ELCON INSTRUMENTS

I N T R I N S I C S A F E T Y a n d S P E C I A L I S T S

SERIES µD
INTRINSIC SAFETY ISOLATORS
User Instruction Manual
 ELCON INSTRUMENTS
I N T R I N S I C S A F E T Y a n d S P E C I A L I S T S
µD RANGE INTRINSIC SAFETY ISOLATORS
User Instruction Manual

Warning: This manual is copyright of Elcon Instruments with all rights reserved. This manual may not
be copied, in whole or in part, without the written consent of Elcon Instruments.
Elcon Instruments reserves the right to make changes of this manual without notice.
RD-ZIP-004

DOC.TECN. IM-ENG-110/GB-A3-PN991168
I
Table of contents
1 Introduction........................................................................................................................................ 1-1
1.1 Overview .................................................................................................................................... 1-1
1.2 Explanation of Contents .............................................................................................................. 1-1
1.3 Key Features............................................................................................................................... 1-1
1.4 Hazardous Area Interfacing......................................................................................................... 1-2
1.5 Quality Management Policy ........................................................................................................ 1-2
2 Specifications .................................................................................................................................... 2-1
2.1 Product Selection........................................................................................................................ 2-1
2.2 Ordering Information ................................................................................................................... 2-2
2.3 Mechanical Specifications........................................................................................................... 2-3
2.4 Safety Specifications................................................................................................................... 2-4
2.5 Approvals and Markings.............................................................................................................. 2-5
2.6 Electrical Specifications - general ............................................................................................... 2-6
2.7 Electrical Specifications - modules.............................................................................................. 2-6
2.7.1 µD 301 Signal Converter Universal Input ............................................................................. 2-7
2.7.2 µD 321 Analog Input Repeater Dual Signal Outputs ............................................................. 2-9
2.7.3 µD 323 Analog Input Repeater Fully Floating Output.......................................................... 2-10
2.7.4 µD 325/326 Analog Input Repeater .................................................................................... 2-11
2.7.5 µD 333/334 Analog Output Driver ...................................................................................... 2-12
2.7.6 µD 337/338 Powered I/P Driver, Smart Compatible............................................................ 2-13
2.7.7 µD 411/412 Switch Repeater Relay Output ........................................................................ 2-14
2.7.8 µD 421/422 and µD 421/422 LVAC Switch Repeater Relay Output with line fault detection2-15
2.7.9 µD 431/432 Switch Repeater Open Collector Output .......................................................... 2-16
2.7.10 µD 441/442 Switch Repeater Open Collector Out with line fault detection .......................... 2-17
2.7.11 µD 471/472 Loop Powered Solenoid / Alarm Driver........................................................... 2-18
3 System Operation .............................................................................................................................. 3-1
3.1 General description of the system ............................................................................................... 3-1
3.2 System design considerations ..................................................................................................... 3-1
3.3 Wiring of intrinsically safe circuits ............................................................................................... 3-1
3.4 Grounding information ................................................................................................................ 3-2
4 Installation and Configuration............................................................................................................. 4-1
4.1 Unpacking................................................................................................................................... 4-1
4.2 Configuration .............................................................................................................................. 4-1
4.3 Installation .................................................................................................................................. 4-2
4.4 EMC Guidelines .......................................................................................................................... 4-3
4.5 Heat Dissipation and Thermal Behaviour .................................................................................... 4-4
4.6 Cabinet Heat-Dissipation............................................................................................................. 4-5
5 Unit Operation.................................................................................................................................... 5-1
5.1 µD 301 ........................................................................................................................................ 5-1
5.2 µD 321 ........................................................................................................................................ 5-5
5.3 µD 323 ........................................................................................................................................ 5-7
5.4 µD 325/326 ................................................................................................................................. 5-9
5.5 µD 333/334 ............................................................................................................................... 5-11
5.6 µD 337/338 ............................................................................................................................... 5-13
5.7 µD 411/412 ............................................................................................................................... 5-15
5.8 µD 421/422 and µD 421/422 LVAC ........................................................................................... 5-17
5.9 µD 431/432 ............................................................................................................................... 5-21
5.10 µD 441/442 ............................................................................................................................... 5-23
5.11 µD 471/472 ............................................................................................................................... 5-27
6 Servicing............................................................................................................................................ 6-1
6.1 Maintenance ............................................................................................................................... 6-1
6.2 Functional Check & Troubleshooting ........................................................................................... 6-1
6.3 Warranty ..................................................................................................................................... 6-8
7 Glossary ............................................................................................................................................ 7-1
8 Index.................................................................................................................................................. 8-1

I
1 Introduction

1.1 Overview
µD is the range of Elcon Intrinsic Safety Galvanic Isolators. The µD products can be DIN-rail mounted and
provide the simplest and cost effective mean to implement Intrinsic Safety in your Hazardous Area
applications.
The µD product range provides:
• high packing density, due to innovative circuit design based on advanced surface mount
components
• high performance, with high signal transfer accuracy and repeatability, low power consumption,
low heat dissipation
• wide functionality, with a wide range of I/O signals, galvanic isolation, line fault alarm
• Intrinsic Safety certification according to CENELEC, CSA, FM, GOST, SEV, SABS, SAA and
other world-wide standards
• Compliance with applicable European directives (including EMC), all modules carry the CE
marking.

1.2 Explanation of Contents

This instruction manual describes how to install, connect, check and maintain the µD range:
• section 2 supplies the technical specifications of the units in a concise form
• section 3 describes system operation, and contains some µD products application guidelines
• section 4 describes how to install and configure the µD modules
• section 5 shows how to operate the units
• section 6 deals with maintenance and troubleshooting issues
The document is completed by a Glossary and an analytical Index for easy reference to topics.

1.3 Key Features

• high channel density results from innovative circuit design using surface mounted components
• high packing density, with ultra slim 2 channel 16 mm (5/8”) wide DIN-rail mounting modules, 8
mm (5/16”) per channel, 120 I/O channels per metre (36 per foot) of DIN rail
• single and dual channel models. Single channel versions available if required to provide single
loop integrity on Emergency Shut Down and Fire & Gas Applications
• high signal transfer accuracy and repeatability
• low power consumption and heat dissipation
• wide operating temperature range
• wide range of digital switches and analog I/O, including 4-20 mA, signal conversion, loop
powered and external supply configurations
• relay contacts rated for 2 amp to directly switch high loads
• galvanic isolation to eliminate noise, ground loop problems and to provide Intrinsic Safety
without a high integrity safety earth connection
• line fault alarm detects open or short circuit of field cables
• configuration of sink or source outputs available on analog models
• universal microprocessor based programmable unit permits conversion of wide range of TC,
RTD, mV and potentiometer input to standard 4-20 mA or 1-5 V output
• configure using DIP switch located behind front access panel for easy field set up
• LED indication for power, signal status and line fault condition
• secure fixed terminations
• loop identification, coding and tagging
• accept DC power supply over a wide range (24V, -15% +20%)
• digital switch repeater models also available with AC power supply over a wide range (115 or
230 V, no configuration required)

1-1
1.4 Hazardous Area Interfacing
The installation must be performed by qualified personnel, it must comply with the relevant national and
international standards (e.g. BS5345 Pt. 4, DIN VDE 165) and it must conform to established installation
rules and recommended practice (e.g. ISA RP-12.6).
The conformity of hazardous area devices with the related system documentation must be always carefully
checked. These isolators are not intended for hazardous area installation unless it is included in a proper
“explosion proof” enclosure that conforms to the applicable standards.
For I.S. applications, the maximum limit for AC power supply is 250 V rms.
A suggested reading for more information about the constraints imposed by the I.S. regulation is the
comprehensive tutorial “Guide to intrinsic Safety” - available on request from Elcon
More details are provided in Section 4.

