Trolex TX9131-2-6-7-9 Programmable Trip Amplifier User Manual

1. Principal Operating Features

The TROLEX TX9130 series of Programmable Trip Amplifiers offer versatile sensor monitoring through an easy-to-use, fully programmable menu system with a wide range of operating options. Developed for the mining industry, these amplifiers provide unparalleled simplicity of operation.

The Trip Amplifier accepts input signals from various analog sensors. The input signal is conditioned and processed by a microprocessor to control two independent output relays with indicating LEDs and a dot matrix data display.

Some versions include a repeater output signal for communication with remote data systems. All functions are programmable via a 4-way keypad, guided by an intuitive menu system. Settings are retained during power failure.

External control functions include POWER ON DELAY to inhibit output relays during warm-up or process stabilization, and an external reset input for latched alarm functions.

Further technical application data is available upon request from the Applications Department.

2. Application

Applications include:

• Underground machinery protection
• Pump and compressor monitoring
• ITP monitoring
• On-board underground machinery monitoring

Mounting formats include DIN Rail Mounting and 19" Rack Mounting (TX9139 only). Modules can be integrated into existing equipment or TROLEX housings.

To comply with certification requirements, the Trip Amplifier must be mounted in an enclosure with an ingress protection rating better than IP54. The TX9130 is certified Intrinsically Safe for underground use when paired with an approved power supply and input devices.

3. Preparation

3.1 Pre-installation Checks

• Verify correct supply voltage (7.5 to 16.5 V).
• Ensure the power supply is an approved Intrinsically Safe source.
• Confirm the INPUT signal format is compatible with the sensor/system.
• Confirm the OUTPUT contact/signal format is compatible with the system.

3.2 Relay Output Contacts

The default fail-safe mode for relay output contacts is NORMALLY OPEN (NO), meaning the contact opens upon power supply failure or output failure. The Trip Amplifier is supplied with output contacts set to NORMALLY OPEN when the output relay is de-energised.

To change contacts to NORMALLY CLOSED (NC):

1. Remove the back cover.
2. Locate miniature plastic connectors on the bottom PCB for contact mode and change as required.
3. Replace the back cover.

This setting does not affect the electrical operation of the relay and can also be programmed for RISING or FALLING alarm functions (Refer to Sections 6.2 & 14.3).

3.3 Intrinsically Safe (IS) Labeling

If the Trip Amplifier is fitted into a standard TX9200 series metal enclosure, ensure a visible, legible, and permanent IS label is affixed to the outside. If fitted in a special or proprietary enclosure, the IS label is provided loose and must be permanently affixed to the outside in a visible position.

4. Dimensions

4.1 DIN Rail Mounting

Dimensions: Height: 110 mm, Width: 66 mm, Depth: 61 mm.

4.2 19" Rack Mounting (TX9137 ONLY)

Dimensions: Height: 1/6 Rack, Width: 74 mm.

The TX9130 must be installed in a protective metal enclosure with an IP rating better than IP54 for Intrinsically Safe certification. A polycarbonate window is permissible for viewing the display, with a maximum area of 100 cm². Terminal identification labels must be visible and adjacent to the terminals.

5. Technical Details

IMPORTANT: 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.

6. Connections

The TX9130 Series Trip Amplifier supports various analogue input signals:

• TX9131: Current signals (4 to 20 mA)
• TX9132: Voltage signals (0.4 to 2 V)
• TX9134: PT100 signals
• TX9136: Balanced bridge signals
• TX9137: AC input signals

Versions are available with a repeater output signal in place of the second relay (R2) in three formats: 4 to 20 mA, 0.4 to 2 V, or 5 to 15 Hz.

6.1 Connections Diagrams

Refer to diagrams showing terminal connections for Output Relays and Output Relay + Repeater Output Signal.

6.2 Relay Status

Relays are shown de-energised (POWER OFF or setpoint EXCEEDED). Refer to Section 3.

6.3 Power ON Delay Control

Terminal 12 controls the POWER ON DELAY. 0 V = INHIBIT. An open input starts the POWER ON DELAY time period (leave open if not used). Refer to Section 12.

6.4 Reset Function

Terminal 11 resets any LATCHED relays and the count display via an external contact impulse. 0 V = RESET. Refer to Section 14.6.

6.5 TX9131 Current Input

Fully floating differential input. Range: 0 to 20 mA, 4 to 20 mA. Impedance: 10 Ω.

6.6 TX9132 Voltage Input

Fully floating differential input. Range: 0.4 to 2 V. Impedance: 100 kΩ.

6.6 TX9134 Resistance Temperature Device

Standardised to DIN43760 and BS1904. Range: PT100, -50 to +200°C or -50 to +400°C.

