TROLEX TX6141 Pressure Sensor Transmitter Instruction Manual

: June 16, 2024
: Trolex

Table of Contents

TROLEX TX6141 Pressure Sensor Transmitter
PRINCIPAL OPERATING FEATURES
APPLICATION
DIMENSIONS
TECHNICAL DETAILS
- Specification
INSTALLATION
CONNECTIONS
CONTROLS AND INDICATORS
THEMENU OF FUNCTIONS
PROGRAMMING AND CALIBRATION
MAINTENANCE
References
Read User Manual Online (PDF format)
Download This Manual (PDF format)

TROLEX TX6141 Pressure Sensor Transmitter

PRINCIPAL OPERATING FEATURES

The TX6140 Series Pressure Sensors employ a high accuracy pressure diaphragm which provides exceptional corrosion resistance to the most aggressive media. The Differential Pressure Series uses stainless steel diaphragms for best performance in double sided wet/wet applications. The measuring element is a Piezo resistive strain gauge giving a high electrical output with excellent linearity, and negligible zero drift. The information from the sensing bridge is processed by a specially designed software programme to provide user configurable information display and a conditioned output signal.

High accuracy pressure capsule with characterised temperature compensation incorporating EPROM intelligence to give a standardised output signal. This simplifies service and replacement of the sensing element.
Programmable information display for zero, span, signal offset, turndown, signal transfer characteristic, engineering units, signal damping, display suppression, fault mode, mode, contrast and signal clamp.
Language display text options.
Keycode software security option.
Simple pushbutton scaling to match on-site parameters: signal offset, elevated zero, etc.
Output signal versions: 4 to 20 mA / 0.4 to 2 V / 5 to 15 Hz.
Choice of pressure ranges from 0 to 600 bar. Gauge, Absolute and Differential.
Intrinsically Safe version for use in hazardous areas.
Automatic self test function.

APPLICATION

High accuracy analogue pressure measurement in process systems and plant monitoring applications, with data communications for interfacing with display/control instruments and distributed control systems.

GAUGE pressure measurement in pipes, vessels, containers, receivers and process equipment.
ABSOLUTE pressure measurement for atmospheric pressure monitoring, environmental monitoring and process systems.
DIFFERENTIAL pressure measurement, hydrostatic level sensing in pressurised vessels, process pressure comparison, DP flow measurement in pipes and ventilation ducts, blocked filter detection, DP measurement across pumps and hydraulic machinery, transformer cooling circuits, etc.
A choice of output signals for direct interfacing with most standard industrial monitoring systems.
A range of primary instrumentation and monitoring modules is available from Trolex to which the sensors can be directly connected to provide a flexible choice of display and control functions.

TRIP AMPLIFIER

for use with analogue output pressure sensors. ****

CONFIGURABLE SENSOR CONTROLLER

for monitoring up to 8 pressure sensors.

COMMANDER DISTRIBUTED I/O SYSTEM

for large-scale general plant monitoring systems and the mining and tunnelling industries.

DIMENSIONS

TX6141
- GAUGE ABSOLUTE
TX6143
- DIFFERENTIAL
- STAINLESS STEEL DIAPHRAGM

TECHNICAL DETAILS

Specification

Electrical Details

GENERAL PURPOSE AND Ex GROUP II APPLICATIONS (24 V dc)

Ex GROUP I APPLICATIONS (12 V dc)

Pressure Measurement Range

TX6141

GAUGE CERAMIC DIAPHRAGM (21)
FOR GAS & LIQUID APPLICATIONS

TX6141

ABSOLUTE CERAMIC DIAPHRAGM (22)
FOR GAS & LIQUID APPLICATIONS

INSTALLATION

Conformity Check

(Refer to Test Certificate provided with the sensor).

Does the output signal of the sensor concur with the input requirement of the monitoring equipment being used?
Is the correct supply voltage available for the sensor?
Is the pressure operating range of the system within the stated measuring range of the sensor?
Does the pressure measuring format of the sensor concur with the requirements of the process?
Is the maximum static pressure of the system within the stated pressure rating of the sensor?
Is the temperature variation range of the process medium within the stated temperature range of the sensor?
Is the hazardous area classification correct?

STANDARD OPTIONS AVAILABLE

Process Fittings

Ensure that the pressure rating of the process fittings used is compatible with the maximum pressure anticipated in the system.
Isolating valves should be fitted where pressure surges may be anticipated during commissioning or shutdown.

The sensor will tolerate reasonable levels of contamination and foreign particles present in the process medium but where conditions are particularly aggressive, the sensor should be protected with a U-bend or an isolating seal.

