Trolex TX9042 User manual

TX9042-UM-EN-A • P5423.1600-A2
TX9042 Programmable Sensor Controller (PSC)
Contents
1. Product Overview 4
1.1 Operating Features 4
1.2 Application 5
1.3 Product Options 6
1.3.1 TX9042 PSC Input Module Types 6
1.4 Dimensions 7
1.5 Technical Information 7
1.6 Electrical Details 9
2. Certication & Conformity 10
3. Functional Safety 13
3.1 Overview of Safety Integrity Level 13
3.2 SIL Suitability 13
3.3 Summary of the Veried
Functional Safety Data 14
3.4 Conditions or Restrictions for
use in SIL Applications 15
3.5 Proof Test 16
3.6 System Conguration Drawing 17
4. Installation 18
4.1 Precautions 18
4.2 Labelling 18
4.3 Tools & Test Equipment Required 19
4.4 Mechanical Installation 19
4.5 Connections 20
4.6 Input Channel Conguration 22
4.6.1 Analogue Input Modules 23
4.6.2 Display of Connection Details 28
4.6.3 Replacing an Input Module 28
4.6.4 Cable Distance for Loop Powered
4 to 20 mA Sensors 28
4.6.5 Cable Distance for Voltage 28
Inputs (0.4 to 2 V) 29
4.6.6 Dual Input Signals (Dierential) 29
5. Setup and Calibration 30
5.1 Controls and Indicators 30
5.2 Power-up 32
5.3 Signal Display 32
5.4 Reviewing the Input Module
Conguration 33
5.5 Close-up Information Display 33
5.5.1 Close-up1 Display 34
5.5.1.1 Close-up 1 Display for an
Analogue Input Module 34
5.5.1.2 Close-up 1 Display for a
Digital Input Module 36
5.5.2 Close-up 2 Display 37
5.5.2.1 Close-up 2 Display for an
Analogue Input Channel 37
5.5.2.2 Close-up-2 Display for a
Digital Input Channel 38
5.6 Menu of Functions 39
5.6.1 Default Values 39
5.6.2 Programming the Operating
Values 39
5.7 Main Menu 40
5.7.1 Main Setup 41
5.7.2 Escape/Return
5.7.3 Communications Setup 42
5.7.4 Clock 44
5.7.5 Keycode Security 44
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TX9042 User Manual
TX9042-UM-EN-A • P5423.1600-A 3
5.7.6 Datalog Interval Period 45
5.7.7 Datalog Display Review 45
5.7.8 Clear the Data in the Datalog 46
5.7.9 Relay Reset Mode Options 47
5.7.10 Relay Voting 48
5.7.11 Relay Operation 50
5.7.12 Software Version 50
5.7.13 Self Test 50
5.7.14 Display Cycling 51
5.8 Contrast Control 51
5.9 Channel Function and
Calibration 52
5.9.1 Power On Delay (POD) Period 53
5.9.2 Scale and Display Settings 55
5.9.2.1 Reset Peak 56
5.9.2.2 Constant 56
5.9.2.3 Update 57
5.9.2.4 Units 59
5.9.2.5 Decimal Points 59
5.9.2.6 Lower 60
5.9.2.7 Upper 60
5.9.2.8 Calibrate (Temperature Input Module) 61
5.9.2.9 Identication 63
5.9.2.10 Connections 63
5.9.3 Setpoint Characteristics 64
5.9.3.1 Level 65
5.9.3.2 Hysteresis 65
5.9.3.3 Alarm (Rising/Falling) 66
5.9.3.4 Setpoint On Delay 66
5.9.3.5 Setpoint O Delay 67
5.9.3.6 Operation 67
5.9.3.7 Relays 69
5.9.4 Fault Signal Alarm Assignation 70
5.9.5 Threshold Acceptance Level 71
5.9.6 Keycode Security for Each
Channel - 1 to 8 72
5.9.7 Digital Level 74
5.9.8 Setting a Digital Failsafe
Input Module 75
5.9.9 Channel Display Mode 78
5.10 Datacommunications 79
5.10.1 RS485 79
6. Maintenance 81
6.1 TX9042 PSC Planned
Preventative Maintenance 81
6.1.1 Overview 81
6.1.2 TX9042 PSC
- Physical Check 81
6.1.3 TX9042 PSC
- Replace the battery 83
6.1.4 TX9042 PSC - Proof Test 83
6.2 TX9042 PSC - Repair 86
6.3 Maintenance Records 86
6.4 Maintenance Log 87
7. Disposal 88
Disclaimers 89
Trademarks 89
Document History 89
Contact Details 89
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TX9042-UM-EN-A • P5423.1600-A4
1. Product Overview
TX9042.55
Up to 8 analogue or digital inputs.
Up to 16 On/O inputs
RS485 data communications
Data logging facility for up to 26,000 input readings per
channel
1.1 Operating Features
• Up to eight channels of analogue or digital inputs or sixteen on/o inputs
• Input and output functions are programmed directly using the keypad
• RS485 data protocol for integrating multi-point sensor collecting into mine wide
systems
• Accepts analogue or digital inputs from a variety of source types
• Simple to use, just four keys to programme the TX9042 PSC, no special
software and no software programming skills required
• Full functional compatibility with the entire range of Trolex sensors
• Up to 32 TX9042 PSC can be connected to a single mine wide data system
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TX9042 User Manual
TX9042-UM-EN-A • P5423.1600-A 5
1.2 Application
The TX9042 Programmable Sensor Controller (PSC) is for sensor management and
data communications in arduous industrial environments and hazardous areas.