1.5 Quality Management Policy

The Elcon mission is to guarantee the highest standards of Quality for the products and services offered and
in Elcon "Quality" means to keep up with customer expectations and to assure the customers’ satisfaction.
In practice, the products must conform with specifications, defects must be prevented and the costs due to
non conformance must be reduced.
In order to achieve these targets Elcon has enlarged the concept of "Customer" and introduced the concept
of Company internal Customer. In this way all those persons that within the Company benefit from other
people's work or service are considered as if they are the Customer.
Elcon considers Total Quality as one of the fundamental factors in achieving its mission.
At Elcon the two key elements of Total Quality are the “Quality System" and "Continuous Improvement".
The Elcon Quality Assurance System is the set of organisational structure, responsibilities, procedures,
processes and resources for implementing Quality management.
Elcon has adopted the standard EN ISO 9001 as reference for its own Quality System.
In accordance with this choice our key suppliers also have to comply with a Quality System conforming to
the EN ISO 9000 standard.
This Quality System guarantees confidence in Elcon capability to supply the required Quality and at the
same time, it ensures that Elcon maintains Quality at an optimal cost.
Elcon products satisfy Customers and meet the specifications and rules of international standards. Safety,
performance, reliability, product documentation and truth in advertising are the basic principles of product
Quality.
Quality in Services is a factor of growing importance to achieve market penetration and Elcon considers
service as an integral part of the Customer package and checks continuously that its services meet
Customer's requirements.
Constant improvement is the foundation of Total Quality. Elcon continuously ensures that the performance
of products, services, management and the Quality System, meet customer requirements. Improvement
can only be obtained with the active participation and involvement of all personnel and therefore Elcon
management recognises that the human resources of the company play a vital role in the achievement of its
objectives.

1-2
2 Specifications
This section lists the relevant specifications for all µD modules. For a detailed description of unit functions
and operation, please refer to Section 5.

2.1 Product Selection

The following table summarises the modules features.

Model Supply Config. Field Device N° of Hazardous Area Safe Area

Number Values Ch.

Universal fully programmable for all input types

TC, RTD,
and temperature ranges. Voltage or current
µD 301 DC 24 Vdc USER 1 mV, mA, Volt &
output, RS232 serial line configuration
Potentiometer ®
(Windows software available)

2 outputs 4-20 mA (or 1-5 V).

4-20 mA (15.5 V)
No. 1 output totally isolated from input and
floating supply to
µD 321 DC 24 Vdc USER 1 supply, configurable as sink or source.
Smart or non Smart
No. 2 output common to power supply for
two wire Tx
monitoring
4-20 mA (15.5 V)
4-20 mA (or 1-5 V) output totally isolated from
floating supply to
µD 323 DC 24 Vdc USER 1 input and supply, configurable as sink or
Smart or non Smart
source
two wire Tx
µD 325 DC 24 Vdc FIXED 1 4-20 mA (15.5 V)
floating supply to
4-20 mA (or 1-5 V).
µD 326 DC 24 Vdc FIXED 2 Smart or non Smart
two wire transmitters
µD 333 DC Loop powered FIXED 1 4-20 mA to I/P
converters, Loop Powered 4-20 mA signal from DCS, PLC
µD 334 DC Loop powered FIXED 2 electrovalve actuators or other control device.
and displays.
µD 337 DC 24 Vdc FIXED 1 4-20 mA and smart
signal to I/P
Bus Powered 4-20 mA signal from DCS, PLC
converters,
µD 338 DC 24 Vdc FIXED 2 or other control device. Smart compatible.
electrovalve actuators
and displays.
µD 411 AC 98 to 250Vac Dry Contact /
FIXED 1 DPDT (relay contact) 2A/250V
µD 411 DC 24 Vdc Proximity Switch

µD 412 AC 98 to 250Vac Dry Contact / 1 SPDT

FIXED 2
Proximity Switch (relay contact) 2A/250V per channel
µD 412 DC 24 Vdc

µD 421 AC 98 to 250Vac
1 Dry Contact DPDT (relay contact) or 1 SPDT plus line fault
USER
Proximity Switch detection contact and LED.
µD 421 DC 24 Vdc
µD 421LVAC 24 Vac
µD 422 AC 98 to 250Vac
µD 422 DC 24 Vdc 2 Dry Contact 1 SPDT per channel plus line fault detection
USER
Proximity Switch LED indication only.
µD 422LVAC 24Vac

2-1
µD 431 AC 98 to 250Vac
Dry Contact /
24 Vdc FIXED 2 open collector
µD 431 DC 1
Proximity Switch

µD 432 AC 98 to 250Vac Dry Contact /

FIXED 2 1 open collector per channel
µD 432 DC 24 Vdc Proximity Switch

µD 441 AC 98 to 250Vac Dry Contact /

USER 1 2 open coll. Or 1 open coll. plus line fault
Proximity Switch detection open coll. and LED.
µD 441 DC 24 Vdc
µD 442 AC 98 to 250Vac
24 Vdc USER 2 Dry Contact / 1 open collector per channel plus line fault
µD 442 DC Proximity Switch detection and LED indication only

Loop powered
µD 471 DC FIXED 1 40 mA at 12 V to drive External 24 Vdc controlled via an external
solenoid valve, audible contact, or voltage level from DCS or control
Loop powered or visual alarms (LED) device.
µD 472 DC FIXED 2

2.2 Ordering Information

The ELCON family of Intrinsic Safety Isolators are designed for simple ordering, you must simply specify
the Model Number from the product selection table.
The models µD 301, µD 321 (Ch.2), µD 325, µD 326 can be provided with an 1-5 volt output as an
alternative to the standard 4-20 mA output. To request this feature, please add a letter ”V” after the Model
Number (e.g. µD 326 DC V). Remember that this is a “Factory Configuration” option, and it can not be
changed by the end user. As for Ch.1 of µD 321/3, the voltage output is an user configuration option, so no
special ordering code is required.

Additional ordering options:

• order “TAG1” for tagging kit comprising five tag holders and inserts, holders clip neatly onto the
µD terminal block.
• order “CONF1” for µD301 configuration kit (Windows 95® software and cable with DB9 PC
connector).

All user configurable units are delivered with a “default” configuration as specified in Section 5. For an
additional charge, Elcon can deliver units configured as specified by the customer.
Each unit is delivered with a detailed Installation Sheet containing all the information required to set up the
isolator on site.

