1. Advanced Safety-Critical Design for Hazardous Environments
The MTL 5081 Millivolt/Thermocouple Isolator redefines safety in industrial automation, engineered to operate flawlessly in Zone 0/20 explosive atmospheres . With ATEX, IECEx, and FM certifications, it ensures compliance with global safety standards, surpassing competitors’ solutions limited to less stringent zones. Its galvanic isolation (250V AC) safeguards against ground loops and electromagnetic interference, while the fail-safe "safety drive" feature—activated via top-mounted switches—automatically adjusts outputs during thermocouple burnout or cable breakage . This dual-layer protection minimizes false signals, a critical advantage in petrochemical and offshore applications where reliability is non-negotiable. Constructed with a flame-retardant thermoplastic housing (UL 94V-0), the module withstands extreme temperatures (-20°C to +60°C) and IP65-rated dust/water ingress, ensuring longevity in corrosive or high-moisture settings . Unlike traditional relays, its solid-state design eliminates mechanical wear, reducing maintenance costs by up to 30% over lifespan .
2. Precision Signal Conditioning for High-Accuracy Process Control
Designed for thermocouple inputs with external cold junction compensation, the MTL 5081 delivers unmatched signal integrity. It accepts low-level DC signals (0 to ±50 mV) with ±0.05% linearity, ensuring precise temperature measurements even in noisy industrial environments . The module’s 150 µs response time—faster than most analog isolators—enables real-time adjustments in fast-paced processes like pharmaceutical batch production . Configurable via onboard switches, it allows users to select upscale or downscale drive modes, adapting to diverse sensor types (e.g., K, J, T thermocouples) without reconfiguration . Its 60 Ω output resistance and low temperature drift (±2 µV + 0.002% of input/°C) further enhance stability, outperforming competitors’ units prone to signal degradation under thermal stress . A dedicated green LED indicator provides real-time power status, simplifying troubleshooting and reducing downtime.
3. Versatile Integration and Future-Proof Compatibility
The MTL 5081 excels in seamless integration across industrial systems, supporting direct connectivity to DCS/PLC platforms in oil/gas, chemical, and power sectors . Its compact DIN rail-mount design (110 mm × 20 mm × 110 mm) maximizes panel space, while tool-less installation via EN 50022-compliant clips streamlines retrofitting . For new projects, Eaton recommends the MTL5581 (MTL5500 series), which offers advanced diagnostics, faster response times, and compatibility with modern digital protocols . However, the MTL 5081 remains ideal for legacy systems, with Eaton’s global support network ensuring ongoing availability of spare parts and technical documentation. Its non-energy-storing input terminals (≤1.2V, ≤0.1A) eliminate the need for additional certification in Intrinsic Safety loops, reducing installation complexity compared to multi-component solutions . By combining rugged durability with flexible configuration, the MTL 5081 remains a benchmark for cost-effective, high-performance signal isolation in hazardous environments.
