MTL 8202-HO-IS

Product Brief Introduction

3. Technical Specifications

• Working Power Source: Loop-powered design, power extracted directly from safe side 4–20mA instrument loop; safe side rated input supply range: 12VDC ~ 32VDC
• Channel Configuration: Independent 2 fully isolated signal channels inside single unit, channel circuits electrically separated mutually
• Process Signal Standard: Full-range compatible with standard 4–20mA DC analog loop signal
• Intrinsic Safety Rated Parameters (Field Side IS Parameters):

  Uo = 28VDC, Io = 93mA, Po = 0.65W, certified for Ex ia IIC / Ex ia IIB hazardous field installation

• Galvanic Isolation Voltage Rating: 2500VAC isolation withstand between safe circuit and hazardous field circuit for 60 seconds
• Module Mounting Standard: Standard 35mm DIN top-hat rail mounting dimension
• Overall Outer Dimension: Width 22.5mm × Height 114.5mm × Depth 99mm
• Continuous Operating Ambient Temperature Range: -40°C ~ +70°C; sealed storage temperature: -45°C ~ +85°C
• Allowable Working Relative Humidity: 5%~95% non-condensing relative humidity across full rated operating temperature range
• Signal Loop Load Resistance: Max permissible safe-side load impedance per single channel: 500Ω @24VDC loop supply
• Certification Approvals: IECEx, ATEX, UL913 intrinsic safety certification, CE EMC compliance certification
• Max Cable Capacitance & Inductance Matching: Co = 0.9μF, Lo = 1.5mH per field channel for intrinsically safe field wiring matching

4. Functional Features

1. Dual independent fully isolated channel layout, each channel works separately without mutual electrical interference during signal transmission.
2. Pure loop-powered operating mode eliminates external 24VDC auxiliary power wiring requirement, simplifying control cabinet internal power distribution layout.
3. Built-in multi-stage Zener plus electronic current limiting intrinsic safety protection circuit, rigidly clamping output voltage/current toward hazardous field within certified IS rated values permanently.
4. Integrated multi-level transient surge suppression circuit at both safe side and field side terminals, absorbs lightning induced surge and cabinet power switching transient voltage spikes.
5. Full galvanic isolation cuts common-mode interference path between field hazardous ground loop and control room earthing network to eliminate 50Hz/60Hz power frequency signal noise drift.
6. Zero built-in adjustable potentiometer component; factory fixed signal linear calibration enables plug-and-play installation without field on-site trimming or calibration.
7. Terminal pin definition strictly classified by safe-side/field-side marking to prevent reverse cross wiring between hazardous and non-hazardous circuit during field installation.
8. Passive design without heat generating power consumption component, no auxiliary cooling accessory required under full-load continuous operation.

5. Performance Parameters

• Full scale signal transmission accuracy: ≤±0.1%FS factory calibrated static precision
• Signal transmission response delay: ≤25μs from input signal variation to output full response completion
• Full range signal linearity error: ≤±0.08% across entire 4mA~20mA rated signal span
• Internal isolation component rated service lifespan: Module overall MTBF = 235000 working hours under standard industrial ambient environment
• Temperature drift coefficient within rated working temperature range: ≤10ppm/°C full scale signal variation
• Max permissible loop voltage drop per single channel: ≤1.8VDC at 20mA full load rated current
• Terminal screw repeated wiring cycle life: ≥2000 times tightening/loosening operation without thread sliding damage
• EMC anti-interference compliance: Conforms to EN61000-6-2 industrial environment electromagnetic immunity standard

6. Material Composition

1. Main Printed Circuit Board: FR-4 high flame retardant glass fiber PCB with full immersion tin anti-oxidation surface coating, SMT full surface mount component production process.
2. Outer Enclosure Housing: UL94-V0 flame retardant modified PA66 engineering plastic casing with anti-ultraviolet and anti-oil industrial grade formulation.
3. Wiring Screw Terminals: Nickel-plated solid brass conductive insert, zinc alloy anti-loose locking screw with PA66 flame retardant terminal base.
4. Core Protection Electronic Components: Certified intrinsic safety Zener diodes, automotive grade TVS transient suppression diodes, high precision metal film fixed resistors, X7R multilayer ceramic capacitors.
5. Internal Isolation Component: Encapsulated insulation transformer with epoxy sealed isolation layer for high dielectric withstand requirement.
6. Internal PCB Fixing Parts: High temperature resistant modified nylon positioning pillars for vibration-proof circuit board fixation inside plastic shell.

7. Structural Characteristics

1. Compact slim single-width DIN rail modular structure, dual channel circuit symmetrically arranged inside unified plastic housing.
2. Internal PCB functional physical separation: Safe side terminal circuit concentrated on one end, field-side intrinsically safe circuit arranged on opposite end, isolation transformer placed at middle partition area for separation of two electrical domains.
3. Front casing permanent silkscreen printed marking including part number, safe/field terminal definition and IS certification parameters with high temperature fade-resistant ink.
4. Rear casing integrated integrated DIN35 buckle clamping structure for direct snap-on mounting onto standard top-hat rail without auxiliary fixing accessories.
5. Internal plastic isolation rib separates two independent channel circuits to block cross-channel electrical crosstalk and heat conduction.
6. Top and bottom reserved small ventilation slit for passive natural heat dissipation without built-in fan structure.

