Trolex TX9042 User manual

TX9042 User Manual
TX9042-UM-EN-02 3
TX9042 Programmable Sensor Controller (PSC)
Contents
1. Product Overview 5
1.1 Operating Features 5
1.2 Application 6
1.3 Product Options 7
1.3.1 TX9042 PSC Input Module
Types 7
1.4 Dimensions 8
1.5 Technical Information 8
1.6 Electrical Details 10
2. Certification 11
2.1 Europe (ATEX) 11
2.1.1 Special Conditions for
Safe Use 11
2.1.2 General Conditions of Use 12
2.2 IECEx Certification 12
2.2.1 Conditions of Certification 12
2.2.2 General Conditions of Use 13
2.3 Russia (Customs Union) 13
2.3.1 General Conditions of Use 13
2.4 South Africa (MASC) 13
2.4.1 Special Conditions for
Safe Use 13
2.4.2 General Conditions of Use 14
2.5 Australia/NZ (ANZEx) 15
2.5.1 Conditions of Safe Use 15
2.6 USA (MSHA) 15
2.6.1 Conditions of Use 15
3. Functional Safety 16
3.1 Overview of Safety Integrity
Level 16
3.2 SIL Suitability 16
3.3 Summary of the Verified
Functional Safety Data 17
3.4 Conditions or Restrictions for
use in SIL Applications 18
3.5 Proof Test 19
3.6 System Configuration
Drawing 20
4. Installation 21
4.1 Precautions 21
4.2 Labelling 21
4.3 Tools and Test
Equipment Required 22
4.4 Mechanical Installation 22
4.5 Connections 23
4.6 Input Channel Configuration 25
4.6.1 Analogue Input Modules 26
4.6.2 Digital Input Modules 31
4.6.3 Display of Connection Details 33
4.6.4 Replacing an Input Module 33
4.6.5 Cable Distance Calculation
for Loop Powered 4 to 20 mA
Sensors 33
4.6.6 Cable Distance for Voltage
Inputs (0.4 to 2 V) 34
4.6.7 Dual Input Signals
(Differential) 34
5. Setup and Calibration 35
5.1 Controls and Indicators 35
5.2 Power-up 37
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5.3 Signal Display 37
5.4 Reviewing the Input Module
Configuration 38
5.5 Close-up Information Display 38
5.5.1 Close-up 1 Information
Display 39
5.5.2 Close-up 2 Information
Display 42
5.6 Menu of Function 44
5.6.1 Default Values 44
5.6.2 Programming the Operating
Values 44
5.7 Main Menu 45
5.7.1 Entering the Main Menu 45
5.7.2 Escape/Return 46
5.7.3 Communication Setup 47
5.7.4 Clock 49
5.7.5 Keycode Security 49
5.7.6 Interval Period of the Datalog 50
5.7.7 Data Display Review of the
Datalog 50
5.7.8 Clear the Data in the Datalog 51
5.7.9 Relay Reset Mode Options 52
5.7.10 Relay Voting 53
5.7.11 Relay Operation 55
5.7.12 Software Version 55
5.7.13 Self Test 55
5.7.14 Display Cycling 56
5.8 Contrast Control 56
5.9 Channel Function and
Calibration 57
5.9.1 Power On Delay (POD)
Period 58
5.9.2 Scale and Display Settings 60
5.9.3 Setpoint Characteristics 79
5.9.4 Fault Signal Alarm
Assignation 85
5.9.5 Threshold Acceptance Level 86
5.9.6 Keycode Security for Each
Channel - 1 to 8 87
5.9.7 Mode Setting for a Digital
Input Module 88
5.9.8 Setting a Digital Failsafe
Input Module 96
5.9.9 Channel Display Mode 99
5.10 Datacommunications 100
5.10.1 RS485 100
6. Maintenance 102
6.1 TX9042 PSC Planned
Preventative Maintenance 102
6.1.1 Introduction 102
6.1.2 TX9042 PSC - Check 102
6.1.3 TX9042 PSC Battery
- Replace 104
6.1.4 TX9042 PSC - Proof Test 104
6.2 TX9042 PSC - Repair 107
6.3 Maintenance Records 107
6.4 Maintenance Log 108
7. Disposal 109
Disclaimers 110
Trademarks 110
Document History 110
Contact Details 110
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TX9042 User Manual
TX9042-UM-EN-02 5
1. Product Overview
TX9042.55
Up to 8 analogue or digital inputs.
Up to 16 On/Off 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/off 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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6 TX9042-UM-EN-02
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 any conditions or
restrictions.
