Dwyer Instruments MTL5041 Operating Manual

Instruction Manual

INM5000

MTL5000 Series
isolating interface units

ii

INM5000-6 Jul 2010

iii

1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

2 DESCRIPTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3.1 Installing unenclosed isolators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

4 ACCESSORIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.1 MTL5000 power bus - Installation and use . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

4.2 Earth rail and tagging accessories . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

5 DX ENCLOSURES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

5.1 Environmental conditions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

5.2 Mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

5.3 Accessories in enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

5.4 IS warning label . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

6 UNIT DESCRIPTIONS, SETTING-UP, CONNECTIONS AND TESTING . . . . . . . . . . . . . . . . . . . . . . . 11

6.1 MTL5011 single-pole relay single-channel switch/proximity detector with phase reversal (Discontinued use MTL5011B) . . . . . . . . . . . . . . . 11

6.2 MTL5011B single-pole changeover relay single-channel switch/proximity detector with line fault detection and phase reversal . . . . . . . . . . . 12

6.3 MTL5012 solid-state single-channel switch/proximity detector with line fault detection and phase reversal . . . . . . . . . . . . . . . . . . . . . . . . 12

6.4 MTL5014 single-pole changeover relay single-channel dual-output switch/proximity detector with line fault detection and phase reversal . . . . 13

6.5 MTL5015 solid-state two-channel switch/proximity detector with line fault detection and phase reversal . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6.6 MTL5016 single-pole relay two-channel switch/proximity detector with phase reversal (Discontinued, use MTL5018) . . . . . . . . . . . . . . . . . 15

6.7 MTL5017 single-pole relay two-channel switch/proximity detector with line fault detection and phase reversal . . . . . . . . . . . . . . . . . . . . . 15

6.8 MTL5018 single-pole, changeover relay, two-channel, switch/proximity detector with line fault detection and phase reversal . . . . . . . . . . . . 16

6.9 MTL5018AC single-pole, changeover relay, two-channel, switch/proximity detector with line fault detection and phase reversal . . . . . . . . . 16

6.10 MTL5021 loop-powered solenoid/alarm driver, IIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17

6.11 MTL5022 loop-powered solenoid/alarm driver, IIB . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.12 MTL5023 solenoid/alarm driver with line fault detection and phase reversal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

6.13 MTL5024 solenoid/alarm driver, logic drive with phase reversal . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6.14 MTL5025 low-current loop-powered solenoid/alarm driver, IIC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6.15 MTL5031 vibration transducer interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

6.16 MTL5032 pulse isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

6.17 MTL5040 2-channel 4 to 20mA loop isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.18 MTL5041/42 repeater power supplies . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21

6.19 MTL5043 repeater power supply dual output, 4 to 20mA for 2-wire transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.20 MTL5044 repeater power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

6.21 MTL5045/46 isolating drivers . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.22 MTL5048 analogue input/output, loop-powered isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

6.23 MTL5049 two-channel isolating driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.24 MTL5051 serial data comms isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 24

6.25 MTL5053 isolator/power supply for 31.25kbit/s fieldbuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25

6.26 MTL5061 two-channel loop-powered fire/smoke detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.27 MTL5074 temperature converters, THC or RTD input . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

6.28 MTL5081 millivolt isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

6.29 MTL5082 resistance isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.30 MTL5099 dummy isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

6.31 MTL5113P fail-safe switch/proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.32 MTL5314 trip amplifier for 2– or 3– 2 wire transmitters . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

6.33 MTL5344 Repeater power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.34 MTL5349 two-channel isolating driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

6.35 MTL5991 24V dc power supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.36 MTL5995 fieldbus power supply for 31.25kbit/s fieldbuses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

6.37 FBTI-IS fieldbus terminator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

CONTENTS Page

© 2010 MTL Instruments Group plc. All rights reserved.

INM5000-6 Jul 2010

iv

INM5000-6 Jul 2010

7 MAINTENANCE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.1 Routine maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

7.2 Enclosures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

8 OTHER USEFUL DOCUMENTATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34

9 APPENDIX A - INSTRUCTIONS FOR MTL5500 SERIES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.1 MTL5521 rotational speed monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35

9.2 MTL5531 voltage/current converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

9.3 MTL5536 potentiometer converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

1

INM5000-6 Jul 2010

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 INA5000 must
be consulted before installation.

