Crouse Hinds Mtl4500 4600 Isolating Interface Units Manual

Instruction manual
October 2022
MTL intrinsic safety solutions INM 4500/4600 Rev 13
MTL4500/4600 range
Isolating interface units
DECLARATION OF CONFORMITY
A printed version of the Declaration of Conformity has been provided separately within
the original shipment of goods. However, you can find a copy of the latest version at:
http://www.mtl-inst.com/certificates
ii INM 4500/4600 Rev 13

CONTENTS
DECLARATION OF CONFORMITY. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . II
IMPORTANT NOTE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . v
ATEX/UKCA/IECEx SAFETY INSTRUCTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . vi/vii
1 INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.2 The MTL4500 concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.3 The MTL4600 concept . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
2 MTL4500 RANGE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

2.1 Standard backplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.2 Customised backplanes. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
2.3 Accessories. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3 INSTALLATION – PRECAUTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.1 General . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
3.2 Precautions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
4 BACKPLANE INSTALLATION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.1 Backplane mounting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
4.2 Identification and tagging . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
4.3 Backplane earth rails . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.4 Backplane electrical connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8
4.5 Backplanes – customised . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
4.6 Backplanes - module clip replacement. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10
5 INSTALLATION – MODULES . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.1 Modules – pre-installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
5.2 Modules – installation. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12
6 UNIT DESCRIPTIONS, SETTING-UP AND CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

6.1 Digital Input modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.1 Phase reversal. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.2 Line-Fault Detection (LFD). . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
6.1.3 MTL4501-SR - Fail-safe Switch/Proximity detector interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16
6.1.4 MTL4504 - Switch/Proximity detector interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
6.1.5 MTL4510 & MTL4510B - Switch/Proximity detector interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
6.1.6 MTL4511 - Switch/Proximity detector interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
6.1.8 MTL4514/MTL4514B/MTL4514D - Switch/Proximity detector interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . 24
6.1.9 MTL4514N - Switch/Proximity detector interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 25
6.1.11 MTL4516C - Switch/Proximity detector interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27
6.2 Digital Output modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.1 MTL4521/MTL4521L - Solenoid Alarm driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29
6.2.2 MTL4523/MTL4523R - Solenoid Alarm driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30
6.2.3 MTL4523L - Solenoid Alarm driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
6.2.4 MTL4523V/MTL4523VL - Solenoid Alarm driver . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6.2.5 MTL4524 - Solenoid Alarm driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.2.6 MTL4524S - Solenoid Alarm driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.2.7 MTL4525 - Solenoid Alarm driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35
6.2.8 MTL4526 - Switch operated relay . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36
6.3 Pulse and Vibration modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .37
6.3.1 MTL4531 - Vibration Transducer Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37
6.3.2 MTL4532 - Pulse Isolator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38
6.3.3 MTL4533 - Vibration Transducer Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
(continued on next page)
iii INM 4500/4600 Rev 13

6.4 Analogue Input modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4.1 MTL4541/MTL4541S/MTL4541Y - Repeater Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
6.4.2 MTL4541A/MTL4541AS/MTL4541YA - Current Repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
6.4.3 MTL4541B/MTL4541P/MTL4541T - Repeater Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43
6.4.4 MTL4544/MTL4544S - Repeater Power Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44
6.4.5 MTL4544A/MTL4544AS - Current Repeater . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45
6.4.6 MTL4544B - Repeater Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 46
6.4.7 MTL4544D - Repeater Power Supply. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47
6.5 Analogue Output modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5.1 MTL4545Y/MTL4546/MTL4546C/MTL4546S/MTL4546Y - Isolating Driver. . . . . . . . . . . . . . . . . . . . . . . . . . 48
6.5.2 MTL4549/MTL4549C/MTL4549Y - Isolating Driver. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49
6.6 Fire and Smoke Interface modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.6.1 MTL4561 - Fire and Smoke Detector Interface. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 50
6.7 Temperature Input module . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
6.7.1 MTL4573 - Temperature Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52
6.7.2 MTL4575 - Temperature Converter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 53
6.7.3 MTL4576-RTD - Temperature Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54
6.7.4 MTL4576-THC - Temperature Converter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 55
6.7.5 MTL4581 - mV/Thermocouple Isolator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 56
6.8 General modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.8.1 MTL4599 - Dummy Isolator. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.8.2 MTL4599N - General purpose feedthrough module. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57
6.9 PCS45/PCL45USB configurator for MTL temperature converters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58
7 FAULT FINDING AND ROUTINE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

7.1 Maintenance precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.2 Fault finding . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
7.3 Routine maintenance. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59
8 BENCH TESTING MODULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

8.1 Digital Input (DI) modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61
8.2 Digital Output (DO) modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .62
8.3 Analogue Input (AI) Modules . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63
8.4 Analogue Output (AO) Modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
8.5 Testing the functioning of other modules. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 65
9 APPLICATIONS INVOLVING ZONE 2 AND/OR ZONE 22 HAZARDOUS AREAS . . . . . . . . . . . . . . . . . . 66

9.1 Enclosure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 66
10 APPENDIX. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.1 Table A - Safety descriptions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67
10.2 Table B - Maximum cable parameters. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 68
© 2022 Eaton Electric Limited. All rights reserved.
iv INM 4500/4600 Rev 13

IMPORTANT NOTE
This manual describes the installation and use of:
• MTL4500 range of isolating interfaces for Intrinsic Safety
• MTL4600 range of signal conditioners
The MTL4500 range of products are intended for protection of hazardous areas in process
plants that apply Intrinsic Safety techniques.
Although functionally similar to the MTL4500 range, the MTL4600 range of isolator
modules are NOT certified or approved for connection to hazardous area circuits.
To ensure both the segregation of equipment and the requisite separation of wiring,
operation and maintenance activities, it is recommended that the MTL4500 and the
MTL4600 range of modules are NOT mounted on the same backplane.
The use of separate backplanes for I.S. and non-I.S. signals reduces the possibility of
confusion over ‘safe operating practice’ and is strongly recommended.
MTL4500 range of products

WARNING !
This manual has content describing 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 2014/34/EU [the ATEX Directive - safety of
apparatus] then consult the ATEX safety instructions for safe use in this manual before
installation.
Note: Refer to the website for multiple language safety instructions.
ELECTRICAL PARAMETERS
Refer to the certification documentation for the electrical rating of these products.
CERTIFICATION DOCUMENTATION
Our website http://www.mtl-inst.com contains product documentation regarding
intrinsic safety certification for many locations around the world. Consult this data for
information relevant to your local certifying authority.
FUNCTIONAL SAFETY
If the MTL4500 range of products are to be used in functional safety applications check
that each module has been asssessed for that service and refer to the Safety Manual
for details.
REPAIR
MTL4500 range of products MUST NOT be repaired. Faulty or damaged products must
be replaced with an equivalent certified product.
CLEANING
Should modules require cleaning, use water only on a damp cloth.
CAUTION - CAUTION -
Read the instructions Hot surface
Symbols used on the product and in this manual
v INM 4500/4600 Rev 13

ATEX/UKCA/IECEx SAFETY INSTRUCTIONS
The following information is in accordance with the Essential Health and Safety
Requirements (Annex II) of the EU Directive 2014/34/EU [the ATEX Directive - safety
of apparatus), and Schedule 1 of the Equipment and Protective Systems Intended for
Use in Potentially Explosive Atmospheres Regulations 2016 (UK S.I. 2016/1107) and
is provided for those locations where the ATEX Directive or UKCA regulations are
applicable.
General
a) This equipment must only be installed, operated and maintained by competent
personnel. Such personnel shall have undergone training, which included instruction
on the various types of protection and installation practices, the relevant rules and
regulations, and on the general principles of area classification. Appropriate refresher
training shall be given on a regular basis. [See clause 4.2 of IEC/EN 60079-17].
b) This equipment has been designed to provide protection against all the relevant
additional hazards referred to in Annex II of the ATEX directive (such as clause 1.2.7)
or Schedule 1 of the UK regulation (such as clause 13).
c) This equipment has been designed to meet the requirements of IEC/EN 60079-0, IEC/
EN 60079-7, IEC/EN 60079-11 and IEC/EN 60079-15.
Installation
a) The installation must comply with the appropriate European, national and local
regulations, which may include reference to the IEC code of practice IEC/EN 60079-
14. In addition, particular industries or end users may have specific requirements
relating to the safety of their installations and these requirements should also be
met. For the EU, Directive 1999/92/EC [the ATEX Directive - safety of installations} is
also applicable. For the UK, the Dangerous Substances and Explosive Atmospheres
Regulations 2002 (DSEAR) is also applicable.
b) This apparatus is an associated electrical apparatus and is normally mounted in a non-
hazardous [safe] area. The equipment may be installed in a Zone 2 location providing
that equipment is covered by a suitable certificate and the relevant installation
conditions are met. Refer to “Special Conditions for Safe Use – Zone 2 mounting”
below.
c) Unless already protected by design, this equipment must be protected by a suitable
enclosure against:
i) mechanical and thermal stresses in excess of those noted in the certification
documentation and the product specification
ii) aggressive substances, excessive dust, moisture and other contaminants.
Read also the Special Conditions for Safe Use (below) for any additional or more specific
information.
Special Conditions of Safe Use for Zone 2 applications

a) When used in Zone 2, the equipment must be installed in an enclosure
or an environment that provides a degree of protection of at least IP54
and meets the relevant material and environmental requirements of
IEC/EN 60079-0 and IEC/EN 60079-15.
b) The equipment must not be inserted or removed unless either:
i) the area in which the equipment is installed is known to be non-
hazardous or
ii) the circuit to which it is connected has been de-energised.
c) The 24V supply for this equipment must be derived from a regulated
power supply complying with the requirements of European
Community Directives.
d) For MTL4511, MTL4514, MTL4514B, MTL4514D, MTL4516, MTL4516C,
MTL4517, MTL4526 & MTL4532 only: Relay contacts may switch up to
35V, 2A and 100VA.
For MTL4575: Relay contacts may switch up to 35V, 250mA.
e) Any backplane used does not form part of this certificate and shall be
separately certified for use in Zone 2.
vi INM 4500/4600 Rev 13

f) The associated backplane must be fitted with MTL4500 retention clips
(use type MCK45 if not fitted) that allow the equipment to be ‘clipped’
to the backplane. The retention clips shall always be in place when the
equipment is energised.
g) For 4573 Maximum Input/Output parameters – see certificate

h) Special Conditions will vary on individual certificates.
Inspection and maintenance

a) Inspection and maintenance should be carried out in accordance with European,
national and local regulations which may refer to the standard IEC/EN 60079-17.
In addition specific industries or end users may have specific requirements which
should also be met.
b) Access to the internal circuitry must not be made during operation.
Repair
a) This product cannot be repaired by the user and must be replaced with an equivalent
certified product.
Marking
Each device is marked in compliance with the EU Directive and UK regulation, and
CE and UKCA marked accordingly.
Example label showing markings:
MTL4541B Repeater power supply, 4/20mA, for 2 or 3 wire transmitters
Hazardous area -20°C Ta +60°C

Um = 253V
II(1)GD [Ex ia Ga] IIC, [Ex ia Da] IIIC
4/20mA I(M1) [Ex ia Ma] I Baseefa 06ATEX0156
BAS21UKEX0468
[Ex ia Ga] IIC, [Ex ia Ma] I, [Ex ia Da] IIIC
IECEx BAS 06.0034
4/20mA II 3 G
Ex nA IIC T4 Gc
MTL08ATEX4541X
1 2 3
Ex nA IIC T4 Gc IECEx BAS 15.0118X
4 5 6
Associated apparatus providing
IS circuits for
FM CL I II III, DIV 1, GP ABCD
CL I DIV 2 GP ABCD T4
US: CL I ZN 2 AEx nA IIC T4
CA: CL I ZN 2 Ex nA IIC T4
FM16US0173 US: CL I ZN 0 [AEx ia] IIC
FM16CA0102 CA: CL I ZN 0 [Ex ia] IIC
Install as per SCI-1028
SUITABLE FOR USE IN
7 8 9 10 11 12 13 14 CLI, DIV2 GRPS ABCD HAZ LOC
WITH IS CONNECTIONS TO CLI,
GRPS ABCD; CLII, GRPS EFG
Vs+ & CLIII, T4. HAZ LOC, WHEN
4/20mA Vs- INSTALLED AS PER SCI-1036
Um = 250V
Load 20 - 35V dc
PROC. CONT. EQ. (ASSOCIATED APPARATUS)
1.3W Max FOR USE IN HAZ LOC.
Safe area EU Importer – Eaton, 69412 Eberbach, Germany
EATON ELECTRIC LTD, Luton, England,

LU2 8DL. Made in England. www.mtl-inst.com
!
N695
0598 1180
vii INM 4500/4600 Rev 13

This page is left intentionally blank
viii INM 4500/4600 Rev 13

1 INTRODUCTION
1.1 General
This instruction manual describes the procedures for installing, connecting, checking and
maintaining MTL4500/4600 range of isolating interfaces and accessories. The MTL4500
products provide an intrinsically safe (IS) interface to a hazardous area of a process plant,
while the MTL4600 range is exclusively for non-hazardous area service.
The individual sections cover the following topics
• Section 2 describes the range and its accessories
• Section 3 specifies precautions before installation
• Section 4 covers the installation of backplanes
• Section 5 describes the installation of modules onto the backplanes
• Section 6 provides relevant technical data
• Section 7 outlines fault-finding and maintenance
• Section 8 describes bench test procedures
• Section 9 provides hazardous-area application information
• Section 10 provides safety parameter information
1.2 The MTL4500 concept

The MTL4500 range of modules and accessories are designed for use with process
connected systems. It consists of compact isolating interface modules mounted on
backplanes, which carry safe-area signals and power supplies. Hazardous-area circuits
connect to the blue terminals on the modules. Backplanes can be integrated into a user’s
process system architecture or mounted in separate enclosures.
1.3 The MTL4600 concept

The MTL4600 range of modules and accessories are designed for use with process
connected systems, but in non-hazardous area applications. They are based on the MTL4500
range but have been given a separate identity to avoid the burden of administration
previously associated with the use of IS modules in non-IS applications. Field equipment,
located in non-hazardous areas, connects to the grey terminals on the modules.
Most of the mechanical and electrical characteristics shared by the two ranges are identical.
The information contained in this manual relates specifically to the MTL4500 range of
products; however, where an MTL4600 version of the module exists, the information is also
applicable unless otherwise specified.
1 INM 4500/4600 Rev 13

The table below lists the related products in the MTL4500/4600 ranges. Please refer to the
MTL4500 data provided in this manual for both ranges. Any variation from the MTL4500
specification is indicated. Refer also to the individual MTL4500 and MTL4600 data sheets.
MTL4500/4600 modules
Digital Input Channels Function
MTL4501-SR – 1 fail-safe, solid-state output + LFD alarm
MTL4504 MTL4604 1 switch/prox input, phase reversal + LFD
MTL4510 MTL4610 4 switch/prox input, solid-state output
MTL4510B – 4 multi-function, switch/prox input, solid-state output
MTL4511 MTL4611 1 switch/prox input, c/o relay output
MTL4513 MTL4613 2 switch/prox input, solid-state output
MTL4514 MTL4614 1 switch/prox input, relay + LFD
MTL4514B – 1 switch/prox input, relay + LFD
MTL4514D – 1 switch/prox input, relay + LFD
MTL4514N – 1 switch/prox input, LFD passthrough
MTL4516 MTL4616 2 switch/prox input, relay + LFD outputs
MTL4516C – 2 switch/prox input, relay + LFD outputs
MTL4517 MTL4617 2 switch/prox input, c/o relay + LFD outputs
Digital Output
MTL4521 MTL4621 1 loop-powered solenoid driver
MTL4521L – 1 low powered, loop-powered, IIC
MTL4521Y – 1 loop-powered solenoid driver
MTL4523 MTL4623 1 solenoid driver with LFD
MTL4523L MTL4623L 1 loop- powered solenoid driver with LFD
MTL4523R MTL4623R 1 solenoid driver with reverse LFD
MTL4523V – 1 solenoid driver with LFD + voltage control, IIC
MTL4523VL – 1 solenoid driver with LFD + voltage control, IIC
MTL4523Y – 1 solenoid driver with LFD + voltage control, IIC
MTL4524 MTL4624 1 switch operated solenoid driver
MTL4524S MTL4624S 1 switch operated solenoid driver, 24V override
MTL4525 – 1 switch operated solenoid driver, low power
MTL4526 MTL4626 2 switch operated relay
Pulse & Vibration Output
MTL4531 – 1 vibration probe interface
MTL4532 MTL4632 1 pulse isolator, digital or analogue output
MTL4533 – 2 vibration probe interface
Analogue Input
MTL4541 MTL4641 1 2/3 wire transmitter repeater
MTL4541A MTL4641A 1 transmitter repeater, passive input
MTL4541AS MTL4641AS 1 transmitter repeater, passive input, current sink
MTL4541S MTL4641S 1 2/3 wire transmitter repeater, current sink
MTL4541T – 1 2/3 wire transmitter repeater
MTL4541Y – 1 2/3 wire transmitter repeater
MTL4541YA – 1 transmitter repeater, passive input
MTL4544 MTL4644 2 2/3 wire transmitter repeater
MTL4544A MTL4644A 2 transmitter repeater, passive input
MTL4544AS MTL4644AS 2 transmitter repeater, passive input, current sink
MTL4544S MTL4644S 2 2/3 wire transmitter repeater, current sink
MTL4544D MTL4644D 1 2/3 wire transmitter repeater, dual output
Analogue Output
MTL4545Y – 1 4-20mA smart isolating driver + oc LFD
MTL4546 MTL4646 1 4-20mA smart isolating driver + LFD
MTL4546C – 1 4-20mA smart isolating driver + oc LFD
MTL4546S – 1 4-20mA smart isolating driver + oc LFD
MTL4546Y MTL4646Y 1 4-20mA smart isolating driver + oc LFD
MTL4549 MTL4649 2 4-20mA smart isolating driver + LFD
MTL4549C – 2 4-20mA smart isolating driver + oc LFD
MTL4549Y MTL4649Y 2 4-20mA smart isolating driver + oc LFD
Fire and Smoke
MTL4561 – 2 loop-powered for fire & smoke detectors
Temperature Input
MTL4573 MTL4673 1 temperature converter, THC or RTD
MTL4573Y – 1 temperature converter, THC or RTD
MTL4575 MTL4675 1 temperature converter, THC or RTD
MTL4576-RTD MTL4676-RTD 2 temperature converter, RTD
MTL4576-THC MTL4676-THC 2 temperature converter, THC
MTL4581 – 1 mV/thermocouple isolator for low level signals
General
MTL4599 – 1 dummy module
MTL4599N – 1 general purpose, feedthrough module
2 INM 4500/4600 Rev 13

