2 3 4 5 6 7 8
BPS4508
PWR1
Figure 4.11:
Terminal pin
assignments

8INM4500-2
Mar 2009
5 INSTALLATION – MODULES
Important
Work should be carried out in accordance with all relevant local standards, codes of
practice and site regulations
Check that the hazardous-area equipment complies with the descriptive system document
Refer to the certificate/catalogue for clarification of any aspects of intrinsic safety or
contact MTL or your local MTL representative for assistance
When installing MTL4500 Series isolators it is essential to make sure that intrinsically safe and
non-intrinsically safe wiring is segregated, as required by a nationally accepted authority or as
described in EN 60079-14, ISA RP 12.6 or DIN VDE-165.
Make sure the correct hazardous-area connector (field-wiring plug) is plugged into the
corresponding isolator. It is recommended that the connector is identified by the same tag
number as the matching isolator.
5.1 Modules – pre-installation
Some modules have line fault detection (LFD), which can recognise open or short circuit conditions on
the input wires going to the field sensors; and some Digital Input ( DI) modules have the facility to reverse
the effect of the input on the output (phase reversal). Where provided, these facilities involve
user-selectable switches located on the edge of the module on the hazardous area terminal side. It
may be easier to set these switches before fitting the module to the backplane.
5.1.1 Phase reversal
Set the switches for applicable modules as shown in Figure 5.1.
5.1.2 Line fault detection (LFD)
The following information applies to all DI modules with LFD except for the MTL4501-SR.
When using the LFD facility with a contact input, resistors must be used. Fit 500Ωto 1kΩin series with
switch and 20kΩto 25kΩin parallel with switch.
For hazardous-area inputs conforming to EN 60947-5-6:2001 (NAMUR), a line fault is
judged by the following rules:
Open circuit condition if hazardous-area current <50µA
Line integrity (no open circuit) if hazardous-area current >250µA
Short circuit condition if hazardous-area load <100Ω
Line integrity (no short circuit) if hazardous-area load >360Ω
Note: the open circuit window (between 250µA and 50µA), and the short circuit window (between
100Ωand 360Ω), is not hysteresis. All MTL4500 Series modules, with inputs conforming to EN 60947-
5-6:2001 (NAMUR), will switch between open and complete circuit conditions within these limits.
5.1.3. Relay outputs
Reactive loads on all units with relays should be adequately suppressed. In order to achieve maximum
contact life, a minimum switching current of 10mA at ≥ 5V is recommended.
5.1.4 Earth leakage detection
An MTL4220 earth leakage detector can be used with a number of MTL4500 Series units to detect
hazardous-area earth faults which can then be rectified without needing to shut down the loop ('no-fail'
operation).
Note:
If the hazardous area signal plug does not have a screw terminal in position 3 then part
number ‘HAZ1-3’ can be ordered and fitted to facilitate access to this function.
◆
◆
◆
◆
◆
OFF position
ON position
1 2 3 4
CH1 CH2
PR LF PR LF
PR = ph se revers l
LF = line f ult MTL4511 & MTL4514
MTL4513,MTL4516,
MTL4516C nd MTL4517 - Ch 1 & 2
- Ch 1 only
Figure 5.1:
Phase reversal and
Line Fault switches

9
INM4500-2
Mar 2009
5.1.5 Ambient temperature considerations
Ambient temperature limits for unenclosed MTL4500 Series isolators are from –20°C to +60°C with units
close-packed.
5.2 Modules - installation
5.2.1 Signal conductors
Removable blue hazardous area signal plugs, located on the front of the modules, are mechanically
keyed to fit in only one position and are fitted with screw clamp terminals. Note that the conductors
should be between 14 and 24 AWG (1.6 and 0.5mm dia) in size.
5.2.2 Making connections
Trim back the insulation of conductors by 12mm.
Check the terminal assignments shown in section 6 or on
the side label of the unit.
Insert conductors according to the terminal assignments
and tighten screws.
Note: Smaller section wire than that stated can often be successfully
used if the crimping is good.
5.2.3 Finishing
Wire up individual isolators in accordance with wiring
schedules. Segregate hazardous- and safe-area wiring into
separate trunking or looms wherever possible to avoid errors
and maintain a tidy installation.
Use an MTL4599 dummy isolator to provide termination and
earthing for unused cores from the hazardous area.
5.2.4 Module mounting and removal
Check for the correct orientation of the module then locate it between the latching clips. Press the
module straight onto the backplane. See Figure 5.3.
To remove the module, unclip the latch nearest the CE mark shown on the module label and rotate
the module away from this latch. When the module is unplugged from the power connector, move
the module clear of the other latch and remove it. See Figure 5.4.
a)
b)
c)
14mm 12mm
Figure 5.3:
Mounting a module
onto a backplane
Figure 5.2:
Hazardous-area
plug
Figure 5.4:
Removing a module
from a backplane