CERTIFICATION DATA

The MTL web site

http://www.mtl-inst.com

contains 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.

1 INTRODUCTION

This instruction manual explains how to install, connect, test and
maintain MTL5000 Series isolating interface units (isolators).

2 DESCRIPTION

MTL5000 Series isolators provide intrinsically safe (IS) communication
and signal conditioning for a wide range of hazardous-area devices.
Total ac and dc isolation exists between input, output and power supply
on separately powered units, and between input and output on loop­powered units. No IS earth is required. DIN-rail mounting and plug-in
signal and power connectors simplify installation and maintenance.
Units are powered from a 20 to 35V dc supply, or, in some cases, from
the signal itself.

3 INSTALLATION

Mount all MTL5000 Series isolators on low-profile (7mm) or high-profile
(15mm) type T35 (top-hat) DIN-rail to EN50022, BS5584, DIN46277.
This is available from MTL, in 1 metre lengths (THR2 DIN rail). Install
isolators within the safe area unless they are enclosed in approved
flameproof, pressurised or purged enclosures and ensure that the local
environment is clean and free of dirt and dust. Note the ambient
temperature considerations of section 3.1.7.

It is recommended that, in normal practice, the DIN rail is earthed to
ensure personnel safety in the event of mains being put accidentally on
the rail.

3.1 Installing unenclosed isolators

On new installations, if isolators are mounted in several rows orcolumns,
mount alternate rows or columns so that units face in opposite directions.
This allows safe- and hazardous-area wiring looms to be shared.

See figure 3.1 for isolator dimensions.

INM5000-6

July 2010

Note: All MTL products are tested for electrical safety to EN 61010 to

comply with the EC Low Voltage Directive

MTL5000 Series Interface units

Figure 1.1: MTL5000 Series isolators

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INM5000-6 Jul 2010

3.1.1 Mounting isolators on DIN rail

Clip isolators onto type T35 DIN rail as shown in figure 3.2, with the
blue signal plugs facing towards the hazardous-area wiring.To remove
an isolator from the rail, insert a screwdriver blade into the clip as shown
and lever the clip gently outwards; pivot the isolator off the rail. Allow a
maximum mounting pitch of 16.2mm for each unit.

3.1.2 Wiring up isolators

Each unit is supplied with the appropriate number and type of safe- and
hazardous-area connectors (see figure 3.3), as dicatated by the
terminals used and the type of power supply. Loop-powered devices do
not require power connectors. Depending on the installation, it may be
easier to wire up isolators with power and signal plugs either in place
or removed. Either way, allow sufficient free cable to permit plugs to be
removed easily for future maintenance and/or replacement purposes.
See section 6 for individual unit wiring instructions.

Note: Units for use with 31.25kbit/s fieldbuses may require additional
terminators to be fitted. See section 6.33 for details of MTL's FBT1
fieldbus terminator.

Signal and power conductors

Removable signal and power plugs 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. Signal plugs, located on top of the
modules, are mechanically keyed to fit in only one position. They are

coloured grey, for safe-area connections, and blue, for hazardous-area
connections.

For externally powered units, a power plug slots into the socket at
terminals 13 and 14 on the safe-area side of each module. The socket
is coloured blue if the unit is dc powered. Power plugs are coloured
grey, for plugging into the blue sockets of dc powered units.

Making connections

a) Trim back the insulation of conductors by 12mm.
b) Check the terminal assignments shown in section 6 or on the

side label of the unit.

c) Insert conductors according to the terminal assignments and

tighten screws.
If the wires are to be fitted with crimp ferrules, the following is a list of
those recommended with required trim lengths for each:

*2- to 3-week lead time

† These ferrules have 18mm length metal tubes which should be cut to
12mm after crimping

Note: Smaller section wire than that stated can often be successfully
used if the crimping is good.

Crimp tool: Phoenix Contact Crimpfox UD6 part number 1204436

Finishing

Wire up individual isolators in accordance with wiring schedules. Daisy­chain power supply connections between individual power plugs or use
the power bus (see section 4.1).

