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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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-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-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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TX9042-UM-EN-A • P5423.1600-A 11
TX9042.xx.xx.05
Programmable Sensor Controller
MASC M/11-359X
Baseefa03ATEX0292X
I M1
Ex ia I Ma
Ta = -20
o
C to +40
o
C
TX9042.xx.xx.14
Programmable Sensor Controller
RU C-GB.AA87.B.00137/19
PO Ex ia I Ma X
Ta = -20
o
C to +40
o
C
The following Special conditions for Use apply to the certificates listed above:
Specific Conditions of Use pertaining to Baseefa03ATEX0292X and IECEx BAS 15.0065X are reproduced
below. For conditions associated with other certificates listed above, please refer to individual
certificates. Copies of certificates are available on www.trolex.com.
i. The Programmable Sensor Controller Type TX9042 must be mounted in a secondary
enclosure as shown on drawing P5423.02 or in an alternative metal enclosure (not light
alloys) which is appropriately certified as providing a degree of protection of IP54.
ii. Up to 11 RS485 Comms Modules (in separate Programmable Sensor Controllers type TX9042)
may be daisy-chained together (i.e. terminals B1 all linked together, terminals B2 all linked
together and terminals B3 all linked together). Provided that the number of daisy-chained
PSC’s is reduced to 10, these comms lines may be connected to unspecified safe area
equipment via an appropriately certified shunt zener diode safety barrier (dual channel a.c.),
whose output parameters do not exceed the following per channel:
U
o
= 9 V, I
o
= 100 mA, P
o
= 225 mW
OR
U
o
= 12 V, I
o
= 80 mA, P
o
= 240 mW
e.g. suitably certified MTL 761, MTL766 to BAS01ATEX7202 or MTL7761ac, MTL7766ac to
BAS01ATEX7217.
For the purposes of this certificate, these shunt zener safety barriers may be considered
equivalent to Category I (M1) equipment.
The cable parameters shall not exceed the following: C
c
= 2.8 µF, L
c
/R
c
= 222 µH/Ω.
iii. For the purpose of this certificate, a P+F Cylindrical Inductive Proximity Sensor Type NC… and
NJ…. to PTB00ATEX2048X to Category II 1G Ex ia IIC T6 connected to terminals T1 to T4 of a
Digital Input Module may be considered equivalent to Category I M1 EPL Mb (ATEX) or Ex ia I
Mb (IECEx). In this instance, the power supply selected to power the PSC must have an output
voltage not exceeding 16 V.
Intrinsic safety parameters
For intrinsic safety parameters associated with certificates listed above, please refer to individual
certificates. Copies of certificates are available on www.trolex.com.
Installation of equipment
The installation of the product must only be carried out by competent personnel. Each installation
needs to be considered with reference to the local safety regulations and authorities. Refer to the
following standards for additional guidance:
-IEC/EN 60079-14
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TX9042-UM-EN-A • P5423.1600-A12
-IEC/EN 60079-25
Refer to the Certification Section of this User Manual and to the relevant certificates for any
installation parameters and special conditions of safe use.
Commissioning / verification tests prior to first use.
Prior to commissioning and first use, the product shall be inspected for any visible damages and
integrity of the enclosure. Never use the product that has damaged housing in hazardous locations.
Maintenance
The maintenance of the product must only be carried out by competent personnel. Maintenance shall
be considered with reference to the local safety regulations and authorities. Refer to the following
standards for additional guidance:
-IEC/EN 60079-17
It is recommended to periodically check the condition of the product.
The product shall only be serviced and repaired by Trolex Ltd. or a local Trolex service agent approved
by Trolex Ltd in order to maintain the explosion protection of the product.
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TX9042-UM-EN-A • P5423.1600-A 13
3. Functional Safety
3.1 Overview of Safety Integrity Level
The following instructions are applicable when the TX9042 Programmable Sensor
Controller (PSC) is used as an element in a safety instrumented function that is
specied to achieve a Safety Integrity Level (SIL), eg. SIL 1, 2, etc.
The reliability of the TX9042 Programmable Sensor Controller (PSC) has been
independently assessed in accordance with IEC 61508 for use in SIL applications.