DP Sensors

Differential pressure sensors must be protected against excessive static pressure particularly during commissioning or shutting down a system. It is recommended that a direct mounted valve manifold is included in the process connection for pressure isolation purposes. Trolex TX9200.11 pipe mounting bracket for convenient mounting of DP sensors.

High Pressure

Where the sensor is used on high pressure systems, care should be taken to isolate or relieve the system pressure before installation or removal. Ensure that all couplings are fully tightened before applying pressure to the system.

Pressure Surges

High pressure surges in the system can cause permanent damage or de-calibration to the pressure capsule. Protect the sensor pressure inlet whenever maintenance work is being carried out on the system.

Caution

Do not insert sharp or metallic objects into the pressure orifice, this may cause damage to the sensing element. Excessive test pressure applied to the diaphragm of low pressure sensors may also de-calibrate the output signal.

Mounting Attitude of the Sensor Housing

In most cases the sensor is not significantly affected by its mounting attitude. A small amount of zero shift may be observed in very low pressure sensors, as a result of gravitational influence on the diaphragm in some positions. This can be corrected by calibration of the sensor.

Orientation of the Housing (Differential Pressure only)

The housing of the sensor can be adjusted to a choice of four angular positions after installation for the preferred mounting orientation or for the most convenient cable routing access.

Remove the four socket cap head screws (1) to release the pressure capsule (2).
Disconnect the ribbon cable (3) from the capsule PCB (4).
Open the top cover (5) of the housing.
Remove the electronic module (6).
Remove the four internal screws in the base of the housing (7) to release the adaptor (8).
Rotate the adaptor to the desired position and refit the four internal screws.
Refit the electronic module, being careful not to trap the ribbon cable.
Reconnect the ribbon cable to the capsule PCB.
Refit the four socket cap head screws to secure the pressure capsule (2).
Close and secure the top cover of the housing.

System Integrity

If a pressure monitoring system should fail for any reason, it is important that the system is capable of immediately alerting operational staff to this fact. The sensor will indicate a system failure or mechanical defect and this information can be utilised to initiate a warning alarm. It is good practice to provide emergency facilities to protect against the loss of the mains power supply. Standby batteries can be incorporated with automatic changeover facilities, so guaranteeing continued operation of the pressure sensing system even in the event of a plant breakdown as a result of a power supply failure. Certainly, in critical plants, duplication or triplication of sensors is recommended. The Trolex TX9042 or TX9044 Programmable Sensor Controller can be programmed to operate with sensors in the multiple voting mode.

Sensor Management

A very important part of an efficient pressure monitoring system is the training of plant personnel in operation and maintenance of the sensors and the complete monitoring system. Training facilities can be provided by qualified Trolex application engineers.
Once a sensor installation is complete, the sensor locations and types should be formally recorded and a planned test and maintenance procedure instituted.

Hazardous Areas

Do not disassemble the sensor whilst in the hazardous area or use a sensor that has a damaged housing in the hazardous area.

CONNECTIONS

4 to 20 mA Output Signal

The output signal from terminals 1 and 4 is a conventional 4 to 20 mA two wire current regulated signal loop. The same loop also powers the sensor and no separate power supply is required.

The sensor can also be operated in the 3 or 4 wire mode using a separate power supply. The 4 to 20 mA signal loop still functions in the normal current regulation mode, so ensuring the accuracy of the system.

0.4 to 2 V Output Signal

A low impedance two-wire voltage output signal requiring a separate power supply to the sensor. This can be derived from a Trip Amplifier or Programmable Sensor Controller, when one of those is used as the monitoring instrument.

This connection configuration works well up to about 100 metres distance between the sensor and the monitoring equipment. Both the signal and the power supply to the sensor are being carried in the common 0V conductor so at some point –influenced by the length of the cable and the resistance of the cable cores – the current flowing in the 0V conductor will impose an unacceptable voltage error onto the signal. This effect can be reduced on long distance connections by increasing the size of the cable cores, or even better, running a separate 0V conductor to power the sensor.