Segregate hazardous- and safe-area wiring into separate trunking or
looms wherever possible to avoid errors and maintain a tidy installation.

Use an MTL5099 dummy isolator to provide termination and earthing
for unused cores from the hazardous area.

Hazardous-area
connections

Non-hazardous
(safe) area
connections

Power
connectors

104

115

110

16

16.2 pitch

Plug Entry Wire Metal tube Trim Recommended ferrules
type size length length

(mm2) (mm) (mm)

Signal Twin 2x1.5 12 14 Cembre PKET 1512
Signal Single 0.75 12 14 Weidmuller 902591
Signal Single 1.0 12 14 Cembre PKC112
Signal Single 1.0 12 14 Phoenix Contact AI 1-12 RD

(3200674)*
Signal Single 1.5 12 14 Cembre PKE1518†
Signal Single 2.5 12 14 Cembre PKE2518†
Power Twin 2x0.75 10 12 Cembre PKET7510
Power Twin 2x0.75 10 12 AMP (non-preferred) 966144-5
Power Twin 2x1.0 10 12 Phoenix Contact AI-TWIN 2X 1-10 RD
Power Single 0.75 10 12 AMP 966067-0
Power Single 1.0 10 12 Phoenix Contact AI 1-10 RD

Figure 3.1: Dimensions of MTL5000 Series isolators

Figure 3.2: DIN rail – mounting and removing isolators

12mm

14mm

Power Plugs

Grey: dc supplies (PWR5000)

Signal Plugs

Grey: safe-area side
Blue: hazardous-area side

Figure 3.3: Removable power and signal plugs

Consult table below for

additional details.

Note: the open circuit window (between 350µA and 50µA) is not
hysteresis, all MTL5000 Series modules with inputs conforming to
NAMUR/DIN 19234 will switch between open and complete circuit
conditions within these limits.

Note: the short circuit window (between 100

Ω

and 360Ω) is not
hysteresis, all MTL5000 Series modules with inputs conforming to
NAMUR/DIN 19234 will switch between open and complete circuit
conditions within these limits.

Modules with LFD and inputs conforming to NAMUR/DIN
19234:

MTL5011B, 5014* and 5018: LFD enable switch on top label

* The MTL5014 has a Slave/LFD output relay arrangement
(see module description in section 6).

MTL5012 and 5015: LFD enable switch on top label

MTL5017: LFD permanently enabled

Other modules with LFD facility

MTL5023 solenoid/alarm driver: LFD automatic

MTL5046 isolating driver: LFD automatic

Note: The safe-area circuit impedance will increase with hazardous­area load and will rise >150kΩ for the 'open circuit' line fault.

MTL5113x: LFD automatic

Hazardous-area load Safe-area input

<50Ω High impedance (>150kΩ)
>90Ω Normal operation

Hazardous-area input (either channel) Line-fault-detect relay

<50µA De-energised

>350µA Energised

>360Ω Energised
<100Ω De-energised

LFD switch setting Hazardous-area input(s) Solid-state output(s)

On <50µA Non-conducting
On >350µA Conducting
On >360Ω Conducting
On <100Ω Non-conducting

LFD switch setting Hazardous-area input(s) Output relay(s)

On <50µA De-energised
On >350µA Energised
On >360Ω Energised
On <100Ω De-energised

3.1.3 Phase reversal

Switch(es) to change the phase of the output(s) relative to the input(s) are
provided on the top labels of some of the MTL5000 Series modules and
on the base of others. The following applies:

MTL5011B, 5014 and 5018: Phase reversal switch on top label

MTL5017: Phase reversal switch on base of module

MTL5012 and 5015: Phase reversal switch on top label

MTL5023 and 5024: Phase reversal switch on base of module

Positions for base-located switches are set as shown in figure 3.4.

3.1.4 Line fault detection (LFD)

Line fault detection on hazardous-area sensor lines (open circuit or short
circuit) is provided on some MTL5000 Series modules.

Note: resistors must be fitted when using the LFD facility with a contact
input: 500Ωto 1kΩin series with switch and 20kΩto 25kΩin parallel
with switch.

