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TX9042 User Manual

1. Slip Frequency 9 00 Differential Frequency O 7 o Soo Refer to Section 5 9 7 for details of Mode Setting for a Digital Inout Module www trolex com TX9042 UM EN 01 31 TROLEX lt Type of Input Range Module Ref Connections Digital Voltage free Pode 2 voltage free contacts Failsafe contacts with Channel On Off switches series diode connected In series with a diode to give combined open circuit short circult sensor connection protection mojej Digital Vortex 5 V output Channel 1 airflow sensor TX5925 Vortex TTL input P9423 924 ls Airflow Sensor TX5925 32 TX9042 UM EN 01 www trolex com TX9042 User Manual 4 6 3 Display of Connection Channel 2 4 20mA Details Ab Ey uun AG CURRENT IN For convenience input terminal connection AT L ciuirirlelNit OUT details for any channel can be displayed on the LCD screen Refer to Section 5 9 2 21 for details 4 6 4 Replacing an Input Module The individual channel input conditioning modules are plug in and can easily be replaced if required by removing the rear panel of the housing The main processor will automatically be re programmed for the new function of the replacement module Checkpoint Channel input conditioning modules MUST NOT be replaced underground 4 6 5 Cable Distance Calculation for Loop Powered 4 to 20 mA Sensors Maximum cable distance Vs Vms 0 02 x R cable km Vs Supply Volta
2. 104 TX9042 UM EN 01 www trolex com TX9042 User Manual 3 On one of the input channel s identified in the previous step connect an Intrinsically Safe meter across the output channel relay terminals See section 4 5 for details of relay terminal locations Each relay has three terminals Checkpoint Relay shown de energised Relay R1 B7 common B8 amp B9 Relay R2 B10 common B11 amp B12 Relay R3 B13 common B14 amp B15 Relay R4 B16 common B17 amp B18 4 The IS meter should be connected to the common terminal and the higher numbered terminal for the output channel relay being tested Relay R1 B7 and B9 Relay R2 B10 and B12 Relay R3 B13 and B15 Relay R4 B16 and B18 5 On the first input channel to be proof tested apply a load or stimulus to the sensor or detector Ihe load or stimulus should be sufficient that it exceeds the programmed setpoint level for that input channel Checkpoint How load or stimulus is applied to the sensor or detector is the responsibility of the person responsible for SIL in the location where the IX9042 is installed The determination of the correct load or stimulus and how this is applied to the sensor or detector is beyond the scope of this User Manual www trolex com TX9042 UM EN 01 105 TROLEX lt 106 Remove the IS meter connection from As the load or stimulus exceeds the alarm threshold observe that the reading on the IS meter fluctuates
3. Time Duration of the previous time interval in seconds 32 7 seconds Bar Graph Progressive overview of the length of the time interval between each successive reset pulse on Input 1 The bottom end of the bar graph the estimated minimum interval period is programmed by the Lower setup The top end of the bar graph the estimated maximum interval period is programmed by the Upper setup 90 TX9042 UM EN 01 www trolex com Signal OVER Setpoint UNDER Input1t U UUUUU LI LI uuu www trolex com TX9042 User Manual 5 9 73 Pulse Frequency The frequency level or pulse rate on Input 1 IS measured Setpoint levels are determined as an Absolute frequency Feed rate monitoring speed monitoring flow rate etc Close up 1 Display Refer to Section 5 5 1 for details Checkpoint This mode is used for the Vortex Airflow Sensor input module TX9042 UM EN 01 91 TROLEX lt 5 9 7 4 Slip Frequency The frequency level or pulse rate on Input 1 Is measured Setpoint levels are determined as a percentage of a programmed frequency setpoint for example the underspeed or overspeed of a machine can be expressed as a percentage of the normal running speed Close Up 1 Display Additional dynamic information is displayed in this mode T1 incoming frequency or pulse rate on Input 1 Run the programmed Run frequency the percentage difference between Input 1 and Run Bar Grap
4. maii 20 mA Signal 4 MA 0 Pressure 50 bar www trolex com TX9042 User Manual Checkpoint Any relays that are programmed to Latch will not be reset Refer to Relay Reset Mode Options in Section 5 79 for details 5 9 2 9 Lower 5 9 2 10 Upper Independently adjustable these two items are closely interrelated They set the desired Lower limit and Upper limit of the display reading for a given input signal This can be any numeric value through to any positive value The indicating range from zero to full scale of the display can be programmed to show true unit values incorporating multiplication factors or zero offset values Press D to navigate the cursor along the digits to the required digit Press U to increment the digit to the required value Press R to confirm the value selected The signal response between Lower and Upper will be assumed to be linear and signals from non conforming devices such as thermocouples will be automatically linearised to the appropriate standard Non linear relationships such as square law signals trom differential pressure sensors and the polynominals can also be incorporated in software to specific requirements TX9042 UM EN 01 69 TROLEX lt It is also possible to interrelate the signals Input 15 Hz Si l between two separate channels to apply a signal differential comparison correction factors and compensation a Z 0 C Flow 10 m sec 5 9 2 11 Calibrate Te
5. Scale amp Display gt Update gt Uinitit QO 0 0 si lt l www trolex com TX9042 User Manual 5 9 2 22 Run Speed When a digital input is set to Slip Frequency mode an additional menu Item called Run Speed will be available The Slip Frequency mode is most often used for monitoring the rotational speed of a machine shaft or soeed measuring device by determining the pulse rate from a toothed wheel attached to the shaft Overspeed or underspeed can be detected and is assessed as a percentage or Slip related to the Normal running speed eg 5 Slip Frequency or 5 Underspeed It is not always possible to know or measure the normal running speed of a machine or it may be difficult to establish the speed pulse relationship particularly where gearing or belts are being used At this position in the menu the screen will show the pulse frequency that is coming in from the shaft or sensor being monitored This value can be stored and then automatically used as the Normal Speed reference when setting the Slip setpoint levels Press R to confirm the incoming pulse frequency The entered value of the Pulse Frequency can also be subsequently adjusted if required to allow for loading factors or safety margins on the machine TX9042 UM EN 01 77 TROLEX lt Press D to navigate the cursor along the digits to the required digit Chi Scale amp Display Reset Press U to increment the digits to the
6. 5 75 Keycode Security Access to menus can be prevented by enabling the Keycode Security function It is a selectable function and the Keycode can be changed as and when required Press D to navigate the cursor across the digits Press U to change the value of the digit with the cursor underneath Press R to confirm the Keycode Checkpoint If more than five invalid entries are attempted access to the Main Menu will be denied for 30 mins If you require this feature to be disabled contact your local Trolex service agent or the Trolex Product Support Department service trolex com TX9042 UM EN 01 49 TROLEX lt 5 76 Interval Period of the Datalog Main Setup Keycode Each channel of the TX9042 PSC contains Sinell pllollal loll ladi a 26 000 point data logging system This Data Display can record the channel number and the Time and Date that an event occurs The rate or time interval of recording data can be programmed and data is recorded on a first in first out rolling log Rapid logging is possible to closely capture critical shutdown routines or a catastrophic plant failure The Interval or frequency at which data is recorded in the log can be programmed in hours minutes seconds Press D to navigate the cursor along the digits Press U to change the value of the digit with the cursor underneath Press R to confirm the Interval 5 77 Data Display Review of the Datalog Display Channel
7. The operating characteristics of each channel can be individually programmed The menu procedure is the same for all eight channels but the contents of the menu will be different for Analogue input modules and Digital input modules Checkpoint If enabled the Keycode Security will prevent access into Individual channels until the correct Keycode is entered Press U or D to navigate to the mode of Reset required Press R to confirm the mode of Reset Checkpoint Terminology in the menu will vary slightly where a digital input module is selected into the Digital Level mode This mode is used for simple On Off inputs such as thermostats limit switches or NAMUR proximity sensors See the Menu of Functions for individual menu listings Refer to Section 5 6 for details TX9042 UM EN 01 57 TROLEX lt 5 9 1 Power On Delay POD Period Ciihiiaiiniiniielit 4 4 20mA gt Piojn D e laly IDILE SI Ri The setpoint alarm signals SP1 and SP2 can Scale amp Display be inhibited for an adjustable time period Setpoint 1 after the power Is switched on Each channel can be independently set This feature is usetul for an initial start up override when a machine is running up to speed or a process is stabilising Checkpoint The range of configurable values is O to 255 seconds Press U or D to navigate through the digits to the required POD Period value 2 40 RI
8. gt iCihialninie Ul il The data recorded in the log can be reviewed Chlanna ib on the screen for individual channels Clhlalnintedl i B Press U or D to navigate up or down the Channel List to the required Channel Channel 7 Press R to confirm the selected Channel Press U or D to navigate up or down the Log to the required information 50 TX9042 UM EN 01 www trolex com Clhllalininjelt Nol 44 leic 22 4 03 57 19 212 8 o 3 1517 09 ii iol Jl ol 3 5 4 s 9 TT BL bE Idd Aste latol I I LE J2i3ih 5 lo 3 leB i Ll Talal ail lol 3 e siel aioll i RK k k KK k R HK RANK KK k k OR OK OF wel Ghannel 5 j aly Not fitted ji kik k k KK k K AK HANK k k k OR OK k NO MEASUREMENTS t ILR E C O R D E D k k M a ilal sllelt alp LULL LLa tv L LOL Data Display L bidltlelallr lit Cllo nllFlii r im www trolex com TX9042 User Manual Press R to return to the Channel List Supplementary information is displayed momentarily where appropriate 5 78 Clear the Data in the Datalog Press R to confirm the instruction to clear the Data in the Datalog TX9042 UM EN 01 51 TROLEX lt 5 79 Relay Reset Mode Options The four output relays R1 R2 R3 and R4 can be programmed to latch in the alarm condition Any relays that are latched can be reset in four different ways Off Reset from an external contact or push button is not poss
9. Channel 3 Channel 4 Chhiainne l 5 Channel 6 Cihiaini nie l 7 Channel 8 Main Setup IU ACCESSI I 1 DEN HED L Matin Setup Enter Keycode 0000 gt gt gt qf IX Matn Setup gt Comi m Pjolr it Clock Keycode www trolex com TX9042 User Manual 5 7 Main Menu All the operating functions can be programmed through the keypad by entering the Main Menu 5 7 1 Press L to enter the Main Menu Entering the Menu Cursor arrows will indicate the first of the function options available in the Main Menu If enabled the Keycode Security lockout will inhibit entry into the Main Menu until the correct entry code is confirmed Refer to Section 5 7 5 for details Press D to navigate the cursor along the digits Press U to increment the number Press R to confirm the selection Press L to escape and return to the previous menu TX9042 UM EN 01 45 TROLEX lt Press U or D to navigate up and down the menu to the preferred menu Press R to confirm the selection Previously programmed settings will be displayed alongside each item in a menu Function changes can now be programmed as described in the following sections Data Saved will flash briefly on the screen whenever a new value is entered during function programming iL DIA TIA SAVED f Not Saved will flash briefly on the screen if a value is not entered during function progr
10. Press R to confirm the selection Press U or D to navigate to Yes or No as required Press R to confirm the selection 5 9 5 Threshold Acceptance Level When a Digital Input Module is fitted the Threshold selection will appear in the Channel Menu The input signal threshold voltage level can be set so that only pulse amplitudes above a preset magnitude will be accepted by the Input Background noise or spurious interference can be eliminated in this way This is particularly useful in a high speed pulse processing system where a simple time delay on the pulse would be unacceptably Slow Press U or D to navigate to the Threshold Acceptance Level value required Press R to confirm the value selected 86 TX9042 UM EN 01 Chini at ep IRielLa y 1 ILIY ESI ad Relay 2 NO Relay 13 ILY ES Fault Relays I IRleh bY la NOI YTIIIII NORMAL HIGH FAULT LOW RELAY YES DE ENERGISED T Threshold Ciihllaliniinijellli t gt TI his hi Uid gt Keycode Mode www trolex com TX9042 User Manual 5 9 6 Keycode Security for Each Channel 1 to 8 The same Keycode number previously entered in the Main Menu can also be used to prevent unauthorised access to any individual channel function programming or to prevent disclosure of programmed parameters Each channel can be selectively inhibited SO an operator can still have access to adjust other channels where this would be appropriate Refe