The compliance with IEC 61508 includes hardware reliability (probabilistic type
failures) and measures to address systematic type failures.
The information that follows forms the ‘Safety Manual’ required by IEC 61508-2
and is intended to allow correct product selection, system integration, installation,
operation and maintenance to enable the SIL specied for the safety instrumented
function to be achieved and maintained, as far as the TX9042 Programmable Sensor
Controller (PSC) is concerned.
The actual SIL will depend on many system considerations that are outside the
scope of the TX9042 Programmable Sensor Controller (PSC) and will rely on
personnel who are competent in the functional safety aspects of the various
lifecycle activities mentioned above.
3.2 SIL Suitability
The versions and congurations of the TX9042 Programmable Sensor Controller
(PSC) identied in Table 1 in Section 3.3 below and are suitable for use in safety
functions that have a specied Safety Integrity Level (SIL) in accordance with IEC
61508 or IEC 61511 up to and including:
SIL 2 - when used in a ‘Low Demand’ safety function [1]
with proof test interval of 3 months
SIL 1 - when used in a ‘Low Demand’ safety function [1]
with proof test interval of 12 months
SIL 1 - when used in a ‘High Demand’ safety function [1]
The functional safety data in Tables 1 and 2 in Section 3.3 must be taken into
account by integrators and end-users, including compliance with the restrictions in
use (Section 3.4) and all other provisions and conditions in this User Manual.
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TX9042-UM-EN-A • P5423.1600-A14
System integrators and end users responsible for other lifecycle phases (system
specication, integration, installation, commissioning, operation, maintenance, etc)
need to perform assessments on the complete scope of their activities to ensure a
target SIL for the safety function is and continues to be met.
[1]
Low Demand and High Demand modes of operation are dened in IEC 61508-4, 3.5.16
3.3 Summary of the Veried Functional Safety Data
The product, conguration and Safety Manual that have been assessed are shown
in Table 1.
Product Information Details
Product identication TX9042.55 Programmable Sensor Controller
Product specication See Section 1.5 of this User Manual
Product conguration
4 to 20 mA input conditioning modules tted
OR
0.4 to 2 V input conditioning modules tted
To achieve SIL the TX9042 with 4 to 20 mA or
0.4 to 2 V input conditioning modules tted, must be
congured to de-energise an output channel relay if
either the input signal transitions a pre-determined
alarm threshold or an internal fault is indicated.
Neither the display nor the RS-485 data link are part
of the specied safety function.
System conguration
Monitoring of signals from devices congured as
2/3-wire current loop devices, 4-wire current inputs
with separate power connection, or voltage inputs.
Element safety function
To de-energise an output channel relay (open relay
contacts) if either the input signal transitions a pre-
determined alarm threshold or an internal fault is
indicated.
Safety Manual See Section 3 of this User Manual
Table 1 Basic Element Information
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TX9042-UM-EN-A • P5423.1600-A 15
The hardware failure data for the TX9042 element safety function based on an
extensive analysis of eld failure data with a 90% single sided condence limit is
shown in Table 2.
Parameter Value
Dangerous failure rate (λD)2.3E-06
Safe failure rate (λs)N/R [1]
Safe failure fraction (SFF) N/R [1]
Element type Type B
Hardware fault tolerance (internal architecture) 0
Diagnostic coverage (DC) 60%
Diagnostic test interval N/A [2]
Probability of Failure on Demand (PFDAVG) [12 month proof test; 24hr MTTR] 1.0E-02 [2]
Probability of Failure on Demand (PFDAVG) [3 month proof test; 24hr MTTR] 2.6E-03 [2]
Probability of dangerous Failure per Hour (PFH) 2.3E-06
Table 2 Hardware Failure Data
[1] Not required by Route 2H
[2] To be conservative, no credit has been taken for the diagnostics
3.4 Conditions or Restrictions for use in SIL Applications
The sections of this User Manual shall be strictly complied with to ensure validity of
the failure data and systematic safety integrity. The following additional restrictions
and conditions apply when the unit is used in SIL applications:
1. The TX9042 must be repaired within the MTTR assumed in the PFD
calculations shown in the table above if an internal fault is detected in the unit.