For hazardous-area inputs conforming to NAMUR/DIN
19234, a line fault condition is indicated as follows:

Open circuit condition if hazardous-area current <50µA
Line integrity (no open circuit) if hazardous-area current >350µA
Short circuit condition if hazardous-area load <100Ω
Line integrity (no short circuit) if hazardous-area load >360Ω

A

B2

1

Normal Reverse

CH1

CH2

Label face

Base of unit

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INM5000-6 Jul 2010

PR switch setting Hazardous-area input(s) Output relay(s)

Off <1.2mA De-energised
Off >2.1mA Energised
On <1.2mA Energised
On >2.1mA De-energised

PR switch setting Hazardous-area input(s) Solid-state output(s)

Off <1.2mA Non-conducting
Off >2.1mA Conducting
On <1.2mA Conducting
On >2.1mA Non-conducting

Hazardous-area

PR switch setting Safe-area control output

o ← (off) CTRL+Ve >4.5V above CTRL-Ve Enabled
o ← (off) CTRL+Ve <1.4V above CTRL-Ve Disabled

→ + (on) CTRL+Ve >4.5V above CTRL-Ve Disabled
→ + (on) CTRL+Ve <1.4V above CTRL-Ve Enabled

Hazardous-area load Solid-state LFD output

<50Ω Non-conducting
>7kΩ Non-conducting

Hazardous-area input LFD output

< 50µA (open-circuit) de-energised

> 6.6mA (short-circuit) de-energised

Figure 3.4: Phase reversal switch on base of units

PR switch setting Hazardous-area input(s) Output relay(s)

o ← (off) <1.2mA De-energised
o ← (off) >2.1mA Energised

→ + (on) <1.2mA Energised
→ + (on) >2.1mA De-energised

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INM5000-6 Jul 2010

3.1.5. Relay outputs

Reactive loads on all units with relays should be adequately
suppressed.Changeover relay outputs are provided on the following
units: MTL5011B, MTL5014, MTL5018 and MTL5314. In order to
achieve maximum contact life, a minimum switching current of 10mA at
≥5V is recommended.

3.1.6 Earth leakage detection

An MTL4220 earth leakage detector can be used with a number of
MTL5000 Series units to detect hazardous-area earth faults which can
then be rectified without needing to shut down the loop ('no-fail'
operation). On units with a single-channel input, the MTL4220 is
connected to terminal 3 and on units with two-channel inputs, to
terminals 3 and 6. Units which can be used with an MTL4220 are:

MTL5011B MTL5012 MTL5014 MTL5015
MTL5017 MTL5018 MTL5021 MTL5022
MTL5023 MTL5024 MTL5025 MTL5061

N.B. HAZ1-3 or HAZ4-6 connectors are required.

3.1.7 Ambient temperature considerations

Ambient temperature limits for unenclosed MTL5000 Series isolators are
from -20°C to +60°C with units close-packed.

4 ACCESSORIES

4.1 MTL5000 power bus - Installation
and use

4.1.1 MTL5000 Series power bus

Power bus kits provide facilities for linking the power supply terminals
(13 and 14) of up to 32 installed MTL5000 Series units to a standard
24V power supply. Buses consist of chains of power plugs and are
available in different lengths to suit various numbers of modules as
follows:

4.1.2. Installation

4.1.2.1 Check to make sure the bus length is correct for the

number of modules involved.

4.1.2.2 If the number of modules is less than the maximum number
the chain will support, cut off the surplus power plugs at
the tail end of the chain - leaving a 'new' tail end.

4.1.2.3 Insert power plugs into the power terminals on the safe­area side of each module in sequence.

4.1.2.4 Connect the power supply source to the tail end of the
chain (using the insulation displacement connectors
(Scotchloks) provided if required).

Notes:

1. To reduce the risk of excessive voltage drop or over­current, DO NOT connect power buses in series.

2. Surplus sections can be used (and, if required)
connected together provided the cut ends are safely
terminated and/or connected together. Use single
ferrules with a crimp tool or insulation displacement
connectors (Scotchloks). Suitable ferrules and connectors
are provided with the kits.

4.2 Earth rail and tagging accessories

This section explains how to specify and assemble earth rail and tagging
strip accessories for the MTL5000 Series.

The accessories consist of mounting brackets, earth rails, tagging strips
and associated parts. They provide facilities for earthing, terminating
cable screens and tagging (identifying) the positions of individual units.