5 to 15 Hz Output Signal
A square wave, frequency variable output that is proportional to the measured value. The output device

Group II Hazardous Areas

IMPORTANT
Ensure that the sensor is the INTRINSICALLY SAFE version; TX6141.02/TX6143.02

All output signal options of the sensor are certified Intrinsically Safe for use in Group II hazardous areas, zones 0, 1 and 2, when used in conjunction with zener safety barriers or isolation safety barriers. Only the sensor may be mounted in the hazardous

Suggested Zener safety barrier: MTL7087 +
Suggested Isolating safety barrier: MTL5042

If you require any help in the use of safety barriers please contact the Trolex Technical Departmen.t

Group I Hazardous Areas (Mining)

IMPORTANT

Ensure that the sensor is the INTRINSICALLY SAFE Group I version; TX6141.01/TX6143.01

All output signal options of the sensor are certified Intrinsically Safe for the use in Group I hazardous areas (Mining) when used with approved equipment eg. TX9130 Series Trip Amplifier or a TX9042 Programmable Sensor Controller. The complete system, both sensor and monitoring device can be mounted in the hazardous area.

CONTROLS AND INDICATORS

The programming and setting routines for the sensor have been designed for utmost simplicity and the programming system is completely menu driven. There is no special software programme and a data input terminal and/or PC is not required.
There are just four keys for controlling the complete operation and the digital display provides instructions throughout the programming process. All entries are verified in the display.

Hold the SCROLL Keys down for two seconds for rapid self keying.
All data settings are retained under power failure.

Data Review

THEMENU OF FUNCTIONS

PROGRAMMING AND CALIBRATION

Switching On

When switched on, the processor will initialise all the default values unless new values have previously been programmed.

Signal Display

After two seconds, the display will switch to the SIGNAL DISPLAY mode, showing the measured signal value with the selected engineering units (bar).

The bargraph will also show an indication of the input signal level.
Signal over range.

Entering the MENU

All the operating functions of the sensor can be programmed by entering into the MAIN MENU.

Key or to SCROLL up and down the MENU.
Key to CONFIRM

Previously programmed values will be shown in the main sectors of the display. Function changes can be programmed as described in the following sections

Entry SAVED will appear briefly whenever a new value is entered during programming.
NOT SAVED will appear briefly if a value is not entered during programming.

Exit

Key to EXIT from any position in the MENU sequence. Each operation of the key will revert the display one step back in the MENU table until the SIGNAL DISPLAY is reached.

Self Test

The processor will constantly carry-out a self-test routine of the main circuit elements; EPROM, memory, comms and display read/write function. Any malfunction registered will be denoted by a FAIL message in the display. The output signal will also be forced to the UPSCALE or DOWNSCALE condition, whichever one is selected as the FAULT MODE.

Keycode

A four digit security keycode can be entered to prevent unauthorised access to ALL setup items in the menu.

Enter Keycode

This entry screen will only show if an active keycode has been set. If the entered keycode is accepted, the display moves on to the MENU section. If the entered keycode is invalid, the display returns to the normal measurement mode.

Key to TRAVERSE the cursor.
Key to INCREMENT the digit with the cursor under.
Key to CONFIRM

GO or NO GO will appear briefly to confirm keycode status. This request will not appear if the KEYCODE is not active.

Set Keycode

Access to ALL menu items can be prevented. The keycode is a selectable option and the code can be changed at any time. The keycode can also be set to be ACTIVE or NOT ACTIVE.

Key to TRAVERSE the cursor.
Key to INCREMENT the digit with the cursor under.
Key to CONFIRM.

Scaling

The scaling of the output signal and the corresponding value of pressure presented on the display of the sensor is accurately calibrated, in bar, during manufacture. There are three standard output signal formats available, each representing the maximum operating pressure range (bar) of the sensor.

The various parameters of the signal scale and display values can be modified to suit the individual characteristics and imperatives of a particular installation or process.

Turndown or pressure operating range.
Change the units of display from bar to another.
Apply linear or non-linear scale multipliers.
Upscale or downscale fault-mode selections.

Key or to SELECT the function.
Key to CONFIRM.

Making any of the modifications to the SCALING parameters naturally assumes that the fundamental pressure calibration of the sensor is accurate. Although this will be so on a new sensor, it is good safety practice to re-affirm the pressure calibration at periodic intervals. If calibration is necessary – do it BEFORE making any modifications to the scaling parameters.

Turndown

The sensor may be installed in an application that requires a lower operating pressure range than the standard calibrated range (e.g. 5 bar utilisation on a 10 bar full scale sensor). The complete response range of the output signal can be utilised by ‘Turning Down’ the sensor response to the required maximum pressure range of the system being monitored.

Key to TRAVERSE the cursor.
Key to INCREMENT the digit with the cursor under.
Key to CONFIRM.

The overall response accuracy of the sensor is defined at the MAXIMUM calibrated pressure range. Be aware that any TURNDOWN applied will slightly reduce the overall response accuracy in proportion to the amount of turndown introduced.