11. TX9042 UM EN 01 37 TROLEX lt 5 4 Reviewing the Input Module Configuration The format of the operating data presented on each channel will be automatically determined by whichever input module is fitted The input module configuration and the operating mode of each channel can be reviewed from the Signal Display Press U and D to review the Input module configuration Refer to Section 4 6 for details 5 5 Close up Information Display Close up 1 and Close up 2 will show more detailed information about a selected individual channel Press U or D to navigate the cursor to the selected channel Press R to confirm Close up 1 only possible if an input module is fitted on that channel Press R again for Close up 2 38 TX9042 UM EN 01 t PIC OU NIT 141 1210 m All 6i lt 101 14 2 i lt iPi Tl 1 0 0 Hij 8 www trolex com TX9042 User Manual 5 5 1 Close up 1 Information Display 5 5 1 1 Close up 1 Display for an Analogue Input Module A Channel identification 1 to 8 Channel 4 PT100 TANK 400 C B Type of input module PT100 this 9 7115 C a changes to indicate that a channel O O A Setpoint has been exceeded SP1 and or SP2 D User text entry for channel duty identification and other data such as Full Scale calibration eg tank 400 C D Input signal value with appropriate engineering units Channel 4 SPR2IS PI TANK 400 C E 2110 5 C y DEn IL Stead
12. This function only appears in the menu when a flow input module is fitted for use with a TX6022 3 Liquid Flow Sensor The TX6022 3 Liquid Flow Sensor will be supplied with this calibration constant which is then entered into the Programmable Sensor Controller Press R to enter Flow Constant mode Press D to navigate the cursor along the digits to the required digit Press U to increment the digits to the required value Press R to confirm the values selected 5 9 2 16 Zero Mask Flow Input Module This function only appears in the menu when a flow input module is fitted for use with a TX6022 3 Liquid Flow Sensor The sensing principle employed by the TX6022 3 Liquid Flow Sensor means that a low flow reading may be indicated when in fact no flow is present This is usually caused by the weight of fluid on one side of the Differential Pressure sensor This function allows the Programmable Sensor Controller to display zero flow until the flow exceeds the value entered in the zero mask register TX9042 UM EN 01 73 TROLEX lt Press R to enter Zero Mask mode Ch5 Scale amp Display Press D to navigate the cursor along the DIP Zier LULI digits to the required digit LF Cionisti L234 gt ZeroM gt 002 00 Press U to increment the digits to the required value Press R to confirm the values selected 5 9 2 17 Zero Straingauge and STET Modules Ch4 Scale amp Display This function on
13. EN 01 63 TROLEX lt The longer this sample time is the more accurate will be the resulting calculation but there are constraints on this If the sampling time is too long the reaction time of the system may be unacceptable With frequency inputs long sampling times on high pulse rates are not necessary to Chl Scale amp Display maintain accuracy so a short sampling Rllalls lellt time can be used bringing with It a lula a fe fF alli k corresponding improvement In system Units reaction time The sampling time is adjustable making it possible for the user to set the optimum value for the application with the best accuracy There is an added advantage If an input frequency is fluctuating rapidly causing Instability in the system the sample AE UNE time can be adjusted to provide some p measure of damping or suppression For maximum accuracy sampling takes place at the front end prior to pre scaling Press U or D to navigate to the value required j ee me a ae a a a a ee ee ee EE erp ee A eee Press R to confirm the value selected Checkpoint Analogue levels are averaged between samples Pulse frequencies are averaged between samples 64 TX9042 UM EN 01 www trolex com Ch2 Scale amp Display Reset Update lS lull itis Iti eldi Cihi2 cale amp iDusplay Update Units gt D PN L201 007C www trolex com TX9042 User Manual 5 9
14. Poweron ss No delay Press R to confirm the POD Period value Power on SP2 SP1 In a situation where the alarm signals need to be inhibited until after an operation has occurred the Ext POD feature can be used A signal on terminal A35 prevents the internal POD timer from operating at power on until it is removed Power Start up on 58 TX9042 UM EN 01 www trolex com SP2 SP1 Channel 4 4 20mA Pon Delay PIExt PODI OFti iki High LTTTTITT Ete dW te Channel 4 Pon Delay Elx i POD Exit Oluri O f fi LILITILE bight ttt Low Rise iF altit 4 20mA www trolex com TX9042 User Manual Once the unit is powered up a signal on terminal A35 can be used to inhibit SP1 and SP2 On release of the signal SP1 and SP2 are further inhibited by the channel POD period External POD can be selected as Off High or Low Off Disabled High Connect to V to operate Low Connect to 0 V to operate External override can be selected as Off High Low Rise or Full Off Disabled High Connect to V to operate Low Connect to 0 V to operate Rise Positive signal causes internal POD Fall Negative signal causes internal POD TX9042 UM EN 01 59 TROLEX lt 5 9 2 Scale and Display Settings The various characteristics of the signal scale and display can be determined The contents of the menu will vary depending upon which type of input module is fitted on
15. T4 of a Digital Input Module may be considered equivalent to Category M1 In this instance the power supply selected to power the TX9042 PSC must have an output voltage not exceeding 16 V 2 3 2 General Conditions of Use Prior to installation it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex 2 4 Australia ANZEx Ex Certificate number ANZEx 06 3057X ANZEx Ex Certification code Ex ia 2 4 1 Conditions of Safe Use 1 Prior to installation it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex 2 Upto 6 RS485 Communications Modules in separate 1TX9042 Programmable sensor Controllers PSC may be daisy chained together ie terminals B1 all linked together terminals B2 all linked together and terminals B3 all linked together Provided that the number of daisy chained TX9042 PSCs is reduced to 5 these communications lines may be connected to unspecified safe area equipment via an appropriately certified shunt zener diode safety barrier dual channel ac whose output parameters do not exceed the following per channel Uo 9V lo 100 mA Po 225 mW OR Uo 12 V lo 80 mA Po 240 m
16. Velocity 15 Hz to 100 Hz O to 30 mm sec 100 mV g www trolex com TX9042 User Manual Module Ref Connections Type of Input Strain Gauge Load cells pressure sensors bridge circuits Range 2 mV V 10 mV FS 3 mV V 15 mV FS 10 mV V 50 mV FS 50 mV V 250 mV FS 100 mV V P5423 520 01 Channel 1 njejes o P5423 520 02 P5423 520 03 P5423 520 04 P5423 520 05 500 mV FS Flow Module for TX6023 4 Gas sensors load cells For use with TX6023 P5546 18 TX6023 TX6024 0 5 to 4 5 V P5423 552 P5423 553 P5423 554 P5423 5528 Flow Module for TX6022 and 4 to 20 mA AA Differential pressure sensors line pressure www trolex com TX9042 UM EN 01 29 TROLEX lt Type of Input Range Module Ref Connections Digital Dual Input 2 proximity sensors E NAMUR input P5423 523 oe processing me l A1 A2 A3 A4 from proximity DIN 19234 DKE sensors FA photosensors 12 V version contacts SIIN and pulse JUL JUL devices 2 voltage tree contacts On Off switches Channel 1 Input 1 Input 2 30 TX9042 UM EN 01 www trolex com 4 6 2 Digital Input Modules TX9042 User Manual Digital input conditioning modules can be individually programmed into seven distinct operating modes Pulse Counter o Pulse Frequency 0000 S Differential Slip Q Frequency O 1H 0 09 O Digital Level On Off i Pulse Interval A A amp
17. at 12 V Relay 200 V 0 25 A 3 W absolute maximum Checkpoint Circuits switched by the contacts of the output relays MUST emanate from a certified Intrinsically Safe power source and the circult parameters must be within Intrinsically Safe requirements 10 TX9042 UM EN 01 www trolex com TX9042 User Manual 2 Certification 2 1 Europe ATEX Ex Ex Certificate number Baseefa 03ATEX0292X Ex Certification code I M1 Ex ia Ma 2 1 1 Special Conditions for Safe Use 1 The TX9042 Programmable Sensor Controller PSC must be mounted in a secondary enclosure as shown on drawing P5423 02 or in an alternative metal enclosure not light alloys which is appropriately certified as providing a degree of protection of IP54 2 Upto 11 RS485 Communications Modules in separate 1TX9042 Programmable Sensor Controllers PSC may be daisy chained together ie terminals B1 all linked together terminals B2 all linked together and terminals B3 all linked together Provided that the number of daisy chained TX9042 PSCs is reduced to 10 these communications lines may be connected to unspecified safe area equipment via an appropriately certified shunt zener diode safety barrier dual channel ac whose output parameters do not exceed the following per channel Uo 9V lo 100 mA Po 225 mW OR Uo 12V lo 80 mA Po 240 mW eg suitably certified MTL761 MTL766 to BASO1ATEX7202 or MTL7761ac MTL7766ac to BASO1ATEX7217 For the purpo
18. for details 82 TX9042 UM EN 01 Setpoint Signal High Low Channel 4 Setpoint Alarm Sip on Diy I gt Siipi iio fifi Dit iy i gt iE 0 is 1 it Input Signal Setpoint 2222 cee ee Se ag eo ea Se ee t1 t2 t1 t2 www trolex com tl t1 t2 t1 t2 Channel 4 Setpoint Sp on Dly Sipi ot ft Dilly gt Opera t iAU TOR SIT 8t LLLITIT I IdaTchh II JL P LSE TO G Gi LIE www trolex com TX9042 User Manual Latch Until Reset the Setpoint signal will go Low when the input signal exceeds the Setpoint value and latch until reset T1 any Setpoint On Delay that is programmed Refer to Section 5 9 3 4 for details Refer to Section 5 79 for details of Relay Reset Mode Options Toggle the setpoint signal will go Low High alternately each time the setpoint value is exceeded T1 T2 any Setpoint On Delay and or Setpoint Off Delay that is programmed Pulse the setpoint signal will give an impulse equal to the T1 time each time the setpoint value is exceeded Press U or D to navigate to the required function Press R to confirm the function selected TX9042 UM EN 01 83 TROLEX lt 5 9 3 7 Relays The TX9042 PSC has four common output relays R1 R2 R3 and R4 Any setpoint signal can be assigned to operate any one or all of the relays by selecting Yes or No in each case This enables alarm status groupings selective shutdown routines and logic eleme
19. in the menu when a Straingauge module is fitted Press R to enter Sensitivity mode Press U or D to Increment the displayed value to a value that matches the sensitivity of the straingauge being used Press R to confirm the value selected TX9042 UM EN 01 75 TROLEX lt 5 9 2 20 Identification Channel identification text can be entered to denote the input duty the location or the tag reference of the input device Up to 11 digits of text can be entered into the display and there is a menu ot letters numbers and symbols to choose from thus enabling channel identification or location data to be entered Checkpoint User specified text may have been entered during manufacture Press D to navigate the cursor along the digits to the required digit Press U to increment the digits to the required value Press R to confirm the values selected 5 9 2 21 Connections Terminal identification details are listed on the display for a particular channel input electrical connections Press U or D to navigate through the data 76 TX9042 UM EN 01 Cih 2 a lej amp Diis pilla y Lower Upper P LD PT ANIK TEMP 1 lt Channel 4 20mA gt AS V OUTPUT h A6 CURRENT IN Al CURRENT OUT l lall 4dV lbUPPIVIITIIII 73 www trolex com aS 7 9 ot Ae a AS p 4 gt A 4 gt a 4 lt E 4 E F QO p 1 4 op NY L 3 4 al Z Pa 7 Cih Reset
20. licenced waste handling organisation with the appropriate licences for handling electronic waste In the geographic area where the TX9042 PSC is located Checkpoint Consult your local Trolex service agent or the Trolex Product Support Department If you require assistance service trolex com TX9042 UM EN 01 109 TROLEX lt Disclaimers The information provided in this document contains general descriptions and technical characteristics of the performance of the product It is not intended as a substitute for and is not to be used for determining suitability or reliability of this product for specific user applications It is the duty of any user or installer to perform the appropriate and complete risk analysis evaluation and testing of the products with respect to the relevant specific application or use Trolex shall not be responsible or liable for misuse of the information contained herein If you have any suggestions for improvements or amendments or find errors in this publication please notify us at marketing trolex com No part of this document may be reproduced in any form or by any means electronic or mechanical including photocopying without express written permission of Trolex All pertinent state regional and local safety regulations must be observed when installing and using this product For reasons of safety and to help ensure compliance with documented system data only Trolex or its affiliates should perf