2-2
2.3 Mechanical Specifications
Connections screw terminals conductors max size 2.5 mm2
(14 AWG)
Mounting symmetrical top hat TS35 DIN rail or
surface mountable by screws
Dimensions Width 16.4 mm
Depth 92 mm
Height 112 mm
Case material Polycarbonate, Halogen free, rated at
130 °C
Flame retardant compliant to UL 94 V2
Unit weight about 150 gr
Blister packing size Width 25 mm
Depth 130 mm
Height 130 mm

Dimensional Drawing

2-3
2.4 Safety Specifications

Term. Safety Description Maximum External Parameters

µ D301 Cenelec (groups) USA µ F)
Co (µ Lo (mH) µ H/Ω
L/R (µ Ω)
Uo = 13.1 V II C AB 1.1 47 373
Io = 26 mA II B C-E 3.3 180 1350
Po = 85 mW II A D-F-G 8.8 400 3100
µ D321-323 Cenelec (groups) USA µ F)
Co (µ Lo (mH) µ H/Ω
L/R (µ Ω)
Uo = 26 V II C A-B O.14 4.1 58
11-12 Io = 93 mA II B C-E O.42 16.5 236
Po = 0.63 W II A D-F-G 1.12 33 471
Uo = 11 V II C A-B 2.1 2000 804
12-13 Io = 2 mA II B C-E 6.3 5000 2010
Po = 6 mW II A D-F-G 16.8 6000 2412
µ D325/6 Cenelec (groups) USA µ F)
Co (µ Lo (mH) µ H/Ω
L/R (µ Ω)
Uo = 26 V II C A-B 0.14 4.1 58
Io = 93 mA II B C-E 0.42 16.5 236
Po = 0.63 W II A D-F-G 1.12 33 471
µ D333/4 Cenelec (groups) USA µ F)
Co (µ Lo (mH) µ H/Ω
L/R (µ Ω)
Uo = 17.1 V II C A-B 0.48 4.1 88
Io = 93 mA II B C-E 1.44 16.5 353
Po = 0.4 W II A D-F-G 3.84 33 706
µ D337/8 Cenelec (groups) USA µ F)
Co (µ Lo (mH) µ H/Ω
L/R (µ Ω)
Uo = 26 V II C A-B 0.14 4.1 58
Io = 93 mA II B C-E 0.42 16.5 236
Po = 0.6 W II A D-F-G 1.12 33 471
µ D411/2-421/2 Cenelec (groups) USA µ F)
Co (µ Lo (mH) µ H/Ω
L/R (µ Ω)
Uo = 11 V II C A-B 2 70 550
Io = 22 mA II B C-E 6 250 1980
Po = 61 mW II A D-F-G 16 580 4300
µ D431/2-441/2 Cenelec (groups) USA µ F)
Co (µ Lo (mH) µ H/Ω
L/R (µ Ω)
Uo = 11 V II C A-B 2 70 550
Io = 22 mA II B C-E 6 250 1980
Po = 61 mW II A D-F-G 16 580 4300
µ D471/2 Cenelec (groups) USA µ F)
Co (µ Lo (mH) µ H/Ω
L/R (µ Ω)
Uo = 27 V II C A-B 0.14 3 48
Io = 110 mA II B C-E 0.42 11 175
Po = 0,75W II A D-F-G 1.12 22 350

2-4
2.5 Approvals and Markings
The µD range is compliant with all the mandatory European standards and carries the CE marking.

AUTHORITY CERTIFICATE/FILE NO. STANDARD APPROVED FOR

EX-95.D.025 EN 50.020
CESI [EEx ia] IIC
EX-96.D.013 EN 50.014
66529-13 C 22.2 No. 157 CL. I, II, III;
CSA
66529-14 C 22.2 No. 142 Div 1; Gr. A to G
J.I. 4Z4A3.AX FM Cl. No. 3610 Entity Cl. I, II, III;
FM
J.I. 3B4A5.AX FM Cl. No. 3600 Div 1; Gr. A to G

D.96C.157 Gost 22782.5

VNIIVE [Ex ia] IIC
D.96C.158 Gost 22782.0

EN 50.020
SEV 96.1 10199 [Ex ia] IIC
EN 50.014

SABS Approved SABS 549-93 [Ex ia] IIC

AS 2380.1
SAA Pending [Ex ia] IIC
AS 2380.7

Certifications to other world wide standards are in existence or pending.

2-5
2.6 Electrical Specifications - general
This section lists the characteristics that apply to all µD modules in the product range. For details about the
individual module features, please refer to Section 2.7.

Reference Conditions
Temperature 23 °C
74 °F
Relative humidity 50 %
Nominal supply, DC powered units 24 V dc
Nominal supply, AC powered units 115 V ac
or 230 V ac
Load where applicable 250 Ω
Full scale value 20 mA

Environmental conditions limits

Operating Temperature 0 to 60 °C
(derating can apply) 32 to 140 °F
Storage temperature -20 to 70 °C
-4 to 158 °F
Relative humidity (non condensing - up to 35 °C) 5 to 90 %

Isolation
Series 400 Series 300
Input to output and to supply circuits 2500 V rms for 1 minute 1500 V rms for 1 minute
Output to supply circuits 1500 V rms for 1 minute 250 V rms for 1 minute
I.S. to I.S. input 500 V rms for 1 minute 500 V rms for 1 minute

Electromagnetic Compatibility (EMC)

EN 50081-2 compliant for emissions
Conducted EN 55011 (AC versions only)
Radiated EN 55011
EN 50082-2 compliant for immunity to
ESD EN 61000-4-2
Radio frequencies EN 50140/141
Fast Transients EN 61000-4-4
N.B. these EMC specifications satisfy the CE marking requirements

Protection

All µD devices are protected against reverse polarity power supply connection.

2.7 Electrical Specifications - modules

This section include the detailed electrical specifications for each module type.
All values are typical and at reference conditions unless otherwise specified.

2-6
2.7.1 µD 301 Signal Converter Universal Input

DC supply
Voltage 24 Vdc -15 % + 20% reverse polarity protected
Current consumption 55 mA 20 mA output load
Power dissipation 1.1 W @ 24 V 20 mA/500 Ω output load

Analog to Digital converter

Resolution 17 bits
Type Σ∆
Conversion time 100 msec

Inputs
Type Range/Type Accuracy Resolution Span limits (min)
TC B, E, J, K, L, N, R, ≤ 20 µV or 0.05% of 1.25 µV or 0.1 °C 2 mV
S,T input value
MV - 100 to + 100 mV ≤ 20 µV or 0.05% of 10 µV 2 mV
input value
RTD Pt 100 2-3-4 wires 0.2 Ω 0.1 °C > 50 °C
Pt50, Cu100, Cu50 0.2 Ω 0.1 °C > 50 °C
Pt100 and Pt50Gost 0.2 Ω 0.1 °C > 50 °C
Ni 100 2-3-4 wires 0.2 Ω 0.1 °C > 35 °C
Pt10, Cu10, Pt10Gost 0.2 Ω 0.2 °C > 50 °C
MA -20 to + 20 mA ≤ 10 µA 1 µA 1 mA
Volt -10 to + 10 V ≤ 5 mV 1 mV 0.5 V
Pot 200 Ω to 10 kΩ ≤ 0.2 % 0.1 %

The inputs are fully user programmable and configurable.