8. Working Principle

Step 1: Loop Power Extraction Phase

Step 2: Safe Side Analog Signal Collection

Step3: Galvanic Isolation & Signal Transmission

Step4: Intrinsically Safe Output Regulation

Step5: Reverse Field Signal Feedback

Step6: Surge Fault Suppression

9. Advantage Highlights

1. Dual channel compact design reduces cabinet DIN rail occupation space versus two discrete single-channel isolators and lowers overall spare part stocking cost.
2. Full loop-powered design eliminates external 24VDC power supply layout work to shorten control cabinet engineering wiring cycle drastically.
3. Certified Ex ia IIC intrinsic safety rating covers all mainstream combustible gas classified hazardous area including hydrogen and acetylene field installation requirement.
4. High 2500VAC galvanic isolation effectively eliminates ground loop induced signal drift, improving whole process control system measuring precision and stability.
5. Ultra-low loop voltage drop minimizes extra load loss on original instrument loop, no need to increase control room loop auxiliary power supply for long-distance field wiring.
6. Standard global DIN35 rail unified mounting specification compatible with all international standard process control cabinet rail layout.
7. Factory pre-calibrated finished unit enables direct replacement without on-site instrument loop re-calibration to shorten field maintenance downtime.

10. Applicable Industries

• Petrochemical Industry: Refinery, petrochemical synthesis plant, hazardous chemical tank farm Zone1/Zone0 field transmitter signal isolation protection
• Natural Gas & LNG Industry: City gas pressure regulating station, LNG receiving terminal, pipeline compressor station hazardous area instrument safety barrier application
• Offshore Oil & Gas Industry: Offshore production platform, FPSO cabin combustible gas classified area process instrument loop safety isolation
• Pharmaceutical Fine Chemical Industry: API synthesis workshop, solvent storage room explosive classified area temperature/pressure transmitter intrinsic safety protection
• Coal Chemical Industry: Coal to olefin plant, coal gasification workshop Zone1 hazardous field analog signal isolation control
• Fertilizer Chemical Industry: Ammonia synthesis plant, urea production workshop toxic and combustible gas hazardous area instrument safety matching
• Waste Hazardous Treatment Industry: Hazardous waste incineration plant flammable waste storage area field instrumentation intrinsic safety protection

11. Model Series Affiliation

• Parent Product Series: MTL 8000 Series Loop-Powered Intrinsically Safe Signal Isolator Family
• Same series sibling standard models:
  1. 8201-HO-IS: Single channel loop powered IS isolator for 4–20mA instrument loop
  2. 8203-HO-IS: Three channel compact loop powered intrinsically safe signal isolator module
• Compatible matching field equipment: Global standard two-wire loop powered pressure transmitter, RTD converted 4–20mA temperature transmitter, flow differential pressure transmitter; compatible host: Siemens, ABB, Honeywell, Yokogawa mainstream DCS/PLC analog input cards

12. Installation Requirements

1. Mounting Environment Standard: Install inside closed ventilated non-hazardous control cabinet only; field hazardous classified area direct cabinet installation is prohibited per intrinsic safety installation specification.
2. DIN Rail Mount Specification: Snap module rear buckle onto standard 35mm top-hat DIN rail, push down fully until body locks tightly onto rail without loose displacement.
3. Wiring Classification Rule: Safe-side terminal wiring connects exclusively to control room non-hazardous DCS/PLC circuit; field-side terminal wiring runs strictly toward Zone0/1 hazardous field transmitters, cross wiring of two terminal groups is forbidden.
4. Wiring Cable Specification: Hazardous field instrument cable must use intrinsically safe dedicated shielded twisted pair control wire; cable shielding single-point grounding at control cabinet PE protective earth terminal only.
5. Heat Dissipation Clearance Requirement: Minimum 5mm vacant gap reserved between adjacent mounted modules for natural convection heat dissipation inside cabinet.
6. Pre-installation Confirmation: Verify field transmitter intrinsic safety parameters match module certified Uo/Io/Po rating before field wiring connection execution.

13. Use & Maintenance Precautions

1. Strictly prohibit connecting non-intrinsically safe high voltage signal into field-side terminals; overrating voltage input permanently damages internal IS protection circuit and voids intrinsic safety certification validity.
2. All field wiring modification operation must be completed after cutting off full loop control power supply from DCS side to prevent live wiring induced surge component breakdown.
3. Quarterly routine maintenance only uses dry lint-free cloth to wipe outer plastic casing dust; organic solvent, alcohol or liquid detergent cleaning directly contacting PCB and terminals is forbidden.
4. Spare unused modules shall be sealed inside anti-static shielding bag and stored under 10°C~35°C dry constant temperature environment; open-air damp and high-temperature long-term storage is prohibited.
5. On-site fault replacement only permits original factory certified genuine MTL 8202-HO-IS module; third-party refurbished or imitation substitute modules cannot be used on certified intrinsically safe hazardous area control loop.
6. Avoid high-frequency inverter, arc welding equipment installed within 30cm distance of control cabinet housing to prevent strong electromagnetic radiation inducing abnormal 4–20mA signal deviation.