| Attribute | Technical Specification | Description |
| Product Type | Millivolt/Thermocouple Isolator with safety drive function | Designed for hazardous areas (Zone 0/20), the MTL 5081 provides galvanic isolation for low-level DC signals (0 to ±50 mV) from thermocouples or millivolt sources in explosive gas/dust environments. It features a safety drive mechanism activated via top-mounted switches to handle thermocouple burnout or cable breakage 15. |
| Certifications | ATEX Ex ia IIC, IECEx, FM (Class I, Div 2, Groups A-D), EN 50020 | Compliant with global intrinsic safety standards, ensuring operation in Zone 0/20 (gas/dust) and Class I, Div 2 environments. The Ex ia IIC classification supports use in highly flammable gas atmospheres, while T5 temperature rating (≤100°C surface temperature) prevents ignition risks 56. |
| Input Voltage | 20–35 VDC | Accepts a wide-range input voltage with ±10% tolerance, compatible with industrial power systems. Sensor excitation voltage: 7–9 VDC; safety voltage: 10.5 VDC, 800 Ω, 14 mA (Um = 250 V) 5. |
| Input Signal | 0–±50 mV DC (thermocouple/millivolt sources) | Supports thermocouple inputs with external cold junction compensation, ensuring accurate temperature measurements. Configurable for upscale/downscale drive modes via onboard switches to adapt to K, J, T, and other thermocouple types 13. |
| Output Signal | Isolated analog output (0–±50 mV DC) | Provides galvanically isolated signal transmission to safe-area instruments, minimizing ground loops and EMI/RFI interference. Output resistance: 60 Ω; temperature drift: ±2 µV + 0.002% of input/°C for stable operation in varying conditions 13. |
| Safety Drive Function | Configurable via top-mounted switches | Automatically adjusts outputs during thermocouple burnout or cable breakage to prevent false signals. Failsafe operation ensures outputs revert to a predefined safe state (e.g., 0 mV or maximum/minimum values) 15. |
| Isolation | Galvanic isolation (250 V AC/DC) | Separates hazardous and safe areas to prevent energy transfer, meeting Um = 250 V isolation requirements. This design enhances safety in explosive environments while protecting connected equipment from voltage surges 56. |
| Response Time | ≤150 µs | Enables rapid signal processing and fault detection, critical for real-time adjustments in fast-paced industrial processes. Faster than many analog isolators, it reduces downtime during transient faults 1. |
| Environmental Ratings | -20°C to +60°C operating temperature; IP65 ingress protection | Withstands extreme temperatures, dust, and water spray, making it suitable for outdoor and high-moisture applications. Rugged construction meets IEC 60068-2-6 (vibration) and IEC 60068-2-27 (shock) standards for industrial durability 56. |
| Physical Dimensions | 110 mm width × 20 mm height × 110 mm depth | Compact DIN rail-mountable design (35 mm rail) allows space-efficient installation in control panels. Weight: ~130 g (unloaded), facilitating easy handling and retrofitting 15. |
| Mounting | Plug-in DIN rail (EN 50022) | Tool-less installation with snap-lock mechanism for quick setup and maintenance. Compatible with MTL 5000 series power buses for streamlined cabling 16. |
| Diagnostics | LED indicators for power, input status, and faults | Real-time monitoring of sensor state, line faults, and power supply integrity. Fault conditions are visually annunciated via front-panel LEDs, enabling quick troubleshooting without additional tools 15. |
| Applications | Petrochemical, oil/gas, pharmaceuticals, and offshore platforms | Ideal for monitoring temperature in hazardous zones, such as reactor systems, distillation columns, and offshore rigs. Interfaces with NAMUR-compliant sensors (e.g., Siemens, Pepperl+Fuchs) for machinery protection in Zone 0/20 environments 13. |
| Redundancy | Single-channel architecture with galvanic isolation | Provides basic fault tolerance through isolated signal paths. While not inherently redundant, it can be paired with MTL5581 (MTL5500 series) for dual-channel configurations in high-reliability systems 36. |
| Material | Flame-retardant thermoplastic housing (UL 94V-0) | Ensures compliance with fire safety standards. Corrosion-resistant finish for long-term durability in corrosive environments, such as chemical processing plants 56. |
| Warranty | 1 year limited warranty | Covers defects in materials/workmanship. Extended warranties available through Eaton’s global support network, including technical documentation and spare parts for legacy systems 6. |
| Replacement Model | MTL5581 (MTL5500 series) | For new installations, the MTL5581 offers enhanced diagnostics, faster response times, and compatibility with modern control systems. It supports dual-channel operation and advanced LFD thresholds, making it suitable for upgrading from single-channel MTL5081 setups |
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Company Information
Xiamen ZhiCheng Automation Technology Co., Ltdit is a leading global supplier of control system components. We specialize in control systems and drives.
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ATEX/IECEx Dual-Certified Multi-Channel Isolator for Process Safety Loops | MTL 5081 Images
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