Note: the input temperature sensors shown in bold can only be selected and configured by using the
µD301 configuration kit (Windows 95® software plus connection cable).
Burn out detection is available for TC/RTD and it can be set to user configurable value, i.e. down scale, up
scale or “frozen” to the last valid input value.

2-7
Automatic Cold Junction Compensation
Range - 20 + 70 °C
Accuracy ≤ 1°C

Output
Range (programmable via DIP 0 - 20 mA
switches)
4-20 mA
Accuracy ≤ 20 µA
Temperature drift Typical < 0.005%/°C of span
Resolution 3 µA
Load error ≤ 20 µA from 0 to 650 Ω
Internal shunt for voltage output 250 Ω (0.1%, 25 ppm)

Configuration
Configuration is performed using DIP switches for pre-programmed ranges and most frequently used sensor
types (see Section 5.1 for details). For extended configuration options and additional input types, you must
use the µD301 configuration kit (Windows® software plus connection cable) running on a PC connected via
an RS-232 serial line to the µD301 top connector.
LED Indicators
Power ON (green), Fault (RED)

2-8
2.7.2 µD 321 Analog Input Repeater Dual Signal Outputs

DC supply
Voltage 24 Vdc -15 % + 20% reverse polarity protected
Current consumption 90 mA @ 24 V, 20 mA output load
105 mA Max
Power dissipation 1.6 W @ 24 V
Inputs
2 wire transmitter terminals 11-12
Current source terminals 12-13
Input range 4-20 mA
Voltage available for transmitter and lines 15.5 V min @ 20 mA
Ripple content ≤10 mVrms
Input resistance on terminals 12-13 70 Ω

Output Ch. 1 on terminal 1-2 (isolated from power supply)

Output (source mode)
Overload limited at 25 mA on a 0 to 650 Ω load 4-20 mA
user configurable on an internal shunt 1-5 V
Internal shunt for voltage output 250 Ω (0.1%, 25 ppm)
Ripple content ≤ 10 mVrms (on the 250 Ω load required for
communication)
Load effect ≤ 0.1 % of full scale for a 0 to 650 Ω load change
Output (sink mode from external supply)
Overload limited at 25 mA 4-20 mA
Working voltage range 7 to 28 V
Frequency response of comm. channel
Tx to output 0.5 to 40 kHz (within 3 dB, -6 dB @ 100 kHz)
Output to Tx 0.5 to 40 kHz (within 3 dB, -6 dB @ 100 kHz)
Response time 40 ms, 10 to 90% step change
Calibration accuracy ± 0.1 % of full scale
Linearity ± 0.05 % of full scale
Temperature drift ≤ 0.01 % for a 1°C temperature change
Output Ch. 2 on terminal 4-5
Output
Overload limited at 25 mA on a 0 to 650 Ω load 4-20 mA
Factory configurable on an internal shunt 1-5 V
Internal shunt for voltage output 250 Ω (0.1%, 25 ppm)
Ripple content ≤ 30 mVrms
Load effect ≤ 0.1 % of full scale for a 0 to 650 Ω load change
Calibration accuracy ± 0.2 % of full scale
Linearity ± 0.1 % of full scale
Temperature drift ≤ 0.01 % for a 1°C temperature change
Operation mode
Factory set as: 4-20 mA output in source mode on both channels
LED Indicators
Power ON (green)

2-9
2.7.3 µD 323 Analog Input Repeater Fully Floating Output

DC supply
Voltage 24 Vdc -15 % + 20% reverse polarity protected
Current consumption 65 mA @ 24 V, 20 mA output load
75 mA Max
Power dissipation 1.1 W @ 24 V

Input
2 wire transmitter Terminals 11-12
Current source Terminals 12-13
Input range 4-20 mA
Voltage available for transmitter and lines 15.5 V min @ 20 mA
Ripple content ≤10 mVrms
Input resistance on terminals 12-13 70 Ω

Output
Output (source mode)
overload limited at 25 mA on a 0 to 650 Ω load 4-20 mA
user configurable on an internal shunt 1-5 V
Internal shunt for voltage output 250 Ω (0.1%, 25 ppm)
Ripple content ≤10 mVrms (on the 250 Ω load required for
communication)
Load effect ≤ 0.1 % of full scale for a 0 to 650 Ω load change
Output (sink mode from external supply)
overload limited at 25 mA 4-20 mA
Working voltage range 7 to 28 V
Frequency response of comm. channel
Tx to output 0.5 to 40 kHz (within 3 dB, -6 dB@ 100 kHz)
Output to Tx 0.5 to 40 kHz (within 3 dB, -6 dB@ 100 kHz)
Response time 40 ms, 10 to 90% step change
Calibration accuracy ± 0.1 % of full scale
Linearity ± 0.05 % of full scale
Temperature drift ≤ 0.01 % for a 1°C temperature change

Operation mode
Factory set as: 4-20 mA output in source mode
LED Indicators
Power ON (green)

2-10
2.7.4 µD 325/326 Analog Input Repeater

DC supply
Voltage 24 Vdc -15 % + 20% reverse polarity protected
Current consumption 50 mA @ 24 V, 20 mA output load
65 mA max per channel
Power dissipation 0.8 W @ 24 V (per channel)

Input
Voltage available for transmitter and lines 15.5 V min @ 20 mA
Ripple content ≤10 mVrms

Output
Output
Overload limited at 26 mA on a 0 to 650 Ω load 4-20 mA
Factory configurable on an internal shunt 1-5 V
Internal shunt for voltage output 250 Ω (0.1%, 25 ppm)
Ripple content ≤10 mVrms (on the 250 Ω load required for
communication)
Load effect ≤ 0.1 % of full scale change for a 0 to 650 Ω load change
Frequency response of comm. channel
Tx to output 0.5 to 40 kHz (within 3 dB, -6 dB@ 100 kHz)
Output to Tx 0.5 to 40 kHz (within 3 dB, -6 dB@ 100 kHz)
Response time 40 ms, 10 to 90% step change
Calibration accuracy ± 0.1 % of full scale
Linearity ± 0.1 % of full scale
Temperature drift ≤ 0.01 % for a 1°C temperature change

Operation mode
Factory set as: 4-20 mA output
LED Indicators
Power ON (green)

2-11
2.7.5 µD 333/334 Analog Output Driver

DC supply
Input Voltage 7 to 30 Vdc powered by the loop, reverse polarity
protected
Current 4-20 mA loop powered
voltage drop 7 V at 20 mA and 500 Ω load
Open circuit consumption ≤ 0.8 mA @ 24 V
Power dissipation 0.14 W @ 20 mA

Output
Output 4-20 mA on a 0 to 500 Ω load max
Output ripple 100 µA peak to peak
Load effect ≤ 0.2 % of full scale for a 0 to 500 Ω load change
Response time 50 msec, 10 to 90% step change
Calibration accuracy ± 0.1 % of full scale
Linearity ± 0.1 % of full scale
Temperature drift ≤ 0.01 % for a 1°C temperature change