21. must be mounted in a protective metal enclosure to comply with Intrinsically Sate requirements Once input channels have been connected to the X9042 PSC the channel identification labels MUST be completed Any changes to the input channels MUST be recorded on the channel identification labels 24 TX9042 UM EN 01 www trolex com TX9042 User Manual 4 6 Input Channel Configuration The duty of each of the eight input channels is determined by an interchangeable input conditioning module carried on the main I O control card Each input conditioning module has calibration and functionality information stored in a non volatile EPROM On powerup the main processor reads this information and sets up the channel accordingly The eight input channels of the TX9042 PSC are configured during manufacture for the operational duty required This is marked on the identification label on the rear of the housing refer to Section 4 2 for details Input conditioning modules can be changed if required refer to Section 4 6 4 for details There are two categories of input module type e Analogue e Digital In total there are eleven possible input conditioning modules options for each channel Analogue e Current e Voltage e Resistance Iemperature Device e Semi conductor Temperature Device e ac Voltage e Strain Gauge e Flow Module for TX6023 4 e Flow Module for TX6022 e Digital Pulse Processing Digital e Failsafe digital e
22. the channel being programmed Press U or D to navigate to the value required Press R to confirm the value selected The contents of the menu for a digital input module will vary in relation to which of the sensor operating modes It Is set Into See the Menu of Functions for individual menu listings Refer to Section 5 6 for details 60 TX9042 UM EN 01 ANALOGUE INPUT MODULE Ciihi2i Seall el 8 Dits pilay gt R els e t P ela ki lt Units DHE I eloWwlelr PIG TPT rigdtdil Up pern i Update Temperature Caltbrate P irjiejs is Fi Si Pio ns tl ii DP Zero HEomns enl ZeroM I Straingauge Zero modules Span DR Silen s U tiiv ity D Cioni nl ela tiuolnlis DIGITAL INPUT MODULE ChL D itf H reld S amp D gt Reset Peak lt Cllainisi tian t APIE d DhPEDIIIRTIEEEET tt Frequency Update Measurement Ulp d ai tiel Input Modules Ulnits If ia DIDIE Sequence Direction PULSE COUNT INPUT MODULES ONLY Lower Ulpe es il I D Ciolini n elci tit olnls Slip frequency Runspeed Input Modules Count Reset Lal www trolex com TX9042 User Manual 5 9 2 1 Reset Peak Cih2 a llel amp Dii sipilay The previous maximum value Peak and gt Reset gt Confirm kI minimum value Low that the signal has Units reached since the last occasion that It was Di FP reset Dangero
23. to 8 Channel 4 PT100 B Type of input module P1100 cM velvet lala isi lo 4 lie This changes to indicate that a channel Pile 3 84 isl lsiplai tobl ob setpoint has been exceeded ie SP1 Lwil 12 e S Ri2 21010 0 and or SP2 CG Input signal Level D The previous Peak signal value recorded since last reset Cihiaininiell 4 SPi2 SPL Lielviell amp 2 1 0 45 09 15 Pik 38215 ISIPILi L100 0 Liwi 22 16 ISIPI2Zi 21001 0 The previous Lowest signal value recorded since last reset F The value of Setpoint 2 G The value of Setpoint 1 H 24 hour clock Press R to return to Close up 1 Press L to escape and return to the Signal Display 42 TX9042 UM EN 01 www trolex com TX9042 User Manual 5 5 2 2 Close up 2 Display for a Digital Input Channel Checkpoint Not applicable for the Digital level mode A Channel identification 1 to 8 Channel 1 PCOUNT a Lelket tip 12 15 B Programmed mode of the digital input Plk 10 SPL 100 module Pcount This changes to Lwil 25 P2 1000 indicate that a channel setpoint has been exceeded ie SP1 and or SP2 C Count or frequency Level D The previous Peak count or frequency recorded since last reset Cihiaininiell 14 SPi2 SPL Level 1435 14 30 E Piik 11435 SIPIT 100 l Lw 12115 SP21 1111000 The previous Lowest count or frequency recorded since last reset F The value of Setpoint 2 G The value of Set
24. 1 This is useful for alarm verification to apply time delay in a process control action or to override a spurious fluctuation of the input signal If the input signal falls below the setpoint before the programme time has elapsed the timer will reset to zero ready to start again Press U or D to navigate to the Setpoint On Delay value required Press R to confirm the value selected TX9042 UM EN 01 81 TROLEX lt 5 9 3 5 Setpoint Off Delay The resetting of the Setpoint signal can also be delayed by an adjustable time period T2 If the input signal exceeds the Setpoint before the programme time has elapsed the timer will reset to zero ready to start again Press U or D to navigate to the Setpoint Off Delay value required Press R to confirm the value selected Checkpoint Both the Setpoint On Delay and the Setpoint Off Delay can be combined if required and are independently programmable Refer to Sections 5 9 3 4 and 5 9 3 5 for details 5 9 3 6 Operation A set point signal can be set to function in four different ways Auto Reset the Setpoint signal will go Low when the input signal exceeds the Setpoint value and will reset when the input signal recedes T1 T2 any Setpoint On Delay and or Setpoint Off Delay that is programmed Refer to Sections 5 9 3 4 and 5 9 3 5 for details Checkpoint The reset point will also be influenced by any hysteresis value that is programmed Refer to Section 5 9 3 2
25. 2 5 Units A menu of more than 35 standard engineering units is available for adding on to the signal value display to represent the actual parameter being measured ie bar mA m sec C etc Checkpoint Where a temperature input module is fitted the choice will be limited to C F or ne Press U or D to navigate to the units required Press R to confirm the units selected 5 9 2 6 Decimal Point Once the numerical value of the Upper and Lower limits of the display have been set the decimal point can be navigated to any desired position within the number Press U or D to navigate the decimal point to the required position within the number Press R to confirm the location selected TX9042 UM EN 01 65 TROLEX lt 5 9 2 7 Sequence When a digital input module is selected into the Pulse Counter mode an additional item called Sequence will appear in the menu choice The counting sequence of pulse counting can be determined Single the counter will count indefinitely until reset continuing to count beyond any programmed setpoints Cycle the counter will count to a pre programmed batch setpoint then automatically reset and re start the count cycle continuously Checkpoint It is recommended that the relay operation should not be set for Autoreset in the Cycle mode because the resulting output signal would be too short for any practical use The other modes available Latch Toggle and Pulse ma
26. 33 Cable Distance for Voltage Inputs 0 4 to 2 V 34 Dual Input Signals Differential 34 Setup and Calibration 35 Controls and Indicators 35 Powelr up 3 Signal Display 3 7 Reviewing the Input Module Configuration 38 TX9042 UM EN 01 3 TROLEX lt 5 5 Close up Information Display 38 5 5 1 Close up 1 Information Display 39 5 5 2 Close up 2 Information Display 42 5 6 Menu of Function 44 5 6 1 Default Values 44 5 6 2 Programming the Operating Values 44 5 7 Main Menu 45 5 7 1 Entering the Main Menu 45 5 72 Escape Return 46 5 73 Communication Setup ay 5 74 Clock 49 5 75 Keycode Security 49 5 76 Interval Period of the Datalog 50 5 77 Data Display Review of the Datalog 50 5 78 Clear the Data in the Datalog 51 5 79 Relay Reset Mode Options 52 5 7 10 Relay Voting 53 5 7 11 Relay Operation 55 5 712 Software Version 55 5 713 Self Test 55 5 714 Display Cycling 56 5 8 Contrast Control 56 5 9 Channel Function and Calibration oy 5 9 1 Power On Delay POD Period 58 4 TX9042 UM EN O01 9 9 2 SES 5 9 4 Scale and Display Settings Setpoint Characteristics Fault Signal Alarm Assignation 5 9 5 5 9 6 Keycode Security for Each Channel 1 to 8 5 9 7 Mode Setting for a Digital Inout Module 5 9 8 Setting a Digital Failsafe Inout Module 5 9 9 5 10 Datacommunications 5 10 1 RS485 6 Maintenance 6 1 TX9042 PSC Planned Preventative Maintenance Channel Display Mode 6 1 1 6 1 2 6 1 3 Introduction TX9042
27. AMMABLE SENSOR CONTROLLER gt ey E Channel Signal Channel Output signals Identification values input and data number connections connections The programming and setting routines for the X9042 Programmable Sensor Controller PSC have been designed for utmost simplicity and the programming system is completely menu driven There is no special software programme or data input terminal a PC is not necessary and no computer programming knowledge is required www trolex com TX9042 UM EN 01 35 TROLEX lt There are just 4 keys the keypad for controlling the complete operation and the LCD screen provides instructions throughout the programming process All entries are verified on the LCD screen and incorrect or invalid entries are immediately brought to the attention of the user Each data entry on the keypad is acknowledged by a short bleep Hold down the scroll keys U or D for two seconds for rapid self keying To use the TX9042 Programmable Sensor Controller PSC software and navigate between menus you must press the keypad keys Escape is the Left key L Confirm is the Right key R Scroll Up is the top key U Scroll Down is the bottom key D The use of these keys is abbreviated to L R U and D throughout this User Manual Scroll Up U Scroll Down D Confirm Data R SS Cc Qj a ol PROGRAMMABLE SENSOR CONTROLLER TROLEX lt Checkpoint The TX9042 PSC data m
28. EN 01 Cihjajin injiell J1 DIIFSLUP tLe L200 Oj jt 2 31 2 9 0 0 5 10 www trolex com 220099090909900009900 lt INPUT 1 INPUT 1 C INPUT 2 INPUT 2 SA Setpoint 1 Setpoint 2 www trolex com TX9042 User Manual 5 9 7 7 Digital Level Inputs trom simple On Off switches voltage free contacts thermostats pressure switches limit switches and NAMUR proximity switches Each digital input module will accept two input switches one on Input 1 and one on Input 2 each of these inputs can be programmed independently for most of the standard functions Update time input delay Refer to Section 5 9 3 5 for details Identification text Refer to Section 5 9 2 20 for details Terminal connections display Refer to section 5 9 2 21 for details Alarm on high low input rising falling alarm Refer to Section 5 9 3 3 for details Setpoint delay output delay Refer to section 5 9 3 4 for details Operation auto reset latch toggle pulse Refer to Section 5 9 3 6 for details Relay output assignation Refer to Section 5 9 3 7 for details TX9042 UM EN 01 95 TROLEX lt Signal Display Input 1 Input 2 Close Up 1 Display The state of Input 1 and Input 2 is displayed Channel 1 DIG TILIF s as Low L or High H input Ic OPEN Input 2 CLOSED 5 9 8 Setting a Digital Failsafe T Input Module A channel fitted with Digital Failsafe input module w
29. PSC Check TX9042 PSC Battery Replace 6 1 4 TX9042 PSC Proof Test 6 2 TX9042 PSC Repair 6 3 Maintenance Records 6 4 Maintenance Log 7 Disposal Disclaimers Trademarks Document History Contact Details Threshold Acceptance Level 60 79 85 86 8 88 96 oo 100 100 102 102 102 102 104 104 107 107 108 109 110 110 110 110 www trolex com TX9042 User Manual 1 Product Overview 2 9 9 0 9 0 0 9 0 0 0 0 0 0 9 9 0 0 Q PROGRAMMABLE SENSOR CONTROLLER TROLEX lt www trolex com K SNAN e SESE 689888 Up to 8 analogue or digital inputs Up to 16 On Off inputs TX9042 55 RS485 data communications Data logging facility for up to 26 000 input readings per channel 1 1 Operating Features e Up to eight channels of analogue or digital inputs or sixteen on off inputs e Input and output functions are programmed directly using the keypad e RS485 data protocol for integrating multi point sensor collecting into mine wide systems e Accepts analogue or digital inputs from a variety of source types e Simple to use just four keys to programme the TX9042 PSC no special software and no software programming skills required e Full functional compatibility with the entire range of Trolex sensors e Up to 32 TX9042 PSC can be connected to a single mine wide data system www trolex com TX9042 UM EN 01 5 TROLEX lt 1 2 Application The TX9042 Programmable
30. SP1 and SP2 The various operating characteristics of each Setpoint can be individually determined Setpoint signals are High in the normal condition and switch to Low when activated as a Setpoint is exceeded The Setpoints do not directly control the four output relays R1 R2 R3 and R4 but can be matrix programmed to selectively initiate the four relays Press U or D to navigate to the menu required Press R to confirm the menu selected Checkpoint The contents of the menu for a digital input module will vary slightly depending upon which of the seven operating modes it is set In Refer to Section 5 9 7 for details TX9042 UM EN 01 79 TROLEX lt 5 9 3 1 Level The operating level of the setpoint signal SETPOINT can be programmed This can be set for any numerical value and the polarity can be positive or negative as required Press D to navigate the cursor along the digits to the required digit Channel 4 Setpoint gt Lljelviell gt e1100 P Cid 8 Hyst Alarm Press U to increment the digits to the required value Press R to confirm the Setpoint level 5 9 3 2 Hysteresis Hysteresis is the deadband between the Set point high setpoint switching On and switching Off as the input signal rises and falls This can be Set point low ou set as a percentage of the Set Point Level or Press U or D to Increment the hysteresis value Channel 4 Setpoint Press R to confirm the Hysteresis
