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