2 MTL4500 RANGE DESCRIPTION
Each module has a multi-pin connector in its base that plugs into a matching connector on
the backplane. This connector carries all appropriate safe-area circuits and power supplies.
Additional multiway connectors, located at the front of the module, accept the wiring from
the hazardous-area circuits. All connectors are keyed so that connections cannot be made
the ‘wrong way round’.
Status LEDs and configuration ports (where appropriate) are located on the front of the
modules for easy access, and full dc isolation is provided between the input and output so
that the modules are intrinsically safe without needing an earth.
2.1 Standard backplanes

MTL4500 range of standard backplanes, with quick-release clip connectors, accommodate
4, 8, 16 or 24 modules. The backplane carries the safe-area signals and distributes dual-
redundant 24V dc power supplies with three-point status monitoring. In applications
where a number of 8- and 16-way backplanes are installed, the power supplies can be
interconnected. Optional earth-rail kits are available for 8- and 16-way backplanes and
tagging-strip kits are available for all backplanes.
2.2 Customised backplanes

If the backplane is to be mounted in a safe area (which is the most common type of
application) then it does not need to be certified, because the hazardous area wiring
connects to the I/O modules, not the backplane. This means that non-hazardous area
backplanes can be produced easily by Eaton, or the user, and can be designed to match
exactly the size, shape, method of mounting, type of connector, pin assignments, etc, of a
particular process system. Please contact Eaton’s MTL product line for further information.
When mounting the backplane in Zone 2/Div 2 hazardous areas refer to our website for
documents detailing any approvals.
2.3 Accessories
Accessories are available that enable the user to mount standard MTL backplanes. These
include surface-mounting kits, T-section and G-section DIN-rail mounting kits and end stops
and a horizontal plate for mounting 24-way backplanes in 19-inch racks.
3 INSTALLATION – PRECAUTIONS
3.1 General
Read this section before beginning to install backplanes, enclosures, modules etc.
3.2 Precautions
a) Make sure that all installation work is carried out in accordance with all relevant local
standards, codes of practice and site regulations.
b) When planning the installation of MTL4500 range it is essential to make sure that I.S.
and non-I.S. wiring is segregated, as required by a nationally accepted authority or as
described in EN 60079-14 or ISA RP 12.6.
c) Check that the hazardous-area equipment complies with the descriptive system
document.
d) If in doubt, refer to the certificate/catalogue for clarification of any aspects of intrinsic
safety, or contact Eaton’s MTL product line or your local representative for assistance.
e) Check that the interface unit(s) function(s) are correct for the application(s).
f) When plugging modules into backplanes and hazardous-area connectors into
modules, check the identification labels to make sure the items match correctly.
g) External power supply shall contain double isolation from hazardous voltages or that
unit shall be supplied by Limited Power Circuit per UL/IEC 60950 or Limited Energy
Circuit per UL/IEC 61010 or Class ll Power Supply per NEC.
h) Environmental conditions: indoor use, altitude (up to 2000m) and humidity less than
95% non condensing.
3 INM 4500/4600 Rev 13

1 3 4 6

MTL45XX

150

Figure 4.1: Standard backplanes with dimensions
4 INM 4500/4600 Rev 13

4 BACKPLANE INSTALLATION
4.1 Backplane mounting

See Figure 4.1 for dimensions and mounting centres andTable 4.1 for a listing of the mounting
options and the kits and accessories applicable to MTL standard backplanes.
Table 4.1: Backplanes, mounting kits and accessories
Backplane Number Safe-area Mounting Kits Accessories

model of connections
Surface DIN-rail 19-inch Earth-rail Tagging Spare
number modules
(T or G) rack kit strip kit fuse pack
CPS04 4 Screw-clamp SMS01 DMK01 – – – FUS1.0ATE5
CPS08 8 Screw-clamp SMS01 DMK01 – ERK08 TSK08 FUS1.0ATE5
CPS16 16 Screw-clamp SMS01 DMK01 – ERK16 TSK16 FUS2.0ATE5
CPS24 24 Screw-clamp SMS01 DMK01 HMP24 – TSK24 FUS4.0ATE5
4.1.1 Surface mounting – with SMS01 mounting kit

Refer to Figures 4.1 and 4.2.

Figure 4.2: Surface mounting

a) Drill mounting surface at centres A (Figure 4.1) and tap, or fit retaining nuts if required.
b) Select the appropriate number of M4 x 20mm screws for the size of backplane
(4 for a 4-way and 8-way, 6 for a 16-way and 8 for a 24-way backplane).
c) Fit each M4 x 20mm screw (1) with a locking washer (2) and a plain washer (3) (Figure 4.2).
d) Insert the screws through the backplane at each mounting centre A.
e) Fit each with an M4 x 10mm spacer (5) and a retaining washer (6) (Figure 4.2).
f) Attach the assemblies to the prepared surface using a suitable nut if the holes are not tapped.
4.1.2 T- or G-section DIN-rail mounting – with DMK01 mounting kit

See Figures 4.1 and 4.3.
6 x 1/2 inch screw (1) 6 x 1/2 inch screw (1)

Locking washer (2) Locking washer (2)
MTL4500 Plain washer (3) MTL4500
backplane Plain washer (3)
backplane
Mounting hole A Spacer (5) Mounting hole A Spacer (5)

Retaining washer (6) Retaining washer (6)
DIN-rail DIN-rail
mounting foot mounting foot
(7) (7)
T-section DIN rail (8) G-section DIN rail (8)
Figure 4.3: Mounting a backplane onto ‘T’ or ‘G’ section DIN rail
a) Cut two pieces of T- or G-section DIN-rail to the required length and fix them side-
by-side with centres spaced appropriately – 132mm (CPS04), 113mm (CPS08/16) or
100mm (CPS24).
5 INM 4500/4600 Rev 13

b) With reference to Figure 4.3, clip the appropriate number of mounting feet (7) to the
DIN rail (8) at centres ‘A’ (4 for each 4/8-way, 6 for each 16-way and 8 for each 24-way
backplane) (Figure 4.3).
c) Select the appropriate number of No. 6 x 1/2-inch screws (1) and fit each with a
locking washer (2) and a plain washer (3) (Figure 4.3).
d) Insert the assemblies through the mounting holes A on the backplane (Figures 4.1 and
4.3).
e) Fit spacers (5), retaining them with the washers (6) (Figure 4.3).
f) Locate the assemblies over the mounting feet and attach the screws (1) to the feet
(Figure 4.3).
NOTE: For vertically orientated backplanes it is recommended that end stops with screw
fixings are fitted on the DIN rails immediately below the lowest backplane fixing. This will
avoid the chance of backplane slippage down the DIN rail.
4.1.3 19-inch rack mounting – CPS24 backplanes with HMP24 mounting plate
See Figure 4.4.
a) Place an unloaded backplane onto the HMP24 mounting plate.

b) Attach the backplane to the mounting plate at centres A with the eight M4 x 12mm
screws provided.
c) Attach the assembly to the 19-inch rack centres at D.

Figure 4.4: 19-inch rack mounting

4.2 Identification and tagging

Backplane labelling facilities include marked areas for identifying backplanes, specific module
locations and system connections (multiway backplanes only). Mounting holes for earth-rail
and tagging-strip attachments are similarly marked
4.2.1 Backplane identification labels

a) Attach a suitably marked label to the area marked BACKPLANE IDENT to identify an
individual backplane (Figure 4.5).
b) Attach suitably marked MPL01 module position labels to the areas marked MODULE
IDENT (Figure 4.5).
4.2.2 Tagging strip mounting kit (TSK08, TSK16, TSK24)

See Figures 4.1, 4.6 and 4.7.
a) Attach the tagging strip mounting posts (1) at backplane centres B (Figure 4.1) using
two M3 x 12mm mounting screws (2) and washers (3) (Figure 4.6).
b) Attach colour coding labels (4) to the tag label (5) (Figure 4.6). See Table 4.2 for
suggested colour codes for individual modules.
c) Mark the tag label (5) with the tag reference.
d) Slide the tag label (5) into the plastic holder (6) and retain with a plastic rivet (9)
(Figure 4.6).
e) Attach the plastic retaining tie (7) with two plastic rivets (8) (Figure 4.6).
f) Clip the tag strip holder (6) onto the mounting posts (1) by pushing it downwards
(Figure 4.7).
g) If required, swivel the tagging strip vertically (Figure 4.7)
6 INM 4500/4600 Rev 13

Colour Module no. Function
MTL4501-SR
Yellow
MTL4504 Digital Inputs
White MTL451x
Red MTL452x Digital Outputs

Blue MTL4531/33 Vibration
Purple MTL4532 Pulse
MTL4541x
Blue Analogue Inputs
MTL4544x
MTL4546x
Green Analogue Outputs
MTL4549x
Blue MTL456x Fire & Smoke
MTL457x
Orange Temperature inputs
MTL4581
Grey MTL4599 Dummy isolator
Table 4.2: MTL4500 front label colour coding

Figure 4.5: Locations for labels and attachments

Figure 4.6: Mounting a tagging-strip post

Figure 4.7: Attaching and swivelling a tagging-strip
7 INM 4500/4600 Rev 13

4.3 Backplane earth rails
Optional earth rails are available for 8- and 16-way backplanes (kits ERK08 and ERK16
respectively). Cable screens from hazardous-area circuits, or spare pairs from a multicore
cable, can be connected to the terminals on the earth rails, which are mounted on the
backplane at about the same height as the front of the modules, close to the hazardous-
area connectors. Proceed as follows.
4.3.1 Earth rail kit (ERK08 and ERK16)

See Figures 4.1 and 4.8.
a) Locate the earth rail mounting posts (1) at backplane centres C (Figures 4.1 and 4.8).
b) Attach the mounting posts (1) with M3 x 12 screws (3) and washers (4).
c) Slide the earth rail (5) through the slots in the of the mounting posts (1).
d) Fit the earth terminal(s) (6) on the rail (5).
e) Attach plastic retaining rivets (7) to each end of the earth rail (5).

Figure 4.8: Earth rail post kit details
4.4 Backplane electrical connections

Safe-area circuit connections are made to the backplane by fixed screw-clamp terminals.
Power supply connections are also made to the backplanes via pluggable screw-terminal
connectors.
For optimum EMC performance, cables from local power supplies should not exceed 10m
in length.
See section 4.4.2 for details, section 4.4.3 for a procedure to interconnect power supplies
on multiple 8- and 16-way backplanes, and section 4.4.4 for details of connecting power
supplies on
24-way backplanes.
4.4.1 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. Torque
range 0.4Nm to 0.6Nm.
If the wires are to be fitted with crimp ferrules, the following is a list of those recommended
with required trim lengths for each:
Plug Entry Wire size Metal tube Trim Recommended ferrules

type (mm2) length (mm) length
Signal Single 0.75 12 14 Weidmuller 902591
Signal Single 1.0 12 14 Cembre PKC112
Phoenix Contact
Signal Single 1.0 12 14
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
† These ferrules with 18mm length metal tubes 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
8 INM 4500/4600 Rev 13

4.4.2 Safe-area - signal connections
Each module position is provided with a 6-way split-level terminal block for safe-area signals.
The six terminals reproduce the module terminals numbered 7 to 12 as shown in Figure 4.9.

Figure 4.9:
Terminal pin
assignments

a) Make the appropriate connections to the terminal block in accordance with the pin
assignment numbers reproduced in Figure 4.9.
b) Wire entry for each terminal is from the side of the block.
c) The maximum permissible wire gauge is 2.5mm2 (14 AWG).
4.4.3 Safe area – power supply connections (8- and 16-way backplanes)
Dual-redundant 24V DC power supplies can be connected to each backplane using plug-in
connectors. The supplies are connected in parallel, through diodes, and bussed by the
backplanes to individual isolators. LEDs on the backplane will light to show that the two
independent supplies are operational. The diodes between the two supplies means that the
one with the higher voltage is used at any given moment, but provide automatic switchover
of supplies if one source fails.
Primary
+ PWR 1 PWR 2 Secondary
Power Power
Supply Supply
+
Figure 4.10: SKT 1 SKT 2
PSU connections
8- & 16-way
0V PWR1 0V PWR2
a) Connect each of the two 21V to 35V dc power supply connectors to the independent
supply sources according to the terminal assignments shown in Figure 4.10. The
maximum permissible wire size is 2.5mm2 (14 AWG).
b) Plug the power supply connectors into the base connectors on the backplanes.
c) The fuses on the backplanes are rated as follows:-
8-way: 1A (FUS1.0ATE5) 16-way: 2A (FUS2.0ATE5)
4.4.4 Interconnecting power supplies for multiple 8- and 16-way backplanes
Power supplies for 8- and 16-way backplanes can be interconnected in the form of a ring.
This can reduce wiring and also permits individual backplanes to be taken out of service
without affecting supplies to the other backplanes.
0V
+
0V
1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 1 2 3 4 5 6 7 8 +
BPS4508
BPS4508
BPS4508
PWR1 – This ‘ring’ wiring configuration can

PSU + be repeated for the PWR2 supply
Figure 4.11: “Ring main” wiring for DC power
9 INM 4500/4600 Rev 13

More than one backplane can be removed, provided that they are immediate neighbours
and ensures that other backplanes are not left without an active supply. The connection
method is shown in Figure 4.11.
Note: a mixture of 8- and 16-way backplanes can be interconnected, provided that the
maximum circuit current does not exceed 12A. Wire sizes up to 2.5mm2 (14 AWG) can be
used and should be chosen after calculating the voltage drop for the current load.
4.4.5 Safe area – discrete power supply connections (24-way backplanes)

Dual-redundant 24V DC power supplies can be connected to each backplane using plug-
in connectors. The supplies are connected in parallel, through diodes on the backplane,
and bussed to individual isolators. LEDs on the backplane will light to show that the two
independent supplies are operational. The diodes between the two supplies means that the
one with the higher voltage is used at any given moment, but provide automatic switchover
of supplies if one source fails.