4.2.1 Parts list
IMB57 Insulating mounting block (figure 4.5)

One required at each end of a tagging strip/earth rail. Suitable for low­profile (7.5mm) and high-profile (15mm) symmetrical DIN rail.

ERB57S Earth-rail bracket, straight (figure 4.6)

Nickel-plated; supplied with two push fasteners, one earth-rail clamp
(14mm, 35mm

2

) and one earth cable clamp (10mm, 16mm2).

Note: ERB57S is the preferred choice of earth-rail bracket. It is usually
fitted in the upper slot on insulating mounting block IMB57

.

Number of modules Kit ID code

(contains grey power plugs for 24V dc supply)

1 to 8 PB-8T

9 to 16 PB-16T
17 to 24 PB-24T
25 to 32 PB-32T

 +

Optional insulation

displacement

connectors

x2

OR

Figure 4.1: Installing a chain of power plugs into MTL5000
Series modules

Figure 4.2: Using crimp ferrules or insulation displacement
connectors (Scotchloks) to terminate cut ends

133.5mm

16mm

2

35mm

2

16mm235mm

2

10mm

3mm

14mm

10mm

14mm

10mm

5

INM5000-6 Jul 2010

Where the earth rail is required to be positioned at a lower height and
to allow access to the IMB57 mounting screws, the straight earth-rail
bracket ERB57S can be inserted in the lower slot, but only after
insulating mounting blocks IMB57 are clamped to the DIN rail. This may
not be possible if, for example, trunking is fitted. In this case, fit offset
earth-rail bracket ERB57O (see figure 4.7) in the upper slot: the
mounting blocks can then be fitted in a restricted space with this bracket
already fitted.

ERB57O Earth-rail bracket, offset (figure 4.7)

Nickel-plated; supplied with two push fasteners, one earth-rail clamp
(14mm, 35mm2) and one earth cable clamp (10mm, 16mm2).

ERL7 Earth rail, 1m length (figure 4.8)

Nickel-plated; may be cut to length.

TAG57 Tagging strip, 1m length (figure 4.9)

Cut to size. Supplied with tagging strip label.

TGL57 Tagging strip labels, set of 10 x 0.5m

Spares replacement, for use with TAG57 tagging strip.

MS010 DIN rail module spacer, 10mm, pack of 5 (figure 4.10)

Grey spacer, one required between each MTL5995 and any adjacent
module on a DIN rail, to provide 10mm air-circulation space between
modules.

TGL57

TAG57

ERB57

ERB570

ETM7

Snap off extension
when using IMB57
as central support

10mm Earth
clamp

ERB57S
in upper
position

ERB57S
in lower
position

IMB57

Push
fastener

14mm
Earth-rail
clamp

ERL7

82mm

135mm

28mm

66mm

15mm

150mm

10mm

3mm

16mm

2

35mm

2

16mm235mm

2

10mm

14mm

10mm

14mm

3mm

10mm

THR2

IMB57

ERL7

HAZ1-3

HAZ4-6

TH5000

TAG57

TGL57

SAF7-9

SAF10-12

ERB57S

PWR5000

ETM7

Figure 4.3: Assembly drawing showing part numbers

Figure 4.4: Mounting details

Figure 4.5: IMB57 Insulating mounting block

Figure 4.6: ERB57S Earth-rail bracket, straight (end-on view), and clamps

Figure 4.7: ERB57O Earth-rail bracket, offset (end-on view), and clamps

Figure 4.8: ERL7 Earth-rail, 1m length

31mm

Figure 4.9: TAG57 Tagging strip,1m length

x 5

Figure 4.10: MS010 DIN rail module spacers

Type A

Type B

6

INM5000-6 Jul 2010

ETM7 Earth terminal, bag of 50 (figure 4.11)

For terminating cable screens and 0V returns on the ERL7 earth rail.
For cables ≤ 4mm

2

.

TH5000 Tag holder

Spares replacement.

Connectors

Spares replacement: HAZ1-3, HAZ4-6, HAZ-CJC, PWR5000, SAF7-9,
SAF10-12 (SAF1-3 and SAF4-6 grey connectors, also available for use
in safe-area applications).