6.8 TX9136 Bridge Input

Balanced four-arm bridge input. Pellistor, Strain gauge, Pressure. Range: 0.1 mV/V to 10 mV/V. Programmable bridge energising voltage: 2 to 6 V.

6.9 TX9137 AC Voltage Input

Load cells, AC generators, Accelerometers, Velocity sensors, Power measuring instruments. Peak detection: 10 Hz to 100 kHz, 10 V pk/pk. RMS detection: 10 Hz to 10 kHz, 1 V rms.

6.10 Cable Distance Calculation for Loop Powered, 4 to 20 mA Sensors

Maximum cable distance calculation provided.

6.11 Adding a Digital Display into a 0.4 to 2 V Signal Loop

A Trolex TX9181 digital display can be added to a 0.4 to 2 V signal loop for remote readout.

6.12 Cable Distance Calculation for Voltage Inputs (0.4 to 2 V)

Input impedance is high, so cable distance is usually not an issue. Voltage drop in the power supply line is critical, especially on three-wire systems. Use a 4-wire system for distances over 100 m.

6.13 Dual Input Signals (Differential)

The differential input stage allows monitoring of two input signals simultaneously, responding to their difference. This is useful for monitoring differential temperature, pressure, or speed. Ensure sensors are calibrated to the same operating parameters.

6.14 Repeater Output Signal

Displaces output relay R2. Three options: 4 to 20 mA, 0.4 to 2 V, or 5 to 15 Hz. Signal magnitude is proportional to the display value.

6.15 TX9139 Interposing Relay

A repeater unit providing three independent changeover output relays, driven directly from the input supply voltage. Does not offer programmable functionality.

7. Controls and Indicators

7.1 Unit Overview

Components include Terminals, Measured value display, Polarity indicator, Keypad, Relay indicating LEDs, Engineering units display, Signal trend arrows, and Signal bar graph.

7.2 Keypad Functions

Keys include MENU/ESCAPE, SCROLL UP, SCROLL DOWN, and CONFIRM. Holding SCROLL keys enables rapid self-keying.

DATA MEMORY: Permanent data memory; all settings retained during power failure.

8. Information Display

8.1 Switching ON

On initial power-up, the processor initializes programmed settings and default values. Refer to Section 9 for menu functions and default values.

8.2 Signal Display

The display shows the main SIGNAL DISPLAY. Trend arrows indicate signal tendency: steady, rising, or falling. Slowly changing signals may indicate issues.

If POWER ON DELAY is programmed, the display shows the delay time in seconds, counting down until completion, then reverts to the SIGNAL DISPLAY.

8.3 Measuring the Supply Voltage

Press the Key to display the supply voltage and software version. A warning appears if the supply drops below 7.0 V.

8.4 Relay Setpoint Review

Press the Key to review programmed relay setpoint levels. 'R' denotes a RISING alarm function; 'F' denotes a FALLING alarm function. Refer to Sections 14.1 and 14.3.

8.5 Peak/Low Review

PEAK displays the maximum signal value since the last reset. LOW displays the minimum signal value since the last reset. Press the Key to display PEAK and LOW. Press Key then to reset PEAK/LOW values. Stored values reset to zero on power-up.

8.6 Signal Error Information

Conditioned input versions display input signal ERROR conditions. Signals exceeding normal boundaries (e.g., >2.2V or <0.2V) trigger warnings and ERROR signals. Error signals de-energise Relays 1 and 2.

• HIGH: Signal exceptionally HIGH (>2.2 V).
• OVER RANGE: Signal exceeds calibrated range (>2.1 V).
• NORMAL: Signal within normal range (0.4 to 2 V).
• UNDER RANGE: Signal below calibrated range (<0.3 V).
• LOW: Signal exceptionally LOW (<0.2 V).
• SIGNAL FAIL: Indicates signal failure.

9. The Menu of Functions

Provides a flowchart of the unit's functions, including MAIN SETUP, BRIDGE SETUP (for TX9136), CAL OUTPUT, and various settings like SETPOINT, HYSTERESIS, ALARM, ON DELAY, OFF DELAY, CONTRAST, KEYCODE, and UNITS.

10. Entering the Main Setup

10.1 ENTER

Access the MAIN SETUP menu by pressing the Key. The display shows available options. Previously programmed settings appear in brackets. If KEYCODE security is enabled, an access code is required.

Use Keys to traverse cursor, scroll numbers, and confirm entries. Use Keys to scroll through the menu and confirm.

DATA SAVED flashes upon successful entry. !! NOT SAVED !! flashes if a value is not entered.

10.2 ESCAPE

Press the Key to exit the menu sequence, stepping back one level at a time until the SIGNAL DISPLAY is reached. The display steps back every 10 seconds if no keys are operated.