10 INM4500-2
Mar 2009
6 UNIT DESCRIPTIONS, SETTING-UP AND CONNECTIONS
This section describes the function (briefly), the setting-up procedure and the wiring connections for each
MTL4500 Series unit. For a fuller functional description and a detailed technical specification, refer to
the individual datasheets, which can be found on the MTL web site at http://www.mtl-inst.com or in the
current MTL IS catalogue. If a fault is suspected, first check that the power LED is lit (not applicable to
loop-powered devices). If necessary, check that all signal and power plugs are properly inserted, that
no wires are loose and that the unit is mounted correctly. If operation is still suspect, the unit should be
replaced with a servicable unit.
There are no replaceable parts insided MTL4500 Series units, so any that appear to be inoperative
should be returned to the manufacturer/supplier for repair or replacement.
WARNING
When disconnecting units for maintenance purposes,
take care to segregate hazardous and safe-area
cables.
Short circuit hazardous-area cable cores to an
IS earth or insulate and secure the ends.
Insulate and secure safe-area cables.
If testing a unit 'in situ' note that the test equipment
used MUST be intrinsically safe.
•
•
The rest of this section is divided into sub-sections based upon the type of module, as follows.
6.1 Digital Input modules
MTL4501-SR, MTL4510, MTL4510B, MTL4511, MTL4513, MTL4514, MTL4516, MTL4516C, MTL4517
6.2 Digital Output modules
MTL4521, MTL4523, MTL4523R, MTL4523L, MTL4524, MTL4524S, MTL4525, MTL4526
6.3 Analogue Input modules
MTL4541, MTL4541B, MTL4541P, MTL4544, MTL4544B
6.4 Analogue Output modules
MTL4546, MTL4546C, MTL4546Y, MTL4549, MTL4549C, MTL4549Y
6.5 Temperature Input modules
MTL4575
6.6 General modules
MTL4599, MTL4599N
6.7 PCS45/PCL45USB configurator for MTL temperature converters
Note: Any LED indicators provided on the modules will display in the following colours:
LED label LED colour
PWR (power) Green
STS (status) Yellow
LFD (line fault) Red
FLT (fault) Red
OPx (o/p status) Yellow

11
INM4500-2
Mar 2009
6.1 Digital Input modules
The Digital Input (DI) module range offers solid state or relay output switches in a safe area that respond
to input switches located in a hazardous area. Single or multiple channel (2 or 4) options are available,
as well as Line Fault Detecion (LFD).
6.1.1 MTL4501-SR - Failsafe Switch/Proximity detector interface
Failsafe single channel module with line fault detection
The MTL4501-SR, enables a fail–safe switch/proximity detector located in the hazardous area to control
an isolated fail–safe electronic output. The MTL4501–SR unit provides line fault detection alarm contacts.
The MTL4501–SR is designed for use with approved fail–safe sensors.
1 2 3 4 5 6
7 8 9 101112 1314
+
Fail-safe
o p t
10kW
1k4W
LFD
Resistors m st
always be fitted
for switch inp ts
+
Vs
Vs+ 2035V dc
Terminal Function
1 Input –ve
2 Input +ve
7 Output +ve
8 Output –ve
10 LFD
11 LFD
13 Supply –ve
14 Supply +ve
Hazardous area
Safe area
PWR
LFD
O/P
SR
MTL4501-SR
Figure 6.1
LED indicators
for MTL4501-SR

12 INM4500-2
Mar 2009
6.1.2 MTL4510 & MTL4510B - Switch/Proximity detector interface
4-channel digital input and multifunction modules
These digital modules provide solid state output switches in a safe area that respond to switches (inputs)
located in a hazardous area. The way they respond - their “mode” - can be configured using a bank of
four DIL selector switches accessible through the side of the module - see Figure 6.2.
Model MTL4510 has an one output channel for each input channel and the user can reverse the output
phase if necessary to suit the application. Model MTL4510B has more varied modes that can, for
example, enable one input to affect multiple outputs or create latched outputs, etc.)
Tables 6.1 and 6.2 show details of the modes available and the switch settings required to obtain
them.
Figure 6.2
LED indicators
for MTL4510
& MTL4510B
Terminal Function
1 Input channel A
2 Input channel AB common (+)
3 Input channel B
4 Input channel C
5 Input channel CD common (+)
6 Input channel D
7 Output channel 1
8 Output channel 1/2 common
9 Output channel 2
10 Output channel 3
11 Output channel 3/4 common
12 Output channel 4
13 Supply –ve
14 Supply +ve
Safe area
1 2 3 4 5 6
7 8 9 101112 1314
Vs+
Vs
2035V dc
Ch A Ch B
1
+
Ch C Ch D
243
common
common
O tp ts
+ 
Hazardous area
PWR
OPB
OPC
OPD
FLT
MTL4510
OPA
PWR
OPB
OPC
OPD
FLT
MTL4510B
OPA