Figure 4.12:
PSU connections
24-way

a) Connect the power supply cables to the connector according to the pin assignments
shown in Figure 4.12. The maximum permissible wire size is 2.5mm2 (14 AWG).
b) Plug the power supply connector into the base connector on the backplane.
c) The rating of the fuse is:– 24-way: 4.0A (FUS4.0ATE5 fuse kit)
4.5 Backplanes – customised

For information about installing customised backplanes (whether supplied by Eaton or by a
third party), see the separate instructions provided with the units.
4.6 Backplanes - module clip replacement

Any broken module retaining clips must be replaced to maintain safe operation. Clips are
constructed in moulded strips of four and are secured to the backplane with plastic rivets.
Spare sets are available as part number SCK45 which contains 10 strips of four clips plus
40 rivets.
Figure 4.13:
Module clips
and rivets
4.6.1 Changing a damaged strip

a) Identify the strip of four clips that includes the damaged clip and remove the modules
that are retained by that strip.
b) Using a small pointed tool, such as a small screwdriver, push out from the underside
the four rivets securing the clips and remove the strip.
c) Fit a new strip of four clips and insert new rivets, pressing them in fully. Do not reuse
the existing rivets as they will be deformed by previous use.
10 INM 4500/4600 Rev 13

5 INSTALLATION – MODULES
IMPORTANT
• Work should be carried out in accordance with all relevant local standards, codes of
practice and site regulations.
• Check that the hazardous-area equipment complies with the descriptive system
document.
• Refer to the certificate/catalogue for clarification of any aspects of intrinsic safety or
contact Eaton’s MTL product line or your local representative for assistance.
• Make sure the correct hazardous-area connector (field-wiring plug) is plugged into the
corresponding isolator. It is recommended that the connector is identified by the same tag
number as the matching isolator.
5.1 Modules – pre-installation

5.1.1 Switch settings for operating conditions
Some modules have operating conditions, such as Line-Fault Detection (LFD), Phase
Reversal, etc., that can be established by the setting of switches on the unit. The
subminiature switches are accessible through an aperture on the side of the module (see
Figure 5.1) and can be set in the required positions with, for example, the blade of a small
screwdriver.
Figure 5.1:
Location of
switches
1234
OFF position
ON position
The switch setting options are always indicated on the side label of the module, but the user
may also consult the individual module information in Section 6 of this manual for details.
5.1.2 Relay outputs

Reactive loads on all units with relays should be adequately suppressed. To achieve maximum
contact life on all mechanical output relays, the load should not be less than 50mW, e.g. 10mA
at 5V DC.
5.1.3 Ambient temperature considerations

The MTL4500 range of isolators are rated for an ambient operating temperature range of
–20°C to +60° even when they are mounted (close-packed) on a backplane, except where
otherwise noted.
5.1.4 Module and backplane orientation

The orientation of the backplane will have an influence on the amount of air flow through
and around the modules, so this must be considered if this operating temperature range is
to be maintained. There are two main orientations for the backplanes, as shown in Figure 5.2.
Although orientation b), where the modules are aligned in a vertical plane, is the optimum for
heat transfer, orientation a), where the modules are horizontal, is the most frequent because it
is probably the most convenient for cabling.
5.1.5 Cabinet and enclosure mounting

The backplanes are normally mounted with other equipment in an enclosure or wiring cabinet,
so particular consideration must be given to the management of the internal temperature and
the need to remove heat from around the modules. Space around the modules is essential for
the free movement of air and adequate ventilation is required for its removal.
The larger the source of heat, the higher it should be mounted in the cabinet, this is in order
to avoid the creation of an undesirable temperature gradient from the bottom of the cabinet to
the top.
Principal sources of heat in such circumstances are ac/dc power supplies for the internal
equipment. These should certainly be located at the top of the cabinet to limit the effect of their
dissipated heat.
11 INM 4500/4600 Rev 13

a) b)
Figure 5.2: Backplane orientations when mounted in cabinets
Clearly, the temperature of the air surrounding the cabinet must also be considered. In
a control room environment with control and maintenance staff present, this should be
reasonably well defined, but other locations may require additional shielding to reduce the
exposure to excess heat or cold.
Ventilation for modest amounts of dissipation can be achieved by natural convection but, for
larger sources of heat, forced movement of air with fans is normally required. If orientation
a) (see diagram) is used, then forced ventilation is recommended to ensure adequate air
movement around the modules.
The cabinet manufacturer should be approached for best advice on how much ventilation can
be achieved by natural convection, or else on the quantity of fans required for forced cooling.
Table 5.1 shows some typical figures for the permitted power dissipation in a cabinet 2200mm
high x 600mm wide x 500mm deep, with front and rear doors. This should only be taken as a
rough guide and appropriate calculations should be carried out to assess the true figures.
Air flow Natural Forced Forced 500m³/ Forced 1000m³/

requirements convection 250m³/hour hour hour
Watts per cabinet
300 420 550 600
@ 25°C
Watts per cabinet
260 350 450 470
@ 35°C
Table 5.1: Typical air flow volumes in cabinet
5.2 Modules – installation

5.2.1 Signal conductors
The removable, field-device, signal connectors are located on the front of the module.
They are fitted with screw clamp terminals and mechanically keyed to fit only in the
correct position. Note that the conductors should be between 14 and 24 AWG (1.6 and
0.5mm dia) in size.
5.2.2 Electrical connections

See Figure 5.3 and also Section 4.4.1 on page 8for details on choosing ferrules.
a) Trim back the insulation for solid
conductors by 12mm (or to the length shown in
the table on page 8 when fitting a ferrule for
stranded wire).
b) Check the module 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. Torque range
0.4Nm to 0.6Nm.
Note: Smaller section wire than that stated can
be used successfully if care is taken to ensure
that the wire is properly secured after crimping
the ferrule.
Figure 5.3:
Hazardous-area connector (blue)
Non-hazardous area connector (grey)
12 INM 4500/4600 Rev 13

5.2.3 Finishing
Connect individual isolators in accordance with wiring schedules.
Ensure hazardous- and safe-area wiring is segregated into separate trunking or looms
and maintain a tidy installation.
Use an MTL4599 dummy isolator to provide termination and earthing for unused cores
from the hazardous area.
5.2.4 Module mounting and removal

Check for the correct orientation of the module then locate it between the latching clips.
Press the module straight onto the backplane. See Figure 5.4.
To remove the module, unclip the latch nearest the CE mark shown on the module label
and rotate the module away from this latch. When the module is unplugged from the
power connector, move the module clear of the other latch and remove it. See Figure 5.5.
Figure 5.4: Mounting a module onto a backplane
Figure 5.5: Removing a module from a backplane
13 INM 4500/4600 Rev 13

6 UNIT DESCRIPTIONS, SETTING-UP AND CONNECTIONS
This section describes the function (briefly), the setting-up procedure and the wiring
connections for each MTL4500 range of unit. For a fuller functional description and a detailed
technical specification, refer to the individual datasheets, which can be found on our website
at http://www.mtl-inst.com or in the current MTL IS catalogue.
If a fault is suspected, first check that the power LED is lit (not applicable to loop-powered
devices). If necessary, check that all signal and power plugs are properly inserted, that no
wires are loose and that the unit is mounted correctly. If operation is still suspect, the unit
should be replaced with a servicable unit.
There are no replaceable parts inside the MTL4500 range of units, so any that appear to be
inoperative should be returned to the manufacturer/supplier for repair or replacement.
WARNING !
MTL4500 range
When disconnecting units for maintenance purposes, take care to segregate
hazardous and safe-area cables.
• Short circuit hazardous-area cable cores to an IS earth or insulate and
secure the ends.
• Insulate and secure safe-area cables.
If testing a unit ‘in situ’ note that the test equipment used MUST be
intrinsically safe.
The rest of this section is divided into sub-sections based upon the following module types.
6.1 Digital Input modules

MTL4501-SR, MTL4504, MTL4510, MTL4510B, MTL4511, MTL4513, MTL4514, MTL4514B,
MTL4514D, MTL4514N, MTL4516, MTL4516C, MTL4517
6.2 Digital Output modules
MTL4521, MTL4521L, MTL4521Y, MTL4523, MTL4523Y, MTL4523L, MTL4523R, MTL4523V,
MTL4523VL, MTL4524, MTL4524S, MTL4525, MTL4526
6-3 Pulse and Vibration modules
MTL4531, MTL4532, MTL4533
6.4 Analogue Input modules
MTL4541, MTL4541A, MTL4541AS, MTL4541B, MTL4541P, MTL4541S, MTL4541 T,
MTL4541YA, MTL4541Y, MTL4544, MTL4544A, MTL4544AS, MTL4544B, MTL4544D,
MTL4544S
6.5 Analogue Output modules
MTL4545Y, MTL4546, MTL4546C, MTL4546S, MTL4546Y, MTL4549, MTL4549C, MTL4549Y
6-6 Fire and Smoke Interface modules
MTL4561
6.7 Temperature Input modules
MTL4573, MTL4573Y, MTL4575, MTL4576-RTD, MTL4576-THC, MTL4581
6.8 General modules
MTL4599, MTL4599N
6.9 PCS45/PCL45USB configurator for MTL temperature converters
Note: Any LED indicators provided on the modules will display in the following colours:
LED label LED colour

PWR (power) Green
STS (status) Yellow
LFD (line fault) Red
FLT (fault) Red
OPx (o/p status) Yellow
14 INM 4500/4600 Rev 13

6.1 Digital Input modules
The Digital Input (DI) module range offers solid state or relay output switches in a safe area
that respond to input switches located in a hazardous area. Single or multiple channel (2 or
4) options are available, as well as Line-Fault Detection (LFD).
Modules with LFD can recognise open or short circuit conditions on the input wires going to
the field sensors, and some DI modules have the facility to reverse the effect of the input
on the output i.e. phase reversal.
These options are chosen with switches located on the edge of the module on the
hazardous area terminal side. In some applications it may be easier to set these switches
before fitting the module to the backplane.
Figure 6.1:
Switches 1234
OFF position
to set LFD and
ON position
phase reversal
MTL4513, MTL4516 - Ch 1 & 2
PR = phase reversal CH1 CH2 MTL4516C & MTL4517
LF = line fault PR LF PR LF MTL4504
MTL4511,MTL4514 & - Ch 1 only
MTL4514N
6.1.1 Phase reversal

Set the PR switch ON or OFF for the appropriate channel(s).
6.1.2 Line-Fault Detection (LFD)

Where fitted, set the LF switch ON or OFF for the appropriate channel(s). Note: LFD is
permanently active on the MTL4501-SR.
For all DI modules with LFD except for the MTL4501-SR; when using the LFD facility with a
contact input, resistors must be used. Fit 500 to 1k (preferred value 680 ) in series with the
switch and 20k to 25k (preferred value 22k ) in parallel with the switch.
For modes of operation of the MTL4510 & MTL4510B that include LFD, resistors should be fitted
as described above.
For MTL4501-SR use 1k4 in series and 10k in parallel with switch contact inputs.
For hazardous-area inputs conforming to EN 60947-5-6:2001 (NAMUR), a line fault is judged by

the following rules:
• Open circuit condition if hazardous-area current <50µA
• Line integrity (no open circuit) if hazardous-area current >250µA
• Short circuit condition if hazardous-area load <100
• Line integrity (no short circuit) if hazardous-area load >360
Note: the open circuit window (between 250µA and 50µA), and the short circuit window (between
100 and 360 ), is not hysteresis. All MTL4500 range of modules, with inputs conforming to
EN 60947-5-6:2001 (NAMUR), will switch between open and complete circuit conditions within
these limits.
The MTL4501-SR, MTL4514N and the MTL4504 LFD relays de-energise when a fault condition
is detected. The MTL4514 and the MTL4517 energise the LFD relay to indicate a fault condition.
15 INM 4500/4600 Rev 13

6.1.3 MTL4501-SR - Fail-safe Switch/Proximity detector interface
Single channel, fail-safe module with line-fault detection
The MTL4501-SR enables a fail-safe switch/proximity detector located in the hazardous

area to control an isolated fail-safe electronic output. It provides line-fault detection (LFD)
alarm contacts and is designed for use with approved fail-safe sensors in loops that
require operation up to SIL3 according to the functional safety standard IEC 61508.
Note: For reliable, long-term operation the load on the LFD switching relay should not be
less than 50mW, e.g. 10mA at 5V DC.
Hazardous area Safe area

Figure 6.2:
Top label for Terminal Function
MTL4501-SR
1 Input –ve
2 Input +ve
7 Output +ve
8 Output –ve
10 LFD
11 LFD
13 Supply –ve
14 Supply +ve
Input / output characteristics

Input value in Fail–safe Operation LFD
sensor circuits output contacts
2.9mA < Is < 3.9mA ON Normal CLOSED
Is < 1.9mA & Is > 5.1mA OFF Normal CLOSED
Is < 50µA OFF Broken line OPEN
Rs < 100 OFF Shorted line OPEN
Correct operation of the fail-safe output and LFD is indicated by the LEDs on the front of
the unit. The yellow O/P LED is ON when the fail-safe output is energised. The red LFD LED
flashes if a line fault is detected. The fail-safe output is de-energised (OFF) if the module
detects an incorrect sensor current, an open circuit or a short circuit in the sensor circuit.
Input signal sensors may be either suitable proximity sensors or switches. The proximity
sensor properties are specified in the standard EN60947-5-6:2001; however, when used with
MTL4501-SR modules, additional requirements for the “low-impedance” current of
3.4±0.5mA must be met. The list below shows suitable proximity sensors, all manufactured
by Pepperl+Fuchs Group, Germany, and specified as usable to SIL3, according to IEC 61508:
SJ 2-SN NJ 4-12GK-SN NJ 10-30GK-SN

SJ 3,5-SN NJ 5-18GK-SN NJ 15-30GK-SN
SJ 3,5-S1N NJ 8-18GK-SN NJ 6S1+U1+N
NJ 2-11-SN NJ 6-22-SN NJ 15S+U1+N
NJ 2-11-SN-G NJ 6-22-SN-G NJ 20S+U1+N
NJ 2-12GK-SN NJ 5-30GK-S1N NJ 40-FP-SN-P1
16 INM 4500/4600 Rev 13

6.1.4 MTL4504 - Switch/Proximity detector interface
Single-channel, with LFD and phase reversal
The MTL4504 enables a safe–area load to be controlled, through a relay, by a proximity

detector or switch located in a hazardous area. Line faults are signalled through a
separate relay and indicated on the top of the module. MTBF information for the LFD
relay is available from Eaton to allow the failure rate for the LFD relay to be calculated
when used in the critical path with the output relay for safety critical applications.
Switches are provided to select phase reversal and to enable the line fault detection.
Note that series and parallel resistors are required for switch inputs with LFD - see Section 6.1.2
for recommended values.
Note: For reliable, long-term operation the load on the output switching relays should not
be less than 50mW, e.g.10mA at 5VDC.
6 12
5 To earth-leakage
LFD 11 LFD
4 detector * 10
680Ω
3 9
+
2 8 Output
22kΩ
– 1 7

Switch-type sensors

require resistors 13 14
if LFD is selected 20 to 35V dc
Vs+
Vs–
Figure 6.3:
MTL4504
1 Input –ve
2 Input +ve
3 To earth leakage detector*
7 Normally-open contact (output)
8 Common (output)
9 Normally-closed contact (output)
10 Normally-open contact (LFD)
11 Common (LFD)
12 Normally-closed contact (LFD)
13 Supply – ve
14 Supply +ve
17 INM 4500/4600 Rev 13

6.1.5 MTL4510 & MTL4510B - Switch/Proximity detector interface
4-channel, digital input and multifunction modules
These digital modules provide solid state output switches in a safe area that respond to
switches (inputs) located in a hazardous area. The way they respond - their “mode” - can
be configured using a bank of four DIL selector switches accessible through the side of the
module - see Figure 6.5.
Model MTL4510 has an one output channel for each input channel and the user can reverse
the output phase if necessary to suit the application. Model MTL4510B has more varied modes
that can, for example, enable one input to affect multiple outputs or create latched outputs,
etc. The channel output transistors - Ch1/Ch2 and Ch3/Ch4 - share a common terminal and
can switch +ve or –ve polarity signals.
Note that series and parallel resistors are required for switch inputs with LFD - see Section 6.1.2
for recommended values.