It is suitable for use in SIL 1 and SIL 2 applications, in accordance with specic
conditions or restrictions.
The uses of the TX9042 PSC include:
• Underground machinery protection
• Environmental monitoring using a combination of gas sensors and ow sensors
• Gas detection systems
• Conveyor control
• Pump and compressor monitoring
• Machine condition monitoring
• Fan vibration monitoring
• ITP monitoring
• On-board underground machinery monitoring
• Plant protection
• Data collection from groups of diverse sensors
• Area network sensor collection and monitoring
The data logging facility can be used to record operational trends and to analyse
events where serious incidents may have occurred. All data acquired can also be
transmitted over a communication link to a remote point. The system can also be
used for collecting sensor information from several distributed monitoring stations
on a mine wide sensor network. Up to 32 sensor collectors can be networked on
a data link and communicated to a central control and monitoring computer via the
data link.
Intrinsically Safe:
TX9042.55
Supply Voltage:
12 V dc from an approved intrinsically
safe power source
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TX9042-UM-EN-A • P5423.1600-A6
1.3 Product Options
TX9042 PSC General Purpose Mining Ex ia
12 V dc - TX9042.55
1.3.1 TX9042 PSC Input Module Types
Input Module Description Mining Ex ia
Order Code
Current - 0 to 20 mA P5423.516
Current - 4 to 20 mA P5423.508
Voltage - 0.4 to 2 V P5423.509
Flow TX6023 - not lo limited P5423.552
Flow TX6023 - 4 to 20 mA lo limited P5423.556
Flow TX6022 - Flow P5423.528
Flow TX6022 - Pressure P5423.518
PT100 - -50 to +200°C P5423.510
ac RMS - 500 Hz to 10 kHz - TX5630 P5423.506.01
ac RMS - 15 to 100 Hz - TX5630 P5423.506.02
Digital 12 V/24 V P5423.523
Digital Failsafe P5423.522
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TX9042 User Manual
TX9042-UM-EN-A • P5423.1600-A 7
1.4 Dimensions
1.5 Technical Information
Display accuracy +/-0.25% (analogue channels)
Setpoint accuracy +/-0.5%
Ambient temperature limits -10 to +40°C
Electrical connections 4 mm barrier/clamp terminals
Housing material ABS
Nett weight 800 g
Environmental protection Must be housed in a protective metal enclosure
to comply with Intrinsically Safe requirements
Information display LCD screen
20 characters x 4 lines
6 mm high characters
Mounting DIN rail
Microprocessor Microprocessor controlled menu operation, with
non-volatile data retention and 10 bit analogue to
digital conversion (analogue channels)
Setpoints 2 per channel plus Fault signal
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TX9042-UM-EN-A • P5423.1600-A8
Output relays 4 encapsulated reed relays with function
programming
Relay contact rating 200 V
0.25 A
3 W absolute maximum
Checkpoint
Circuits switched by the contacts of the
output relays MUST emanate from a certied
Intrinsically Safe power source and the circuit
parameters must be within Intrinsically Safe
requirements.
Setpoint adjustment 0 to 99% of full scale
Hysteresis adjustment 0 to 99%
Power on delay adjustment 0 to 255 seconds for each channel
Output delay adjustment 0 to 18 hours for each setpoint in one second
steps
Input update period
adjustment
0 to 60 seconds for each channel in 0.05 second
steps
Engineering units menu V, mV, mA, °C, °F, K, g, kg, mbar, bar, Pa, kPa,
PSI, %, ppm, %RH, mm, m, mm/s, m3/s, rpm,
pps, Hz, kHz, secs, m:s, h:m, m/s, m3/H, m3/m,
A, l/m, g/m, l/s, g/s, l/h and g/h
Fault signal Open or short circuit signal line or sensor fault,
will generate a fault signal, the fault will be
identied and displayed on the LCD screen
Data communications RS485 Modbus
Data logging Up to 26,000 readings with on-demand down
loading
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TX9042 User Manual
TX9042-UM-EN-A • P5423.1600-A 9
1.6 Electrical Details
TX9042.55 - Programmable Sensor Controller (PSC)
Supply voltage: 12 V dc +20%/-2.5% at 125 mA
Output: Modbus protocol
Supply current: 125 mA at 12 V
Relay contact rating: 200 V
0.25 A
3 W absolute maximum
Checkpoint
Circuits switched by the contacts of the output relays
MUST emanate from a certied Intrinsically Safe
power source and the circuit parameters must be
within Intrinsically Safe requirements.
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TX9042-UM-EN-A • P5423.1600-A10
2. Certification and Conformity
ATEX (European Union) certification for use in underground mines (Group I).
Complies with ATEX Directive 2014/34/EU.
Standards:
EN IEC 60079-0:2018
IEC 60079-11:2023
IECEx (International) certification for use in underground mines (Group I).
Standards:
IEC 60079-0:2017
IEC 60079-11:2013
ANZEx certification for use in underground mines (Group I) in Australia.
MASC IA certification for use in underground mines (Group I) in South Africa.
EAC certification for use in underground mines in Eurasian Customs Union (including
Russia).
Product Code:
Ex Certificate Number:
Ex Certification Code:
TX9042.xx.xx.19
Programmable Sensor Controller
Baseefa03ATEX0292X
IECEx BAS 15.0065X
I M1
Ex ia I Ma
Ta = -20oC to +40oC
TX9042.xx.xx.10
Programmable Sensor Controller ANZEx 06.3057X Ex ia I Ta = -20oC to +40oC
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