Operation mode
Factory set as: only available, 4-20 mA input and output

2-12
2.7.6 µD 337/338 Powered I/P Driver, Smart Compatible

DC supply
Voltage 24 Vdc -15 % + 20% reverse polarity protected
Current consumption 40 mA @ 24 V, 20 mA output load (per channel)
Power dissipation 0.85 W @ 24 V (per channel)

Input (Safe Area Signal)

Input current 4-20 mA reverse polarity protected
Input drop-out < 4 V with field wiring intact
Input current < 1.2 mA with field wiring open

Output (Hazardous Area Signal)

Output 4-20 mA on a 0 to 750 Ω load max
Output ripple ≤15 mVrms
Load effect ≤ 0.1 % of full scale from 0 to 750 Ω
Response time 50 msec, 10 to 90% step change
Frequency response of comm.
channel
field to input 0.5 to 40 kHz (within 3 dB, -6 dB@ 100 kHz)
input to field 0.5 to 40 kHz (within 3 dB, -6 dB@ 100 kHz)
Calibration accuracy ± 0.1 % of full scale
Linearity ± 0.1 % of full scale
Temperature drift ± 0.01 % /°C

Operation mode
Factory set as: 4-20 mA input and output
LED Indicators
Power ON (green)

2-13
2.7.7 µD 411/412 Switch Repeater Relay Output

µ D411DC / µ D412DC)
DC supply (µ
Voltage 24 Vdc -15 % + 20% reverse polarity protected
Current consumption - model 411 25 mA @ 24 Vdc
30 mA Max
Current consumption - model 412 30 mA @ 24 Vdc
34 mA Max
Power dissipation - model 411 0.6 W @ 24 V
Power dissipation - model 412 0.72 W @ 24 V

µ D411AC / µ D412AC)
AC supply (µ
Voltage – model 411 98 to 264 Vac 50 / 60 Hz
Voltage – model 412 98 to 264 V ac 60 Hz
Voltage – model 412 198 to 264 V ac 50 / 60 Hz
Current 37 mA rms (4.2 VA) @ 115 Vac
75 mA rms (17 VA) @ 230 Vac
Power dissipation 1W
Warning: Limit supply voltage to 250 Vac maximum for I.S. applications !

Input
Contact Voltage free
Proximity sensor NAMUR DIN 19234
Threshold load values
Contact closed or proximity without target < 3 kΩ
Contact open or proximity with target > 5 kΩ

Output
Model 411 1 DPDT (2 SPDT driven in parallel)
Model 412 1 SPDT per channel
Contact ratings 250 Vac @ 2 A (100 VA)
125 Vdc @ 2 A (50 W)
Response time < 40 ms (20 ms typ.)
Max repetition frequency 5 Hz

Operation mode
Fixed as: Contact closed / Proximity without target à Relay Energised
Contact open / Proximity with target à Relay De-energised
LED Indicators
Power ON (green), Output Status (yellow)

2-14
2.7.8 µD 421/422 and µD 421/422 LVAC Switch Repeater Relay Output
with line fault detection

µ D421DC / µ D422DC)
DC supply (µ
Voltage 24 Vdc -15 % + 20% reverse polarity protected
Current consumption – model 421 25 mA @ 24 Vdc
30 mA Max
Current consumption – model 422 30 mA @ 24 Vdc
36 mA Max
Power dissipation - model 421 0.6 W @ 24 V
Power dissipation - model 422 0.72 W @ 24 V

µ D421AC / µ D422AC)
AC supply (µ
Voltage – model 421 90 to 264 Vac 48 / 62 Hz
Voltage – model 422 98 to 264 Vac 48 / 62 Hz (90 to 264 Vac at 60 Hz only)
Current 37 mA rms (4.2 VA) @ 115 Vac
75 mA rms (17 VA) @ 230 Vac
Power dissipation - model 421 0.77 W
Power dissipation - model 422 1W
Warning: Limit supply voltage to 250 Vac maximum for I.S. applications !

µ D421LVAC / µ D422LVAC)
24 VAC supply (µ
Voltage 19.2 to 28.8 Vac 50 / 400 Hz
Current 41 mA rms @ 24.0 Vac
45 mA rms @ 28.8 Vac (Inrush = 0.5 A max, 1 cycle)
Power dissipation - model 421 0.8 W
Power dissipation - model 422 1W

Input
Contact Voltage free
Proximity sensor NAMUR DIN 19234
Threshold load values
wire break (fault for proximitor mode operation) 0 to 0.2 mA
wire short (fault for proximitor mode operation) 6.5 to max mA
Contact open / proximity sensor with target 0.2 to 1.2 mA
Contact closed / proximity sensor without target 2.1 to 6.5 mA

Output
Model 421 1 DPDT (2 SPDT driven in parallel) or
1 SPDT (status) + 1 SPDT (line fault indication)
Model 422 1 SPDT per channel
Contact ratings 250 Vac @ 2 A (100 VA)
125 Vdc @ 2 A (50 W)
Response time 20 msec
Input pulse length/interval > 300 msec (> 20 msec for DC type)
Switching Frequency < 1.5 Hz (< 10 Hz msec for DC type)

Operation mode
User configurable: NO/NC Input with NE/ND relay. Line fault detection signalling.
Factory set as: Contact closed / Proximity without target – Relay Energised
Contact open / Proximity with target – Relay De-energised
LED Indicators
Power ON (green), Output Status (yellow), Input fault (line open or short circuit) (red)

2-15
2.7.9 µD 431/432 Switch Repeater Open Collector Output

µ D431DC / µ D432DC)
DC supply (µ
Voltage 24 Vdc -15 % + 20% reverse polarity protected
Current consumption - model 431 15 mA @ 24 Vdc
24 mA Max
Current consumption - model 432 23 mA @ 24 Vdc
28 mA Max
Power dissipation - model 431 0.36 W @ 24 V
Power dissipation - model 432 0.56 W @ 24 V

µ D431AC / µ D432AC)
AC supply (µ
Voltage 98 to 264 V ac 50 / 60 Hz
Current 37 mA rms (4.2 VA) @ 115 Vac
75 mA rms (17 VA) @ 230 Vac
Power dissipation 1W
Warning: Limit supply voltage to 250 Vac maximum for I.S. applications !

Input
Contact voltage free
Proximity sensor NAMUR DIN 19234
Threshold load values
Contact closed or proximity without target < 3 kΩ
Contact open or proximity with target > 5 kΩ

Output
Optocoupled transistors - model 431 2 transistors driven in parallel
Optocoupled transistors - model 432 1 transistor per channel
Rating 30 V @ 50 mA
Leakage
Max
50 µA
Typical
5 µA
Response time (max frequency 1 kHz) 200 µs
Saturation voltage 1 V max
Zener protection for inductive loads

Operation mode
Fixed as: Contact closed / Proximity without target à output transistor conducting (“closed” status)
Contact open / Proximity with target à output transistor not conducting (“open” status)
LED Indicators
Power ON (green), Output Status (yellow)

2-16
2.7.10µD 441/442 Switch Repeater Open Collector Out with line fault detection

µ D441DC / µ D442DC)
DC supply (µ
Voltage 24 Vdc -15 % + 20% reverse polarity protected
Current consumption - model 441 20 mA @ 24 Vdc
28 mA Max
Current consumption - model 442 28 mA @ 24 Vdc
34 mA max
Power dissipation - model 441 0.4 W @ 24 V
Power dissipation - model 442 0.7 W @ 24 V

µ D441AC / µ D442AC)
AC supply (µ
Voltage 98 to 264 Vac 50 / 60 Hz
Current 37 mA rms (4.2 VA) @ 115 Vac
75 mA rms (17 VA) @ 230 Vac
Power dissipation - model 441 0.77 W
Power dissipation - model 442 1W
Warning: Limit supply voltage to 250 Vac maximum for I.S. applications !