Ch D Outputs

–
6 12 4
+ common
5 11
Ch C – 4 10 3

–
3 9 2
+ 2 8 common
Ch B
– 1 7 1
Ch A

13 14
20 to 35V dc
Vs+
Vs–

Terminal Function

1 Input channel A
2 Input channel AB common (+)
Figure 6.4
3 Input channel B
Top labels for
4 Input channel C
MTL4510
5 Input channel CD common (+)
& MTL4510B
6 Input channel D
7 Output channel 1
8 Output channel 1/2 common
9 Output channel 2
10 Output channel 3
11 Output channel 3/4 common
12 Output channel 4
13 Supply –ve
14 Supply +ve
18 INM 4500/4600 Rev 13

Figure 6.5:
DIL switches
for setting
1234
MODE OFF position
ON position
Tables 6.1 and 6.2 show details of the modes available and the switch settings required to obtain
them.For ease of access, it is recommended that switches are set to the required mode before
installation.Table 6.1 indicates whether the output follows the input, or the output is the reverse or
antiphase of the input.
For example, in mode 0, o/p 1 = chA; so, if channel A switch is closed, then output 1 will
also be closed or short circuit. However, in mode 1, o/p 1 = chA rev., so if channel A switch
is closed, then output 1 will be the reverse, i.e. open-circuit.
Table 6 .1 - MTL4510 mode options
Switch setting
MODE o/p 1 o/p 2 o/p 3 o/p 4 i/p type
1 2 3 4
OFF OFF OFF OFF 0 chA chB chC chD
ON OFF OFF OFF 1 chA rev. chB chC chD
OFF ON OFF OFF 2 chA chB rev. chC chD
ON ON OFF OFF 3 chA chB chC rev. chD
switch
OFF OFF ON OFF 4 chA chB chC chD rev.
ON OFF ON OFF 5 chA rev. chB chC rev. chD
OFF ON ON OFF 6 chA chB rev. chC chD rev.
ON ON ON OFF 7 chA rev. chB rev. chC rev. chD rev.
OFF OFF OFF ON 8 chA chB chC chD
ON OFF OFF ON 9 chA rev. chB chC chD
OFF ON OFF ON 10 chA chB rev. chC chD
ON ON OFF ON 11 chA chB chC rev. chD prox.
detector
OFF OFF ON ON 12 chA chB chC chD rev. + LFD
ON OFF ON ON 13 chA rev. chB chC rev. chD
OFF ON ON ON 14 chA chB rev. chC chD rev.
ON ON ON ON 15 chA rev. chB rev. chC rev. chD rev.
Table 6.2 shows the MTL4510B modes. The logic tables and timing diagrams on the
following pages provide more detailed information on these modes.
Table 6.2 - MTL4510B mode options

Switch settings
MODE Function Equivalent
1 2 3 4
OFF OFF OFF OFF 0 4-ch switch input (see MTL4510 mode 0) MTL4510
ON OFF OFF OFF 1 2-ch each channel one input, two outputs MTL4016
Same as mode 1 with all outputs phase
OFF ON OFF OFF 2* MTL4016
reversed
ON ON OFF OFF 3 2-ch, 2-pole changeover output
OFF OFF ON OFF 4 1-ch with line fault output MTL4014
ON OFF ON OFF 5 As mode 4 with changeover outputs
OFF ON ON OFF 6 1-ch with start-stop latch MTL2210B
ON ON ON OFF 7* As mode 2 with LFD enabled MTL4016
OFF OFF OFF ON 8 4-ch switch input, see MTL4510 mode 8 MTL4510
ON OFF OFF ON 9 2-ch with line fault output MTL4017
OFF ON OFF ON 10 As mode 9 with LFD changeover
ON ON OFF ON 11 As mode 10 with channel phase reversed
OFF OFF ON ON 12 3-ch with normally-open LFD output
ON OFF ON ON 13 3-ch with normally-closed LFD output
OFF ON ON ON 14 2-ch monostable, pulse stretcher
ON ON ON ON 15 4-ch switch input, see MTL4510 mode 15 MTL4510
*Mode of operation changed August 2015
MTL4510 & MTL4510B diagnostics

If an internal fault is detected, all outputs and channel LEDs will turn off and the red Fault
LED will turn ON.
19 INM 4500/4600 Rev 13

MTL4510B modes
The following logic and timing diagrams are provided to assist the user in understanding the behaviour of the
MTL4510B module when a specific mode is chosen.
The open switch ( ) and closed switch ( ) symbols are used to represent both the input conditions of Ch A, Ch
B, Ch C or Ch D and then the output conditions of o/p 1, 2, 3 or 4. Note that in certain modes a Line Fault can cause an
override of the output.
Mode 1: 2 ch, each ch 1 input 2 outputs How to use these mode tables - examples
i/p - Ch A i/p - Ch C The logic tables for Mode 1 represent Ch A controlling outputs 1
& 3, while Ch C controls outputs 2 & 4.
Output 1 & 3 are shown following input Ch A (open or closed)
o/p 1 - -
while Outputs 2 & 4 follow input Ch C.
- - o/p 2 Mode 2 however shows o/p 1, 2, 3 and 4 being in antiphase
o/p 3 - - to their inputs.
Mode 9 operates with both outputs for each channel being
- - o/p 4
in antiphase to their inputs.
Mode 2: As mode 1 with all outputs phase reversed Mode 3: 2 ch, 2 pole c/o output
i/p - Ch A i/p - Ch C i/p - Ch A i/p - Ch C
o/p 1 - - o/p 1 - -
- - o/p 2 o/p 2 - -
o/p 3 - - - - o/p 3
- - o/p 4 - - o/p 4
Mode 4: 1 ch with line fault output Mode 5: As mode 4 with c/o outputs
i/p - Ch A i/p - Ch A
No Line No Line No Line No Line

fault fault fault fault fault fault fault fault
o/p 1 o/p 1
o/p 2
No Line No Line
fault fault fault fault
No Line No Line
o/p 3 fault fault fault fault
LFD o/p 3
LFD o/p 4
Mode 6: 1 ch with start/stop latch Mode 7: As mode 2 with LFD enabled
i/p Ch C Non-latching i/p Ch C Latching i/p - Ch A

i/p Ch B Enable Start Reset
i/p Ch A
i/p Ch A No Line No Line
Stop fault fault fault fault
i/p Ch B No effect
o/p 1 o/p 1
o/p 1
o/p 2 OR
o/p 2 o/p 3
o/p 3 o/p 3
i/p - Ch C
o/p 4 o/p 4
o/p 2
o/p 4
A B BRes
Start Stop et
i/p Ch A i/p Ch A *
Non-latching (enable) Latching

i/p Ch B i/p Ch B
Ch C open Ch C closed
o/p 1&3 o/p 1&3
o/p 2&4 o/p 2&4
* i/p Ch A can be open or closed when i/p Ch B opens to stop latch

* i/p Ch A can be open or closed when i/p Ch B opens to stop latch
20 INM 4500/4600 Rev 13

MTL4510B modes - continued
Mode 9: 2 ch with line fault output Mode 10: As mode 9 with line fault c/o

o/p 1 o/p 1
i/p - Ch C
i/p - Ch C
No Line No Line
No Line No Line fault fault fault fault
o/p 2
o/p 2
No Line No Line
LFD o/p 3
LFD o/p 3
LFD o/p 4
Mode 11: As mode 10 with ch phase reversed Mode 12: 3 ch with common LFD output

o/p 1 o/p 1
i/p - Ch B
i/p - Ch C
No Line No Line
o/p 2
o/p 2
i/p - Ch C
No Line No Line
No Line No Line
LFD o/p 3 fault fault fault fault
LFD o/p 4 o/p 3
No Line No Line
Mode 13: As mode 12 but with LFD o/p 4 reversed
LFD o/p 4
No Line No Line
LFD o/p 4
Mode 14
This mode provides a two channel pulse stretcher for in- transition and the output polarity as shown in the timing
puts A and C. Outputs 1 and 2 respond to Ch A, while 3 and diagrams below.
4 respond to Ch C. When triggered by A (or C) the outputs hold the change
Input B (or D) being open or closed affects the input of state for a minimum of 1 second or as long as the input
(A or C) remains in the same triggered state.
Input Ch B (or D) closed Input Ch B (or D) open
i/p B (D) Initiate End

i/p B (D) Initiate End
i/p A (C)
i/p A (C)
1sec (min.)
o/p 1 (3)
o/p 1 (3)
1sec (min.)
o/p 2 (4)
o/p 2 (4)
21 INM 4500/4600 Rev 13

Single channel, with line-fault detection
The MTL4511 contains a changeover relay, which enables a safe-area load to be

controlled by a switch or proximity detector located in a hazardous-area. When selected,
the line-fault detect (LFD) facility detects open or short circuit conditions in the field wiring
and also indicates this on the top of the module. Line-Fault Detect and Phase Reversal for
the channel are selected by DIL switches on the side of the module and output is provided
by the changeover relay contacts.
See page 15 for LFD and PR switch details. Channel 1 only switch settings apply.
For switch sensor inputs, with LFD selected, make sure resistors (22k and 680 ) are fitted.
Note: For reliable, long-term operation the load on the output switching relay should not
6 12
5 11
4 10
680Ω
3 9
+
22kΩ 2 8 Output
– 1 7

Switch-type sensors
Vs+
Vs–

Figure 6.6:
Terminal Function
Top label for
MTL4511 1 Input –ve
2 Input +ve
7 Output normally-open contact
8 Common
9 Output normally-closed contact
13 Supply –ve
14 Supply +ve
22 INM 4500/4600 Rev 13

Two-channel, with line-fault detection and phase reversal
The MTL4513 enables two solid-state outputs in the safe area to be controlled by two
switches or proximity detectors located in the hazardous area. The Ch1/Ch2 output
transistors share a common terminal and can switch +ve or –ve polarity signals. Line-
Fault Detect and Phase Reversal for the channel are selected by DIL switches on the side
of the module. LFD indication is provided on the top of the module.
See page 15 for LFD and PR switch details. Channel 1 & 2 switch settings apply.
680Ω
22kΩ + 6 12
5 11
– 4 10 Outputs

680Ω 3 9 Ch 2
+
2 8
– Ch 1
1 7
22kΩ

Switch-type sensors 13 14
require resistors 20 to 35V dc
if LFD is selected Vs+
Vs–

Figure 6.7:
MTL4513 1 Input –ve (Ch 1)
2 Input +ve (Ch 1)
4 Input –ve (Ch 2)
5 Input +ve (Ch 2)
7 Output (Ch 1)
8 Output (Ch 1/Ch 2)
9 Output (Ch 2)
13 Supply –ve
14 Supply +ve
23 INM 4500/4600 Rev 13

6.1.8 MTL4514/MTL4514B/MTL4514D - Switch/Proximity detector interface
Single channel, with line-fault detection and phase reversal
The MTL4514 and MTL4514B enables a safe-area load to be controlled, through a relay,
by a proximity detector or switch located in a hazardous area. Line faults are signalled
through a separate relay and indicated on the top of the module. The MTL4514D enables
two safe-area loads to be controlled by a single hazardous area proximity detector or
switch, with line faults indicated on the top of the module. Line-Fault Detect and Phase
Reversal for the channel are selected by DIL switches on the side of the module. Output is
provided by changeover relay contacts in the MTL4514 and single-pole relay contacts in
the MTL4514B and MTL4514D.
See page 15 for LFD and PR switch details. Channel 1 only switch settings apply.

Function
Terminal
MTL4514 MTL4514B MTL4514D
1 Input –ve
2 Input +ve
7 Output contact N.O. Output contact N.O. Output 1 contact N.O.
8 Output common Output contact N.O. Output 1 contact N.O.
9 Output contact N.C. – –
10 LFD contact N.O. LFD contact N.O. Output 2 contact N.O.
Figure 6.8: 11 LFD common LFD contact N.O. Output 2 contact N.O.
Top labels for 12 LFD contact N.C. – –
MTL4514, 13 Supply – ve
MTL4514B & 14 Supply +ve
MTL4514D
N.O. = normally open N.C. = normally closed
24 INM 4500/4600 Rev 13

6.1.9 MTL4514N - Switch/Proximity detector interface
Single channel, with line-fault detection with passthrough and phase reversal
The MTL4514N is designed to work with system inputs which monitor the impedance
of the field circuit in order to detect line faults. Low and high impedance states reflect a
switch closed or open in the field. An open circuit state is used to signal a line fault.
There are 2 relays and resistors provided, the main channel relay switches the 2k2
resistor across the system input. The LFD relay switches a 15k resistor in parallel with the
2k2. When a line fault is detected the main relay is open and the LFD relay is open thus
providing an open circuit condition on the system input.
A custom backplane designed for the MTL4514N must be used or, if a general purpose
backplane is used, the module outputs must be wired in parallel (terminals 8-10 and
9-11 linked). Switch contacts in the field must be fitted with end of line resistors if LFD
passthough is required.
6 12 ID
5 To earth-leakage
LFD 11
detector * LFD
4 10
15K
680Ω
3 9
+ Output
2 8
22kΩ 2K2
– 1 7
Switch-type sensors
Vs+
Vs–
Figure 6.9:
MTL4514N 1 Input –ve
2 Input +ve
8 Output N.O.
9 Output Common
10 LFD N.O.
11 LFD Common
12 ID resistor
25 INM 4500/4600 Rev 13

Two channel, with line-fault detection and phase reversal - normally-open contacts
The MTL4516 contains two normally-open contact relays, which enable two safe-area
loads to be controlled by switches or proximity detectors located in a hazardous-area.
When selected, the line-fault detect (LFD) facility detects open or short circuit conditions
in the field wiring and also indicates this on the top of the module. Line-Fault Detect and
Phase Reversal for the channel are selected by DIL switches on the side of the module
and output is provided by the changeover relay contacts.
680Ω
22kΩ 6 12
+
5 11
– 4 10

680Ω 3 9 Ch 2
+
2 8
– 7
22kΩ 1 Ch 1

20 to 35V dc
require resistors
Vs+
if LFD is selected
Vs–

Figure 6.10:
2 Input +ve (Ch 1)
5 Input +ve (Ch 2)
7 Output (Ch 1)
8 Common (Ch 1/Ch 2)
9 Output (Ch 2)
13 Supply –ve
14 Supply +ve
26 INM 4500/4600 Rev 13

6.1.11 MTL4516C - Switch/Proximity detector interface
Two channel, with line-fault detection and phase reversal - changeover contacts
The MTL4516C contains two changeover relays, which enable two safe-area loads to
be controlled by switches or proximity detectors located in a hazardous-area. When
selected, the line-fault detect (LFD) facility detects open or short circuit conditions in the
field wiring and also indicates this on the top of the module. Line-Fault Detect and Phase
Reversal for the channel are selected by DIL switches on the side of the module and
output is provided by the changeover relay contacts.
See page 15 for LFD and PR switch details. Channel 1 & 2 switch settings apply..
680Ω
22kΩ 6 12
+
5 11 Ch 2
– 4 10

680Ω 3 9
+ Ch 1
2 8
– 1
7
22kΩ

20 to 35V dc
require resistors Vs+
if LFD is selected
Vs–
Figure 6.11:
Top label for Terminal Funct ion
MTL4516C 1 Input –ve (Ch 1)
2 Input +ve (Ch 1)
5 Input +ve (Ch 2)
7 Normally-open contact (Ch 1)
8 Common (Ch 1)
9 Normally-closed contact (Ch 1)
10 Normally-open contact (Ch 2)
11 Common (Ch 2)
12 Normally-closed contact (Ch 2)
13 Supply –ve
14 Supply +ve
27 INM 4500/4600 Rev 13

Two channel, with line-fault detection and phase reversal
The MTL4517 enables two safe-area loads to be controlled, through a relay, by switches
or proximity detectors located in a hazardous-area. When selected, the line-fault detect
(LFD) is signalled through a separate relay and indicated on the top of the module.
Line-Fault Detect and Phase Reversal for the channel are selected by DIL switches on the
side of the module and output is provided by the relay contacts.
680Ω
22kΩ + 6
12
LFD 11 LFD
5
– 4 10

680Ω 3 9
+ 2
2 8
– 1
1 7
22kΩ

20 to 35V dc
require resistors
Vs+
if LFD is selected
Vs–

Figure 6.12:
2 Input +ve (Ch 1)
5 Input +ve (Ch 2)
7 Output (Ch 1)
8 Common (Ch 1/Ch 2)
9 Output (Ch 1)
10 Normally-open contact (LFD)
11 Common (LFD)
12 Normally-closed contact (LFD)
13 Supply –ve
14 Supply +ve
28 INM 4500/4600 Rev 13

6.2 Digital Output modules
The single channel Digital Output (DO) module range enables on/off devices in a hazardous
area to be controlled from the safe area. Some units are loop powered while others enable
solid-state switching by providing independent power supplies.
6.2.1 MTL4521/MTL4521L - Solenoid Alarm driver

Single channel, loop powered, IIC
The MTL4521 and MTL4521L are loop-powered modules that enable a device located
in the hazardous area (IIC gas group) to be controlled from the safe area. They can both
drive up to 48mA into a certified intrinsically safe low-power load, as well as non-energy-
storing simple apparatus such as an LED. The only difference is that the MTL4521L has a
lower current safety description i.e. 108mA instead of 147mA.