The uses of the TX9042 PSC include:
• Underground machinery protection
• Environmental monitoring using a combination of gas sensors and flow 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
periods 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 User Manual
TX9042-UM-EN-02 7
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 to 2 V P5423.514
Voltage - 0.4 to 2 V P5423.509
Voltage - 0 to 10 V P5423.515
Flow TX6023 - not lo limited P5423.552
Flow TX6023 - lo limited P5423.553
Flow TX6023 - 4 to 20 mA lo limited P5423.556
Thermocouple - K type P5423.539
Thermocouple - I/R -50 to +400°C P5423.527
PT100 - -50 to +200°C P5423.510
PT100 - -50 to +400°C P5423.513
KTY21 - -50 to +150°C P5423.519
KTY81 - -50 to +150°C P5423.511
KTY84 - 0 to +300°C P5423.512
Flow TX6022 - Flow P5423.528
Flow TX6022 - Pressure P5423.518
ac RMS - 500 Hz to 10 kHz - TX5630 P5423.506.01
ac RMS - 15 to 100 Hz - TX5630 P5423.506.02
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1.4 Dimensions
1.5 Technical Information
Display accuracy +/-0.25% (analogue channels)
Setpoint accuracy +/-0.5%
Ambient temperature limits -10 to +50°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 User Manual
TX9042-UM-EN-02 9
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 certified
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
identified 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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10 TX9042-UM-EN-02
1.6 Electrical Details
TX9042.55 - Programmable Sensor Controller (PSC)
Supply voltage: 12 V dc +20%/-2.5% at 125 mA
Output: Modbus protocol
Type of sensor: Flammable
Supply current: 125 mA at 12 V
Relay: 200 V
0.25 A
3 W absolute maximum
Checkpoint
Circuits switched by the contacts of the output relays
MUST emanate from a certified Intrinsically Safe
power source and the circuit parameters must be
within Intrinsically Safe requirements.
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TX9042 User Manual
TX9042-UM-EN-02 11
2. Certification
2.1 Europe (ATEX)
Ex Certificate number:
Ex Certification code:
Baseefa 03ATEX0292X
I M1 Ex ia I Ma
2.1.1 Special Conditions for Safe Use
1. 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.
2. Up to 11 RS485 Comms Modules (in separate Programmable Sensor
Controllers type TX9042) may be daisy-chained together (ie. 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 ac),
whose output parameters do not exceed the following per channel:
Uo = 9 V, Io = 100 mA, Po = 225 mW
OR
Uo = 12 V, Io = 80 mA, Po = 240 mW
eg. suitably certified MTL761, MTL766 to BAS01ATEX7202 or MTL7761ac,
MTL7766ac to BAS01ATEX7217. For the purposes of this certificate, these
shunt safety barriers may be considered equivalent to Category I (M1)
equipment.
The cable parameters shall not exceed the following:
Cc = 2.8 µF, Lc/Rc = 222 µH/Ω.
3. For the purpose of this certificate, a P+F inductive sensor to PTB00ATEX2048X
to Category II 1G EEx ia IIC T6 connected to terminals T1 to T4 of a Digital
Input Module may be considered equivalent to Category I M1. In this instance,
the power supply selected to power the PSC must have an output voltage not
exceeding 16 V.
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12 TX9042-UM-EN-02
2.1.2 General Conditions of Use
Prior to installation, it is essential that user refers to the above certificate to
ensure that the termination and cable parameters are fully complied with and are
compatible with the application. Copies of certificates are available from Trolex.
ATEX Directive (94/9/EC)
EMC Directive (2004/108/EC)
2.2 IECEx Certification
Ex Certificate number:
Ex Marking:
IECEx BAS 15.0065X
Ex ia I Ma
2.2.1 Conditions of Certification
1. 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.
2. 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 ac),
whose output parameters do not exceed the following per channel:
Uo = 9 V, Io = 100 mA, Po = 225 mW
OR
Uo = 12 V, Io = 80 mA, Po = 240 mW
eg. suitably certified MTL761, MTL766 to BAS01ATEX7202 or MTL7761ac,
MTL7766ac to BAS01ATEX7217. For the purposes of this certificate, these
shunt safety barriers may be considered equivalent to Category I (M1)
equipment.
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TX9042 User Manual
TX9042-UM-EN-02 13
The cable parameters shall not exceed the following:
Cc = 2.8 µF, Lc/Rc = 222 µH/Ω.
3. For the purpose of this certificate, a P+F inductive sensor to PTB00ATEX2048X
to Category II 1G EEx ia IIC T6 connected to terminals T1 to T4 of a Digital
Input Module may be considered equivalent to Category I M1. In this instance,
the power supply selected to power the PSC must have an output voltage not
exceeding 16 V.
2.2.2 General Conditions of Use
Prior to installation, it is essential that user refers to the above certificate to
ensure that the termination and cable parameters are fully complied with and are
compatible with the application. Copies of certificates are available from Trolex.