11. Calibrate the Repeater Output Signal

Some versions have a repeater output signal proportional to the display value. Calibration is performed during manufacture to match LOWER and UPPER programmed values (0.4 to 2 V version: 0.4-2; 4 to 20 mA version: 4-20; 5 to 15 Hz version: 5-15).

Recalibration can be done using a test instrument connected to the output circuit. The display shows pulse width modulation, aiding adjustment.

Use Keys to select and adjust readings, and Key to confirm.

12. Power On Delay Period

Setpoint output relays R1 and R2 can be inhibited for a set time after power-on. This is useful for start-up overrides when machinery is stabilizing.

Use Keys to scroll and Key to confirm the delay value (Range: 0-255s).

The delay can be controlled remotely via terminal 12. A 0 V signal on terminal 12 prevents the delay timer from starting. The delay commences upon instruction from a control contact associated with the machine start-up. The delay resets when power is removed. Refer to Section 6.3.

13. Scale and Display Settings

Various characteristics of the signal scale and display can be determined. Menu content varies by input version.

13.1 Units

Standard engineering units (e.g., bar, mA, m/s, °C, °F) can be added to the signal value display. For temperature inputs (TX9133, TX9134, TX9135), units are limited to °C, °F, or °K.

Specific units can be entered using a simple ASCII routine (up to 4 characters). Contact Trolex for programming details.

13.2 Decimal Point

The decimal point can be traversed to any position in the number after setting UPPER and LOWER display readings.

13.3 Update

The input signal is sampled at a pre-determined interval. The update period is adjustable, allowing for rapid reaction or damping of fluctuating inputs in noisy environments. For maximum accuracy, sampling occurs before pre-scaling. Analogue signal levels are averaged between samples.

13.4 Lower & 13.5 Upper

These independently adjustable parameters set the LOWER and UPPER LIMITS of the display reading for a given input signal. The display range can be programmed to show true unit values, including multiplication constants, zero offsets, or negative values. The signal response between LOWER and UPPER is assumed linear, but non-linear signals (e.g., from thermocouples or DP sensors) can be linearized in software.

14. Setpoint Characteristics

The Trip Amplifier has two setpoint output relays (R1 and R2) or alarm points. Relays are normally energized and de-energize when a setpoint is exceeded.

14.1 Level

The operating LEVEL or setpoint of each relay can be set. Use Keys to traverse digits and scroll values. Refer to Section 9.2 for menu options.

14.2 Hysteresis

Hysteresis is the deadband between relay switching OFF and ON at the setpoint as the input signal rises and falls. It can be set as a percentage of the SETPOINT LEVEL. Low hysteresis (e.g., 5%) prevents hunting in closed-loop systems. High hysteresis can act as a control function for pumps.

14.3 Alarm (Rising/Falling)

Relays can be set to de-energize on a RISING or FALLING input signal. This is useful for failsafe alarm functions (e.g., excess vibration, high gas concentration) or monitoring failures (e.g., flow failure, low pressure). Use Keys to select RISING/FALLING and Key to confirm.

14.4 ON Delay

The setpoint signal can be delayed by an adjustable time period (t_on). This is useful for alarm verification, process control delays, or overriding spurious fluctuations. If the input signal falls below the setpoint before the programmed time elapses, the timer resets. Refer to Section 14.6.

14.5 OFF Delay

The resetting of the setpoint signal can be delayed by an adjustable time period (t_off). If the input signal exceeds the setpoint before the programmed time elapses, the timer resets. Refer to Section 14.6.

ON Delay and OFF Delay can be combined and are independently programmable.

14.6 Operation

The relay can function in four ways at its setpoint:

• AUTO RESET: Relay de-energizes when the input signal exceeds the setpoint and resets when the signal recedes. Includes programmed delay.
• LATCH UNTIL RESET: Relay de-energizes when the input signal exceeds the setpoint and latches until reset. Includes programmed delay.
• TOGGLE: Relay energizes/de-energizes each time the setpoint value is exceeded. Includes programmed delay.
• PULSE: The setpoint signal triggers an impulse of duration t₂ each time the setpoint value is exceeded. Includes programmed delay (t₁).

Relays can be reset via Impulse on Input 2, 0 V on Terminal 11, or by temporarily removing the power supply.

15. Contrast Control

LCD contrast can be adjusted to compensate for ambient temperature variations. Use Keys to set contrast and Key to confirm.

16. Keycode

A security code can be set to restrict access to MAIN SETUP programming. The code can be changed at any time. Use Keys to traverse digits and change values, then Key to confirm.

17. Accessories

• TX6641 Exd/INTRINSICALLY SAFE POWER SUPPLY: For underground use. Available in 24, 110, or 230 V ac. Features relays in the Ex d compartment for direct switching of pilot circuits. Offers total compatibility with Trolex mining sensors, controllers, and standby batteries.
• TX9204 ENCLOSURE: Protective enclosure.