Terminal Function

1 Output –ve

2 Output +ve
10 Supply +ve
Figure 6.13: 11 Supply –ve
Top labels for
MTL4521 &
MTL4521L
29 INM 4500/4600 Rev 13

6.2.2 MTL4523/MTL4523R - Solenoid Alarm driver
Single channel, with line-fault detection, IIC
The MTL4523 interface controls an on/off device in a hazardous area using a volt-free
contact or logic signal in the safe area, and is suitable for driving loads such as solenoids.
Line-Fault Detection (LFD) operates independently of the output state and is signalled by
a safe-area, solid-state switch output which, when a field line is open or short-circuited,
becomes de-energised in the MTL4523, and energised in the MTL4523R. Earth fault
detection can be provided by connecting an MTL4220 earth leakage detector to terminal 3.
Control
6 12
5 11 –
4 10
+
3 9
+ –
2 8
LFD†
7
– 1 +
Solenoid, alarm or † MTL4523R
LFD phase reversed
other IS device
13 14
20 to 35V dc
Vs+
Vs–

Terminal Function

1 Output –ve
2 Output +ve
7 Line fault signal +ve
Figure 6.14: 8 Line fault signal –ve
Top labels for 10 Control +ve
MTL4523 & 11 Control –ve
MTL4523R 13 Supply –ve
14 Supply +ve
30 INM 4500/4600 Rev 13

6.2.3 MTL4523L - Solenoid Alarm driver
Single channel, loop-powered with line-fault detection, IIC
The MTL4523L interface controls an on/off device in a hazardous area using a voltage signal
in the safe area, and is suitable for driving loads such as solenoids. Line-Fault Detection
(LFD) operates only when the output is energised and is signalled by a safe-area solid-state
switch which, when a field line is open or short-circuited, becomes energised.
6 12 20 to 35V dc
5 11 Vs–
4 10 Vs+
3 9
+ –
2 8
LFD
7
– 1 +
Solenoid, alarm or

other IS device
13 14

Figure 6.15:
MTL4523L 1 Output –ve
2 Output +ve
8 Line fault signal –ve
10 Supply +ve
11 Supply –ve
31 INM 4500/4600 Rev 13

6.2.4 MTL4523V/MTL4523VL - Solenoid Alarm driver
Single channel, voltage controlled with line-fault detection, IIC
With the MTL4523V or MTL4523VL interface, an on/off device in a hazardous area can
be controlled by a voltage signal in the safe area. It is suitable for driving loads such
as solenoids. Line fault detection (LFD), which operates irrespective of the output
state, is signalled by a safe-area solid-state switch which energises if a field line is
open or short–circuited.
The VL version has a lower current capability to suit alternative load requirements -
see datasheet.
6 12
5 11 – V Control
4 10
+

3 9
+ –
2 8
LFD
7
– 1 +
Solenoid, alarm or
other IS device
13 14
20 to 35V dc
Vs+
Vs–

Terminal Function

1 Output –ve

2 Output +ve
Figure 6.16:
8 Line fault signal –ve
Top labels for
10 Control +ve
MTL4523V &
11 Control –ve
MTL4523VL
13 Supply –ve
14 Supply +ve
32 INM 4500/4600 Rev 13

6.2.5 MTL4524 - Solenoid Alarm driver
Single channel, switch operated with override, IIC
The MTL4524 enables an on/off device in a hazardous area to be controlled by a volt-free

contact or logic signal in the safe area. It can drive loads such as solenoids, alarms, LEDs
and other low power devices that are certified as intrinsically safe or are classified as non-
energy-storing simple apparatus. Short-circuit the Control input terminals to switch the
output on.
A second safe-area input (Override) is provided. When short-circuited, the Override input
will force the output to the off state; when open-circuit it has no effect.
Control
6 12
5 11 –
4 10
+
9
+
3
+
2 8 –
7
– 1
Solenoid, alarm or Override
other IS device
13 14
20 to 35V dc

Vs+
Vs–

Figure 6.17:
MTL4524 1 Output –ve
2 Output +ve
8 Override –ve
9 Override +ve
10 Control +ve
11 Control –ve
13 Supply –ve
14 Supply +ve
33 INM 4500/4600 Rev 13

6.2.6 MTL4524S - Solenoid Alarm driver
Single channel, switch operated with 24V override, IIC
The MTL4524S enables an on/off device in a hazardous area to be controlled by a volt-

free contact or a floating logic signal in the safe area. It can drive loads such as solenoids,
alarms, LEDs and other low power devices that are certified as intrinsically safe or
are classified as non-energy-storing simple apparatus. Short-circuit the Control input
terminals to switch the output on.
A second safe-area voltage input (Override) is provided. With 9– 24V applied the Control
input is enabled; when below 2V it forces the output to the off state.
Note: The Control input must be from an isolated source with respect to the Override
input. The Override + (terminal 8) is joined internally to the Control – (terminal 11).
Control
6 12
5 11 –
4 10
+
3 9 –
+
2 8
+ 24V
7
– 1
other IS device
13 14
20 to 35V dc

Vs+
Vs–
Figure 6.18:
MTL4524S
1 Output –ve
2 Output +ve
8 Override +ve
9 Override –ve
10 Control +ve
11 Control –ve
13 Supply –ve
14 Supply +ve
34 INM 4500/4600 Rev 13

6.2.7 MTL4525 - Solenoid Alarm driver
Single channel, switch operated with override, IIC
The MTL4525 enables an on/off device in a hazardous area (IIC gas group) to be
controlled by a volt-free contact or logic signal in the safe area. It can drive loads such as
solenoids, alarms, LEDs and other low power devices that are certified as intrinsically safe
or are classified as non-energy-storing simple apparatus. Short-circuit the Control input
terminals to switch the output on.
A second safe-area input (Override) is provided. When short-circuited, the Override input
will force the output to the off state; when open-circuit it has no effect.
Control
6 12
5 11 –
4 10
+
9
+
3
+
2 8 –
7
– 1
other IS device
13 14
20 to 35V dc
Vs+
Vs–

Figure 6.19:
MTL4525 1 Output –ve
2 Output +ve
8 Override –ve
9 Override +ve
10 Control +ve
11 Control –ve
13 Supply –ve
14 Supply +ve
35 INM 4500/4600 Rev 13

6.2.8 MTL4526 - Switch operated relay
Two channel, IS output
The MTL4526 enables two separate IS circuits in a hazardous area to be relay-contact

controlled by two on-off switches or logic signals in a safe area. Applications include
the calibration of strain-gauge bridges; changing the polarity (and thereby the tone) of
an IS sounder; the testing of IS fire alarms; and the transfer of safe-area signals into an
annunciator with IS input terminals not segregated from each other. The output-relay
contacts are certified as non-energy-storing apparatus, and can be connected to any IS
circuit without further certification, provided that separate IS circuits are such that they
would remain safe if connected together.
Contact Loop
inputs powered
1 12 –
1 2 11
–
IS relay
3
+
10 + Control
2 20 to
–
4 9
– 35V dc
IS relay +
2 5 8 +
6 7 1
All contacts shown

in normal position Sw4
(relays de-energised) 13 14
20 to 35V dc

Vs+
Vs–

Figure 6.20:
MTL4526
1 IS relay output 1 (normally open)
2 IS relay output 1 (normally closed)
3 IS relay output 1 (common)
4 IS relay output 2 (common)
5 IS relay output 2 (normally closed)
6 IS relay output 2 (normally open)
8 Relay 1 control +ve
9 Relay 1 control –ve
10 Relay 2 control +ve
11 Relay 2 control –ve
13 Supply –ve
14 Supply +ve
Mode Function SW1 SW2 SW3 SW4
Contact/ 2 ch Off On On On
Logic
Input 1in2out On On On On
Loop Powered 2 ch Off Off Off Off
Table 6.3 Switch settings for modes
1234
OFF position
ON position
36 INM 4500/4600 Rev 13

6.3 Pulse and Vibration modules
Single and dual channel modules are available to transfer vibration probe signals from
a hazardous area to a safe one. Similarly, pulses from a switch, proximity detector, current
pulse transmitter or voltage pulse transmitter, located in the hazardous area, can be safely
transferred to the safe area.
6.3.1 MTL4531 - Vibration Transducer Interface

Single channel
The MTL4531 repeats a signal from a vibration sensor in a hazardous area, providing an
output for a monitoring system in the safe area. The interface is compatible with 3-wire,
eddy-current probes and accelerometers or 2-wire current sensors, and selection of the
mode is made with a switch located on the side of the module.
6 12
5 11
4 10
COM
3- Vibration 3 9 –ve
SIG
wire transducer 2 8 Monitor
V–
1 7
0V
3
2- Vibration
wire 2
transducer
1 13 14
20 to 35V dc
Vs+
Vs–
Figure 6.21:
MTL4531 1 Transducer power V–
2 Signal
3 Common
7 Signal output 0V
8 Signal output –ve
13 Supply –ve
14 Supply +ve
2-/3-wire transducer setting switch
OFF position
ON position
2-/3-wire
* Note: When using 2-wire

Mode SW
sensors, ensure that
2-wire (3.3mA)* OFF terminals 1 and 2 are linked
3-wire (20mA) ON as shown in the wiring
diagram above.
WARNING! - Revision status 05 and below*

To enable optimum heat dissipation the recommended orientation for mounting is with
the module vertical, i.e. with the vents in the case at the top and bottom.
This enables air to flow through the module.
In any other orientation, i.e. with the module horizontal, then the maximum ambient
temperature is limited to:
• Close packed = 45°C
• Minimum of one module spacing = 55°C
*Revision status is the 2 digits after the +++ in the barcode
37 INM 4500/4600 Rev 13

6.3.2 MTL4532 - Pulse Isolator
Pulse & 4/20mA current outputs
The MTL4532 isolates pulses from a switch, proximity detector, current pulse transmitter
or voltage pulse transmitter located in a hazardous area. It is ideal for applications
involving high pulse rates and fast response times, by repeating the pulses into the safe
area, and the transistors used on the pulse output will switch +ve or –ve polarity signals.
It may be used immediately in simple or legacy mode, or it may be software configured

for more specific applications - see next page for either option. With configuration, an
analogue output proportional to frequency is available, together with a relay output,
which may act as an alarm.
Note: For reliable, long-term operation the load on the output switching relay should not
5
Current Configuration
pulse socket
3
V Inhibit
4/20
mA +
1 1 6 12
Alarm
5 11
Voltage
pulse 4 4 10 –

4/20mA Load
3 Pulse +
3-wire 3 9
4/20 + –
current 2 8
mA Pulse
pulse 1 – 1 7 +
5 2-wire
4 current 4
14
13
3-wire pulse 20 to 35V dc
voltage 3 Vs+
4/20
pulse mA Vs–
1
Figure 6.22:
MTL4532 1 Common input –ve
2 Switch/proximity input +ve
3 Current pulse input +ve
4 Transmitter supply +ve
5 Voltage pulse input +ve
6 Inhibit input +ve
7 Pulse output +ve
8 Pulse/Current output –ve
9 Current output +ve
11 Alarm/Current output –ve
12 Alarm
13 Supply –ve
14 Supply +ve
Switches located on the edge of the module define the mode of operation.
SW1 SW2 SW3 SW4

Vsp Vsp LFD Mode
1234
OFF position
ON position
Vsp SW1 SW2 LFD SW3

3V ON ON OFF OFF
6V ON OFF ON ON
12V OFF OFF
38 INM 4500/4600 Rev 13

Switch input operation
If switch contacts are used for this Pulse Input (terminals 1 & 2), then series and parallel
resistors must be fitted - see Section 6.1.2 for recommended values.
Simple or Legacy mode - SW4 - OFF

If simple “pulse-in/pulse-out” operation is required or, if a replacement for the earlier
MTL4032 pulse isolator is required, then SW4 should be set to OFF. The input switching
point voltage (Vsp) thresholds can then be defined by Switches 1 & 2, and the LFD
operation can be set with Switch 3. When Switch 3 is ON, the Alarm output (terminals 11
& 12) become active.
Configurable mode - SW4 - ON

In this mode, analogue, alarm and pulse outputs are available but the module must be
software configured to define its operating mode. In this mode, software controls the LFD
function and Switch 3 has no effect. Switches 1 & 2 continue to define the switching point
threshold (Vsp). Configuration requires a personal computer, a PCL45USB interface and
PCS45 software. See Section 6.9 on page 58 for details of the configurator.
Alarm inhibiting
The Inhibit input is provided to inhibit alarm output operation. This facility is useful, for
example, during power-up, when pulse rates are below the alarm threshold. When normal
operational values are established the inhibit can be disabled. Such a facility is sometimes
referred to as a start-up delay. Inhibit is enabled by connecting a switch or proximity
detector between terminals 6 and 3. If switch contacts are used for this input, then series
and parallel resistors must be fitted - see Section 6.1.2 for recommended values.
LED indicators
Use the following LED information to understand the module status.
LED Description
PWR
ON - Power OK OFF - No power or insufficient voltage
Power (green)
O/P The LED will follow the pulse output state. If the output is pulsing
Output then the LED brightness will pulse. If the pulsing is rapid or very
(yellow) short, the LED may dim if it is unable to respond to such changes.
If the output is high, the LED will be ON.
STS In legacy mode a line fault will cause the LED to turn ON.
Status In µC mode, the LED is programmable to display a line fault or an
(red - flashing) Alarm trip operation. In the event, it will also indicate a µC fault
condition.
39 INM 4500/4600 Rev 13

6.3.3 MTL4533 - Vibration Transducer Interface
WARNING!
Note: This module has been terminated and not available for use
on new projects.
For existing applications spacing of one module position between active
modules must be implemented to ensure reliable operation.
Two channel
The MTL4533 repeats signals from vibration sensors in a hazardous area, providing
outputs for monitoring systems in the safe area. The interface is compatible with 3-wire
eddy-current probes and accelerometers or 2-wire current sensors, and selection of the
mode for each channel is made with the switches on the side of the module.
6
2- Vibration
wire transducer 5
4 Ch 2
Ch 2 –ve
COM 12
6 Monitor
3- Vibration SIG
wire transducer 5 11
V– 0V
4 10
COM Ch 1
3- Vibration 3 9 –ve
SIG
wire transducer 2 8 Monitor
V–
1 7
Ch 1 0V
3
2- Vibration
2
wire transducer
1 13 14
20 to 35V dc
Vs+
Vs–
Figure 6.23:
Terminal Function
Top label for
MTL4533 1 Ch 1 Transducer power V–
2 Ch 1 Signal
3 Ch 1 Common
4 Ch 2 Transducer power V–
5 Ch 2 Signal
6 Ch 2 Common
7 Ch 1 Signal output 0V
8 Ch 1 Signal output –ve
11 Ch 2 Signal output 0V
12 Ch 2 Signal output –ve
13 Supply –ve
14 Supply +ve
2-/3-wire transducer setting switches
OFF position
ON position
Ch 1 Ch 2
* Note: When using 2-wire sensors, ensure

Mode SW
that terminals 1 & 2 and 4 & 5 have wiring
2-wire (3.3mA)* OFF links as shown in the wiring diagram
3-wire (20mA) ON above.
Power dissipation
Because of its higher power dissipation (2.7W), it is mandatory that the MTL4533 is given
additional spacing on the backplane by leaving vacant the module positions on either
side of it.
40 INM 4500/4600 Rev 13

6.4 Analogue Input modules
The analogue input (AI) modules support 2-wire or 3-wire 4/20mA or HART transmitters
located in a hazardous area; repeating the current in other circuits to drive safe-area
loads.
6.4.1 MTL4541/MTL4541S/MTL4541Y - Repeater Power Supply

Single channel, 4/20mA, HART® for 2- or 3-wire transmitters
The MTL4541 provides a fully-floating dc supply for energising a conventional 2- or

3-wire 4/20mA transmitter which is located in a hazardous area, and repeats the current
in another floating circuit to drive a safe-area load. For HART 2-wire transmitters, the
unit allows bi-directional communications signals superimposed on the 4/20mA loop
current. Alternatively, the MTL4541S acts as a current sink for a safe-area connection
rather than driving a current into the load. Seperately powered current sources, such as
4-wire transmitters, can be connected but will not support HART communication.
6 12 ID
5 * 11
4 10 MTL4541 MTL4541S
+ Load
Com
3 I 9 – –
Tx+ 4/20mA
2 I 8 – +
Input
1 7 +
4/20mA Load
13 14
20 to 35V dc
Vs+
Vs–
Terminal Function

1 Current input
Figure 6.24: 3 Common
Top labels for 8 Output –ve (+ve current sink)
MTL4541 & 9 Output +ve (–ve current sink)
MTL4541S 12 ID resistor (MTL4541Y only)
13 Supply –ve
14 Supply +ve
* MTL4541Y is functionally identical to the MTL4541 but has an additional ID resistor

connected to terminal 12.
41 INM 4500/4600 Rev 13

6.4.2 MTL4541A/MTL4541AS/MTL4541YA - Current Repeater
Single channel, 4/20mA, passive input for HART® transmitters
The MTL4541A provides an input for separately powered 4/20mA transmitters and also
allows bi-directional transmission of HART communication signals superimposed on the
4/20mA loop current. Alternatively, the MTL4541AS acts as a current sink for a safe-area
connection rather than driving a current into the load.
6 12 ID
5 * 11
4 10 MTL4541A MTL4541AS
Load Load
I + – –
9
+ 3 4/20mA
2 I 8 – +
4/20mA
7
+
– 1
13 14
20 to 35V dc
Vs+
Vs–
Terminal Function