13
INM4500-2
Mar 2009
For ease of access, it is recommended that switches are set to the required mode before installation.
Table 6.1 indicates whether the output follows the input, or the output is the reverse or antiphase
of the input.
For example, in mode 0, o/p 1 = chA; so, if channel A switch is closed, then output 1 will also
be closed or short circuit. However, in mode 1, o/p 1 = chA rev., so if channel A switch is closed,
then output 1 will be the reverse, i.e. open-circuit.
Table 6.2 shows the MTL4510B modes. The logic tables and timing diagrams on the following
pages provide more detailed information on these modes.
MTL4510 & MTL4510B diagnostics
If an internal fault is detected, all outputs and channel LEDs will turn off and the red Fault LED will
turn ON.
Table 6.2 - MTL4510B mode options
Switch settings MODE Function Equivalent
1234
OFF OFF OFF OFF 0 4-ch switch input (see MTL4510 mode 0) MTL4510
ON OFF OFF OFF 1 2-ch each channel one input, two outputs MTL4016
OFF ON OFF OFF 2 Same as mode 1 with repeat output phase
reversed MTL4016
ON ON OFF OFF 3 2-ch, 2-pole changeover output
OFF OFF ON OFF 4 1-ch with line fault output MTL4014
ON OFF ON OFF 5 As mode 4 with changeover outputs
OFF ON ON OFF 6 1-ch with start-stop latch MTL2210B
ON ON ON OFF 7 4-ch switch input, see MTL4510 mode 7 MTL4510
OFF OFF OFF ON 8 4-ch switch input, see MTL4510 mode 8 MTL4510
ON OFF OFF ON 9 2-ch with line fault output MTL4017
OFF ON OFF ON 10 As mode 9 with LFD changeover
ON ON OFF ON 11 As mode 10 with channel phase reversed
OFF OFF ON ON 12 3-ch with normally-open LFD output
ON OFF ON ON 13 3-ch with normally-closed LFD output
OFF ON ON ON 14 2-ch monostable, pulse stretcher
ON ON ON ON 15 4-ch switch input, see MTL4510 mode 15 MTL4510
Table 6 .1 - MTL4510 mode options
Switch setting MODE o/p 1 o/p 2 o/p 3 o/p 4 i/p type
1234
OFF OFF OFF OFF 0 chA chB chC chD
switch
ON OFF OFF OFF 1 chA rev. chB chC chD
OFF ON OFF OFF 2 chA chB rev. chC chD
ON ON OFF OFF 3 chA chB chC rev. chD
OFF OFF ON OFF 4 chA chB chC chD rev.
ON OFF ON OFF 5 chA rev. chB chC rev. chD
OFF ON ON OFF 6 chA chB rev. chC chD rev.
ON ON ON OFF 7 chA rev. chB rev. chC rev. chD rev.
OFF OFF OFF ON 8 chA chB chC chD
prox.
detector
+ LFD
ON OFF OFF ON 9 chA rev. chB chC chD
OFF ON OFF ON 10 chA chB rev. chC chD
ON ON OFF ON 11 chA chB chC rev. chD
OFF OFF ON ON 12 chA chB chC chD rev.
ON OFF ON ON 13 chA rev. chB chC rev. chD
OFF ON ON ON 14 chA chB rev. chC chD rev.
ON ON ON ON 15 chA rev. chB rev. chC rev. chD rev.
OFF position
ON position
1 2 3 4
Figure 6.2
DIL switches
for setting
MODE