18. Bridge Voltage Supply

18.1 Bridge Voltage

The Strain Gauge version (TX9136) is factory calibrated but can be re-calibrated in situ without specialized equipment. User options are limited to ±10% of the 'Upper' value in the 'Scale & Display' menu.

The bridge voltage is factory set to 5 V for maximum output. It can be checked and adjusted via the 'Bridge Setup' menu. Use Keys to access 'MAIN SETUP', then select 'Bridge Setup', then 'Bridge Voltage'. Use Keys to set the voltage and Key to save.

18.2 User Set Zero

This option allows zeroing the unit to cancel strain gauge zero error or system pre-load (e.g., weighbridge calibration). The indication can be trimmed to zero without affecting factory span calibration. Use Keys to select 'User Set Zero' and Key to access. Confirm with Key. During auto zero operation, values change but are not critical. 'Data Saved' indicates completion. NB: OVER LIMIT or UNDER LIMIT warnings mean the offset adjustment is outside the permitted range.

18.3 User Set Load

Calibrates the span using a known input (e.g., weighbridge load). Enter the known weight value using 'Set Load'. The TX9136 adjusts relative to the full scale setting. Use Keys to select 'User Set Load' and Key to access. Enter the known input load value using Keys and save with Key. Confirm with Key when the known load is applied.

18.4 Sensitivity

Displays existing sensitivity value. Use Keys to enter the known mV value (not mV/V from certificate) and Key to save.

18.5 Restore Defaults

Restores the TX9136 to original factory calibration settings. Use Keys to select 'Restore Defaults' and Key to access. Confirm the restore action with Key. 'Data Saved' indicates completion.

19. Certification and Conformity

1. European Union

ATEX certification for underground mines (Group I) in the European Union. Complies with ATEX Directive 2014/34/EU, EN IEC 60079-0:2018, EN IEC 60079-11:2012, IEC 60079-11:2023.

Product Codes and Ex Certificate Numbers listed. Entity parameters for various TX913x models provided, detailing voltage (Uo, Ui), current (Io), power (Po), capacitance (Co, Ci), inductance (Lo, Li), and resistance (Ro).

Special Conditions of Use: Installation in an enclosure with at least IP54 protection (EN 60529). Metallic enclosures must comply with EN IEC 60079-0:2018, clause 8.2. Outer enclosure marking requirements specified.

2. Australia and New Zealand

ANZEX certification for underground mines (Group 1) in Australia and New Zealand. Product Codes and Ex Certificate Numbers listed. Entity parameters for TX9131/2/5 and TX9133 provided.

3. Eurasian Customs Union (including Russia)

EAC certification for underground mines in Eurasian Customs Union. Product Codes and Ex Certification Code (RU C-GB.HB66.B.00026-24) provided.

Installation: Must be carried out by competent personnel, considering local safety regulations and standards (IEC/EN 60079-14, IEC/EN 60079-25). Refer to the Certification Section and relevant certificates.

Commissioning/Verification: Inspect for visible damage before first use. Never use if housing is damaged.

Maintenance: Must be carried out by competent personnel, considering local safety regulations and standards (IEC/EN 60079-17).

Repair: Servicing and repair by Trolex Ltd or approved agents only, to maintain explosion protection. Refer to IEC/EN 60079-19.

20. Application Examples

20.1 Control and Alarm

A pump replenishes liquid stock in a tank. A TX6140 Pressure Transmitter measures hydrostatic pressure. Alarm warnings are required for pump failure (high level) or failure to start (low level). Settings example provided for a TX9131 controlling a pump based on gallons.

20.2 TX9132 Trip Amplifier Monitoring a Gas Sensor

Two setpoints (R1 and R2) provide WARNING and ALARM on rising gas concentration. Settings example provided for a TX9132 monitoring ppm.

20.3 TX9132 Trip Amplifier Monitoring an Airflow Sensor

Similar system using a Trolex TX5920 Air Flow Sensor. The current input version (TX9131) accepts the sensor's analogue output. Setpoints can detect flow failure, with 'failure mode' set for a FALLING signal.

20.4 Fan Vibration Monitoring

A Vibration Monitor (TX9137) used with a Trolex TX5633 Vibration Sensor to check fan condition. Settings example provided for monitoring 'g' units.

Disclaimer

The information in this document provides general descriptions and technical characteristics. It is not a substitute for determining suitability or reliability for specific applications. Users must perform their own risk assessments and testing. Trolex is not liable for misuse of information. All pertinent safety regulations must be observed. Only Trolex or its affiliates should perform repairs.

Trolex Ltd. reserves the right to revise and update this documentation without notice. Changes in equipment design or performance may occur.

Trademark: © 2025 Trolex® Ltd. Reproduction without written permission is prohibited. Trolex is a registered trademark.