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Trolex TX9042 User Manual

Programmable sensor controller
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Summary of Contents for Trolex TX9042

  • Page 2: Table Of Contents

    TX9042 Programmable Sensor Controller (PSC) Contents 4.6.5 Cable Distance for Voltage Product Overview Inputs (0.4 to 2 V) Operating Features 4.6.6 Dual Input Signals (Differential) Application Setup and Calibration Product Options Controls and Indicators 1.3.1 TX9042 PSC Input Module Types...
  • Page 3 - Physical Check 5.9.2.2 Constant 6.1.3 TX9042 PSC 5.9.2.3 Update - Replace the battery 5.9.2.4 Units 6.1.4 TX9042 PSC - Proof Test 5.9.2.5 Decimal Points TX9042 PSC - Repair 5.9.2.6 Lower Maintenance Records 5.9.2.7 Upper Maintenance Log 5.9.2.8 Calibrate (Temperature Input Module) 61 Disposal 5.9.2.9...

  • Page 4: Product Overview

    Simple to use, just four keys to programme the TX9042 PSC, no special software and no software programming skills required • Full functional compatibility with the entire range of Trolex sensors • Up to 32 TX9042 PSC can be connected to a single mine wide data system TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 5: Application

    TX9042 User Manual Application The TX9042 Programmable Sensor Controller (PSC) is for sensor management and data communications in arduous industrial environments and hazardous areas. It is suitable for use in SIL 1 and SIL 2 applications, in accordance with specific conditions or restrictions.

  • Page 6: Product Options

    Product Options TX9042 PSC General Purpose Mining Ex ia 12 V dc TX9042.55 1.3.1 TX9042 PSC Input Module Types Mining Ex ia Input Module Description Order Code Current - 0 to 20 mA P5423.516 Current - 4 to 20 mA P5423.508...

  • Page 7: Dimensions

    20 characters x 4 lines 6 mm high characters Mounting DIN rail Microprocessor Microprocessor controlled menu operation, with non-volatile data retention and 10 bit analogue to digital conversion (analogue channels) 2 per channel plus Fault signal Setpoints www.trolex.com TX9042-UM-EN-A • P5423.1600-A 7...
  • Page 8 Open or short circuit signal line or sensor fault, will generate a fault signal, the fault will be identified and displayed on the LCD screen Data communications RS485 Modbus Data logging Up to 26,000 readings with on-demand down loading TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 9: Electrical Details

    TX9042 User Manual Electrical Details TX9042.55 - Programmable Sensor Controller (PSC) Supply voltage: 12 V dc +20%/-2.5% at 125 mA Output: Modbus protocol Supply current: 125 mA at 12 V Relay contact rating: 200 V 0.25 A 3 W absolute maximum...

  • Page 10: Certification & Conformity

    Ex Certification Code: I M1 TX9042.xx.xx.19 Baseefa03ATEX0292X Ex ia I Ma Programmable Sensor Controller IECEx BAS 15.0065X Ta = -20 C to +40 TX9042.xx.xx.10 Ex ia I ANZEx 06.3057X Programmable Sensor Controller Ta = -20 C to +40 TX9042-UM-EN-A • P5423.1600-A www.trolex.com...
  • Page 11 IP54. Up to 11 RS485 Comms Modules (in separate Programmable Sensor Controllers type TX9042) may be daisy-chained together (i.e. terminals B1 all linked together, terminals B2 all linked together and terminals B3 all linked together).
  • Page 12 It is recommended to periodically check the condition of the product. The product shall only be serviced and repaired by Trolex Ltd. or a local Trolex service agent approved by Trolex Ltd in order to maintain the explosion protection of the product.

  • Page 13: Functional Safety

    SIL specified for the safety instrumented function to be achieved and maintained, as far as the TX9042 Programmable Sensor Controller (PSC) is concerned.

  • Page 14: Functional Safety Data

    See Section 1.5 of this User Manual 4 to 20 mA input conditioning modules fitted 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 Product configuration...

  • Page 15: Conditions Or Restrictions For Use In Sil Applications

    TX9042 User Manual 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 (λ...

  • Page 16: Proof Test

    For redundant arrangements refer to IEC 61508-6 for the equations. Checkpoint Those responsible for specifying proof testing of safety functions should refer to IEC 61508-6:2010 clause B.3.2.5 for considerations of the effect of non-perfect proof tests. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 17: System Configuration Drawing

    TX9042 User Manual System Configuration Drawing The illustration below shows how the TX9042 is to be used with other system elements. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 17...

  • Page 18: Installation

    Installation Precautions Do not disassemble the TX9042 PSC whilst in the hazardous area or use a TX9042 PSC that has a damaged housing in the hazardous area. The TX9042 PSC must be installed within a metal protective enclosure to ensure compliance with certification requirements.