Units

PRESSURE UNITS

The sensor is calibrated in bar (gauge pressure) during manufacture. There is a choice of alternative units of pressure measurement:

All display values within the SCALING and CALIBRATION functions will automatically be presented in the PRESSURE units selected.
If the sensor is being used to measure hydrostatic pressure (level) using the metre (m) or feet (ft) units, remember to include a correction factor for the specific gravity of the liquid, if necessary.

Catuion

Units of measurement must be restricted to the choice listed in the PRESSURE UNITS menu. Special consideration is needed for units within the VOLUMETRIC and FLOW menus.

Key or to SELECT the UNITS
Key to CONFIRM

VOLUMETRIC UNITS

When the sensor is being used to measure the hydrostatic pressure level of a liquid, the processor can be setup to calculate the contained VOLUME. It will also be necessary to enter an appropriate multiplication factor relating to the response characteristics of the orifice plate or venturi system used. relating to the response characteristics of the orifice plate or venturi system being used.

FLOW UNITS (Differential Pressure)

One of the three FLOW measurement units may be selected where a TX6143 series Differential Pressure Sensor is installed across an orifice plate or venturi to monitor flow velocity. Any one of these selections will automatically produce a square-root transfer function in the sensor processor for use with DP measuring points, so enabling the sensor to provide a linearised output signal. It will be necessary to enter an appropriate multiplication factor

Scale Factor

Multiplication factors can be entered for SPECIFIC GRAVITY correction or for use with the VOLUMETRIC and FLOW functions.

Specific Gravity Correction

Where the sensor is applied to hydrostatic level measurement, the choice of units available is m or ft, calibrated with respect to water. If the specific gravity of the liquid being monitored is different to that of water a correction factor may be entered:
Factor = SG of liquid (ie: 0.9).

Key to TRAVERSE the cursor.
Key to INCREMENT the digit with the cursor under.
Key to CONFIRM

VOLUMETRIC UNITS

If one of the five VOLUMETRIC measurement units is selected, it will be necessary to enter a multiplication factor relating to the cross-sectional area of the vessel.

Factor = Cross-sectional area x SG.

Key to TRAVERSE the cursor.
Key to INCREMENT the digit with the cursor under.
Key to CONFIRM.

FLOW UNITS (Differential Pressure)

One of the three FLOW measurement units flow may be selected where a TX6143 series Differential Pressure Sensor is installed across an orifice plate or venturi to monitor flow velocity. Any one of these selections will automatically produce a square-root law transfer function in the sensor processor for use with DPmeasuring points, so enabling the sensor to provide a linearised output signal. It will be necessary to enter an appropriate multiplication factor relating to the response characteristics of the orifice plate or venturi system used. This relationship can be mathematically calculated if sufficient data is available relating to the structure of the process flow system and the dynamic characteristics of the flow medium. Alternatively the scaling factor can be easily established by taking a sample measurement of the actual flow velocity, together with a measurement of the associated differential pressure and applying the formula:

Flow measured in the units of flow selected in the menu.
DP measured in bar.
Key to TRAVERSE the cursor.
Key to INCREMENT the digit with the cursor under.
Key to CONFIRM.

Fault Mode

The output signal of the sensor can be selected to go UPSCALE or DOWNSCALE when a sensor malfunction or connection failure occurs. If a sensor is monitoring low pressure failure on a pressurised system the DOWNSCALE failure mode will force the output signal down into the system alarm region. Similarly, the UPSCALE failure mode will initiate an alarm in a system that is employed to monitor excess pressure level.

Key or to SELECT the MODE.
Key to CONFIRM.

Calibration

The scaling of the output signal and the corresponding value of pressure presented on the display of the sensor is accurately calibrated, in bar, during manufacture. There are three standard output signal formats available, each representing the maximum operating pressure range (bar) of the sensor.

The fundamental calibration of the sensor with respect to an applied pressure should be checked at periodic intervals using a calibrated pressure source. Setup functions are available when fundamental pressure re-calibration has become necessary.

The language used in the display.
Damping adjustment of the sensor response.
Fix the output signal during calibration or servicing.
Adjust the contrast of the display.

Key or to SELECT the function.
Key to CONFIRM.

Language

The display text can be shown in five different languages.

English (GB) French (F) Spanish (E) German (D) Czech (CZ)

Key or to SELECT.
Key to CONFIRM.

Decimal Place

Key or to TRAVERSE the decimal point.
Key to CONFIRM

When the sensor is measuring a rapidly fluctuating signal, the fluttering minor digits in the display can be distracting. The position of the decimal point can be moved to any position in the figure to minimise this effect.