1 Input –ve
2 Input +ve
8 Output –ve (+ve current sink)
Figure 6.25:
9 Output +ve (–ve current sink)
Top labels for
12 ID resistor (MTL4541YA only)
MTL4541A &
13 Supply –ve
MTL4541S
14 Supply +ve
* MTL4541Y is functionally identical to the MTL4541 but has an additional ID resistor

connected to terminal 12.
42 INM 4500/4600 Rev 13

6.4.3 MTL4541B/MTL4541P/MTL4541T - Repeater Power Supply
Single channel, 4/20mA, HART® for 2- or 3-wire transmitters
These modules are intended for use as replacements for previous MTL4000 range of
modules on existing backplane installations. They provide a fully-floating dc supply
for energising a conventional 2- or 3-wire 4/20mA transmitter located in a hazardous
area, and repeat the current in another circuit to drive a safe-area load. For HART 2-wire
transmitters, the units allow bi-directional communications signals superimposed on the
4/20mA loop current.
The MTL4541P is a higher power version of the MTL4541B, usable for all gas groups
provided that the field equipment is suitably certified.
The MTL4541T has a reduced maximum open-circuit voltage which, together with a
corresponding increase in allowed cable capacitance, permits the use of longer field lines
compared to the MTL4541.
6 12 Load
5 11 –
4/20mA
4 10

I +
9
+ 3
2 I 8
– 1 7
4/20mA
13 14
20 to 35V dc
Vs+
Vs–
Terminal Function
1 Current input

Figure 6.26: 3 Common
Top labels for 8 Output –ve
MTL4541B, 9 Output +ve
MTL4541P & 11 Output –ve
MTL4541T 13 Supply –ve
14 Supply +ve
Note: Safe area outputs are referenced to PSU –ve
43 INM 4500/4600 Rev 13

6.4.4 MTL4544/MTL4544S - Repeater Power Supply
Two channel, 4/20mA, HART® for 2- or 3-wire transmitters
The MTL4544 is intended for use as a replacement for a previous MTL4000 range of
modules on existing backplane installations. It provides fully-floating dc supplies for
energising two conventional 2-wire or 3-wire 4/20mA or HART transmitters located in a
hazardous area, and repeats the current in other circuits to drive two safe-area loads. For
HART transmitters, the unit allows bi-directional transmission of digital communication
signals superimposed on the 4/20mA loop current. Alternatively, the MTL4544S acts as
a current sink for a safe-area connection rather than driving a current into the load.
Seperately powered current sources, such as 4-wire transmitters, can be connected but
will not support HART communication.
MTL4544 MTL4544S
Ch 2 Com + Ch 2 Load
12 –
Tx+ 6 I
4/20mA
5 11 –
Input
4 I 10
+
4/20mA Load
Load
Com +
3 I 9 –
Tx+ 4/20mA
2 8 –
Input
1 I 7
+
4/20mA Load
Ch 1
Ch 1
13 14
20 to 35V dc
Vs+
Vs–
Terminal Function
1 Ch1 current input

2 Ch1 transmitter supply +ve
Figure 6.27: 3 Ch1 common
Top labels for 4 Ch2 current input
MTL4544 & 5 Ch2 transmitter supply +ve
MTL4544S 6 Ch2 common
8 Ch1 output –ve (+ve current sink)
9 Ch1 output +ve (–ve current sink)
13 Supply –ve
14 Supply +ve
The MTL4544 or MTL4544S Hazardous Safe area

can also be used to drive area
two safe-area loads from
a single 2-wire transmitter
(i.e. 1 in, 2 out) by
6 12
interconnecting the input 5
I
11
channels as shown in the
4/20mA – 4 I 10
diagram (right). 3 I 9
+ 2 8
Note: In this mode the 1 I 7
HART data is transferred

via channel 1 output only. 14
20 to 35V dc
Vs+
See also the MTL4544D. Vs–
44 INM 4500/4600 Rev 13

6.4.5 MTL4544A/MTL4544AS - Current Repeater
Two channel, 4/20mA, passive input for HART® transmitters
The MTL4544A provides inputs for separately powered 4/20mA transmitters and also
allows bi-directional transmission of HART communication signals superimposed on the
4/20mA loop current. Alternatively, the MTL4544AS acts as a current sink for a safe-area
connection rather than driving a current into the load.
MTL4544A MTL4544AS
Ch 2 + Ch 2 Load Load
12
+ 6 I
4/20mA
5 11
4/20mA
I 10
+
4
+ Ch 1 Load Load
3 I 9
4/20mA
2 8
4/20mA
1 I 7
+
Ch 1
13 14
20 to 35V dc
Vs+
Vs
Terminal Function

1 Ch1 input –ve
2 Ch1 input +ve
Figure 6.28: 4 Ch2 input –ve
Top labels for 5 Ch2 input +ve
MTL4544A & 8 Ch1 output –ve (+ve current sink)
MTL4544AS 9 Ch1 output +ve (–ve current sink)
13 Supply –ve
14 Supply +ve
45 INM 4500/4600 Rev 13

6.4.6 MTL4544B - Repeater Power Supply
Two channel, 4/20mA, HART® for 2- or 3-wire transmitters
The MTL4544B is intended for use as a replacement for a previous MTL4000 range of
modules on existing backplane installations. It provides fully-floating dc supplies for
energising two conventional 2-wire or 3-wire 4/20mA or HART transmitters located in a
hazardous area, and repeats the current in other circuits to drive two safe-area loads. For
HART transmitters, the unit allows bi-directional transmission of digital communication
signals superimposed on the 4/20mA loop current.
Ch 2 + Ch 2
12
+ 6 I 4/20mA
5 11 –
– 4 10
4/20mA Load
+
9
+ 3 I 4/20mA
2 8 –
– 1 I 7
4/20mA Load
Ch 1
Ch 1
13 14
20 to 35V dc
Vs+
Vs–
Figure 6.29:
MTL4544B 1 Ch1 current input
3 Ch1 common
4 Ch2 current input
6 Ch2 common
8 Ch1 output –ve
9 Ch1 output +ve
11 Ch2 output –ve
12 Ch2 output +ve
13 Supply –ve
14 Supply +ve
Note: Safe area outputs are referenced to PSU –ve
46 INM 4500/4600 Rev 13

6.4.7 MTL4544D - Repeater Power Supply
Single channel, 4/20mA, HART® for 2- or 3-wire transmitters, two outputs
The MTL4544D provides a fully-floating dc supply for energising a conventional 2- or

3-wire 4/20mA transmitter located in a hazardous area, and repeats the current in other
circuits to drive two safe-area loads. For HART 2-wire transmitters, the unit allows bi-
directional transmission of digital communication signals superimposed on the 4/20mA
loop current. Seperately powered current sources, such as 4-wire transmitters, can be
connected but will not support HART communication.
+ O/P 2
6 12
I 4/20mA
5 11 –
4 10 Load
Com I +
3 9
Tx+ 4/20mA
2 8 –
Input
1 I 7 Load
4/20mA
O/P 1
13 14
20 to 35V dc

Vs+
Vs–

Figure 6.30:
MTL4544D
1 Current input
3 Common
8 Output 1 –ve
HART supported
9 Output 1 +ve
11 Output 2 –ve HART not
12 Output 2 +ve available
13 Supply –ve
14 Supply +ve
NOTE
For correct operation of the module, a suitable load must be present on both output
channels.
This is of particular importance during testing, commissioning or maintenance activities

when the temporary disconnection, or absence, of a load can affect the transfer accuracy
of the analogue variable.
47 INM 4500/4600 Rev 13

6.5 Analogue Output modules
The analogue output (AO) modules accept 4/20mA floating signals from safe-area
controllers to drive current/pressure converters (or any other load up to 800 ) in a
hazardous area.
6.5.1 MTL4546/MTL4546C/MTL4546S/MTL4546Y/MTL4545Y - Isolating Driver

Single channel, 4/20mA, HART® for valve positioners with line-fault detection
The MTL4546 accepts a 4/20mA floating signal from a safe-area controller to drive
a current/pressure converter (or any other load up to 800 ) in a hazardous area. For
HART valve positioners, the module also permits bi-directional transmission of digital
communication signals so that the device can be interrogated either from the operator
station or by a hand-held communicator. Process controllers with a readback facility
can detect open or short circuits in the field wiring: if these occur, the current taken into
the terminals drops to a preset level. The MTL4546C and MTL4546Y are identical to the
MTL4546 except that they provide open circuit detection only (no short-circuit detection).
The MTL4546S has a reduced maximum open-circuit voltage which permits the usage of
longer field lines compared to the MTL4546.
+
6 12
4/20mA
5 11 –
4 10

I 9
+ 3
P 4/20mA
2 8
I 7
I – 1
13 14
20 to 35V dc
Vs+
Vs–
S Terminal Function Term MTL4545Y only

1 Output –ve 1 Output –ve
2 Output +ve 2 Output +ve
11 Input –ve 8 Input –ve
Figure 6.31:
Top labels for 12 Input +ve 9 Input +ve
MTL4546, 13 Supply –ve 12 ID resistor
MTL4546C, 14 Supply +ve 13 Supply –ve
MTL4546Y & 14 Supply +ve
MTL4546S
Input Characteristics
Field wiring state MTL4546 MTL4546C MTL4545Y/

MTL4546Y
Normal < 6.0V < 6.0V < 6.0V
Open-circuit < 0.9mA < 0.9mA < 0.5mA
Short-circuit < 0.9mA N.A. N.A.
48 INM 4500/4600 Rev 13

6.5.2 MTL4549/MTL4549C/MTL4549Y - Isolating Driver
Two channel, 4/20mA, HART® for valve positioners with line-fault detection
The MTL4549 accepts 4/20mA floating signals from safe-area controllers to drive 2
current/pressure converters (or any other load up to 800 ) in a hazardous area. For
HART valve positioners, the module also permits bi-directional transmission of digital
communication signals so that the device can be interrogated either from the operator
station or by a hand-held communicator. Process controllers with a readback facility
can detect open or short circuits in the field wiring: if these occur, the current taken into
the terminals drops to a preset level. The MTL4549C and MTL4549Y are identical to the
MTL4549 except that they provide open circuit detection only (no short-circuit detection).
Ch 2
Ch 2 +
+ 6 I 12
4/20mA
P 5 11 –
4/20mA
I – 4 I 10 Ch 1

+
9
+ 3 I
4/20mA
P 4/20mA
2 8 –
I 1 I 7
–
Ch 1
13 14
20 to 35V dc
Vs+
Vs–
Terminal Function

1 Output –ve (Ch 1)
2 Output +ve (Ch 1)
Figure 6.32: 4 Output –ve (Ch 2)
Top labels for 5 Output +ve (Ch 2)
MTL4549C & 9 Input +ve (Ch 1)
MTL4549Y 11 Input –ve (Ch 2)
12 Input +ve (Ch 2)
13 Supply –ve
14 Supply +ve
Input Characteristics
Field wiring state MTL4549 MTL4549C MTL4549Y

Normal < 6.0V < 6.0V < 6.0V
Open-circuit < 0.9mA < 0.9mA < 0.5mA
Short-circuit < 0.9mA N.A. N.A.
49 INM 4500/4600 Rev 13

6.6 Fire and Smoke Interface modules
Interfaces for use with conventional fire and smoke detectors located in hazardous areas.
6.6.1 MTL4561 - Fire and Smoke Detector Interface

Two channel
The MTL4561 is a loop-powered 2–channel interface for use with conventional fire and
smoke detectors located in hazardous areas. In operation, the triggering of a detector
causes a corresponding change in the safe–area current. The unit features reverse input
polarity protection, while ‘no-fail’ earth fault detection on either line can be provided by
connecting an earth leakage detector to terminal 3 and/or 6.
Ch 2
+
+ 6 I 12
Ch 2
5 11
–
– 4 I 10
Fire
detectors +
9
+ 3 I
Ch 1
2 8 –
1 I 7
–
Ch 1
13 14

Figure 6.33:
Top labels for Terminal Function
MTL4561
2 Output +ve (Ch 1)
5 Output +ve (Ch 2)
9 Input +ve (Ch 1)
12 Input +ve (Ch 2)
50 INM 4500/4600 Rev 13

6.7 Temperature Input modules
These modules accept inputs from low-level dc sources such as thermocouples or RTDs
in hazardous areas and convert them into 4/20mA signals to drive safe area loads.
Thermocouples early burnout detection (EBD)

When EBD is selected, the resistance of the thermocouple circuit is monitored and an
alarm is raised when there is an increase of more than 50 . This enables preventative
maintenance to be conducted on the field installation before the thermocouple actually
breaks.
Configuration using PCS45/PCL45USB

Use PCS45 software, in conjunction with the PCL45USB serial link, to configure these
modules. Instructions are contained within the software. See Section 6.9 on page 58 for
further details.
All MTL4573 and MTL4575 modules are supplied with the following default configuration.
Input type Type K thermocouple

Linearisation enabled
Units °C
CJ Compensation enabled
Damping value 0 seconds
Smoothing value 0 seconds
Output zero 0°C
Output span 250°C
Tag and description fields blank
Open circuit alarm set high (upscale)
Transmitter failure alarm set low (downscale)
CJ failure alarm set low (downscale)
Line frequency 50Hz
Use PCS45 software, in conjunction with the PCL45USB serial link, to modify these default values.
51 INM 4500/4600 Rev 13

6.7.1 MTL4573 - Temperature Converter
Single channel, THC or RTD input
The MTLx573 converts a low-level dc signal from a temperature sensor mounted

in a hazardous area into a 4/20mA current for driving a safe-area load. Software
selectable features include linearisation, ranging, monitoring, testing and tagging for all
thermocouple types and 2-, 3- or 4-wire RTDs. (For thermocouple applications the HAZ-
CJC plug on terminals 1–3 includes an integral CJC sensor). Configuration is carried out
using a personal computer with PCS45 software.

Configuration
socket
*
4-wire 6 12 ID
5 11
4 mV 10 Load
3-wire
+ +
3 9
4/20mA
mV 2 I 8
–
– 1 7
3 13 14
20 to 35V dc
Vs+
Vs–
Figure 6.34:
Top labels for Terminal Function
MTL4573
1 THC/mV/RTD input –ve
3 THC/mV/RTD input +ve
4 3-wire RTD input –ve
5 4-wire RTD input +ve
8 Output –ve
9 Output +ve
11 Output –ve
12 ID resistor (*MTL4573Y only)
13 Supply –ve
14 Supply +ve
Top label
Status PWR (green) STS(yellow)

Power ON ON
Insufficient voltage or Power OFF OFF
Normal working ON
Device failure FLASH
Sensor failure/Error FLASH
Early burnout detection (EBD) FAST FLASH
52 INM 4500/4600 Rev 13

6.7.2 MTL4575 - Temperature Converter
Single channel, THC or RTD input with alarm
The MTL4575 converts a low-level dc signal from a temperature sensor mounted

in a hazardous area into a 4/20mA current for driving a safe-area load. Software
selectable features include linearisation, ranging, monitoring, testing and tagging for all
thermocouple types and 2, 3 or 4-wire RTDs. (For thermocouple applications the HAZ-CJC
plug, on terminals 1–3, includes an integral CJC sensor). A single alarm output is provided
and may be configured for process alarm or to provide notice of early thermocouple
failure.

Configuration
socket
Alarm
4-wire 6 12
5 11

4 mV 10 Load
3-wire
+ +
3 9
4/20mA
mV 2 I 8
–
– 1 7
13 14
20 to 35V dc
Vs+

Vs–
Figure 6.35:
MTL4575 1 THC/mV/RTD input –ve
3 THC/mV/RTD input +ve
4 3-wire RTD input –ve
5 4-wire RTD input +ve
8 Output –ve
9 Output +ve
11 Output –ve/Alarm relay
12 Alarm relay
13 Supply –ve
14 Supply +ve
Top label
Status PWR (green) STS(yellow)

Power ON ON
Normal working ON
Device failure FLASH
Sensor failure/Error FLASH
Output relay ON (Trip) ON ON
Output relay OFF (Trip) ON OFF
Early burnout detection (EBD) FAST FLASH
53 INM 4500/4600 Rev 13

6.7.3 MTL4576-RTD - Temperature Converter
Two channel, RTD/potentiometer input
The MTL4576-RTD converts signals from resistance temperature detectors (RTDs)

mounted in a hazardous area, into 4/20mA currents for driving safe-area loads. The
MTL4576-RTD is compatible with 2- and 3-wire RTD inputs.
Performance features, including input type and characterisation, ranging, monitoring,

testing and tagging are selected using PCS45 software, which is loaded onto a personal
computer and connected via the PCL45USB serial link - see Section 6.9.