  • Page 19: Tools & Test Equipment Required

    No special tools are needed to assemble or install the TX9042 PSC. Mechanical Installation The TX9042 PSC is installed on a TS35 low profile DIN rail as follows: Loosen the two securing screws, one each at the end of the TX9042 PSC housing.

  • Page 20: Connections

    A1 and A4. The input signal is fully floating and differential, giving high immunity to electrical interference. This configuration is repeated for channels 1 to 8. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...
  • Page 21 Intrinsically Safe requirements. The unit must be mounted in a protective metal enclosure to comply with Intrinsically Safe requirements. Once input channels have been connected to the TX9042 PSC the channel identification labels MUST be completed. Any changes to the input channels MUST be recorded on the channel identification labels.

  • Page 22: Input Channel Configuration

    Each input conditioning module has calibration and functionality information stored in a non-volatile, EPROM. On power-up, 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.

  • Page 23: Analogue Input Modules

    Analogue Input Modules Type of Input Range Module Ref Connections Current 0 to 20 mA P5423.516 2 wire loop powered 4 to 20 mA P5423.508 Impedance 110 R 3 wire control powered 2 wire remote powered www.trolex.com TX9042-UM-EN-A • P5423.1600-A 23...
  • Page 24 Module Ref Connections Voltage 0 to 2 V P5423.514 0.4 to 2 V P5423.509 Impedance 100 K Resistance PT100 2 wire Temperature -50 to +200°C P5423.510 Device Standardised to DIN43760 and BS 1904 4 wire compensated TX9042-UM-EN-A • P5423.1600-A www.trolex.com...
  • Page 25 500 Hz to 10 kHz 0 to 7g (100 mV/g) ac RMS Velocity Load cells, ac P5423.506.02 generators, 15 Hz to 100 Hz accelerometers, 0 to 30 mm/sec velocity sensors (100 mV/g) & power measuring instruments www.trolex.com TX9042-UM-EN-A • P5423.1600-A 25...
  • Page 26 Type of Input Range Module Ref Connections Flow Module For use with: TX6023 + P5423.552 for TX6023 P5546.18 TX9042-UM-EN-A • P5423.1600-A www.trolex.com...
  • Page 27 Range Module Ref Connections Digital - Voltage free P5423.522 2 voltage free contacts Failsafe contacts with series diode On/Off switches connected in series with a diode to give combined open circuit/short circuit sensor connection protection www.trolex.com TX9042-UM-EN-A • P5423.1600-A 27...

  • Page 28: Display Of Connection Details

    Loop Powered 4 to 20 mA Sensors Maximum cable distance: Vs - Vms 0.02 x R cable (km) Supply Voltage Minimum Acceptable Sensor Voltage (eg. 16 V) R cable = Total Resistance of Connecting Cable in ohms/km TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 29: Inputs (0.4 To 2 V)

    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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 29...

  • Page 30: Setup And Calibration

    Setup and Calibration Controls and Indicators The programming and setting routines for the TX9042 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.
  • Page 31 Scroll Down is the bottom key - D The use of these keys is abbreviated to L, R, U and D throughout this User Manual. Checkpoint The TX9042 PSC data memory is permanent. All settings are retained even in the event of power failure. www.trolex.com...

  • Page 32: Power-Up

    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. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 33: Reviewing The Input Module

    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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 33...

  • Page 34: Close-Up 1 Display For An

    Falling tendency input signal Slowly changing sensor signals under suspicion may be assessed 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. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...
  • Page 35 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) www.trolex.com TX9042-UM-EN-A • P5423.1600-A 35...

  • Page 36: Digital Input Module

    Last count sense indication. Reset or steady input signal Rising count or frequency. Falling count or frequency. Slowly changing sensor signals under suspicion may be assessed. Press R to return to the Signal Display. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 37: Close-Up 2 Display For An Analogue Input Channel

    The previous Lowest signal value recorded since last reset. The value of Setpoint 2. The value of Setpoint 1. 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-A • P5423.1600-A 37...

  • Page 38: Close-Up-2 Display For A Digital Input Channel

    The previous Lowest count or frequency recorded since last reset. The value of Setpoint 2. The value of Setpoint 1. 24 hour clock. Press R to return to Close-up 1. Press L to escape and return to the Signal Display. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 39: Menu Of Functions

    ON command OFF command ON time delay . OFF time delay Hysteresis value NB: Any relay commands generated by the TX9042 Controller will also be functional. Please contact our Product Support Department assistance is required : +44 161 4831435 www.trolex.com...

  • Page 40: Main Menu

    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-A • P5423.1600-A www.trolex.com...

  • Page 41: Main Setup

    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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 41...

  • Page 42: Communications Setup

    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 receive buffer.
  • Page 43 Press U to Stop data stream Press D to Start data stream Checkpoint Communication data protocol information and additional application data is available from the Trolex Technical Department. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 43...

  • Page 44: Clock

    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-A • P5423.1600-A www.trolex.com...

  • Page 45: Datalog Interval Period

    TX9042 User Manual 5.7.6 Datalog Interval Period Each channel of the TX9042 PSC contains a 26,000 point data logging system. This 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.