31. Sensor Controller PSC is for sensor management and data communications in arduous industrial environments and hazardous areas It Is suitable for use in SIL 1 and SIL 2 applications in accordance with any conditions or restrictions The uses of the TX9042 PSC include e Underground machinery protection e Environmental monitoring using a combination of gas sensors and flow sensors e Gas detection systems e Conveyor control e Pump and compressor monitoring e Machine condition monitoring e Fan vibration monitoring e ITP monitoring e On board underground machinery monitoring e Plant protection e Data collection from groups of diverse sensors e Area network sensor collection and monitoring The data logging facility can be used to record operational trends and to analyse periods where serious incidents may have occurred All data acquired can also be transmitted over a communication link to a remote point The system can also be used for collecting sensor information trom several distributed monitoring stations on amine wide sensor network Up to 32 sensor collectors can be networked on a data link and communicated to a central control and monitoring computer via the data link Intrinsically Safe Supply Voltage TX9042 55 12 V dc from an approved intrinsically safe power source 6 TX9042 UM EN 01 www trolex com 1 3 Product Options TX9042 PSC General Purpose 12 V dc 1 3 1 TX9042 PSC Input Module Types Input Module De
32. TX9042 Programmable Sensor Controller 2 User Manual TROLLE TX9042 User Manual TX9042 Programmable Sensor Controller PSC Contents 1 Product Overview 1 1 Operating Features 1 2 Application 1 3 Product Options 1 3 1 TX9042 PSC Input Module Types 1 4 Dimensions 1 5 Technical Information 1 6 Electrical Details 2 Certification 2 1 Europe ATEX 2 1 1 Special Conditions for sate Use 2 1 2 General Conditions of Use 2 2 Russia GOST R 2 2 1 General Conditions of Use 2 3 South Africa MASC 2 3 1 Special Conditions for Safe Use 2 3 2 General Conditions of Use 2 4 Australia ANZEx 2 4 1 Conditions of Safe Use 2 5 USA MSHA 2G 3 Functional Safety Conditions of Use 3 1 Overview of Safety Integrity Level 3 2 SIL Suitability 3 3 Summary of the Verified Functional Safety Data www trolex com NY OOO Ol CO N 16 16 I7 3 4 a0 3 6 4 1 4 2 4 3 4 4 4 5 4 6 4 6 1 4 6 2 4 6 3 4 6 4 4 6 5 OZ a 5 4 Conditions or Restrictions for use in SIL Applications 18 Proof Test 19 System Configuration Drawing 20 Installation 21 Precautions 74 Labelling 21 Tools and Test Equipment Required 22 Mechanical Installation 22 Connections Zo Input Channel Configuration 25 Analogue Input Modules 26 Digital Inout Modules 31 Display of Connection Details 33 Replacing an Input Module 33 Cable Distance Calculation for Loop Powered 4 to 20 mA Sensors
33. Upd ate x ILOILO sU required value Units Press R to confirm the values selected Checkpoint The configurable range of Pulse Frequency is 0 to 9999999 5 9 2 23 Count Reset When a digital input module is set to Pulse Count mode an additional item called Count Reset will be available in the menu Any counts accumulated in the register of a Pulse Counting channel can be individually reset to zero or reset to a Constant that has been previously entered Press R to select Reset Ch2 Scale amp Display Press R to confirm Reset Lower Upper gt D ITT ANIK TEMP 1 lt 4 When Upcounting or Downcounting the count can also be reset by an impulse on Input 2 If the count value to be reset has exceeded and therefore activated a programmed Setpoint value SP1 and or SP2 the Setpoint Output will reset at the same time Refer to Section 5 9 3 6 for details 78 TX9042 UM EN 01 www trolex com HIGH NORMAL Low ACTIVATED OR ALARM Fenn Ciihialininl ell Lt Set plo initil Measurement gt Level Isls Input Module Hyst Alarm I IstPlolniIbly EP Pt dri yd S P o f fD Uyi Olpe nat ii Relay 1 Relay 2 Relay 3 Relay 4 www trolex com TX9042 User Manual Any relays that are programmed to latch will not be reset Refer to Relay Reset Mode Options in Section 5 79 for details 5 9 3 Setpoint Characteristics Each of the eight channels has two Setpoint signals or alarm points
34. Vortex Airflow Sensor digital www trolex com TX9042 UM EN 01 25 TROLEX lt 4 6 1 Analogue Input Modules Type of Input Range Module Ref Connections Current O to 20 mA P5423 516 2 wire loop powered O j Impedance 110 R Sensor transmitter 3 wire control powered Channel 1 mM a a Sensor transmitter 2 wire remote powered Channel 1 al gt ae O RT Remote power 0V supply lt Nn Lo transmitter 26 TX9042 UM EN 01 www trolex com Type of Input Range Voltage Oto2V 0 4to2V Oto 10 V V Impedance 100 K Resistance PT100 Temperature 50 to 200 C DEVICE 50 to 400 C ran Standardised to DIN43760 and BS 1904 www trolex com Module Ref P5423 514 P5423 509 P5423 515 P5423 510 P5423 513 TX9042 User Manual Connections Channel 1 i ox 2 wire Channel 1 4 wire compensated Channel 1 TX9042 UM EN 01 27 TROLEX lt Type of Input Semi conductor Temperature Device A Linearised input ac Voltage Me Load cells ac generators accelerometers velocity sensors amp power measuring instruments 28 TX9042 UM EN 01 Range Module Ref Connections KTY81 P5423 511 2 wire 50 to 150 C Channel 1 KTY84 P5423 512 O to 300 C KTY21 6 P5423 519 7 a 50 to 150 C 4 wire compensated Channel 1 ac RMS Acceleration 500 Hz to 10 kHz O to 7g 100 mV g P5423 506 01 Channel 1 P5423 506 02 ac RMS
35. W eg suitably certified MTL761 MTL766 to BASO1ATEX7202 or MTL7761ac MTL7766ac to BASO1ATEX7217 14 TX9042 UM EN 01 www trolex com TX9042 User Manual The cable parameters shall not exceed the following COS 727 oti Lce Re 222 uH ohm 2 5 USA MSHA MSHA IS Evaluation number A 17501 0 2 5 1 Conditions of Use Prior to installation it is essential that user refers to the above document for any specific conditions of use The user must ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex www trolex com TX9042 UM EN 01 15 TROLEX lt 3 Functional Safety 3 1 Overview of Safety Integrity Level The following instructions are applicable when the X9042 Programmable Sensor Controller PSC is used as an element in a safety instrumented function that is specitied to achieve a Safety Integrity Level SIL eg SIL 1 2 etc The reliability of the TX9042 Programmable Sensor Controller PSC has been independently assessed in accordance with IEC 61508 for use in SIL applications The compliance with IEC 61508 includes hardware reliability probabilistic type failures and measures to address systematic type failures The information that follows forms the Safety Manual required by IEC 61508 2 and is intended to allow correct product selection system integration installation operation and maintenance to ena
36. afety Barrier Surface i Underground TX9042 55 End of Line Resistance www trolex com TX9042 User Manual Checkpoint When the data transmission system extends into a safe area it must be used with an approved safety barrier to comply with intrinsic safety regulations Please contact the Trolex Sales Team for further information and advice on suitable safety barriers sales trolex com Up to 11 RS485 Communications Modules may be dalsy chained together terminals B1 all linked together terminals B2 all linked together and terminals B all linked together These communications lines may be connected to unspecified safe area equipment via a suitable shunt zener diode safety barrier The cable parameters shall not exceed the following G Z ir L R 222 uH ohm Please contact the Trolex Sales Team for further information and advice on suitable shunt zener diode safety barriers sales trolex com www trolex com TX9042 UM EN 01 101 TROLEX lt 6 Maintenance 6 1 TX9042 PSC Planned Preventative Maintenance 6 1 1 Introduction To keep your TX9042 PSC in the best possible condition and fully working Trolex strongly recommends that you carry out regular planned preventative maintenance and keep records of the maintenance carried Out The planned preventative maintenance for the TX9042 PSC consists of tasks carried out at regular intervals The tasks are listed in the maintenance schedule below Equi
37. amming gt tT NOTI SAMED HLK It Checkpoint The screen will automatically return to the Menu being used after a value or selection has been entered 5 72 Escape Return Press L to escape and return to the previous menu from any position in the Menu sequence Each press of L will revert the screen one step back until the Main Menu is reached The screen will progressively step back at 5 second intervals if no keys are pressed 46 TX9042 UM EN 01 www trolex com TX9042 User Manual 5 7 3 Communications Setup RS485 Comms Setup The characteristics required for the data communications output port can be entered Datacomms output is RS485 Refer to section 5 10 for details gt Protcl tl i KI Nia ti ul fily Flolir im at Diatha Fb iltis I Sitio pi jbl uitis if Parity ply The selections available in some items of Baud rate 1 this menu list are dependent upon whichever Verify i protocol function is selected Aldi d rie s s DSR L Press U or D to navigate up or down the TKON aa menu to the preferred menu TKI Ofif RX TO Duplex TE Press R to confirm the selection you have Comms Monitor navigated to Press U or D to set the value or mode Press R to confirm the value or mode TxOn this is the delay between the TX9042 PSC enabling the transmission line and sending data TxOff this is the delay between the end of the received data and disabling of the re
38. as the output channel relay de energises If the IS meter reading fails to fluctuate immediately remove the X9042 PSC from service and replace it with a working TX9042 PSC Return the defective TX9042 PSC to Trolex for repair R1 and testing Remove the load or stimulus from the sensor or detector Reset the output channel relay the higher numbered terminal and connect it to the middle numbered terminal of the output channel relay being tested Relay R1 B8 Relay R2 B11 Relay R3 B14 Relay R4 B17 Relay shown de energised Apply a load or stimulus to the sensor or detector The load or stimulus should be sufficient that it exceeds the programmed setpoint level for that input channel As the load or stimulus exceeds the programmed setpoint level observe that the reading on the IS meter fluctuates as the output channel relay de energises Remove the load or stimulus from the sensor or detector Reset the output channel relay Remove the IS meter connections from the output channel relay terminals TX9042 UM EN 01 www trolex com www trolex com TX9042 User Manual 16 Repeat the test for each input channel that has a 4 to 20 mA or 0 4 to 2V input AND is configured to operate an output channel relay 17 If the IS meter reading fails to fluctuate for any of the output channel relay tests Immediately remove the 1X9042 PSC from service and replace it with a working TX9042 PSC Retu
39. ble the SIL specified for the safety instrumented function to be achieved and maintained as far as the 1X9042 Programmable Sensor Controller PSC is concerned The actual SIL will depend on many system considerations that are outside the scope of the TX9042 Programmable Sensor Controller PSC and will rely on personnel who are competent in the functional safety aspects of the various lifecycle activities mentioned above 3 2 SIL Suitability The versions and configurations of the X9042 Programmable Sensor Controller PSC identified in Table 1 in Section 3 3 below and are suitable for use in safety functions that have a specified Safety Integrity Level SIL in accordance with IEC 61508 or IEC 61511 up to and including SIL 2 when used in a Low Demand safety function with proof test interval of 3 months SIL 1 when used in a Low Demand safety function with proof test interval of 12 months SIL 1 when used In a High Demand safety function The functional safety data in Tables 1 and 2 in Section 3 3 must be taken into account by integrators and end users including compliance with the restrictions in use Section 3 4 and all other provisions and conditions in this User Manual 16 TX9042 UM EN 01 www trolex com TX9042 User Manual system integrators and end users responsible for other lifecycle phases system specification integration installation commissioning operation maintenance etc need to p