Configuration
socket
Load
3-wire +
6 12 4/20mA Ch2
Ch2 5 11 –
Ω
4 10 Load

I
3-wire +
3 9 Ch1
4/20mA
Ch1 2 I 8 –
1 7

13 14
20 to 35V dc
Vs+

Vs–
Figure 6.36:
Terminal Function
Top label for
MTL4576 1 RTD input (Ch1)
2 RTD input (Ch1)
3 3–wire RTD input (Ch1)
4 RTD input (Ch2)
5 RTD input (Ch2)
6 3–wire RTD input (Ch2)
8 Output –ve (Ch1)
9 Output +ve (Ch1)
12 Output +ve (Ch2)
13 Supply –ve
14 Supply +ve
Top label
Status PWR (green) FLT (red) STS(yellow)

Power ON ON
Communication in progress FLASH
Normal working ON OFF OFF
Device failure ON ON
Channel 1 - Sensor failure/Error ON FLASH OFF
Channel 2 - Sensor failure/Error ON FLASH ON
Default configuration for both channels is as shown in 6.7 except:
• Input type: pt100 3 wire RTD

• S/C alarm set low (downscale)
54 INM 4500/4600 Rev 13

6.7.4 MTL4576-THC - Temperature Converter
Two channel, mV/THC input
The MTL4576-THC converts low-level dc signals from temperature sensors mounted in

a hazardous area, into 4/20mA currents for driving safe-area loads. The hazardous area
connections include cold-junction compensation and do not need to be ordered separately.
Performance features, including linearisation for standard thermocouple types, ranging,

monitoring, testing and tagging are selected using PCS45 software, which is loaded onto a
personal computer and connected via the PCL45USB serial link - see Section 6.9.

Configuration
socket
Load
+ 6 +
12 4/20mA Ch2
Ch2 mV 5 11 –
– 4 mV
10 Load
I
+ +
3 9 Ch1
4/20mA
Ch1 mV 2 I 8
– 1 –
7

13 14
20 to 35V dc
Vs+
Vs–
Figure 6.37:
Terminal Function
Top label for
MTL4576 1 THC/mV (Ch1)
3 THC/mV (Ch1)
4 THC/mV (Ch2)
6 THC/mV (Ch2)
9 Output +ve (Ch1)
12 Output +ve (Ch2)
13 Supply –ve
14 Supply +ve
Top label
Status PWR (green) FLT (red) STS(yellow)

Power ON ON
Communication in progress FLASH
Normal working ON OFF OFF
Device failure ON ON
Channel 1 - Sensor failure/Error ON FLASH OFF
Channel 2 - Sensor failure/Error ON FLASH ON
Default configuration for both channels is as shown in 6.7 except S/C alarm set OFF.
55 INM 4500/4600 Rev 13

6.7.5 MTL4581 - mV/Thermocouple Isolator
Single channel, mV/THC input for low power signals
The MTL4581 takes a low-level dc signal from a voltage source in a hazardous area,
isolates it, and passes it to a receiving instrument located in the safe area. The module
is intended for use with thermocouples utilising external cold-junction compensation.
A switch enables or disables the safety drive in the event of thermocouple burnout or a
cable breakage; a second switch permits the selection of upscale or downscale operation
as the application requires.
6 12
5 11
4 10
3 mV 9 Output*
mV 2 8
1 mV 7
*Use compensating
cable with
thermocouple inputs
13 14
20 to 35V dc
Vs+
Vs–

Figure 6.38:
MTL4581
1 THC/mV input –ve
2 THC/mV input +ve
8 Output –ve
9 Output +ve
11 Output –ve
13 Supply –ve
14 Supply +ve
Please note that the safety drive on the MTL4581 responds to a line breakage (i.e. an open
circuit) or a thermocouple burnout. It does not provide detection of a short circuit. It can
however, when chosen, be set to drive the output either upscale or downscale. These
options are selected using the switches located on the side of the module.
Safety drive switches

Line
Sw2 Sw1 Vout value
breakage
Safety drive Drive direction
OFF N/A NO Vin*
OFF N/A YES undetermined
ON + NO Vin*
ON + YES > +50mV
ON – NO Vin*
ON – YES < –50mV
* Within Vin/Vout transfer accuracy and drift error as specified in the product datasheet.
Safety drive switches
OFF position
ON position
Sw 1 Sw 2
Sw1 OFF ON Sw2 OFF ON
Drive direction ‘+’ Upscale ‘–’ Downscale Safety drive OFF ON
56 INM 4500/4600 Rev 13

6.8 General modules
These are general purpose modules that have applications associated with the MTL4500
range of modules.
6.8.1 MTL4599 - Dummy Isolator

The primary function of the MTL4599, is to provide termination and earthing facilities for
unused cable cores from hazardous areas, that can occur, for example, if any MTL4500
module has been removed for maintenance purposes.
6 12
5 11
Unused 4 10 Unused
hazardous- safe-area
area cores 3 9 cores
2 8
1 7
13 14
Unused safe-area cores
6.8.2 MTL4599N - General purpose feedthrough module

The feed-through termination module allows non–IS connections to the MTL4500
backplanes. The wires from the field are connected using screw terminals. Six terminals
are provided for each contact of the multiway connector on the backplane. The terminals
and cables conform to IS regulations so that non–IS and IS signals can be mixed on the
same backplane.
Safe area
12 12
11 11
10 10
9 9
8 8
7 7
13 14
Note: Must not be used with signals >50V or >0.25A
57 INM 4500/4600 Rev 13

6.9 PCS45/PCL45USB configurator for MTL temperature
converters
The PCS45/PCL45USB configurator allows MTL isolating temperature converters to be
configured from a standard PC running a Microsoft® Windows® operating system. The
configurator comprises PC software provided on a CD (PCS45), and an ATEX certified interfacing
link (PCL45USB). Temperature converters can be configured from the safe area, while on-line,
and the software allows configurations to be saved to disk and printed out when required.
Safe area
It is suitable for use with MTL4000, MTL4500, MTL4600, MTL5000 and MTL5500 range of
products.
PCL45USB hardware
The PCL45USB provides the interfacing link between the converter module and the PC
running the software and connects to the PC using the USB cable provided. The PCL45USB
has a built-in cable fitted with a 3.5mm jackplug to connect to the ‘Config’ socket on MTL4500
and MTL5500 range of converters. An adapter cable is also provided to accommodate our
earlier converters.
PCS45 Configuration software

The software provided on the CD requires only approximately 20Mb of hard disk space and is
compatible with Windows 2000, Windows XP or Windows 7. Ensure that the chosen PC has a
CD ROM drive and an available USB port. A local or network printer may also be an advantage.
Safety
It is not permitted to connect the PCL45USB to any device other than one approved by
Eaton. Authorisation is valid provided that the converter type is named on the PCL45USB
certificate or if the PCL45USB is specified on the converter certificate. Repairs to the
PCL45USB are not permitted.
Setting up
The equipment can be used only in the safe area.
Before plugging in the PCL45USB link to the computer, extract the USB driver files to a
known location on your PC. Afterwards, plug in the PCL45USB to the USB port on the PC
and wait for it to find the new device. When requested by the computer, show it the location
of the driver files so that it can complete the device installation.
Place the PCS45 software CD in the computer’s CDROM drive and follow the on-screen
instructions to install the software.
The PCL45USB is powered from the data lines and quickly establishes communication after
plugging the 3.5mm connector to the device socket.
Note: Ensure that the 3.5mm jack plug is fully inserted into the socket of the temperature
converter.
The software and its operations manual (INM PCS45) is available on-line at:
http://www.mtl-inst.com/product/configuration_tools_and_software/
58 INM 4500/4600 Rev 13

7 FAULT FINDING AND ROUTINE MAINTENANCE
WARNING!
On removal, take care that a hazardous-area connector is not laid in a position
in which it may inadvertently come into contact with the backplane or with
components on the backplane.
7.1 Maintenance precautions

Most Codes of Practice for intrinsic safety permit live maintenance on intrinsically safe
devices and systems, provided precautions are taken to preserve the integrity of the device
or system. During live maintenance of MTL4500 modules, the hazardous-area connectors
that plug into the tops of the modules are likely to be removed. Avoid leaving a hazardous-
area connector in a position where it may inadvertently contact non-IS circuits that are
nearby. Prevent this by providing some form of temporary mechanical method of securing
the connector so that it cannot come into contact with the non-IS circuits:
d) By plugging the connector into an MTL4599 dummy isolator
e) By using a tiewrap to constrain the connector in a safe position.
7.2 Fault finding

When fault finding, carry out the following steps as far as is necessary:–
7.2.1
Check that one of the backplane power LEDs is ON.
7.2.2
If a power LED is not on, check the power supply fuse and if necessary, change it. Ratings
are:–
f) 4/8-way backplanes 1A (Spare fuse kit FUS1.0ATE5)
g) 16-way backplanes 2A (Spare fuse kit FUS2.0ATE5)
h) 24/32-way backplanes 4A (Spare fuse kit FUS4.0ATE5)
7.2.3
Check that all modules with power (PWR) LEDs are ON.
With the MTL4532, MTLx573, MTL4575 & MTL4576 models, a flashing LED indicates alarm
or fault conditions - refer to section 8. Note: The LED may also flash during intermediate
stages of configuration.
7.2.4
Exchange potentially faulty modules for working units as follows:–
a) Unplug the hazardous-area connectors.
b) Unplug the module from the backplane.
c) Plug the replacement unit into the backplane.
d) Replace the hazardous-area connectors.
7.2.5
Potentially faulty modules should be tested in workshop conditions, using the following
procedure:–
a) Connect a power supply to a spare CPS backplane (refer to sections 4.4.2 or 4.4.4).
b) Plug the suspect module into any position on the backplane.
c) Carry out the appropriate test procedure described in Section 8 for the particular module.
7.3 Routine maintenance

Check the general condition of the installation occasionally to make sure that no
deterioration has occurred. Carry out the following at least once every two years and more
frequently for particularly harsh environments:–
a) Check that modules are of the types specified in the relevant documentation and that
they are mounted in the correct positions on the associated backplanes.
b) Check that modules and hazardous-area connectors are correctly and legibly tagged,
that the connectors are plugged into the matching modules and that the tag details
given comply with the relevant documentation.
59 INM 4500/4600 Rev 13

c) Check that modules and hazardous-area connectors are securely plugged into their
matching sockets.
d) Check that all connections to the backplane and to the hazardous-area connectors are
properly made.
e) Check that connecting cables to backplanes and to hazardous-area connectors are
of the specified type and rating, are correctly routed and segregated (particularly in
Eaton enclosures), and are not frayed or otherwise damaged.
f) Check that cable screens are properly earthed.
Note: It is strongly recommended that only the tests (described in Section 8) and routine
maintenance (described here) should be undertaken by users. If a module is faulty, DO
NOT attempt to make repairs or modifications as these may affect the intrinsic safety of the
module. All faulty units should be returned to the Eaton’s MTL product line or representative
from which they were purchased, for repair or replacement.
Any faulty backplanes supplied by us should also be similarly returned.
60 INM 4500/4600 Rev 13

8 BENCH TESTING MODULES
The following methods have been devised to permit the user to perform simple module tests
on the bench and confirm basic in put to output operation. Field units that do not perform
as described below, or modules that have ‘unusual’ operating behaviour, should be replaced
and returned to us.
Consult individual module wiring diagrams for terminal connections.
Unless stated specifically, the module will require dc power, as if under normal operating
conditions.
8.1 Digital Input (DI) modules

8.1.1 Modules: MTL4501-SR, MTL4504, MTL4510, MTL4510B, MTL4511, MTL4513,
MTL4514, MTL4514B, MTL4514N, MTL4516, MTL4516C, MTL4517
Input Conditions
1. Connect the appropriate input test circuit to the channel under test (see Figure 8.1 &
Table 8.1).
2. For multi-channel modules with LFD, connect a 22k resistor across the other channel
input(s) to prevent the signalling of an unwanted open-circuit line fault.
3. Where appropriate test with phase reversal switch in both OFF and ON conditions.

Figure 8.1:
DI input
test circuit

Model Resistor values Switch – simulation conditions

MTL4501-SR R1 = 10k R2 = 1k4
MTL4504
a) Normal - field switch open
MTL4510/4510B
MTL4511 b) Normal - field switch closed
MTL4513
R1 = 22k , R2 = 680 c) Line Fault - Test for short circuit
MTL4514x
MTL4516 d) Line Fault - Test for open circuit
MTL4516C
MTL4517
Table 8.1 Input test conditions
Output Results
1. For MTL4510 and MTL4510B modules refer to pages 18-21 of this manual.
2. The phase reversal switch will reverse the channel output conditions, but not the LFD.
3. With LFD disabled (OFF) the Status LED should respond as shown in Table 8.2.
4. With LFD disabled (ON) the LEDs and relay should respond as shown in Table 8.3.
Input switch Channel contacts Status

NOTE MTL4514N Contacts
positions NC NO LED
a Closed Open OFF Closed 2k2

Channel
b Open Closed ON Open OPEN
c Open Closed ON Closed 15k
LFD
d Closed Open OFF Open OPEN
Table 8.2 LFD - OFF output test results
Channel contacts LEDs LFD relay

Input switch
positions NC NO Status LFD MTL450x/ MTL451x
MTL4514N
a Closed Open OFF OFF Energised De-energised
b Open Closed ON OFF Energised De-energised
c Closed Open OFF ON De-energised Energised

d Closed Open OFF ON De-energised Energised
Table 8.3 LFD - ON output test results
61 INM 4500/4600 Rev 13

8.2 Digital Output (DO) modules
Apply tests per channel.
8.2.1 Loop powered: - MTL4521 & MTL4521L, MTL4521Y & MTL4523L
Figure 8.2: +
Vs–
Loop powered V A o/p i/p
DO test circuit – Vs+
1. Connect a voltmeter between the + & – output terminals of the module, observing polarity.
2. Apply 24V between the supply terminals (Vs+, Vs–)
3. The voltmeter should indicate a value between 21.4 and 24 volts
4. Switch off the power to the module
5. Connect an ammeter between the + & – output terminals of the module, observing
polarity
7. The ammeter should indicate no less than 48mA (or 70mA for MTL4621)
8.2.2 Powered:- MTL4523, MTL4523R, MTL4523V, MTL4523VL, MTL4523Y, MTL4524 & MTL4524S
& MTL4525
Figure 8.3: MTL4523V/VL

Powered + + +
DO test circuit V A o/p i/p Control 24V
– – –
1. Connect a voltmeter between the + & – output terminals of the module, observing polarity
2. Apply 24V between the supply terminals Vs+, Vs–
3. The voltmeter should now indicate no more than 4V
4. Close the Control switch or, for the MTL4523V ot MTL4523VL apply the 24V source
5. The voltmeter should now indicate a value between 21.4 and 24 volts
6. Switch off the power to the module
7. Connect an ammeter between the + & – output terminals of the module, observing polarity
9. Close the Control switch or, for the MTL4523V or MTL4523VL apply the 24V source
10. The ammeter should indicate no less than 48mA (or 70mA for equivalent MTL4600 models)
8.2.3 Relay: - MTL4526
Figure 8.4:
DO test circuit NO +
for relay type NC o/p i/p Control
Common –
1. Set in 2-channel mode (SW1 - SW4 respectively to Off, On, On, On)
2. Confirm continuity between NC and Common
3. Apply 24V between the supply terminals Vs+, Vs–
4. Close the Control switch
5. Confirm continuity between NO and Common
62 INM 4500/4600 Rev 13

8.3 Analogue Input (AI) Modules
All of these tests compare the output current with the input current (A1) over the normal
range of operation, and measure the “error current” i.e. the difference - as indicated on A2.
Apply these tests per channel, as appropriate.
Ammeter A2 must be capable of handling either polarity. If it is not an auto-ranging

instrument, set it to a high range before switch on, then adjust sensitivity to obtain the
required reading.
8.3.1 Modules: MTL4541, MTL4541B/P/T, MTL4541Y, MTL4544, MTL4544B &

MTL45544D

Figure 8.5:
AI test circuit #1

Output Measurements
Note: Do not connect a voltmeter in circuit to measure V1 until requested in Step 4 below,
because current measurement A2 could be affected.
1. Adjust RV1 to vary the current (A1) through the range 4 to 20mA
2. The measured current imbalance (A2) over this range should not exceed ± 20µA
3. Adjust RV1 for a 20mA reading on A1
4. The voltage V1, across the channel input, should typically be >16.5V.
8.3.2 Modules: MTL4541S, MTL4544S & MTL4561
– A1
+
+
Ii A2 Io
–
Figure 8.6:
AI test circuit #2 –
“o/p sinking” 24V
RV1
+
10kΩ lin. 250Ω
+ +
V1 i/p o/p
– –
Output Measurements
Note: Do not connect a voltmeter in circuit to measure V1 until requested in Step 4 below,
because current measurement A2 could be affected. Set A2 range to
1. Adjust RV1 to vary the current (A1) through the range 4 to 20mA.
2. The measured current imbalance (A2) over this range for the MTL4541S and the
MTL4544S should not exceed ± 20µA. For the MTL4561 the imbalance should not
exceed ± 400µA.
3. Adjust RV1 for a 20mA reading on A1
4. The voltage V1, across the channel input, should typically be >16.5V.
63 INM 4500/4600 Rev 13

8.3.3 Modules: MTL4541A, MTL4541YA & MTL4544A

Figure 8.7:
AI test circuit #3
“active i/p”

Output Measurements
2. The measured current imbalance (A2) over this range should not exceed ± 20µA
8.3.4 Modules: MTL4541AS & MTL4544AS

Figure 8.8:

AI test circuit #4

“active i/p -

o/p sinking”

Output Measurements
8.3.5 The measured current imbalance (A2) over this range should not exceed ± 20µA
64 INM 4500/4600 Rev 13

8.3.6 Module: MTL4581

Figure 8.9:
AI test circuit #5
“mV input”

Note: V1 should be capable of measurement to within 1µV.