2.3 Russia (Customs Union)
Ex Certificate number:
Ex Certification code:
TC RU C-GB.ГБ05.B.00359
PO Ex ia I Ma X
2.3.1 General Conditions of Use
Prior to installation, it is essential that user refers to the above certificate for any
special conditions for safe use. The user must ensure that the termination and
cable parameters are fully complied with and are compatible with the application.
Copies of certificates are available from Trolex.
2.4 South Africa (MASC)
Ex Certificate number:
Ex Certification code:
MASC M/11-359X
Ex ia I
2.4.1 Special Conditions for Safe Use
1. The Programmable Sensor Controller type TX9042 must be mounted in a
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14 TX9042-UM-EN-02
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.
2. 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 ac),
whose output parameters do not exceed the following per channel:
Uo = 9 V, Io = 100 mA, Po = 225 mW
OR
Uo = 12 V, Io = 80 mA, Po = 240 mW
eg. suitably certified MTL761, MTL766 to BAS01ATEX7202 or MTL7761ac,
MTL7766ac to BAS01ATEX7217. For the purposes of this certificate, these
shunt safety barriers may be considered equivalent to Category I (M1)
equipment.
The cable parameters shall not exceed the following:
Cc = 2.8 µF, Lc/Rc = 222 µH/Ω.
3. For the purpose of this certificate, a P+F inductive sensor to PTB00ATEX2048X
to Category II 1G EEx ia IIC T6 connected to terminals T1 to T4 of a Digital
Input Module may be considered equivalent to Category I M1. In this instance,
the power supply selected to power the PSC must have an output voltage not
exceeding 16 V.
2.4.2 General Conditions of Use
Prior to installation, it is essential that user refers to the above certificate to
ensure that the termination and cable parameters are fully complied with and are
compatible with the application. Copies of certificates are available from Trolex.
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TX9042 User Manual
TX9042-UM-EN-02 15
2.5 Australia/New Zealand (ANZEx)
Ex Certificate number:
Ex Certification code:
ANZEx 06.3057X
Ex ia I
2.5.1 Conditions of Safe Use
1. Prior to installation, it is essential that user refers to the above certificate to
ensure that the termination and cable parameters are fully complied with and are
compatible with the application. Copies of certificates are available from Trolex.
2. Up to 6 RS485 Comms Modules (in separate Programmable Sensor Controllers
type TX9042) may be daisy-chained together (ie. 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 5, these comms
lines may be connected to unspecified safe area equipment via an appropriately
certified shunt zener diode safety barrier (dual channel ac), whose output
parameters do not exceed the following per channel:
Uo = 9 V, Io = 100 mA, Po = 225 mW
OR
Uo = 12 V, Io = 80 mA, Po = 240 mW
eg. suitably certified MTL761, MTL766 to BAS01ATEX7202 or MTL7761ac,
MTL7766ac to BAS01ATEX7217.
The cable parameters shall not exceed the following:
Cc = 2.8 µF, Lc/Rc = 222 µH/Ω.
2.6 USA (MSHA)
MSHA IS Evaluation number: IA-17501-0
2.6.1 Conditions of Use
Prior to installation, it is essential that user refers to the above document for any
specific conditions of use. The user must ensure that the termination and cable
parameters are fully complied with and are compatible with the application. Copies
of certificates are available from Trolex.
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16 TX9042-UM-EN-02
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
specified 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 specified 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 configurations of the TX9042 Programmable Sensor Controller
(PSC) identified in Table 1 in Section 3.3 below and are suitable for use in safety
functions that have a specified 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-02 17
System integrators and end users responsible for other lifecycle phases (system
specification, 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 defined in IEC 61508-4, 3.5.16
3.3 Summary of the Verified Functional Safety Data
The product, configuration and Safety Manual that have been assessed are shown
in Table 1.
Product Information Details
Product identification TX9042.55 Programmable Sensor Controller
Product specification See Section 1.5 of this User Manual
Product configuration
4 to 20 mA input conditioning modules fitted
OR
0.4 to 2 V input conditioning modules fitted
To achieve SIL the TX9042 with 4 to 20 mA or
0.4 to 2 V input conditioning modules fitted, must be
configured 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 specified safety function.
System configuration
Monitoring of signals from devices configured 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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18 TX9042-UM-EN-02
The hardware failure data for the TX9042 element safety function based on an
extensive analysis of field failure data with a 90% single sided confidence 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 different from those assumed in
this User Manual, then the PFDAVG must be re-calculated and the SIL capability
re-verified accordingly (refer to the Safety Manual in Section 3.5 of this User
Manual).
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TX9042-UM-EN-02 19
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 configuration.
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
identified 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 different 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 effect of non-perfect
proof tests.
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20 TX9042-UM-EN-02
3.6 System Configuration Drawing
The illustration below shows how the TX9042 is to be used with other system
elements.
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