Input
Contact voltage free
Proximity sensor NAMUR DIN 19234
Threshold load values
wire break, typ. (fault for proximitor mode operation) Ibreak< 50 µA
wire short typ. (fault for proximitor mode operation) Rshort < 100 Ω
contact open / proximity sensor with target 0.2 < I < 1.2 mA
contact closed / proximity sensor without target 2.1 < I < 6.5 mA

Output
Optocoupled transistors - model 441 2 transistors driven in parallel or
1 transistor (status) + 1 transistor (line fault indication)
Optocoupled transistors - model 442 1 transistor per channel
Rating 30 V @ 50 mA
Leakage
Max
50 µA
Typical
5 µA
Response time (max frequency 2 150 µsec
kHz)
Saturation voltage 1 V max
Zener protection for inductive loads

Operation mode
User configurable: Contact or Proximity sensor input. NO/NC Input with NO/NC optocoupler output. Line
fault detection signalling.
Factory set as: Contact closed / Proximity without target à output transistor conducting (“closed” status)
Contact open / Proximity with target à output transistor not conducting (“open” status)
LED Indicators
Power ON (green), Output Status (yellow), Input fault (line open or short circuit) (red)

2-17
2.7.11 µD
µ 471/472 Loop Powered Solenoid / Alarm Driver

DC supply
Input voltage 21.5 to 30 Vdc Powered by the loop
Current (per channel) 20 mA (40 mA max) With open output
70 mA With 300 Ω load
75 mA With shorted output
Inrush current 0.8 A
0.5 ms
Power dissipation (per channel) 1.2 W @ 24 V, 300 Ω load

Input
Contact 21.5 to 30 Vdc
Controlled by external dry contact or open collector,
in positive or negative wire

Output
Response time @ 300 Ω load
turn on time 1 ms
turn-off time 8 ms
max operating frequency 50 Hz
Output characteristic:

Operation mode
Inherently fail safe, supply failure in the barrier forces the output to zero (solenoid de-energises)
LED Indicators
Power ON (green), Output Status Rout ≤ 10 KΩ (yellow)

2-18
3 System Operation

3.1 General description of the system

An Intrinsically Safe system is composed by an assembly of intrinsically safe apparatus, associated
apparatus and interconnecting cables, where the following definitions apply:
• Simple Electrical Apparatus
Apparatus in which neither of the following electrical parameters are exceeded: 1.2 V 0.1 A
(Generated) 20 mJouIes (Stored) 25 mW (Dissipated), in this case the Apparatus does not
require any certificate or labeling.
(Typical examples can be Thermocouples, Resistance Temperature Detectors, Contacts, Strain
Gauges, Light Emitting Diodes, photocells).
• Intrinsically Safe Apparatus
Apparatus in which all circuits are intrinsically safe. It must have suitable approval for the
hazardous (classified) location where it will be mounted and must have a control drawing that
specifies safety parameters: Vi; Ii; Pi; Ci; Li (i.e. Proximity Switches, Transmitters, Active
Sensors, magnetic pick-up) must be Intrinsically Safe Certified.
• Associated Apparatus
Apparatus in which circuits may affect the energy in the intrinsically safe circuits to which it is
connected. It must have suitable approval for connection to devices in the hazardous (classified)
location. Associated apparatus safety parameters are specified as : Vo; Io; Po; Co; Lo.
Associated apparatus and control room equipment shall not be powered or generate any voltage
greater than 250 Volts.

3.2 System design considerations

The system must be evaluated under the "entity concept" where the following rules apply: To determine
acceptable combination of intrinsically safe apparatus and connected associated apparatus the following
conditions must be valid:
Vi> Vo
Ii > l o
Pi > Po
The length of interconnecting cable shall be determinate in accordance with the maximum allowed
parameters by the associated apparatus according to the expression:
Ccable < Co - Ci
Lcable< Lo - Li

3.3 Wiring of intrinsically safe circuits

Installation shall be in accordance with Intrinsic Safety standards and installation rules (eg. ANSI/ISA RP
12.6), applicable in the Country where the application is made. Intrinsically safe circuits shall be so
identified. Color coding may be used for identification if the color used is light blue and no other wiring is
color coded light blue. Other identification means may be for example: signs, tags, markings which shall be
visible after installation.
Wiring of intrinsically safe circuits shall be positively separated from non intrinsically safe wiring (such as
power wiring) by one of the following methods:
• Using separated raceway
• Providing an insulating or grounded metal partition
• Spacing of at least 50mm and separately tied down
Different intrinsically safe circuits shall not be run in the same multiconductor cable unless at least 0.25mm
thick insulation is used on each conductor.
Cables, raceways or conduits used to contain intrinsically safe circuits must not transmit flammable
atmosphere from hazardous to non hazardous location. Otherwise they must be sealed or vented.

3-1
3.4 Grounding information
Grounding of intrinsically safe circuits is not required when connected to associated apparatus having
galvanic isolation between intrinsically safe circuit and all the other circuits. Should grounding be necessary,
for functional reasons, only one point of the intrinsically safe circuit must be grounded.
In case of using shielded cables, proper shield grounding (if needed) shall be provided at one point only.
Metallic enclosures of field devices must be grounded.

3-2
4 Installation and Configuration
The installation must be performed by qualified personnel, it must comply with the relevant national and
international standards (e.g. BS5345 Pt. 4, DIN VDE 165, ISA RP-12.6) and it must conform to established
installation rules.

4.1 Unpacking
Upon receipt of the materials it is recommended to check the integrity of packing and their contents.
In case of damage due to shipping, the receiver should promptly and properly report to the shipper
supplying all necessary information.
If units are not for immediate use is strongly suggested that you verify that all the characteristics listed on
the instrument label meet order specifications (model, supply voltage and frequency, input/output range,
certification, tag, and so on) as well as the actual application requirements
If not installed, the equipment should be stored in their sealed original package, in a place that does not
exceeds the environmental specifications supplied in Section 2.6.

4.2 Configuration
For individual modules configuration please refer to Section 5.
To configure the modules with jumpers, you have to lift the front cover to get access to the jumpers.

4-1
4.3 Installation
The unit can be mounted in two different ways
• on a 35 mm DIN rail (top hat) through the tabs located on the base of the unit (don’t extract
tabs)

• on a surface/panel by fully extracting the tabs and using self-threading screws.