40. ceive buffer RxTO this is the delay between receipt of last message and reset of the receive buffer www trolex com TX9042 UM EN 01 47 TROLEX lt Data Protocol Notify Format Databits Stopbits Parity Baud Rate Verify Address DSR TX On Rx TO TX Off Duplex Comm Monitor Checkpoint Communication data protocol information and additional application data is available from the Trolex Technical Department 48 TX9042 UM EN 01 Modbus Modbus Binary ASCII N A N A Binary ASCII 8 7 8 1 to 2 None Odd Even Mark Space 300 600 1200 2400 4800 9600 14400 19200 28800 5 7600 115000 CRC16 Chksum 1 to 65535 Norm TX High TX Low Oto 99 ms 0 10 99 ms 0 to 99 ms Half Full Scrolling display of incoming data stream Data stream can be stopped and started for closer analysis Press U to Stop data stream Press D to Start data stream www trolex com Sieti Clock gt Date 02V 0196 Tit mie 021568619 Matn Setup Clolimim iPlojr it Cill olcik gt IK lelly ic jio idjie gt D 11121314 www trolex com lt lt U TX9042 User Manual 5 74 Clock Date and time information is used when readings are entered into the Data Log Press U or D to navigate to Date or Time Press R to confirm the selected function Press D to navigate the cursor across the digits Press U to change the value of the digit with the cursor underneath Press R to confirm the Date or Time
41. e LCD screen refer to Section 5 9 2 21 for details If a TX9042 PSC is supplied to be fitted into a customer supplied metal enclosure the two channel identification labels will be provided loose and must be fitted adjacent to the connecting terminals in a visible position in order to comply with certification requirements Ch 1 Flow Ch 5 4 20mA Ch 2 Flow Ch 6 4 20mA Ch 3 Flow Ch 7 4 20mA Ch 4 Flow Ch 8 4 20mA Order Ref Sertal no TX9042 55 21008 A no Before installation check for the correct channel functions and supply voltage on the channel identification label on the rear of the TX9042 PSC housing www trolex com TX9042 UM EN 01 21 TROLEX lt 4 3 Tools and Test Equipment Required No special tools are needed to assemble or install the TX9042 PSC 4 4 Mechanical Installation The TX9042 PSC is installed on a TS35 low profile DIN rail as follows 1 Loosen the two securing screws one each at the end of the TX9042 PSC housing Swing the plastic tabs out of the way Locate the TX9042 PSC on the DIN rail Swing the plastic tabs so that they are behind the DIN rail flange Tighten the two securing screws SE Do not overtighten the two securing screws Securing en a SSS SS screw a 7 a P i oO gt SSS SSS Seas ae securing Screw 22 TX9042 UM EN 01 www trolex com TX9042 User Manual 4 5 Connections The terminals are divided on two horizontal planes The lower leve
42. e of Yes or No as required Press R to confirm the selection 5 9 9 Channel Display Mode Where a channel is out of operation or a system Fault has been diagnosed the channel can be de activated This will be denoted on the Signal Display by Ch OFF Press U or D to navigate the Channel Display Mode to On or Off as required Press R to confirm the selection Checkpoint The channel input will now have no effect on the two related set points SP1 and SP2 or the channel Fault signals TX9042 UM EN 01 99 TROLEX lt 5 10 Datacommunications The TX9042 Programmable Sensor Controller PSC is equipped with RS485 datacommunications 5 10 1 RS485 The RS485 communications module can be used for point to point or multidrop data communications up to 2 km operating distance Maximum total cable length Maximum no of TX9042 PSC per System End of Line 120 ohm Resistance between B2 amp B3 1 5 mm with overall screen 1 5 mm up to 2 km Recommended e 1 twisted pair for Cable Parameters data OV Overall screen Sensor Controller Datacomms RS485 55 TX9042 Module Data Protocol the communications format setup can be individually programmed through the keypad for PC system compatibility and data protocol information is available from the Trolex Technical Department Refer to Section 5 73 for details 100 TX9042 UM EN 01 _ S 950 0095 3 USB to RS485 converter S
43. ed 5 9 2 14 Differential Pressure Flow Input Module This function only appears in the menu when a flow Input module is fitted for use with a TX6022 3 Liquid Flow Sensor The TX6022 3 Liquid Flow Sensor will be supplied with this calibration constant which is then entered into the Programmable Sensor Controller Press R to enter Pressure Constant mode Press D to navigate the cursor along the digits to the required digit 72 TX9042 UM EN 01 Cihi5 a llel amp Display Ulpi dia tie DLLO 0i PressFS 200bar pleidanst ltl jai esai amp Cihi5i 0 ale amp Dilsplay Ulipidatiel if LL O 0 Pirieisis FIS 200 biar DIPIClol n s t gt FID 2 3 4 K It C hi 5 Scale amp Display Piirjiejis js Fi S _ if 2 0 0 b a r PiCiginisit Ll ih 43 4 J gt DIP Zero lt CihiSi ale amp Diisipila y Piiriesiis FiS L200 blair P Cionisti I i2341 gt DP Zero Confirm lt www trolex com Clhis Seale Lelie lal al sle DIP Zero l gt FiCiain sit a lel Jel plis play visit Ell 2 234 Zero tle IED 234d kl Ch5 Scale amp Display DP Zero Ficlolnisit U11234 b lZlellrllol Jt E Jol of tlm www trolex com TX9042 User Manual Press U to increment the digits to the required value Press R to confirm the values selected 5 9 2 15 Flow Constant Flow Input Module
44. elected The linearity response of the input module will be automatically corrected based around the new calibration point entered and the correction factor will be appropriate to whichever type of temperature input module is fitted A simple way to apply a known temperature to an installed sensor is to place it in a small cup of ice and calibrate the display to 0 C as described 5 9 2 12 Pressure Full Scale Flow Input Module for TX6022 only This function only appears in the menu when a flow input module is fitted for use with a TX6022 Liquid Flow Sensor The full scale pressure of the line pressure sensor is entered here to allow the flow readings to be pressure compensated Press R to enter Pressure Full Scale mode Press D to navigate the cursor along the digits to the required digit TX9042 UM EN 01 71 TROLEX lt Press U to increment the digits to the required value Press R to confirm the values selected 5 9 2 13 Pressure Constant Flow Input Module for TX6022 only This function only appears in the menu when a flow input module is fitted for use with a TX6022 Liquid Flow Sensor The TX6022 Liquid Flow Sensor will be supplied with this calibration constant which is then entered into the TX9042 PSC Press R to enter Pressure Constant mode Press D to navigate the cursor along the digits to the required digit Press U to increment the digits to the required value Press R to confirm the values select
45. emory is permanent All settings are retained even in the event of power failure 36 TX9042 UM EN 01 www trolex com Power Up Pi Uitte VS Hla it t lo ni VerisitioiniX X JPO Di 14s JPO D 1 0lls JPO DI 12 iS JIPO D1i5ls www trolex com TX9042 User Manual 5 2 Power up When first switched on the processor will initialise all the default values unless new values have previously been programmed The LCD screen will display the version number of the software currently installed 5 3 Signal Display After ten seconds the screen will switch to the Signal Display mode displaying the status of all eight channels of input signal simultaneously Indicates that a set point has been exceeded on that channel Refer to Section 5 9 3 for details Indicates that a channel input module has not been fitted Refer to Section 5 4 for details Indicates an input signal Error or system Fault on that channel Refer to Sections 5 4 and 5 9 4 for details The flashing cursor frame over the channel identification number indicates that the particular channel is available for individual Close up examination Refer to Section 5 5 for details Any channels with Power On Delay POD programmed will initially show the length of delay in seconds Refer to Section 5 9 1 for details The displayed time will countdown until the POD period is complete then the screen will revert to the appropriate input signal value in each case
46. erform assessments on the complete scope of their activities to ensure a target SIL for the safety function is and continues to be met Low Demand and High Demand modes of operation are defined in IEC 61508 4 3 5 16 3 3 Summary of the Verified Functional Safety Data The product configuration and Safety Manual that have been assessed are shown in Table 1 Product Information Product identification Product specitication Product configuration system configuration Element safety function Safety Manual www trolex com Details TX9042 55 Programmable Sensor Controller See Section 1 5 of this User Manual 4 to 20 mA input conditioning modules fitted OR 0 4 to 2 V input conditioning modules fitted To achieve SIL the TX9042 with 4 to 20 mA or 0 4 to 2 V input conditioning modules fitted must be configured to de energise an output channel relay If either the input signal transitions a pre determined alarm threshold or an internal fault is indicated Neither the display nor the RS 485 data link are part of the specified safety function Monitoring of signals from devices configured as 2 3 wire current loop devices 4 wire current inputs with separate power connection or voltage inputs To de energise an output channel relay open relay contacts if either the input signal transitions a pre determined alarm threshold or an internal fault is indicated See Section 3 of this User Manual Table 1 Basic Element Info
47. fety Manual in Section 3 5 of this User Manual 18 TX9042 UM EN 01 www trolex com TX9042 User Manual 3 The display is for indication only and is not part of the safety function likewise the RS485 communications are not part of the safety function 4 The environmental limits are restricted to e 20 to 40 C e relative humidity lt 90 5 IEC 61508 2 74 4 3 1c limits use to SIL 1 in high or continuous mode of operation when used In a non redundant configuration 3 5 Proof Test Periodic Proof Tests of the element safety function must be carried out to identity any dormant failures particularly when used in low demand safety functions refer to Section 6 1 4 of this User Manual for the Proof Test procedure Faults identified by this Proof Test must be repaired within the MTTR and the unit returned to full working order A suitable Proof Test interval T should be used in order to achieve the required average probability of failure on demand PFD w A nominal interval of 8 760 hrs 1 year and Mean Time To Repair MTTR of 24 hours has been used in the derivation of PFD for illustration purposes If different values are used the PFD for a non redundant arrangement i e where the safety function relies on a single element can be re calculated as follows PFD ave Anu T Msp toe Where le the channel equivalent down time A Ap 1 2 MTTR A A MTTR For redundant arrangements refer to IEC 61508 6
48. for the equations Checkpoint Those responsible for specifying proof testing of safety functions should refer to IEC 61508 6 2010 clause B 3 2 5 for considerations of the effect of non pertect proof tests www trolex com TX9042 UM EN 01 19 TROLEX lt 3 6 System Configuration Drawing The illustration below shows how the 1X9042 is to be used with other system elements Sensor Power supply detector TX9042 output OSC COSTS EH SEEEEDE eg Trolex utpu anaana Ese TX6626 Sensor p gt not required detector for two wire systems _TROLEXC tae Qe sesessaonsanvanen COSOTSVSIOCCODOYS _ s hone Relay controlled circuits input and output connections 20 TX9042 UM EN 01 www trolex com TX9042 User Manual 4 Installation 4 1 Precautions Do not disassemble the TX9042 PSC whilst in the hazardous area or use a I X9042 PSC that has a damaged housing in the hazardous area The TX9042 PSC must be installed within a metal protective enclosure to ensure compliance with certification requirements It is permissible for the enclosure to incorporate a polycarbonate window to allow visibility of the TX9042 PSC LCD screen However window area may be no greater than 100 cm 4 2 Labelling When the TX9042 PSC is supplied fitted into a standard Trolex X9204 metal enclosure two channel identification labels will be fitted to the enclosure near to the connecting terminals Connection details can also be viewed on th
49. ge Vms Minimum Acceptable Sensor Voltage eg 16 V Total Resistance of Connecting Cable in ohms km R cable www trolex com TX9042 UM EN 01 33 TROLEX lt 4 6 6 Cable Distance for Voltage Inputs 0 4 to 2V The input impedance of the input is very high so cable distance is usually not a problem Voltage drop in the power supply line is the critical factor particularly on a three wire system where the 0 V of the power supply line Is common with the signal line Use a 4 wire system on distances above 100 m 4 6 7 Dual Input Signals Differential The differential inout stage of a voltage input module also enables it to monitor two Input signals simultaneously and respond to the difference between the two This technique is frequently used to monitor differential temperature differential pressure and differential speed Checkpoint It is Important that the two sensors or input signals are calibrated to the same operating parameters 34 TX9042 UM EN 01 TX9042 HAR alse Qf oven f Sig V See 0 V Supply NSOR OR SE TRANSMITTER SENSOR TX9042 0 to 10 V 0 to 10 V www trolex com TX9042 User Manual 5 Setup and Calibration 5 1 Controls and Indicators Scroll Scroll Up Down Relay indicating LEDs off Channel U D Confirm with relay energised no set input Escape Data point signal connecttons L R E eq ee m B e Sje Soe jd PROGR