4.2.2 Assembly

4.2.2.1 Fitting earth rails
a)

In upper position

Before fitting insulating mounting blocks IMB57, check that the
swing nuts in the base of each unit are turned back into the
moulding. Locate the mounting blocks on the DIN rail in the
chosen position and tighten the screws (see figure 4.12). Check
that the swing nuts rotate correctly to locate underneath the
flanges of the DIN rail.

Slide a straight earth-rail bracket ERB57S into the upper slot in
each mounting block. Push two plastic push fasteners into each
bracket to locate the brackets in the mounting blocks.

Cut earth rail ERL7 to the length needed. Slide the required
number of ETM7 earth terminals (5mm or 7mm wide) onto the
rail. Clamp each end of the earth rail to earth-rail brackets
ERB57S using the terminal clamps (14mm, 35mm

2

) supplied. Fit
an earth clamp (10mm, 16mm2) to the free end of each earth-rail
bracket.

Note: For lengths of earth-rail greater than 500mm,
provide additional support by installing a third IMB57 mounting

block and earth-rail bracket, mid-way between the end mounting
blocks. Snap out the perforated extension between the lugs on
this mounting block if a continuous tagging strip is to be fitted
(see figure 4.3).

b)

In lower position

, where at least 150mm clearance exists

on one side, measured from the edge of the mounting
block.
As for a), but slide earth-rail brackets ERB57S into the

lower slots in each mounting block.

c)

In lower position, where there is insufficient clearance to fit
earth-rail brackets ERB57S.

As for a), but slide offset earth-rail brackets ERB57O into
the upper slot in each mounting block before assembling
the mounting blocks to the DIN rail. ERB57S brackets
cannot be used because they obscure the mounting
blocks' fixing screws.

4.2.2.2 Fitting tagging strips

Assemble mounting blocks IMB57 to the DIN rail as above. Cut TAG57
tagging strip and label to the length needed, and insert label so that the
appropriate side is visible. Clip the strip onto the lugs on the mounting
blocks. Hinge up the strip to provide access to the tops of the isolators.

Note: If necessary, provide additional support for long lengths of
tagging strip by installing an extra IMB57 mounting block mid-way
between the end mounting blocks. Snap out the perforated extension
between the lugs on this mounting block.

4.2.3 Completed assemblies

Figure 4.13(below) illustrates a complete assembly of MTL5000 isolators
using the accessories mentioned above.

The broken-line boxes either side of the assembly represent cable
trunking, and the accompanying dimensions represent the minimum
spacing between trunking and assemblies.

For further information on the use of the accessories please refer to the
relevant MTL customer drawings listed in section 8.

5.5
mm

7mm

Type A Type B

110mm110mm

Figure 4.11: ETM7 Earth terminal

Figure 4.12: Fitting IMB57

Figure 4.13: MTL5000 Series - complete assembly

7

INM5000-6 Jul 2010

5 DX ENCLOSURES

Enclosures are usually selected on the basis of the number of units they
will accommodate and table 5.1 shows the capacity of each of the
enclosures. Figures 5.2 to 5.4 show each type of enclosure containing
MTL5000 modules.

Table 5.1: DX range of enclosures - module capacities

* Use these figures when two IMB57 mounting brackets for
tagging/earth-rail accessories are included

Note: The user should be aware that some workshop preparation may
be required for the cable gland plates before the enclosure is ready for
on-site installation.

131 (inside)

150

184

147 (inside)

Top of DIN rail

270

540

430

184

147 (inside)

Top of DIN rail

170

102 102

360

270

DX430

DX070

125

70

175

DX170

8080

Enclosure MTL5000 isolators

16.2 mm mounting pitch

DX070 4 (2*)
DX170 10 (8*)
DX430 26 (24*)

MTL5000 Series
Isolators

Figure 5.1: MTL’s DX range of enclosures

Figure 5.2: DX070 enclosure showing MTL5000 modules

mounted

8

INM5000-6 Jul 2010

5.1 Environmental conditions

Environmental conditions that should be taken into account when
installing DX enclosures include:-

See section
Maximum ambient temperature limits 5.1.1
Storage temperatures 5.1.2
Humidity 5.1.3
Corrosion resistance 5.1.4
Flammability 5.1.5
Impact resistance 5.1.6
Chemical resistance 5.1.7

5.1.1 Maximum outside enclosure

temperature limits

The maximum outside enclosure temperature depends upon the total
power dissipated by the installed modules which, in turn, depends upon
their number and type. It can also be influenced by the Authority whose
standards may need to be applied to the system, e.g. BASEEFA
(CENELEC), Factory Mutual Research Corporation, Canadian
Standards Association.