Damping

The immediacy of response of the sensor can be DAMPED to filter unwanted spurious changes in the process pressure.

Key to TRAVERSE the cursor.
Key to INCREMENT the digit with the cursor under.
Key to CONFIRM.

The value entered approximates to the time taken in seconds for the signal to reach 63% of the final value (ie. one time constant).

Fix Output

It may be necessary, to temporarily shut down the process to carry out maintenance or servicing which will probably mean removing the system pressure. To prevent an alarm condition being transmitted by the sensor, the output signal can be temporarily FIXED at any desired PERCENTAGE value of the output signal range. The FIXED LEVEL selected is a calibrated value so this feature can also be used to test the integrity of the signal loop and any remote monitoring equipment, by simulating an output signal of defined value. Remote display systems can be calibrated and any alarm set point levels can be checked for function and accuracy.

Key to TRAVERSE the cursor.
Key to INCREMENT the value of the digit with the cursor under.
Key to CONFIRM.

The signal will be RELEASED when the MENU position is vacated.

Contrast

The contrast of the LCD can be varied to compensate for the effect of ambient temperature and light conditions.

Key or to SET the contrast.
Key to CONFIRM

Master Reset

All data will be re-initialised.
Key to RESET .
The display will return to the SIGNAL DISPLAY mode.

MAINTENANCE

There are no degradable components, but it is good safety practice to carry out regular preventative maintenance to confirm correct operation.

Output Signal

Check at regular intervals, that the value of the output signal agrees with the value of the display reading. Re-calibrate if necessary.

Pressure Capsule

Under normal circumstances, the calibration of the actual pressure capsule will not change by any significant degree. Check the accuracy at least once per year by comparing the display reading with an accurate standard.

Alternatively the sensor can be returned to our Product Support Department for checking and calibration.

Seals and Couplings

Periodically check the tightness of the process couplings and the condition of pressure seals.

Main Circuit Module

The main circuit module inside the sensor housing can be removed from the housing for maintenance purp.oses Disconnect the ribbon cable from the capsule PCB.

Annual Safety Check

The main transmitter itself will not normally require maintenance or calibration but it is advisable to return it to the Trolex Product Support Department for an annual safety check.

Damaged Sensors

A Sensor that has been dropped or damaged in any way should be taken out of service immediately for inspection, repair and re-calibration.

Record Keeping

Institute a regular calibration and maintenance procedure and keep a record. Incorrect use of the Sensor or inadequate maintenance may not necessarily be self evident in the Sensor and consequently it must

Maintenance and Calibration Log

Europe (ATEX)

TX6141 and TX6143 Pressure Sensor/Transmitter

Ex Certificate number: SIRA 00ATEX2001X
Ex Certification codes: I M1 EEx ia I (Ta = -20°C to +60°C) II 1G EEx ia IIC T4 (Ta = -20°C to +60°C)

Special Conditions for Safe Use
The TX614x Pressure Sensors/Transmitters shall not be installed where the external conditions could cause a build-up of electrostatic charges on their non-conducting surfaces. Additionally, the equipment shall only be cleaned with a damp cloth. The safety description of the TX614x Pressure Sensor/Transmitter has changed as a result of variation 2. Consequently, the products that incorporate these modifications may not be suitable as a direct replacement for those that are manufactured to the previous design. Therefore, the user/installer shall ensure that the TX614x Pressure Sensor/Transmitter is compatible with the equipment to which it is intended to be connected.

General Conditions for Safe Use

Prior to installation, it is essential that user refers to the above certificate to ensure that the termination and cable parameters are fully complied with and are compatible with the application. Copies of certificates are available from Trolex.

ATEX Directive (94/9/EC)

Australia/NewZealand (ANZEx)

TX6141 and TX6143 Pressure Sensor/Transmitter

Ex Certificate number: ANZEx 12.3013X
Ex Certification codes: Ex ia I (Ta = -20°C to +60°C) Ex ia IIC T4 (Ta = -20°C to +60°C) IP54

Special Conditions for Safe Use

The TX614x Temperature Sensors / Transmitters shall not be installed where the external conditions could cause a build-up of electrostatic charges on their non-conducting surfaces (clear polycarbonate window). Additionally, the equipment shall only be cleaned with a damp cloth.

General Conditions for Safe 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.

EAC Russia (Customs Union)

Ex certificate number: TC RU C-GB.ГБ05.B.00326
Ex Certification codes: PO Ex ia I Ma X 0Ex ia IIC Ga T4 X

Conditions of Use

Prior to installation, it is essential that user refers to the above certificate 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.

India (CIMFR)