2. If the MTTR or the proof test interval (T1) is dierent from those assumed in
this User Manual, then the PFDAVG must be re-calculated and the SIL capability
re-veried accordingly (refer to the Safety Manual in Section 3.5 of this User
Manual).
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TX9042-UM-EN-A • P5423.1600-A16
3. The display is for indication only and is not part of the safety function; likewise
the RS485 communications are not part of the safety function.
4. The environmental limits are restricted to:
•+20 to +40°C
•relative humidity <90%
5. IEC 61508-2, 7.4.4.3.1c limits use to SIL 1 in high or continuous mode of
operation when used in a non-redundant conguration.
3.5 Proof Test
Periodic Proof Tests of the element safety function must be carried out to identify
any dormant failures, particularly when used in ‘low demand’ safety functions
– refer to Section 6.1.4 of this User Manual, for the Proof Test procedure. Faults
identied by this Proof Test must be repaired within the MTTR and the unit returned
to full working order.
A suitable Proof Test interval (T1) should be used in order to achieve the required
average probability of failure on demand (PFDAVG). A nominal interval of 8,760 hrs
(1 year) and Mean Time To Repair (MTTR) of 24 hours has been used in the
derivation of PFDAVG for illustration purposes. If dierent values are used, the PFDAVG
for a non-redundant arrangement (i.e., where the safety function relies on a single
element) can be re-calculated as follows:
PFDAVG = (λDU + λDD) tCE
Where tCE (the channel equivalent down time) = (λDU/λD) (T1/2 + MTTR) + (λDD/λD) MTTR
For redundant arrangements refer to IEC 61508-6 for the equations.
Checkpoint
Those responsible for specifying proof testing of safety functions should refer to
IEC 61508-6:2010 clause B.3.2.5 for considerations of the eect of non-perfect
proof tests.
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TX9042-UM-EN-A • P5423.1600-A 17
3.6 System Conguration Drawing
The illustration below shows how the TX9042 is to be used with other system
elements.
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TX9042-UM-EN-A • P5423.1600-A18
4. Installation
4.1 Precautions
Do not disassemble the TX9042 PSC whilst in the hazardous area or use a TX9042
PSC that has a damaged housing in the hazardous area.
The TX9042 PSC must be installed within a metal protective enclosure to ensure
compliance with certication requirements. It is permissible for the enclosure to
incorporate a polycarbonate window to allow visibility of the TX9042 PSC LCD
screen. However, window area may be no greater than 100 cm2.
4.2 Labelling
When the TX9042 PSC is supplied tted into a standard Trolex TX9204 metal
enclosure, two channel identication labels will be tted to the enclosure near
to the connecting terminals. Connection details can also be viewed on the LCD
screen, refer to Section 5.9.2.21 for details.
If a TX9042 PSC is supplied to be tted into a customer supplied metal enclosure,
the two channel identication labels will be provided loose and must be tted
adjacent to the connecting terminals in a visible position in order to comply with
certication requirements.
Before installation check for the correct channel functions and supply voltage on the
channel identication label on the rear of the TX9042 PSC housing.
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4.3 Tools and Test Equipment Required
No special tools are needed to assemble or install the TX9042 PSC.
4.4 Mechanical Installation
The TX9042 PSC is installed on a TS35 low prole DIN rail as follows:
1. Loosen the two securing screws, one each at the end of the TX9042 PSC
housing.
2. Swing the plastic tabs out of the way.
3. Locate the TX9042 PSC on the DIN rail.
4. Ensure that the plastic tabs can engage behind the DIN rail ange.
5. Tighten the two securing screws.
Do not overtighten the two securing screws.
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TX9042-UM-EN-A • P5423.1600-A20
4.5 Connections
The terminals are divided on two horizontal planes. The lower level is used for
all input connections and the upper level is used for output signals and data
connections.
Each of the input channels has four connecting terminals available, and these
are utilised in accordance with the type of input module that is tted (refer to the
diagram on the following page).
Channel 1 sensor signal enters on terminals A2 and A3 and if a power supply is
required to feed the sensor, then this is available at terminals A1 and A4. The input
signal is fully oating and dierential, giving high immunity to electrical interference.
This conguration is repeated for channels 1 to 8.
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