14 INM4500-2
Mar 2009
MTL4510B modes
The following logic and timing diagrams are provided to assist the user in understanding the behaviour of the MTL4510B module
when a specific mode is chosen.
The open switch ( ) and closed switch ( ) symbols are used to represent both the input conditions of Ch A, Ch B, Ch C or
Ch D and then the output conditions of o/p 1, 2, 3 or 4.
How to use these mode tables - examples
The logic tables (right) for Mode 1 represent Ch A controlling outputs
1 & 3, while Ch C controls outputs 2 & 4.
Output 1 & 3 are shown following input Ch A (open or closed) while
Outputs 2 & 4 follow input Ch C.
Mode 2 however shows o/p 3 and 4 being in antiphase to their
inputs.
Mode 1
i/p - Ch A i/p - Ch C
o/p 1 --
--o/p 2
o/p 3 --
--o/p 4
Mode 2
i/p - Ch A i/p - Ch C
o/p 1 --
--o/p 2
o/p 3 --
--o/p 4
Mode 3
i/p - Ch A i/p - Ch C
o/p 1 --
o/p 2 --
--o/p 3
--o/p 4
i/p - Ch A
No
fault Line
fault No
fault Line
fault
o/p 1
Mode 4
No
fault Line
fault No
fault Line
fault
o/p 3
i/p - Ch A
No
fault Line
fault No
fault Line
fault
o/p 1
o/p 2
Mode 5
No
fault Line
fault No
fault Line
fault
LFD o/p 3
LFD o/p 4
i/p Ch C Non-latching
i/p Ch B Enable
i/p Ch A
o/p 1
o/p 2
o/p 3
o/p 4
Mode 6
i/p Ch C Latching
i/p Ch A Start Reset
i/p Ch B No effect Stop
o/p 1
o/p 2
o/p 3
o/p 4
A
Start B
Stop
i/p Ch A
i/p Ch B
o/p 2&4
o/p 1&3
B
eset
*
* i/p Ch A c n be open or closed when i/p Ch B opens to stop l tch
o/p 2&4
o/p 1&3
(enable)
i/p Ch A
i/p Ch B
OR
Non-latching
Ch C open
Latching
Ch C closed

15
INM4500-2
Mar 2009
Mode 9
i/p - Ch A
No
fault Line
fault No
fault Line
fault
o/p 1
No
fault Line
fault No
fault Line
fault
LFD o/p 3
i/p - Ch C
No
fault Line
fault No
fault Line
fault
o/p 2
No
fault Line
fault No
fault Line
fault
LFD o/p 3
LFD o/p 4
Mode 10
i/p - Ch A
No
fault Line
fault No
fault Line
fault
o/p 1
i/p - Ch C
No
fault Line
fault No
fault Line
fault
o/p 2
No
fault Line
fault No
fault Line
fault
LFD o/p 3
LFD o/p 4
Mode 11
i/p - Ch A
No
fault Line
fault No
fault Line
fault
o/p 1
i/p - Ch C
No
fault Line
fault No
fault Line
fault
o/p 2
No
fault Line
fault No
fault Line
fault
LFD o/p 4
Mode 12
i/p - Ch A
No
fault Line
fault No
fault Line
fault
o/p 1
i/p - Ch B
No
fault Line
fault No
fault Line
fault
o/p 2
i/p - Ch C
No
fault Line
fault No
fault Line
fault
o/p 3
Mode 13
As mode 12 but with LFD o/p 4 reversed
No
fault Line
fault No
fault Line
fault
LFD o/p 4
Mode 14
This mode provides a two channel pulse stretcher for inputs
A and C. Outputs 1 and 2 respond to Ch A, while 3 and 4
respond to Ch C.
Input B (or D) being open or closed affects the input transition
and the output polarity as shown in the timing diagrams below.
i/p A (C)
o/p 2 (4)
o/p 1 (3)
Initiate
1sec (min.)
End
i/p B (D)
1sec (min.)
i/p A (C)
o/p 2 (4)
o/p 1 (3)
i/p B (D) Initiate End
When triggered by A (or C) the outputs hold the change of
state for a minimum of 1 second or as long as the input
(A or C) remains in the same triggered state.
Input Ch B (or D) closed Input Ch B (or D) open
MTL4510B modes - continued

16 INM4500-2
Mar 2009
6.1.3 MTL4511 - Switch/Proximity detector interface
Single channel with Line Fault Detection
The MTL4511 contains a changeover relay, which enables a safe-area load to be controlled by a
switch or proximity detector located in a hazardous-area. When selected, the line-fault-detect (LFD)
facility detects open or short circuit conditions in the field wiring and also indicates this on the top of
the module. Line Fault Detect and Phase Reversal for the channel are selected by DIL switches
on the side of the module and output is provided by the changeover relay contacts.
See Section 5.1.1 on page 8 for LFD and PR switch details. Channel 1 only switch settings
apply.
For switch sensor inputs, with LFD selected, make sure resistors (22k
Ω and 680 Ω ) are fitted.
Note: Signal plug HAZ1-3 is required for access to the earth leakage detector function.
PWR
STS
LFD
MTL4511
Figure 6.3
LED indicators
for MTL4511
Hazardous area
+
1 2 3 4 5 6
7 8 9 101112 1314
Vs+
Vs
2035V dc
22kW
680W
To MTL earth leakage detector
Switch-type sensors
req ire resistors
if LFD is selected
O tp t
Safe area
Terminal Function
1 Input –ve
2 Input +ve
3 To earth leakage detector
7 Output normally-open contact
8 Common
9 Output normally-closed contact
13 Supply –ve
14 Supply +ve