50. ghten any loose terminals as necessary If any part of the TX9042 PSC shows any signs of damage defect deformation or missing parts Immediately remove it from service and replace it with a working TX9042 PSC Return the defective 1X9042 PSC to your local Trolex service agent for repair and testing After the completion of all maintenance update the maintenance records TX9042 UM EN 01 103 TROLEX lt 6 1 3 TX9042 PSC Battery Replace Checkpoint This maintenance task CANNOT be carried out underground 1 Remove the TX9042 PSC from service and replace It with a working TX9042 PoG 2 Return the TX9042 PSC to your local Trolex service agent for battery replacement and testing 3 After the completion of all maintenance update the maintenance records 6 1 4 TX9042 PSC Proof Test Checkpoint This maintenance task CAN be carried out underground Checkpoint A Proof Test must be carried out at regular intervals if the TX9042 PSC is being used ina SIL rated system The interval of 3 months or 12 months depends upon the SIL rating and whether the safety function is defined as Low or High Demand See section 3 for further information 1 Open the IP rated enclosure housing the TX9042 PSC 2 Establish which input channels have a 4 to 20 mA or 0 4 to 2V input AND are configured to de energise an output channel relay and which output channel relay it is These are the input channels to be proof tested
51. h also gives magnitude comparison of the percentage difference between Input and Run 92 TX9042 UM EN 01 Signal Cihiialiniinjlell Ii DIFSLIP tli obl ol Ta aid dlo f d o A www trolex com Clhilalin injlelit at LJ Di E S ie ile tL 2 OOND H2 3i aao o 5 0 a www trolex com TX9042 User Manual 5 9 7 5 Differential Slip Frequency The frequency level or pulse rate on Input 1 is compared with the frequency level or pulse rate on Input 2 Setpoint levels are determined as an absolute frequency difference Close Up 1 Display Additional dynamic information is displayed in this mode T1 incoming frequency or pulse rate on Input 1 T2 incoming frequency or pulse rate on Input 2 the percentage difference between Input 1 and Input 2 with respect to Input 1 Bar Graph overview of the percentage difference between Input 1 and Input 2 TX9042 UM EN 01 93 TROLEX lt 5 9 7 6 Differential Frequency The frequency level or pulse rate on Input 1 Is measured Setpoint levels are determined as an absolute frequency difference Close Up 1 Display Additional dynamic information is displayed in this mode T1 incoming frequency or pulse rate on Input 1 Run the programmed Run frequency the percentage difference between Input 1 and Input 2 Bar Graph Magnitude comparison of the frequency difference between Input 1 and Input 2 94 TX9042 UM
52. ible his mode is used on critical safety systems where relays latched in the alarm condition can only be reset by an authorised person who has access to the keypad of the controller High Any latched relays will be reset as long as the reset Input is High open contact and the channel input signal has receded trom the programmed setpoint level Low Any latched relays will be reset as long as the reset Input is Low closed contact and the channel input signal has receded from the programmed setpoint level Rise Any latched relays will be reset only as the reset input Rises opening contact and the channel input signal has receded from the programmed setpoint level 52 TX9042 UM EN 01 A36 OV Reset High OV Low OV H High A36 OV Reset owe Reset OV High OV Low www trolex com High aD A36 j a Low Maini Setup Data Display Cilelaiir Dilaltia gt RK Uy Ries gt O f f lt LIIEIIII MiB AHIIT TI Low Rise UFa UU www trolex com TX9042 User Manual Fall Any latched relays will be reset only as the reset input Falls closing contact and the channel input signal has receded from the programmed setpoint level Press U or D to navigate to the mode of reset Press R to confirm the mode of reset Press L and R to reset any latched relays In all four modes Checkpoint The relay reset input does not affect display counts accumulated on a Pu
53. ill show an additional item called Resistor in the channel menu The module will accept inputs from simple gt On Off switches voltage free contacts such E eae Gatien as thermostats pressure switches and limit INPUT 2 switches also providing a failsafe capability p Each digital input module will accept two input switches one on Input 1 the other on Input 2 and each of these inputs can be programmed independently for most of the Standard functions 96 TX9042 UM EN 01 www trolex com Setpoint 1 Setpoint 2 www trolex com TX9042 User Manual Identification text Refer to Section 5 9 2 20 for details Terminal connections display Refer to section 5 9 2 21 for details Alarm on high low input rising falling alarm Refer to Section 5 9 3 3 for details Setpoint delay output delay Refer to section 5 9 3 4 for details Operation auto reset latch toggle pulse Refer to Section 5 9 3 6 for details Relay output assignation Refer to Section 5 9 3 7 for details Short Circuit Detection A diode connected in series with input contacts at the remote point will enable the TX9042 PSC to detect and Identify an open short circuit connection in the sensor connecting cable An open circuit cable connection such as a severed cable will appear as an open Input contact signifying an alarm in the normal way A short circuit connection such as a crushed cable will short the diode that is connected in serie
54. itoring Integrity on the plant and normally triple monitoring On the other hand plant shutdown will only occur when at least two gas sensors are In agreement So Indicating genuine danger The programming of this function is completely flexible Any number of the setpoint signals can be matrixed to a single relay enabling the selection of the Voting function from any two setpoint signals up to sixteen setpoint signals 54 TX9042 UM EN 01 am a 0 4 to 2 V Analogue signals Channel 1 Channel2 Channel 3 www trolex com TX9042 User Manual Press U or D to select the Vote Number Main Setup gt Rie lla y gt Press R to confirm Relay 2 gt 5 711 Relay Operation Main Setup Clear Data RlyRes gt RlyOperat Low lt When relays are not allocated to a setpoint Relay Operation allows the relays to be left in the de energised or energised state Low De energised High Energised 5 712 Software Version Product identification information is presented on the LCD screen this includes the product reference software version number serial number log data memory and input board type TROL EX TX 9040 Version K X sleir No 3 TR 100 0 10 0 10 Miem a niyi I5 7 K q 2 5 713 Self Test This enables all the internal functions of the TX9042 PSC to be tested Self ie iS JE Vie
55. l is used for all input connections and the upper level is used for output signals and data connections exorororororererererore rororo PROGRAMMABLE SENSOR CONTROLLER Input connections lower level Output signals and data connections upper level Each of the input channels has four connecting terminals available and these are utilised in accordance with the type of input module that is fitted refer to the diagram on the following page The sensor signal enters on terminals A2 and A3 and if a power supply is required to feed the sensor then this is available at terminals A1 and A4 The input signal is fully floating and differential giving high immunity to electrical interference www trolex com TX9042 UM EN 01 23 TROLEX lt CHANNEL 5 CHANNEL 6 TET Ere TyaT TTT S RS485 oa o gt 23 ea es a6 o7 os oo Puopuppopuersfeudpuyns o a oO see re CHANNEL 1 CHANNEL 2 CHANNEL 3 CHANNEL 4 Supply The output contacts are shown with the relays de energised in the alarm condition Terminal A35 is used to control the Power On Delay function see Section 5 9 1 for details and the External Override facility Terminal A36 is used to Reset any Latched relays see Section 5 79 for details Circuits switched by the contacts of the output relays must emanate from a certified Intrinsically Safe power source and the circuit parameters must be within Intrinsically Safe requirements The unit
56. lm sec v IIUNDER RANGE Channel 1 PCOUNT CONVEYOR 5 10 IZ L Ciihiiaininiell iL SiPi2 SPL CONVEYOR 5 1435 j A www trolex com TX9042 User Manual 5 Signal exceptionally Low ie 3 8 mA Checkpoint Digital signals are by their nature self monitoring so this facility does not appear on digital channels 5 5 1 2 Close up 1 Display for an Digital Input Module A Channel identification 1 to 8 B Programmed mode of the digital input module Pcount This changes to indicate that a channel setpoint has been exceeded ie SP1 and or SP2 C User text entry for channel duty identification Used to display dynamic function information in some digital modes D Count or frequency to 10 digits 9999999999 E Bar graph of count or frequency with limit markers giving a magnitude comparison of the count or frequency level F Last count sense Indication Reset or steady input signal 4 Rising count or frequency WV Falling count or frequency Slowly changing sensor signals under suspicion may be assessed Press R to return to the Signal Display TX9042 UM EN 01 41 TROLEX lt 5 5 2 Close up 2 Information Display Close up 2 will show information about the setpoint values and historical recorded data relating to the Input signal From Close up 1 press L to display Close up 2 5 5 2 1 Close up 2 Display for an Analogue Input Channel A Channel identification 1
57. lse Counting channel 5 7 10 Relay Voting Each channel of the TX9042 PSC has two adjustable setpoint signals Any or all of these can be matrix programmed to operate any or all of the four output relays R1 R2 R3 and R4 A Voting system can be superimposed on to this facility whereby a selectable number of the setpoint signals must be present before the selected output relay will be operated TX9042 UM EN 01 53 TROLEX lt Take the example of an environmental monitoring system which must protect against the catastrophic consequences of a flammable gas explosion Flammable gas sensors can be installed to detect the presence of the gas and the signals from the sensor can be arranged to trigger setpoint alarm levels in the Programmable Sensor Controller and initiate power shutdown However due to the highly complex nature of the process there are conflicting requirements On one hand for safety reasons the presence of the gas must be swiftly and unequivocally detected so triple gas sensors can be fitted in each critical area to achieve this Conversely the impact of a false plant shutdown would be financially disastrous and must also be protected against In this case if a Two out of Three voting system is programmed Into the Programmable Sensor Controller the selected output relay will only respond when two or more alarm setpoints are activated together This ensures that there is at least dual gas mon
58. ly appears in the menu when ower a straingauge module or PSU Bridge module pper LIL UUL is fitted e r ol q Press R to enter Zero mode Press U or D to Increment the displayed value to a value that matches the zero chia Zed UU reading on the straingauge Reading 0 09 v v gt I 4 flslel ela tl lalalaLL amp Press R to confirm the value selected L Checkpoint This function can also be used to offset the reading from zero to compensate for any SVS EOS 74 TX9042 UM EN 01 www trolex com Ch4 Upper Zero gt 1 5 pilajin Scale amp Display Cihi 2 Reading gt S piain gt Span 1125 Wv N 1 042 lt Ch4 Upper Zero gt Sieim 8 i t i v ity Scale amp Display Cihi2 Seng utivity Le Reading gt Sen gt 02 003mV V lt www trolex com TX9042 User Manual 5 9 2 18 Span PSU Straingauge Module This function only appears in the menu when a PSU Straingauge module is fitted Press R to enter Span mode Press U or D to Increment the displayed value to a value that matches the measured reading on the straingauge Press R to confirm the value selected Checkpoint When the module is used to monitor methane trom a Pellistor head the display will latch at gt 5 methane and turn the power supply off The screen will read SHDWN 5 9 2 19 Sensitivity Straingauge Mode This function only appears
59. mperature Input Module This function only appears in the menu when a temperature input module is fitted P5423 72 94 Platinum Resistance Device PT100 P5423 74 Semiconductor Temperature Device KTY81 P5423 76 Semiconductor Temperature Device KTY84 Po423 253 Semiconductor Temperature Device KTY21 6 It sometimes occurs that the temperature output signal relationship of the temperature sensing device being used is not known or as in the case of a semiconductor sensor the output is not precisely standardised from one device to the next Cable length and size of conductor cores can also affect the calibration of the system The display can be calibrated after installation to concur with a known temperature applied to the sensor being used 70 TX9042 UM EN 01 www trolex com Ch4 Scale amp Display Lower Upper SEE J gt Cial Uli b I gt U21 81 Cihi5 l a lie amp Diis pilay Ulpiplein if 20 000 im Up di ai tie DL 0 0s gt P rie sisi Fi S 1E2000 b a ri yi lt j Cih5 c a lie j amp Display Upper 20 00l m Update 1 005 gt PiriielsiisiiFiS gt 12 0 0 b ar ii lt www trolex com TX9042 User Manual Press R to confirm the calibration mode The screen will show the apparent temperature being measured by the sensor Press U or D to Increment the value displayed to concur with the temperature measured at the sensor Press R to confirm the value s