  • Page 46: Clear The Data In The Datalog

    Press R to return to the Channel List. Supplementary information is displayed momentarily where appropriate: 5.7.8 Clear the Data in the Datalog Press R to confirm the instruction to clear the Data in the Datalog. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 47: Relay Reset Mode Options

    Rise: Any latched relays will be reset only as the reset input Rises (opening pulse contact), and the channel input signal has receded from the programmed setpoint level. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 47...

  • Page 48: Relay Voting

    Pulse 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.
  • Page 49 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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 49...

  • Page 50: Relay Operation

    LCD screen, this includes the product reference, software version number, serial number, log data memory and input board type. 5.7.13 Self Test This enables all the internal functions of the TX9042 PSC to be tested. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 51: Display Cycling

    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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 51...

  • Page 52: Channel Function And

    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-A • P5423.1600-A www.trolex.com...

  • Page 53: Power On Delay (Pod) Period

    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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 53...
  • Page 54 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-A • P5423.1600-A www.trolex.com...

  • Page 55: Scale And Display Settings

    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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 55...

  • Page 56: Reset Peak

    This can be a positive or negative quantity and can be applied to all three modes of counting. It is permanent until re-programmed. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 57: Update

    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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 57...
  • Page 58 Press U or D to navigate to the value required. Press R to confirm the value selected. Checkpoint Analogue levels are averaged between samples. Pulse frequencies are averaged between samples. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 59: Units

    Press U or D to navigate the decimal point to the required position within the number. Press R to confirm the location selected. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 59...

  • Page 60: Lower

    Non linear relationships such as square law signals from differential pressure sensors and the polynomials can also be incorporated in software to specific requirements. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 61: Calibrate (Temperature Input Module)

    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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 61...
  • Page 62 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. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 63: Identification

    Press R to confirm the values selected. 5.9.2.11 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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 63...

  • Page 64: Setpoint Characteristics

    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-A • P5423.1600-A www.trolex.com...

  • Page 65: Level

    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 low level is reached at the bottom of the hysteresis band. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 65...

  • Page 66: Alarm (Rising/Falling)

    Press U or D to navigate to the Setpoint On Delay value required. Press R to confirm the value selected. TX9042-UM-EN-A • P5423.1600-A www.trolex.com...

  • Page 67: Setpoint Off Delay

    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 for details. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 67...
  • Page 68 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-A • P5423.1600-A www.trolex.com...

  • Page 69: Relays

    TX9042 User Manual 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.

  • Page 70: Fault Signal Alarm Assignation

    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: •...

  • Page 71: Threshold Acceptance Level

    Press U or D to navigate to the Threshold Acceptance Level value required. Press R to confirm the value selected. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 71...

  • Page 72: Keycode Security For Each

    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 TX9042-UM-EN-A • P5423.1600-A www.trolex.com...
  • Page 73 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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 73...

  • Page 74: Digital Level

    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-A • P5423.1600-A www.trolex.com...

  • Page 75: Setting A Digital Failsafe

    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. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 75...
  • Page 76 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...
  • Page 77 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.

  • Page 78: Channel Display Mode

    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-A • P5423.1600-A www.trolex.com...

  • Page 79: Datacommunications

    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 5.7.3 for details. www.trolex.com TX9042-UM-EN-A • P5423.1600-A 79...
  • Page 80 Please contact the Trolex Sales Team for further information and advice on suitable safety barriers. sales@trolex.com Please refer to Section 2. Certification and Conformity for additional details.

  • Page 81: Maintenance

    6.1.2 6 months TX9042 PSC Battery Replace 6.1.3 5 years 3 months TX9042 PSC - only to be carried out if the TX9042 is installed in a SIL rated Proof Test 6.1.4 system. 12 months 6.1.2 TX9042 PSC - Physical Check...
  • Page 82 TX9042 PSC are secure within the terminals. Tighten any loose terminals as necessary. 10. 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.

  • Page 83: Tx9042 Psc

    Checkpoint A Proof Test must be carried out at regular intervals if the TX9042 PSC is being used in a 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.
  • Page 84 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 TX9042 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.
  • Page 85 If the IS meter reading fails to fluctuate, immediately remove the TX9042 PSC from service and replace it with a working TX9042 PSC. Return the defective TX9042 PSC to Trolex for repair and testing. Remove the load or stimulus from the sensor or detector.

  • Page 86: Tx9042 Psc - Repair

    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.

  • Page 87: Maintenance Log

    TX9042 User Manual 6.4 Maintenance Log Order Reference: TX9042 Programmable Sensor Controller Serial Number: Date Purchased: Channel 1: Channel 2: Channel 3: Channel 4: Channel 5: Channel 6: Channel 7: Channel 8: Location: Maint Return Date Fault Action Comments Task No.

  • Page 88: 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.

  • Page 89: Disclaimers

    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...

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