MTL 5049 Active Isolator | Loop-Powered, 4-20mA in/out, IS, DIN Rail, ATEX/IECEx/FM

MTL 5049 Active Isolator | Loop-Powered, 4-20mA in/out, IS, DIN Rail, ATEX/IECEx/FM

MTL 5049 active isolator specifications. Loop-powered, 2-wire, 4-20mA input, 4-20mA output, intrinsic safety, 24V DC. ATEX/IECEx/FM approved for hazardous areas.

Product Overview

The MTL 5049​ is a single-channel, loop-powered (2-wire) isolator and repeater​ from MTL's 5000 series. It is designed to be inserted directly into a standard 4-20mA current loop. The device is powered entirely by the loop current​ itself, requiring no separate power supply. It accepts a 4-20mA input signal​ from a hazardous area transmitter, provides intrinsic safety (IS) isolation, signal conditioning, and boosting, and delivers a regenerated, isolated 4-20mA output​ to the safe-area control system. Its loop-powered design simplifies installation and saves wiring costs.

Technical Specifications

Note: Specifications are based on MTL 5000 series documentation. Always verify with the latest product datasheet.

Key Features

• True Loop-Powered (2-Wire) Operation:​ Requires no separate power supply, powered directly from the 4-20mA input signal. Simplifies wiring and reduces costs.

• Signal Boosting/Repeating:​ Regenerates a fresh, isolated 4-20mA output signal, capable of driving long cables or high loop loads.

• Intrinsic Safety:​ Certified for Zone 1/21, providing isolation and protection for hazardous area transmitters.

• Low Input Voltage Drop:​ Minimal burden on the input loop, preserving voltage for the field transmitter.

• High Accuracy & Isolation:​ ±0.1% accuracy with 500V isolation between input and output.

• Wide Output Load Capability:​ Can drive loads up to 600Ω, subject to sufficient input voltage.

• Compact & Simple:​ No configuration required; simply wire into the loop.

• Diagnostic Indication:​ Bicolor LED provides visual status (power, fault).

• Global Hazardous Area Approvals:​ Suitable for installations worldwide.

Operating Principle & Voltage Compliance

The MTL 5049 is a 2-wire device inserted in series​ within the 4-20mA loop. It uses a small amount of power from the loop current to operate its internal electronics and generates a fresh, isolated output current.

Critical System Voltage Check:

For the loop to function, the Power Supply Voltage (Vs)​ must be greater than the sum of all voltage drops:

Vs > V_tx + V_5049 + (I_loop * R_load) + (I_loop * R_wire)

Where:

• V_tx:​ Minimum operating voltage of the field transmitter (e.g., 12V).

• V_5049:​ Voltage drop across the 5049 (approx. 3.5V at 20mA).

• I_loop * R_load:​ Voltage drop across the receiver/load (e.g., 250Ω * 0.02A = 5V).

• I_loop * R_wire:​ Voltage drop in the cable (usually small).

Example Calculation:

• Transmitter (V_tx): 12V

• MTL 5049 (V_5049): 3.5V

• Load 250Ω at 20mA: 5.0V

• Total Required:​ 20.5V

• Minimum Supply (Vs):​ A 24V supply (21.6V min) is adequate. A 18V supply would fail.

Terminal Block Layout

The module has 4 screw terminals for loop connection.

Wiring Diagram

[Hazardous Area]        [Safe Area]              [Safe Area - Output Loop]
                       .----------------------.
Field                  |       MTL 5049       |   Output PSU
Xmtr(+) -------------- | IN+              OUT+| ----[24V DC +]---.
                       |                      |                  |
                       |                      |                  |
Field                  | IN-              OUT-| ---[Load: 250Ω]--+
Xmtr(-) ----[IS PSU -] |                      |                  |
                       '----------------------'                  |
                                                                  |
[IS PSU +] -------------------------------------------------------'

The field transmitter is powered by an IS power supply. The 5049 is powered by the current from this loop. The 5049's output is powered by a separate, standard 24V supply.

Entity Parameters (for Hazardous Area Loop Design)

The connected field device (transmitter) in the hazardous area must be IS certified.

Typical Applications

• Signal Boosting:​ Extending 4-20mA signal transmission distance by regenerating a fresh signal to overcome cable resistance.

• Ground Loop Elimination:​ Isolating grounds between a field transmitter and control system to eliminate ground loop currents and noise.

• Intrinsic Safety Interface:​ Providing IS isolation for a standard 4-20mA transmitter in a hazardous area.

• Signal Re-transmission:​ Sending one transmitter signal to two separate receivers (when used with a signal splitter).

• Legacy System Upgrades:​ Adding isolation to existing loops without rewiring for a separate power supply.

• High Load Driving:​ Driving high-resistance loads (e.g., multiple indicators in series) that the original transmitter cannot drive alone.

Important Technical Notes

1. Voltage Compliance is Critical:​ This is the most important design consideration. You must verify that the existing loop's power supply has sufficient voltage​ to power the field transmitter plus​ the MTL 5049 plus​ the load, at 20mA. Calculate: Vs(min) > V_tx(min) + 3.5V + (0.02 * R_load_total).

2. Two Power Supplies:​ The input side​ of the loop requires an IS power supply for the field transmitter. The output side​ requires a separate, standard 24V DC power supply to power the output loop.

3. Polarity Sensitive:​ The device is polarity sensitive. Ensure correct wiring as per the terminal designations.

4. No Configuration:​ The unit is fixed as a 4-20mA input / 4-20mA output repeater. It cannot be configured for other ranges.

5. LED Status:​ A green LED indicates normal operation. A red or flashing LED may indicate a fault (e.g., open circuit, insufficient voltage).

6. Not a Isolated Barrier:​ It is an active isolator/repeater, not a passive Zener barrier. It conditions and regenerates the signal.

7. Loop Disruption:​ Inserting the 5049 into an active loop will briefly break the circuit. Plan for this during installation.

8. Output Power Supply:​ The output side requires its own 24V DC power supply. Do not connect the output to a passive input card expecting to source power.

Note: This data sheet provides general specifications for the MTL 5049 loop-powered isolator. For complete installation instructions, wiring diagrams, voltage compliance calculations, intrinsic safety guidelines, and certification details, consult the official MTL 5000 Series Technical Manual​ and the product-specific data sheet. Always perform the voltage compliance calculation before installation.

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