60. n 39 HER OULUI eT LEA SiS elo el www trolex com TX9042 UM EN 01 55 TROLEX lt 5 7 14 Display Cycling If the user requires more information on each of the inputs the screen can be set to toggle between screens showing 4 inputs The rate of toggle can be defined if this is set to zero logging is disabled 5 8 Contrast Control The contrast of the LCD screen can be varied to compensate for the effect of local ambient light conditions Press U and D to Increase or decrease the Contrast setting Press R to confirm the selected setting Checkpoint 1 is the minimum contrast setting and 15 is the maximum contrast setting 56 TX9042 UM EN 01 Main Setup Verston Sel Uit Tlelsit Disipitiy iCiyiieil O Ft 2 22 0 Vi Bird ge 0 90 Methane 1 3 0 boop 10 1 C Motortemp Matn Menu Main Setup PILICD Cloinit rst 10 Ji lt 5 Cihiiaiininje li IL www trolex com Channel 4 Pi T 1 00 gt Poin D e laly ii JIl lt i Eix t IPOD Exit iG vn I iskkh bl amp l idg ilalyl IIl Setpoint 1 Selt plojtnit 2 Fiiajul tit Keycode Channel Ciihlaliniinilel 1 FIRIEIQ gt Pion D e laly lt Scale amp Display Sjle it pjojt in jt I IsteltIpfolilnitE BET TIITITI Thirie sjhio lt dif Keycode Mode Riel sitistiol r iif Channel www trolex com TX9042 User Manual 5 9 Channel Function and Calibration
61. ntary functions to be created Press U or D to navigate to Yes or No as required Press R to confirm the selection Checkpoint Any or all of the sixteen setpoint signals can be programmed for Voting operation with the output relays Refer to Section 5 710 for details 84 TX9042 UM EN 01 Channel 4 Setpoint gt RielLajy LiL jE S lt Relay2 YES Relay3 YES TRlehbyY4INGIIIT IIIT Setpoint HIGH Signal LOW RELAY YES SE DE ENERGISED idoa LED INDICATOR tiis www trolex com TX9042 User Manual 5 9 4 Fault Signal Alarm Assignation Each of the 8 channels on the TX9042 PSC has a Fault Output Signal which triggers when a system fault is detected by the processor Refer to Section 5 5 for details The fault types are e Sensor Failure e Input Signal Faults e Loss of Signal www trolex com The Fault signal trom each channel can be cross matrix programmed in the same way as the Set Point signals to interface with any or all of the four output relays R1 R2 R3 and R4 This way it is possible to identity the character of the alarm without causing unnecessary shutdown or giving a false alert TX9042 UM EN 01 85 TROLEX lt This function does not work where a channel has been configured as a Digital Input Channel except for a failsafe Digital Input Channel as most digital input functions are self monitoring by their nature Press U or D to navigate to the relay required
62. orm repairs to components When devices are used for applications with technical safety requirements the relevant instructions must be followed Trademarks 2014 Trolex Limited Trolex is a registered trademark of Trolex Limited The use of all trademarks in this document is acknowledged Document History Issue 01 17 October 2014 Original publication of this document Contact Details Trolex Ltd Newby Road Hazel Grove Stockport Cheshire SK7 5DY UK 44 0 161 483 1435 sales trolex com 110 TX9042 UM EN 01 www trolex com TROLE Trolex Ltd Newby Road Hazel Grove Stockport Cheshire SK7 5DY UK t 44 0 161 483 1435 e sales trolex com www trolex com
63. ormally used for counting and Input 2 for reset or count steering control 88 TX9042 UM EN 01 Channel 1 FREQ Tihiiris hild Keycode 1 gt Mjojdje gt R COUNT I lt 111111 UPON WelRtuLt Ij Il PLS FREQ SLAP LAR EG DIF SUIP FQ DILF Fl FREQ DIGITAL b NAMUR SENSORS www trolex com hannel a PCOUNT PG OUNTER U IL UUI olo Inputd_ JILD Target time www trolex com TX9042 User Manual 5 9 7 1 Pulse Counter Pulses entering on Input 1 will be totalled Setpoint count values can be programmed Counting can be Upcount Downcount or Bidirectional Refer to Section 5 9 2 8 for details Close up 1 Display Refer to Section 5 5 1 for details 5 9 7 2 Pulse Interval This mode measures the time interval between successive pulses on Input 1 against a programmable target time If the interval time between pulses exceeds the programmed target time the setpoint will be triggered This is useful for monitoring slow moving targets or rotating pans and drums or simply as a long delay time TX9042 UM EN 01 89 TROLEX lt Close up 1 Display Additional dynamic function information is displayed in this mode Refer to Section 5 5 1 for details T Elapsed time from the last reset pulse on Input 1 Channel 1 PLNTVL taae SPL aloo SP1 Setpoint 1 or target time Setpoint 2 32 17 Is Je ic is can also be programmed as a second target E JL time but is not displayed
64. ounting uses both inputs Input 1 to count the pulses trom a toothed wheel or similar target and Input 2 as the pulse steering input The proximity sensors or similar should be positioned around the wheel to give a resultant signal overlap of about 90 of tooth angle The counter of the sensor controller will be instructed to count up or down dependent upon the state of Input 2 at the point of count transition Alternatively a remote signal or contact can be used for pulse steering such as auxiliary contacts on a forward reverse motor contactor The count will add or subtract pulses on Input 1 starting from zero or from a Constant offset that has been programmed The display will show the resultant Up Down counts in either the positive or negative sense To reset the Count Display Upcount Downcount Bidirectional Pulse on Input 2 Yes Yes No Keypad Yes Yes Yes Checkpoint If the count value to be reset has exceeded and so activated a programmed Setpoint value the setpoint output will reset at the same time Refer to Section 5 9 3 6 for details 68 TX9042 UM EN 01 ee 1 ial 2 T 4i 902 COUNT inpur1 STEER input2 UP COUNT CCW a DOWN COUNT CW INPUT 2 LOW OPEN ORO V INPUT 2 HIGH aa Retail V DOWN COUNT bes a COUNT www trolex com Ch2 Scale amp Display Units DLR gt Lower 10 Ch2 Scale amp Display Di P Lower gt U p pen 510 010
65. pment Name Task Type eae Interval TX9042 PSC Check Sy 6 months TX9042 PSC Battery Replace 6 1 3 5 years TX9042 PSC only to be carried out if 3 months the TX9042 is installed in a SIL rated Proof Test 6 14 OR system 12 months 6 1 2 TX9042 PSC Check Checkpoint This maintenance task CAN be carried out underground 1 Check the TX9042 PSC enclosure is securely attached If the enclosure is not securely attached resecure as necessary 102 TX9042 UM EN 01 www trolex com www trolex com 10 11 TX9042 User Manual Check the TX9042 PSC enclosure for cracks penetration water ingress signs of having been struck or other damage Repair or replace the enclosure as necessary Check that the TX9042 PSC is securely attached to its enclosure If the TX9042 PSC is not securely attached resecure as necessary Check the exterior of the TX9042 PSC for cracks penetration water ingress signs of having been struck or other damage Check the LCD screen is clear can be easily read and is free from damage or defect Check the LCD screen shows no short circuit Or open circuit conditions on any of the 8 channels Check that the Keypad L R U and D keys are tree from damage or defect Check that the two terminal identification labels are securely attached legible and tree from damage or defect Repair or replace the two labels as necessary Check all wires connected to the TX9042 PSC are secure within the terminals Ti
66. point 1 z 24 hour clock Press R to return to Close up 1 Press L to escape and return to the Signal Display www trolex com TX9042 UM EN 01 43 TROLEX lt 5 6 Menu of Functions 5 6 1 Default Values Initial default values are registered into the Menu of Functions during manufacture The standard values are shown in the bottom right hand corner of each menu function box These values are entered during manufacture via the data communications link by a special PC based software routine Non standard default listings can also be entered This facility can be used to quickly and conveniently programme specific custom operating functions Into single or multiple units 5 6 2 Programming the Operating Values Normally the operating values of the various functions in the menu are programmed by the user through the keypad to enter specific calibrations and selections to individual requirements If the Programmable Sensor Controller is being used as part of a SCADA system the same adjustments can be made from the keypad of the base station via the data communications link The special software required for this purpose is included as part of the SCADA graphic package provided User programmed operating values are permanently retained 44 TX9042 UM EN 01 PROGRAMME www trolex com MAIN MENU gt Main Setup lt LICIDI Contrsiti Cihjain n e l 1 Iclhlad dd Udo PEEP
67. r to Section 5 7 5 for details Press U or D to navigate to On or Off as Channel 4 PT100 required Sie t poli init 2 Fault Press R to confirm the selection gt Keycode OFF lt IIILITTITIKONITATIIII R O Checkpoint Off Programming available On Programming inhibited R O Programming read only parameters are displayed but cannot be changed Checkpoint If more than three invalid entries are attempted access to the channel function programming will be denied for 30 mins If you require this feature to be disabled contact the Trolex Product Support Department service trolex com www trolex com TX9042 UM EN 01 87 TROLEX lt 5 9 7 Mode Setting for a Digital Input Module A channel fitted with a Digital Input Module will show an additional item called Digital in the Channel Menu A Digital Input Module can be set into seven different modes of Pulse Processing Format and one of these must be determined before programming of the various function characteristics can proceed The available modes of Pulse Processing Format are e Pulse Counter e Pulse Interval e Pulse Frequency e Slip Frequency e Differential Slip Frequency e Differential Frequency e Digital Level Press U or D to navigate to the required mode of Pulse Processing Format there are seven modes available Press R to confirm the selection Pulses can be counted from contacts NAMUR sensors or photosensors Input 1 is n
68. rmation TX9042 UM EN 01 17 TROLEX lt The hardware failure data for the TX9042 element safety function based on an extensive analysis of field failure data with a 90 single sided confidence limit Is shown in Table 2 Parameter Value Dangerous failure rate 2 3E 06 Safe failure rate A N R Safe failure fraction SFF N R Element type Type B Hardware fault tolerance internal architecture 0 Diagnostic coverage DC 60 Diagnostic test interval N A fP Probability or Failure on Demand PED yg Ne monpmertest Sane NTT 1 0E 02 Probability of Failure on Demand PFD ge month proof test 24hr MTTRI 2 6E 03 Probability of dangerous Failure per Hour PFH 2 3E 06 Table 2 Hardware Failure Data Not required by Route 2 21 To be conservative no credit has been taken for the diagnostics 3 4 Conditions or Restrictions for use in SIL Applications The sections of this User Manual shall be strictly complied with to ensure validity of the failure data and systematic safety integrity The following additional restrictions and conditions apply when the unit is used in SIL applications 1 The TX9042 must be repaired within the MTTR assumed in the PFD calculations shown in the table above if an internal fault is detected in the unit 2 Ifthe MTTR or the proof test interval T is different from those assumed in this User Manual then the PFD must be re calculated and the SIL capability re verified accordingly refer to the Sa
69. rn the defective 1X9042 PSC to Trolex for repair and testing 18 After the completion of all maintenance update the maintenance records 6 2 TX9042 PSC Repair Should your TX9042 PSC become damaged and require repair Immediately remove it from service replace it with a working TX9042 PSC and contact your local Trolex service agent to arrange repair Checkpoint If your TX9042 PSC is used in a SIL rated system It can only be repaired by Trolex 6 3 Maintenance Records Implement a planned preventative maintenance process and keep good maintenance records Consult your local Trolex service agent or the Trolex Product Support Department service trolex com for help in implementing a planned preventative maintenance process he Maintenance Log gives an example of a typical maintenance record system TX9042 UM EN 01 107 TROLEX lt 6 4 Maintenance Log Maint Return Comiments Task No to Trolex 108 TX9042 UM EN 01 www trolex com www trolex com TX9042 User Manual 7 Disposal Part of the ethos of Trolex is sustainable design TX9042 PSC contains materials that can be recovered recycled and reused At the end of its useful life ensure that the TX9042 PSC is recycled in accordance with local laws and bylaws for the geographic area where it is located The end of its useful life is to be determined by the owner operator of the equipment and not Trolex Ensure that the TX9042 PSC Is recycled by a