4-2
The function and location of each termination need first to be identified (please refer to section 5 for details
about the connections of each module) and then connections must be made using a wire with a section of
2.5 mm2 max (14 AWG).
The blue colour of terminal blocks identifies the hazardous side connections. Wires of this side must be
segregated according to standard BS5345 Pt. 4, ISA RP-12.6 or to other applicable national regulations.

To properly identify each signal Elcon supplies labels (code PN 601136 and PN 601137) that can be
attached to the unit. All isolators must be properly protected against dirt, dust and thermal/mechanical
stresses.
The risk of casual contact should be minimised and any unauthorised unit modification should be avoided.
Be careful not to overtight the screws. The wire is clamped by plate connections.
The screw are M3 type and the tightening torque suggested is 0.50 ÷ 0.60 Nm.

4.4 EMC Guidelines

All µD isolators has been carefully tested to ensure the compliance with the specified EMC standards. The
verifications were either carried out by certified test houses or internally by using equivalent test set-ups.
Comprehensive reports were always used to register test results.
The compliance with the applicable generic standards is not however such to always guarantee the proper
unit behaviour regardless of the operating environment and of the specific system configuration. The
following guidelines are useful minimise this type of risk:
• all the units in the system should comply with the mandatory EMC standards;
• the µD emission level is intrinsically low, no special care should be required;
• in a normal industrial environment, screened cables are not mandatory;
• when very strong radiated fields are expected, properly grounded screened cable are
recommended;
• use proper shield grounding techniques, avoid ground loops as much as possible;
• supply lines voltage dips outside specifications should be avoided;
• for AC connected units, the mains should be decoupled from relevant, inductive switching loads;
• don’t run connection cables side by side with potentially noisy system wiring;
• use proper system level grounding end earthing techniques.

4-3
4.5 Heat Dissipation and Thermal Behaviour
Operating Temperature definition
Elcon Isolators are small, highly integrated electronic devices, which permit high-density installations.
Although Elcon products benefit from special low-power design techniques, it can be necessary to take into
account the internal power dissipation when dealing with operating temperature issues.
For this reason, operating temperature limits are specified for modules in a “reference condition”, and
namely:
- open air mounting, no ventilation;
- wall-mounted, 8 position TB fully equipped with identical units;
- horizontal mounting;
The temperature measured immediately beneath the group of units is then applicable operating
temperature.

Operating Temperature range

The range specified for Elcon products is generally 0–60 °C, with a typical 0.01%/°C stability for analogue
models.
Derating could however apply for certain models, please check the relevant specifications.
The operating temperature limits are maximum ratings. When they are passed, specifications are no more
guaranteed and permanent faults may occur. Continuous operation near the upper temperature limit is not
recommended because it reduces the product life.

Operating Temperature assessment

This section provides some general guidelines to estimate the units operating temperature in a typical
application. When you can keep a reasonable safety margin, no thermal analysis is generally not required.
In the following, the assumption is that the units are mounted within a cabinet.
Recommended temperature limits:
- ambient temperature (outside the cabinet) not higher than 40 °C;
- average air temperature (within the cabinet) not higher than 55 ° C;
- air temperature out from the units venting openings not higher than 80 ° C;
When you think it likely that these limits are passed for extended periods of time, you should perform a
more careful thermal analysis, possibly considering the MTBF implications.
Horizontal mounting:
This type of installation is similar to the “reference condition”, so the temperature just beneath the units is to
be estimated. With a reasonable vertical spacing (around 20 cm / 8 inches) or with some ventilation, the
temperature beneath the units is likely to be close to the average temperature within the cabinet. With
reduced spacing and no ventilation, a safety margin of 10 °C is recommended, unless you can afford to
measure the real temperature beneath the units.
Vertical mounting:
Because this is a less favourable condition for power dissipation, it is recommended that forced ventilation
is used in such a way that a steady air flow is provided on one side of the vertical columns of units. In this
case, the temperature of the air flow –which is the applicable operating temperature- is close to the average
temperature within the cabinet.
If forced ventilation is not possible, it is recommended that the power dissipation of each unit is estimated
within the proposed model mix layout. In most situations, it is acceptable to perform an average power
dissipation assessment, with 70% of digital channels in the energised state and 70% of the analogue
channels operating at full scale.
The following table can be used to assess the temperature situation of a given model when in a vertical
mounting situation. The 70% power dissipation figures are summarised in the following section.
70% Power Dissipation Applicable operating temperature
0-1 W : air temperature immediately below the row (no derating)
1-2 W : air temperature immediately below the row plus 20 °C (derating)
2-3 W : forced ventilation mandatory

4-4
Power Dissipation Summary
The power dissipation specified for each model is shown in the table following (dividing by 2, you can get
the single channel dissipation). The specified figures are at 24V, 20 mA (or energised status) and nominal
loads. The final column provides the 70% power dissipation figures.

Isolator Channels Nominal power 70% power

µD 301 1 1.25 W 0.9 W
µD 321 1 1.7 W 1.2 W
µD 323 1 1.2 W 0.8 W
µD 326 2 1.6 W 1.1W
µD 334 2 0.3 W 0.2 W
µD 338 2 1.7 W 1.2 W
µD 411/412 AC 1-2 1W 0.7 W
µD 411/412 DC 1-2 0.7 W 0.5 W
µD 421/422 AC 1-2 1W 0.7 W
µD 421/422 DC 1-2 0.7 W 0.5 W
µD 421/422 LVAC 1-2 1W 0.7 W
µD 431/432 AC 1-2 1W 0.7 W
µD 431/432 DC 1-2 0.6 W 0.4 W
µD 441/442 AC 1-2 1W 0.7 W
µD 441/442 DC 1-2 0.7 W 0.5 W
µD 472 2 2.4 W 1.68 W

Temperature Accuracy
The accuracy provided in the standard Elcon specifications for analogue units is at an operating
temperature of 23 °C, after a 15 minutes warm-up and in the “reference conditions” as described at the
beginning of section 4.9. When a different operating temperature is applicable -according to the discussion
in the previous sections- you should take into account the thermal drift.
As for digital units (i.e. ON/OFF devices) no thermal drift is usually specified.

4.6 Cabinet Heat-Dissipation

For integration into cabinets, or other enclosures that restrict free air movement, the expected temperature
rise within the enclosure should be calculated. Normal practice is to design for a 10 to 20 °C ambient
temperature rise inside a cabinet. The cabinet should be provided with top and bottom louvers to provide
convection air flow. The use of cabinet fans is recommended for high module density installations.

Effects of operating temperature

The failure rate probability of any electronic component has an exponential relation to the increase of its
operating temperature (Arrhenius theory). For instance, a change from 25 to 50 °C (77 to 122 °F) can cause
a failure rate ten times higher, with consequential downgrading of components and of calibration stability.
The operating temperature of electronic circuits should be as low as possible by placing installations in a
cool or conditioned environment.