Figure 5.5 shows, in graphical form, the maximum outside enclosure
temperatures (T

MO

) for given levels of power dissipation.

The graph was derived from the following equation and should be used
to calculate accurately the suitability of any particular mix of modules.

T

MO

= 60°C - δT

where δT= k

1

x P
P = total power (watts) dissipated by modules in an enclosure
k

1

= is a dissipation constant for a given enclosure and

module series. Select the relevant value from table 5.2.
(60°C is the temperature inside the enclosure)

Table 5.2: Dissipation constant k

1

for enclosures (°C/watt)

Orientation of the enclosures is also important - the optimum position
being on a vertical surface with the internal DIN-rail horizontal as shown
in figure 5.6. Any other position can reduce the maximum allowable
ambient temperature by up to 5°C.

Examples

Tables 5.3 and 5.4 list likely combinations of MTL5000 Series modules
in the three enclosure types and indicate the acceptable maximum
permitted outside enclosure temperature for these based on the graph in
figure 5.5. See the specifications included in the latest version of MTL's
IS catalogue for the power dissipation figures of individual MTL5000
Series modules.

5.1.2 Storage temperatures

Storage temperatures are safe within the range -40°C to +80°C.

5.1.3 Humidity limits

Safe humidity limits are within the range 5 to 95% RH.

MTL5000 Series Isolators

MTL5000 Series Isolators

DX070 DX170 DX430

MTL5000 4.03 1.88 0.82

60

40

20

10

30

50

0

10 20 30 40

Power dissipation (watts)

Max. outside enclosure

temperature (°C)

Enclosures

DX070
DX170
DX430

Figure 5.3: DX170 enclosure showing MTL5000 modules
mounted

Figure 5.4: DX430 enclosure showing MTL5000 modules
mounted

Figure 5.5: Graph depicting outside enclosure temperature
limits for DX enclosures used with MTL5000 Series isolators

Figure 5.6: Optimum orientation for wall-mounted enclosure

9

INM5000-6 Jul 2010

Table 5.3: Typical mix of MTL5000 Series modules

Table 5.4: Power versus maximum outside enclosure temperature

5.1.4 Corrosion resistance

The effect of corrosion on DX enclosures is negligible.

5.1.5 Flammability rating

The flammable properties of the materials used in the construction of the
enclosures are well understood by manufacturers and ratings have been
established to a number of standards. One of the better known
standards is the Underwriter's Laboratory standard UL 94 and the
ratings for the enclosure materials are given as:

Materials UL94 rating
Polycarbonate (all lids) V2/V0
Polycarbonate with glass reinforcement (DX070 base) V1/V0
Polyester with glass reinforcement (DX170 & DX430 bases) V0
Items made from similar materials are well established as suitable for use

in process I/O marshalling areas.

5.1.6 Impact resistance

The enclosure designs have been tested to an impact resistance of
greater than 2 Joules which exceeds the BS EN 61010-1 requirements
of 0.5 Joules.

5.1.7 Chemical resistance

The overall chemical resistance of the enclosures is limited by the
resistance of the transparent polycarbonate lid. The glass-reinforced
polycarbonate/polyester (GRP) bases have a higher resistance than
plain polycarbonate. Table 5.5 lists qualitative evaluations of resistance
to a variety of chemical agents.

5.2 Mounting

5.2.1 General

These instructions are concerned solely with mounting the DX enclosures.
Instructions for wiring and testing individual modules within the
enclosures are provided in Section 6.

Sufficient space is provided within the enclosures to accommodate
tagging and earth-rail accessories but this is at the expense of a
reduction in the number of modules that can be fitted.