Output Measurements
1. With the LINK connected, vary output V2 between 0 and 50mV using RV1. V1 should
show <50µV variation. (Note: Safety Drive can be ON or OFF )
2. With the LINK disconnected and Safety Drive ON, V2 should drive to >+50mV with the
switch set to ‘+’, or <–50mV with the switch set to ‘–’.
8.4 Analogue Output (AO) Modules

The test compares the output current with the input current over the normal range of
operation.
8.4.1 Modules: All variants

Input Conditions
The chosen “load” resistor can be any value between 100 and 800 .
– A1 +
Ii A2 Io
+
Figure 8.10:
470Ω
AO test circuit load current
source
–
+ –
o/p i/p
– +
Output Measurements
1. Adjust the current source to vary the current (A1) through the range 4 to 20mA.
2. The measured current imbalance (A2) over this range should not exceed ± 20µA.
8.5 Testing the functioning of other modules

Simple tests to verify their basic operation can be devised for other modules (e.g.
temperature, pulse, vibration, etc). If any assistance is required for the testing of a particular
module, please contact the technical support department at Eaton for advice.
65 INM 4500/4600 Rev 13

8.5.1 Testing
Make the safe- and hazardous-area connection shown in figure 8.12.
Figure 8.11: Test circuit for MTL4531
Measure the voltage on terminal 3 with respect to terminal 1; this should be >19V. Vary the
potentiometer setting and check that the reading on voltmeter V varies by no more than
±100mV.
9 APPLICATIONS INVOLVING ZONE 2 AND/OR ZONE 22

HAZARDOUS AREAS
IMPORTANT: See the front of this manual for important additional information regarding
the use of these products in countries governed by the ATEX Directive.
The European Community permits Category 3G equipment, such as the MTL4500 range,
to be installed in, or connected to, Zone 2 flammable atmospheres provided it meets the
requirements of the ATEX Directive.
MTL4500 Category 3 products have been designed to meet, and carry approval markings
for, Ex nC and/or Ex nA.
In general, meeting the relevant requirements of the appropriate European (CENELEC)

standards is considered the most appropriate method of demonstrating compliance with the
ATEX directive. However, Eaton often has its products approved by other national bodies,
such as FM and CSA and, because national, European, and international standards are
converging, it is generally possible to use other national approvals as supporting evidence
for the ATEX Technical File.
In the context of this document, Zone 2 (Division 2) and Zone 22 hazardous areas are those
that may become potentially explosive through the presence of flammable gases, vapours
and dusts for periods of up to 10 hours per year. It is recommended that the current version
of the standards is consulted for detailed information on the requirements applicable to the
particular installation.
As a consequence of their IS approvals, MTL4500 products may also be connected into

Zone 22 hazardous areas. Consult individual module approvals for further details.
Unless otherwise specified, the following ambient conditions apply:
Ambient Temperature range –20°C to +60°C

Pollution Degree 2 (See EN 61010-1)
Measurement Category II (See EN 61010-1)
9.1 Enclosure
EN 60079-15 specifies the minimum required degree of protection to be IP54, but generally
this is provided by the external enclosure in which the product is mounted.
The user must refer to the specific certificates relating to the products being installed within
the hazardous area to check that all special conditions of safe use have been complied with.
66 INM 4500/4600 Rev 13

10 APPENDIX:
10.1 Table A - Safety descriptions
All models are Um = 253V
Terminals/
Bornes/Klemme/ Uo Io Po
Model No. Terminales (V) (mA) (mW)
MTL4501-SR 9.7 30 70
MTL4504/ MTL4510 / MTL4510B/

MTL4511 / MTL4513/ MTL4514 10.5
14 37
MTL4514B/ MTL4514D /MTL4516
MTL4516C / MTL4517
MTL4521/ MTL4521Y 25 147 920

MTL4521L 25 108 680
MTL4523/ MTL4523L
25 147 920
MTL4523R/ MTL4523V
MTL4523VL 25 108 680
MTL4524/ MTL4524S 25 147 920
MTL4525 25 83.3 521
MTL4526 1 3, 4 6 Non-energy storing *
3 1 26.6 94 660
MTL4531 3 2 1.1 0.1 0.03
2 1, 6 1 10.5 14 37
3 1 1.1 53 15
93 @ 28V
4+3 1 28 650
MTL4532 146 @ 2.9V
5+4 1 28 9 650
Uo = 8
config † 15 27
Ui = 9.1
MTL4541/ MTL4541B 28 93 651
8.6
MTL4541A/ MTL4541AS – –
(diode)
MTL4541P 28 116.6 820
MTL4541S 28 93 651
MTL4541T 22 167 920
MTL4544/ MTL4544B/ MTL4544D
28 93 651
MTL4544S
8.6
MTL4544A/ MTL4544AS – –
(diode)
MTL4546/ MTL4546C /MTL4546Y

28 93 651
MTL4549/ MTL4549C/ MTL4549Y
MTL4546S 22 100 0.55

MTL4561 28 93 651
1+2+3+4+5+6 6.6 76 130
3 1 Non-energy storing *
MTL4573/ MTL4573Y 3,2 & 1 6.6 10 17
Uo = 8
config † 14.6 26
Ui = 9.1
1+2+3+4+5+6 6.6 76 130
3 1 Non-energy storing *
MTL4575 3,2 & 1 6.6 10 17
Uo = 8
config † 14.6 26
Ui = 9.1
1,2 & 3, 4,5,& 6 6.6 28 46.2
3 1, 6 4 Non-energy storing *
MTL4576
Uo = 5.88
config † 12 17.7
Ui = 9.1
Uo = 1.1 Io = 53
MTL4581 15
Ui = 28 Ii = 120
1+2+3+4 & 5 6.51 16 16.1
1, 3 & 4 6.51 6 9.2
MTL4582B Uo = 1.2
3 1 4 1.2
Ui = 5
Uo = 1.2
config † 12 17.7
Ui = 5
* Appareil ne stockant pas d’energies / Betriebsmittel ohne energiespeicherung /

Aparatos que no almacenan energia (≤ 1.5V; ≤ 0.1A; ≤ 25mW)
† config - configuration socket / fiche de configuration / konfigurationssocket / toma con configuración
Note: Certificate IECEx TSA 20.0021 only includes models MTL4501-SR, MTL4514D, MTL4526, MTL4531, MTL4532,
MTL4533, MTL4541A, MTL4541AS, MTL4541S, MTL4544A, MTL4544AS, MTL4544D, MTL4544S, MTL4561,
MTL4573, MTL4573Y, MTL4576, MTL4581 and MTL4582B.
67 INM 4500/4600 Rev 13

10.2 Table B – Maximum cable parameters
Model No. Terminals/ Group/Groupe/Gruppe/Grupo Group/Groupe/Gruppe/Grupo Group/Groupe/Gruppe/Grupo

Bornes/ I IIB / IIIC IIC
Klemme/
Terminales
C L L/R C L L/R C L L/R
(μF) (mH) (μH/Ω) (μF) (mH) (μH/Ω) (μF) (mH) (μH/Ω)
MTL4501-SR 320 501 6,414 24 145 1,829 3.5 39 475
MTL4054/ MTL4510
MTL4510B/ MTL4511
MTL4513/ MTL4514 95 1000 1,333 16.8 680 1333 2.41 175 983
MTL4514B/ MTL4514D
MTL4516/ MTL4516C
MTL4517
MTL4521 4.87 20.2 478 0.84 7.2 159 0.11 1.4 40
MTL4521L 4.87 40.0 691 0.84 12.19 210 0.11 3.04 52
MTL4523/ MTL4523L 4.87 20.2 478 0.84 7.2 159 0.11 1.4 40
MTL4523R/ MTL4523V
MTL4523VL 4.87 40.0 691 0.84 12.19 210 0.11 3.04 52
MTL4524/ MTL4524S 4.87 20.2 478 0.84 7.2 159 0.11 1.4 40
MTL4525 4.87 64.9 814 0.84 21.8 254 0.11 5.3 68
MTL4526 1 3, 4 6 - - - - - - - - -
3 1 4.27 52.81 746 0.73 16.09 227 0.094 4.02 56
MTL4531
3 2 1,000 1,000 1,000 1,000 1,000 1,000 100 1,000 1,000
2 1, 6 1 95.0 1,000 1,333 16.8 725.6 1,333 2.41 181.4 967
3 1 1,000 166.1 32,018 1,000 50.6 9,757 100 12.6 2,439
MTL4532 4+3 1 3.76 21.8 668 0.65 6.67 210 0.083 1.66 55
5+4 1 3.76 52.8 668 0.65 16.0 210 0.083 4.02 55
config † 12.32 797.5 1,484 2.15 243.0 1,441 0.367 60.7 360
3 1, 6 4 4.27 52.81 746 0.73 16.09 227 0.094 4.02 56
MTL4533
3 2, 6 5 1,000 1,000 1,000 1,000 1,000 1,000 100 1,000 1,000
MTL4541/ MTL4541S 2 1, 5 4 3.76 53.7 668 0.65 12.6 210 0.083 4.2 56
MTL4541B/ MTL4544 3 1, 6 4 1,000 156.2 28,229 1,000 47.8 8,932 100 12.8 2,438
MTL4544B/ MTL4544D
MTL4544S 2 3, 5 6 3.76 59.1 710 0.65 20.2 222 0.083 4.9 59
MTL4541A/ MTL4541AS 2 1, 5 4 1,000 65.82 17,740 55 20.06 5,406 6.2 5.01 1,351
2 1, 5 4 1,000 65.82 17,740 55 20.06 5,406 6.2 5.01 1,351
MTL4544A/ MTL4544AS
501 (Ch 1&2 12.16 65.82 8,870 2.11 20.06 2,703 0.36 5.01 675
series)
MTL4541P 2 1 3.76 33.5 545 0.65 11.8 175 0.083 2.7 45
MTL4541T 2 1 6.00 16.4 517 1.14 5.5 147 0.165 0.91 39
MTL4544A/ MTL4544AS 12.16 65.82 8,870 2.11 20.06 2,703 0.36 5.01 675
MTL4546S 2 1 6.00 44.3 848 1.14 14.6 258 0.165 3.55 64
MTL4546/ MTL4546C
MTL4546Y/ MTL4549 2 1, 5 4 3.76 53.7 668 0.65 12.6 210 0.083 4.2 56
MTL4549C/ MTL4549Y
MTL4561
MTL4573/ 1+2+3+4+5+6 1,000 77.2 3,402 500 25.6 1,057 22 6.42 288
MTL4573Y config † 12.32 1,000 1,453 2.15 591 1,355 0.367 153 349
1+2+3+4+5+6 1,000 77.2 3,402 500 25.6 1,057 22 6.42 288
MTL4575
config † 12.32 1,000 1,453 2.15 591 1,355 0.367 153 349
1 to 4 1,000 264.5 6,363 500 80.6 2,052 22.0 20.1 513
1,2 & 3 500 297.6 2,121 250 90.7 1,537 11.0 22.6 384
MTL4576 4,5 & 6
3 1, 6 4 500 500 1,666 500 500 1,666 50 500 1,666
config † 15.8 1,000 1,412 2.88 317.9 1,412 0.478 79.4 448
MTL4581 1,000 155.7 28,229 1,000 47.3 8,932 100 12.3 2,438
1, 3, 4 & 5 1,000 1,000 1,536 500 1,000 1,536 22.0 355.5 1,536
MTL4582B 1, 3 & 4 1,000 1,000 921 500 1,000 921 22.0 987.6 921
3 1 1,000 1,000 3,333 1,000 1,000 3,333 100 1,000 3,333
config † 15.8 1,000 1,412 2.88 317.9 1,412 0.478 79.4 448
† config - configuration socket / fiche de configuration / konfigurationssocket / toma con configuración
Note: Certificate IECEx TSA 20.0021 only includes models MTL4501-SR, MTL4514D, MTL4526, MTL4531, MTL4532, MTL4533,
MTL4541A, MTL4541AS, MTL4541S, MTL4544A, MTL4544AS, MTL4544D, MTL4544S, MTL4561, MTL4573, MTL4573Y,
MTL4576, MTL4581 and MTL4582B.
68 INM 4500/4600 Rev 13

This page is left intentionally blank
69 INM 4500/4600 Rev 13

EATON Crouse-Hinds series
The safety you rely on.
See the complete MTL product portfolio at www.mtl-inst.com
For more information:

If further assistance is required, please contact
an authorised MTL Distributor, Sales Office,
or Customer Service Department
https://www.mtl-inst.com/contact
Eaton Electric Ltd

Great Marlings, Butterfield, Luton
Beds LU2 8DL
Tel: +44 (0) 1582 723633 Fax: +44 (0)1582 422283
E-mail: [email protected]
www.mtl-inst.com
EUROPE (EMEA): The given data is only intended as a product

Eaton Electric Limited, description and should not be regarded as a legal
+44 (0)1582 723633
Great Marlings, Butterfield, Luton warranty of properties or guarantee. In the interest
[email protected]
Beds, LU2 8DL, UK. of further technical developments, we reserve the
Tel: + 44 (0)1582 723633 Fax: + 44 (0)1582 422283 right to make design changes.
THE AMERICAS:
E-mail: [email protected] +1 800 835 7075
www.mtl-inst.com [email protected]
© 2022 Eaton
ASIA-PACIFIC:
All Rights Reserved
+65 6 645 9888
Publication No. INM 4500/4600 Rev 14 211022
[email protected]
October 2022

Crouse Hinds Mtl4500 4600 Isolating Interface Units Manual

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Instruction manual

ii INM 4500/4600 Rev 13

2 MTL4500 RANGE DESCRIPTION. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

6 UNIT DESCRIPTIONS, SETTING-UP AND CONNECTIONS. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14

(continued on next page)

iii INM 4500/4600 Rev 13

7 FAULT FINDING AND ROUTINE MAINTENANCE. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 59

8 BENCH TESTING MODULES. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 61

9 APPLICATIONS INVOLVING ZONE 2 AND/OR ZONE 22 HAZARDOUS AREAS . . . . . . . . . . . . . . . . . . 66

© 2022 Eaton Electric Limited. All rights reserved.

iv INM 4500/4600 Rev 13

• MTL4500 range of isolating interfaces for Intrinsic Safety

• MTL4600 range of signal conditioners

MTL4500 range of products

Symbols used on the product and in this manual

v INM 4500/4600 Rev 13

Special Conditions of Safe Use for Zone 2 applications

vi INM 4500/4600 Rev 13

g) For 4573 Maximum Input/Output parameters – see certificate

Inspection and maintenance

b) Access to the internal circuitry must not be made during operation.

Example label showing markings:

MTL4541B Repeater power supply, 4/20mA, for 2 or 3 wire transmitters

Hazardous area -20°C  Ta  +60°C

EATON ELECTRIC LTD, Luton, England,

vii INM 4500/4600 Rev 13

viii INM 4500/4600 Rev 13

The individual sections cover the following topics

• Section 2 describes the range and its accessories

• Section 3 specifies precautions before installation

• Section 4 covers the installation of backplanes

• Section 5 describes the installation of modules onto the backplanes

• Section 6 provides relevant technical data

• Section 7 outlines fault-finding and maintenance

• Section 8 describes bench test procedures

• Section 9 provides hazardous-area application information

• Section 10 provides safety parameter information

1.2 The MTL4500 concept

1.3 The MTL4600 concept

1 INM 4500/4600 Rev 13

2 INM 4500/4600 Rev 13

2.1 Standard backplanes

2.2 Customised backplanes

3 INM 4500/4600 Rev 13

4 INM 4500/4600 Rev 13

4.1 Backplane mounting

Table 4.1: Backplanes, mounting kits and accessories

Backplane Number Safe-area Mounting Kits Accessories

CPS04 4 Screw-clamp SMS01 DMK01 – – – FUS1.0ATE5

CPS08 8 Screw-clamp SMS01 DMK01 – ERK08 TSK08 FUS1.0ATE5

CPS16 16 Screw-clamp SMS01 DMK01 – ERK16 TSK16 FUS2.0ATE5

CPS24 24 Screw-clamp SMS01 DMK01 HMP24 – TSK24 FUS4.0ATE5

4.1.1 Surface mounting – with SMS01 mounting kit

Figure 4.2: Surface mounting

4.1.2 T- or G-section DIN-rail mounting – with DMK01 mounting kit

6 x 1/2 inch screw (1) 6 x 1/2 inch screw (1)

Mounting hole A Spacer (5) Mounting hole A Spacer (5)

5 INM 4500/4600 Rev 13

a) Place an unloaded backplane onto the HMP24 mounting plate.

Hazardous area -20°C Ta +60°C

Switch-type sensors