70. rsion analogue channels Setpoints 2 per channel plus Fault signal 8 TX9042 UM EN 01 www trolex com Output relays Relay contact rating Setpoint adjustment Hysteresis adjustment Power on delay adjustment Output delay adjustment Input update period adjustment Engineering units menu Fault signal Data communications Data logging www trolex com TX9042 User Manual 4 encapsulated reed relays with function programming 200 V 0 25 A 3 W absolute maximum Checkpoint Circuits switched by the contacts of the output relays MUST emanate from a certified Intrinsically Safe power source and the circuit parameters must be within Intrinsically Safe requirements O to 99 of full scale 01 SE O to 255 seconds for each channel O to 18 hours for each setpoint in one second steps O to 60 seconds for each channel in 0 05 second steps Viorn imAcei Koo kg mba bar Pa kPa Pol ZA eles aa ann a ane a Wola ops Hz kHz secs m s h m m s mA m m A I m g m l s g s h and g h Open or short circuit signal line or sensor fault will generate a fault signal the fault will be identified and displayed on the LCD screen RS485 Modbus Up to 26 000 readings with on demand down loading TX9042 UM EN 01 9 TROLEX lt 1 6 Electrical Details TX9042 55 Programmable Sensor Controller PSC Supply voltage 12 V dc 20 2 5 at 125 mA Output Modbus protocol Type of sensor Flammable Supply current 125 mA
71. s with the remote Input contact Initiating a Fault F indication and a Fault channel signal TX9042 UM EN 01 97 TROLEX lt Signal Display Input 1 Input 2 Refer to Section 5 3 for details Input contact Open OP Input contact Closed CL Short circuit connection Fault F Open circuit connection Fault F Close Up 1 Display Refer to Section 5 5 1 for details Short Circuit and Open Circuit Detection The module can be programmed to individually identify both short circuit and open circuit conditions If a resistor is also Incorporated into the remote contact connection the TX9042 PSC will be able to exclusively identify both failure modes of the connecting cable conditions Signal Display Input 1 Input 2 Refer to Section 5 3 for details Input contact Open OP Input contact Closed CL Short circuit connection Fault F Open circuit connection Fault F 98 TX9042 UM EN 01 Cihiaininje tl 1 DGTLFS inputi OPEN Input ji2 CLOSED www trolex com Chlainne 1 DG T LIF S Input I OPEN Input 2 CLOSED Channel 1 DIG T L FS Fiault Keycode gt Restistor NIO IIKI IIITITITIITI yE 5 4 20mA 6 ON iE RIMU Zi 3 Ci hjaliniinjel 1 Keycode Mode gt Channel gt ON LIcInlalninlet dd EAT FREQ www trolex com TX9042 User Manual Close Up 1 Display Refer to Section 5 5 1 for details Press U or D to select the resistor stat
72. scription TX9042 User Manual Mining Ex ia TX9042 55 Mining Ex ia Order Code Current 0 to 20 mA P5423 516 Current 4 to 20 mA P5423 508 Voltage 0 to 2 V P5423 514 Voltage 0 4 to 2 V P5423 509 Voltage 0 to 10 V P5473 515 Flow TX6023 not lo limited P5425 552 Flow TX6023 lo limited P5423 553 Flow TX6023 4 to 20 mA lo limited P5423 556 Thermocouple K type P54723599 Thermocouple I R 50 to 400 C P5423 527 PT100 50 to 200 C P5423510 PT100 50 to 400 C P5423 513 KTY21 50 to 150 C P5423 519 KTY81 50 to 150 C P54273 511 KTY84 O to 300 C P5423 512 Flow TX6022 Flow P5423 028 Flow TX6022 Pressure P5423 518 ac RMS 500 Hz to 10 kHz TX5630 P5423 506 01 ac RMS 15 to 100 Hz TX5630 P5423 506 02 www trolex com TX9042 UM EN 01 7 TROLEX lt 1 4 Dimensions 62 203 TROLEX lt All dimensions in mm 1 5 Technical Information Display accuracy 0 25 analogue channels Setpoint accuracy 0 5 Ambient temperature limits 10 to 50 C Electrical connections 4 mm barrier clamp terminals Housing material ABS Nett weight 800 g Environmental protection Must be housed in a protective metal enclosure to comply with Intrinsically Safe requirements Information display LCD screen 20 characters x 4 lines 6 mm high characters Mounting DIN rail Microprocessor Microprocessor controlled menu operation with non volatile data retention and 10 bit analogue to digital conve
73. ses of this certificate these shunt safety barriers may be considered equivalent to Category M1 equipment The cable parameters shall not exceed the following Cee 7 6 uF Le Re 222 uH ohm www trolex com TX9042 UM EN 01 11 TROLEX lt 3 For the purpose of this certificate a P F inductive sensor to PIBOOATEX2048X to Category 1G EEx ia IIC T6 connected to terminals T1 to T4 of a Digital Input Module may be considered equivalent to Category M1 In this instance the power supply selected to power the TX9042 PSC must have an output voltage not exceeding 16 V 2 1 2 General Conditions of Use Prior to installation it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available from Trolex C 4 ATEX Directive 94 9 EC EMC Directive 2004 108 EC 2 2 Russia GOST R amp Ex Certificate number POCC GB ME92 B02874 Ex Certification code PO Ex ia X 2 2 1 General Conditions of Use Prior to installation it is essential that user refers to the above certificate for any special conditions for safe use The user must ensure that the termination and cable parameters are fully complied with and are compatible with the application Copies of certificates are available trom Trolex 12 TX9042 UM EN 01 www trolex com TX9042 User Manual 2 3 South Africa MASC Ex Certifica
74. te number MASC M 11 359X C Ex Certification code Ex ia 2 3 1 Special Conditions for Safe Use 1 The TX9042 Programmable Sensor Controller PSC must be mounted in a secondary enclosure as shown on drawing P5423 02 or in an alternative metal enclosure not light alloys which is appropriately certified as providing a degree of protection of IP54 2 Upto 11 RS485 Communications Modules in separate TX9042 Programmable sensor Controllers may be daisy chained together ie terminals B1 all linked together terminals B2 all linked together and terminals B3 all linked together Provided that the number of daisy chained 1X9042 PSCs is reduced to 10 these communications lines may be connected to unspecified safe area equipment via an appropriately certified shunt zener diode safety barrier dual channel ac whose output parameters do not exceed the following per channel Uo 9V lo 100 mA Po 225 mW OR Uo 12 V lo 80 mA Po 240 mW eg suitably certified MTL761 MTL766 to BASOI1ATEX7202 or MTL7761ac MTL7766ac to BASO1TATEX7217 For the purposes of this certificate these shunt safety barriers may be considered equivalent to Category M1 equipment The cable parameters shall not exceed the following Ce Z7 0 Fr Le Re 222 uH ohm www trolex com TX9042 UM EN 01 13 TROLEX lt 3 For the purpose of this certificate a P F inductive sensor to PIBOOATEX2048X to Category 1G EEx ia IIC T6 connected to terminals T1 to
75. ting to the second input 62 TX9042 UM EN 01 Constant Zero Constant Zero Constant Zero Chili Pulse i ounter Riielsiielit P le laik Ciolini siit S gt 1 IP IF 1 gt T00 0 1 100 K l Chii Pulse i ounter Clon siit PA gt 1 PFI 2 gt L 0 0 0 4 0 0 J lt www trolex com www trolex com TX9042 User Manual Incoming pulses can be multiplied by a selectable pre scale factor This is useful for converting pulse rates from target wheels flow sensors and measuring devices to the required scale factor or for conversion to the appropriate engineering units Press D to navigate the cursor across the digits Press U to change the value of the digit with the cursor underneath Press R to confirm the Input Pre scale Factor 5 9 2 4 Update The channel input signal is sampled at a pre determined interval The value of an Analogue signal is averaged and updated at periodic intervals and the update period is adjustable A low setting will give rapid reaction to the Input signal and higher settings may be entered where damping of a fluctuating input is necessary or simply as a means of applying a delay to the input This is particularly appropriate in electrically noisy environments In the case of a Pulse Frequency input the microprocessor determines the frequency by counting or Sampling the number of pulses that occur during a timed period TX9042 UM
76. usly High or Low sensor conditions may have occurred previously and this feature enables historic trends to be examined Stored values of previous Peak and Low max min can be deleted Press R to select Reset Press R to confirm Reset 5 9 2 2 Constant Cha Pulse Caunter When a Digital Input module is selected Rilel silelit Pilellalk into the Pulse Counter mode an additional gt Const gt 0000000 lt item called Constant will appear in the menu choice When counting pulses or batch counting a fixed Constant can be added into the counting register to provide a displaced or elevated starting point as in the case of a tare value or correction factor This can be a positive or negative quantity and can be applied to all three modes of counting It is permanent until re orogrammed www trolex com TX9042 UM EN 01 61 TROLEX lt Upcount Mode The count will start at the Constant and count up Downcount Mode The count will start at the Constant and count down Bi directional Count Mode The count will start at the Constant and count up and or down trom it Press D to navigate the cursor across the digits Press U to change the value of the digit with the cursor underneath Press R to confirm the Constant 5 9 2 3 IPF 1 and IPF 2 Some modules of a Digital inout module will show IPF 1 Input Pre scale Factor no 1 in the menu The modes that use two Input counting devices will also show IPF 2 rela
77. value Level PJHilyisit gt I 15 A low value of hysteresis say 5 is often Alarm used to override fluctuating signal levels and to prevent hunting in closed loop control systems A high value of hysteresis can also be used as a control function when controlling the operation of pumps The pump will start at high level SP1 and continue pumping until E low level is reached at the bottom of the Hysteresis hysteresis band f OW 80 TX9042 UM EN 01 www trolex com Setpoint RISING ALARM LOW FALLING ALARM LOW LOW Channel 4 Setpoint Level Hyst gt A Uajrjm gt R tisiitinigi lt TITTLE BIKER GHIT son Setpoint High Signal Low Ciihijaiinini eil 4i Hyst Alarm gt ISipi oin S e t po Unit 2 8 K i Dly gt www trolex com TX9042 User Manual 5 9 3 3 Alarm Rising Falling The setpoint signals can be arranged to occur on a rising input signal or a falling input signal For example when monitoring excess vibration or high gas concentration the setpoint signals can be set to activate ona rising signal to give a failsafe alarm function Conversely when monitoring flow failure or low pressure the setpoint signal can be set to activate on a falling signal Press U or D to navigate to rising or falling as required Press R to confirm the selection 5 9 3 4 Setpoint On Delay The operation of the Setpoint signal can be delayed by an adjustable time period T
78. y be utilised to suit the control function Press U or D to navigate to Single or Cycle as required Press R to confirm the selection 66 TX9042 UM EN 01 Cindi Pulse G ounter IPFI Units PiSjeiquPplSiNGUE 4 PITTI beveded FETT Input 1LJUUUUUUUU UU UU Setpoint Input 1 JUUUUU UU UU UU UU Setpoint Zero www trolex com Cihj1j Pulse Ulinitit s Sequ gt D tir it Ul R lt PTT TTY bDOWNET TITTLE Bil DII Counter Input 1 Input 2 Input 1 Input 2 aie www trolex com TX9042 User Manual Checkpoint The Count display can be reset by an Impulse on input 2 or through the keypad Checkpoint Any relays that are programmed to Latch can be reset by an impulse on input Terminal 36 or through the keypad 5 9 2 8 Direction When a Digital input module is selected into the Pulse Counter mode an additional item called Direction will appear in the menu choice The Direction of pulse counting can be determined Press U or D to navigate to Up Down or Bidi as required Press R to confirm the selection Up count up the pulses on Input 1 from zero or from a Constant that has been entered The display will show the number of pulses Counted Down count down the pulses on Input 1 to zero or from a Constant that has been entered The display will show the number of counts Remaining TX9042 UM EN 01 67 TROLEX lt Bidi bidirectional c
79. y unchanging input signal 4 Rising tendency input signal W Falling tendency input signal Slowly changing sensor signals under Suspicion may be assessed Input signal tendency arrows Input signal bar graph with limit markers giving a magnitude comparison of the analogue signal level Press L to escape and return to the Signal Display www trolex com TX9042 UM EN 01 39 TROLEX lt On an Analogue channel Close Up 1 will also display information about any input signal Error condition that has occurred A signal that transgresses beyond Its normal operating boundaries ie above 20 mA or below 4 mA on a 4 to 20 mA input will initiate warnings at preset levels of discrepancy and trigger exclusive Error signals Refer to Section 5 9 4 for details 5 Signal exceptionally High ie 21 mA Scale Signal Over normal scale value ie 20 01 mA Normal Normal operating range ie 0 4 to 2 V Minimum Signal Under normal minimum value ie 3 99 mA applies to Signals with offset zero only 40 TX9042 UM EN 01 Cihiaininiell 2 FAULT FLOW 10m sec FAULT LISENSOR FAULT Ciihiajiniinjeil 2 SP1 FLOW 10m sec 1 0 Q 1 mji isjejic _ a 1 lolVIER IRIAN cie i Cihlalniinjell 2 4 20mA FLOW 10m sec 5 ft 1 m s jeje R Ciihijaliniinjel tl 2 3 S Pi 2 FLOW 10m sec F 0 O IL mii iisiielic iv IIUNDER RANGE www trolex com Ciihilaliniinie l 2i S P 2 FLOW 10m sec 0 01

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