5.2.2 Location and orientation

5.2.2.1 Location

The DX enclosures are intended for safe (non-hazardous) area use.
In N. America or Canada (because the enclosures are rated NEMA 4X)

they can be used in Class 1, Division 2 (gases) location, but check with
local requirements and ensure all cable entries also conform. In this case,
an additional warning label will be required on or near the enclosure
warning that the MTL5000 interfaces must not be removed unless the
area is known to be non-hazardous. The enclosures are NOT suitable
for Class II or III, Division 2 hazardous locations.

5.2.2.2 Orientation

As noted earlier (see section 5.1.1 and figure 5.6), for optimum
temperature performance the enclosures should be mounted on a vertical
surface with the internal DIN rail horizontal.

5.2.3 Mounting details

See figures 5.7 to 5.9 for the dimensions and mounting hole distances,
etc., of the three DX enclosures. The recommended method of mounting­described here-uses the four wall-mounting lugs supplied with each
enclosure. An alternative method of mounting is by direct attachment to
the mounting surface through the corner holes.

Note: When the wall-mounting lugs are used to attach the enclosures,
the overall depth of the enclosure is increased by an additional 3.3 mm
(DX070) or 7 mm (DX170 and DX430).

a) At each of the four corner fixing holes, insert one of the

screws provided and use it to attach a fixing lug to the
base of the enclosure.

b) Each lug can be used in one of two positions as shown in

figures 5.7 to 5.9.

c) Attach the lugs to the mounting surface with suitable fasteners.
d) Diameters of fixing holes in lugs are 5.5mm (DX070) and

7.0mm (DX170 and DX430)

e) Appropriate fixing hole distances are shown in figures 5.7

to 5.9.

Power dissipation Maximum outside

Enclosure Modules installed of modules in watts (P) enclosure temp. (T

MO

)°C

DX070 2xMTL5011B + 2xMTL5044 (2x0.75) + (2x1.5) = 4.5 41.9
DX170 5xMTL5011B + 5xMTL5044 (5x0.75) + (5x1.5) = 11.25 38.9
DX430 13xMTL5011B + 13xMTL5044 (13x0.75) + (13x1.5) = 29.25 36.0

Table 5.5: Qualitative evaluations of resistance to various
chemical agents

Qualitative evaluation

Chemical agents of resistance

Salt water; neutral salts; acids (low concentrations); hydraulic oil Excellent
Alcohols Very good
Acids (high concentrations); alkalis (low concentrations); petrol; cooling fluids Good
Alkalis (high concentrations); solvents. Poor

Number of k

1

Power dissipation Maximum outside

Enclosure installed modules °C/watt of modules in watts (P) enclosure temp. (T

MO

) °C

DX070 4 4.03 4.0 43.9

4 4.03 6.0 35.8

DX170 10 1.88 10.0 41.2

10 1.88 15.0 31.8

DX430 26 0.82 21.6 42.3

26 0.82 39.0 28.0

5.2.4 Cable glanding

All cables into the enclosures must be glanded to IP65 standards to
maintain this rating for the enclosure as a whole. Cable glands and
gland plates are not supplied. Glanding requirements vary for each
enclosure as follows:

DX070

On the DX070, 'knockout' holes are provided, in two different sizes
(15.5 mm and 21 mm), on the side faces of the base. See table 5.7 for
recommended cable glands.

Note: The enclosure may have three or four knockout holes on each
side depending on the manufacturer. Consequently, there may be a
choice of either six or eight positions for cable glands.

DX170

The DX170 can accommodate one gland plate on each side - see figure

5.10 for details. Table 5.6 lists suppliers of suitable gland plate kits and
Table 5.7 lists recommended glands.

DX430

The DX430 can accommodate two gland plates on each side - see figure

5.11 for details. Table 5.6 lists suppliers of suitable gland plate kits and
Table 5.7 lists recommended glands.

10

INM5000-6 Jul 2010

107

137

157

187

Ø 5.5

520

576

249

305

Ø 7.0

Gland plate

Typical gland

positions

Gland plate

Typical gland

positions

249

305

339

395

Ø 7.0

Figure 5.7: Dimensions and location of fixing holes - DX070

Figure 5.8: Dimensions and location of fixing holes - DX170

Figure 5.9: Dimensions and location of fixing holes - DX430

Figure 5.10: Cable gland plate locations on a DX170 enclosure

Figure 5.11: Cable gland plate locations on a DX430 enclosure