4-5
Cooling of control cabinets
The installation of electronic equipment in a control cabinet determines an adverse increase in its operating
temperature proportional to the dissipated power. It is important that optimum power dissipation in the
cabinet as well as the elimination of the produced heat be provided, so as to minimise the increase above
the ambient temperature. An obvious measure consists of installing the equipment which is mostly affected
by temperature in the bottom portion of the cabinet, where temperature can be 15-20 °C (27-36 °F) lower
than in the upper part.
The most common panel cooling methods, in increasing order of effectiveness, are:
a) Natural convection
b) Forced ventilation
c) Air conditioning

a1) Natural convection in closed panels:

It is the least effective and should used only when the dissipated power is moderate and when the system
operates in a dusty or aggressive (harsh) environment. The temperature rise and dissipated power for a
given temperature rise are expressed by the following formulas:
P
∆t = and P = ∆t ⋅ S ⋅ K
S⋅K
∆t (°C) = temperature rise
P (W) = dissipated power
S (m2) = heat exchanging surface
K (W/m2°C) = thermal conductivity coefficient (K = 5.5 for painted steel sheets)
As an example suppose, a typical 600 x 2000 x 600 mm cabinet installed with the four sides free (heat
exchanging surface = 5.2 m2) and considering a temperature rise ∆t = 10 °C (18 °F), the possible power
dissipation in the cabinet is: P = 10 x 5.2 x 5.5 = 286 W

a2) Natural convection in open panels:

In this case, in addition to the heat exchange with panel sides, heat is removed by cool air flowing through
the equipment. Inlet and outlet ports in the lower and upper ends of the cabinet are required and the air flow
path must be kept free from obstacles. For a properly engineered cabinet like the one considered in A1, the
improvement can reach 100%.

4-6
b1) Forced ventilation with heat exchanger in closed panels:
It can be used when either the “harsh” environments or the high dissipated power don’t allow for natural
convection. A heat exchanger with a fan pulls the air into the cabinet and forces it into the heat exchange
plates that are cooled by the external ambient air moved by a second fan. By using such an exchanger,
provided it is efficient and well maintained, the allowable power dissipation for equal temperature rise can
be 5 to 6 times higher than in A1.

b2) Forced ventilation in open panels:

Here filtered air is taken from the bottom cabinet openings by one or more fans creating an air flow through
the equipment which exits at the top of the cabinet. Fan dimensioning must be such to guarantee the
required air flow, as expressed by the formula:
3.1⋅ P
Q=
∆t
Q = required minimum air flow in m3/h
P = power in watts to be dissipated in the cabinet
∆t (°C) = temperature rise of the cabinet
For the example cabinet (neglecting the cooling contribution of the side surfaces) for a ∆t = 10 °C (18°F)
and a power of 1000 W the minimum required air flow is
3.1⋅ 1000
Q= = 310m 3 / h
10

c) Air conditioned cabinets:

This approach offers the advantage of obtaining a cabinet temperature equal or even lower than the
ambient temperature, becoming the ideal solution for hot climates. A specific refrigerating system can be
used or, when applicable, the existing air conditioning system can be used also for cabinet conditioning. In
each case the refrigerator size is related with the amount of heat to be removed due to the internally
dissipated power.

4-7
5 Unit Operation

5.1 µ D 301
Functional description
Accepts TC (also grounded), RTD (2, 3 or 4 wires), potentiometer, mV, Volt and mA field inputs and
converts these to a linearised fully isolated analogue signal in the Safe Area. The microprocessor based
design permits easy user configuration for input type, input/output ranges, burnout direction and other
options via DIP switches or RS-232 serial port. A high accuracy A/D converter provides high performances
and completes the reliable design.
A Windows 95® based Software package (CONF1) is available for unit configuration through the RS232 port
to select specific operating ranges, additional sensor types and other features.
A voltage output version is available as a factory configuration option.
The µD301 unit is a versatile, microprocessor based device intended to interface with the low-level sensor
located within an hazardous area. The analog output is isolated from the power supply (24 Vdc) and is
updated each 100 ms.
The following sensor types are supported:
Thermocouple sensors: (S, R, B, E, J, K, T, N, L)
RDT temperature sensors: (Ni100, Pt100,Pt50, Pt10,Cu100,Cu50,Cu10,Pt100Gost, Pt50 Gost and Pt10 Gost; 2/3/4 wires)
Current-output devices: (+/- 20 mA, passive input)
Voltage-output devices: (+/- 100 mV and +/- 10 V ranges)
Potentiometric sensors: (from 200 ohm to 10 Kohm)
Sensors can works within the following operating limits:

SENSOR TYPE RANGE UNIT NOTE

Thermocouple S -50 +1750 °C
Thermocouple R -50 +1750 °C
Thermocouple B +0 +1800 °C
Thermocouple E -200 +1000 °C
Thermocouple J -200 +750 °C
Thermocouple K -200 +1300 °C
Thermocouple T -200 +400 °C
Thermocouple N -200 +1300 °C
Thermocouple L -200 +800 °C
RTD Pt100 -200 +850 °C α=0.3850
RTD Pt50, Pt10 -200 +850 °C α=0.3850 (only with configurator)
RTD Ni100 -60 +180 °C α=0.6170
Cu100
RTD Cu50 -200 +200 °C α=0.4280 (only with configurator)
Cu10
Pt100 Gost,
RTD Pt50 Gost -200 +1100 °C α=0.3910 (only with configurator)
Pt10 Gost
Current - mA -20 +20 mA (overload at +/- 24 mA)
Voltage - mV -100 +100 mV (overload at +/- 120 mV)
Voltage - Volt -10 +10 V (overload at +/- 12 V)
Potentiometer 0 100 % (overload not applicable)

5-1
The input operating range is defined by a zero value and a span value. The operating range can be set
either through dip-switches or by serial line use. The operating range must always be within the allowed
sensor operating limits. The input zero is usually associated with a 4 mA output, while (zero+span) is
associated with 20 mA output. The digital output doesn’t change when the input operating range is modified.
To avoid accuracy limitations, it is recommended to avoid to set the span below the specified minimum
limits.
The input operating range is normally set through dip-switches with reference to a °C table. It is however
possible to select an °F table, obtained by conversion and truncation to 0 of the less significant digit. When
you set the operating range by the serial line any difference between the °C and °F settings disappears,
because the zero and span values can be precisely set to any desired temperature.
The output range can be set to either 0-20 mA or 4-20 mA; by serial line use, it is also possible to set the
reverse analog ouput mode.

Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of section 4.3.

Screw terminal nmbr. Used for

1 Safe area source +
2 Safe area source -
7 DC supply +
8 DC supply -
3,4,5,6,9 not used
11 Hazardous area TC/ mV +, RTD, Pot
12 Hazardous area Common
13 Hazardous area RTD 3W-4W
14 Hazardous area RTD 4W-Pot
15 Hazardous area V+
16 Hazardous area mA+

5-2
Configuration options
Available dip-switch configuration options (please refer to the installation sheet for more details):
Input operating range (default: zero = 0°C, span = 500°C)
Output operating range (default: 4-20 mA)
Sensor type (default: K thermocouple)
Sensor error action (default: upscale burnout))
°C/°F mode (default: °C)
HW selections (default: normal)

No unit power-down is required to operate switches.

The °F mode sets the table for input operating range configuration in °F units.
The other options for HW selection are “3 wire RTD” and “potentiometer” sensors:
Available serial line configuration options:
Additional input sensor types
Output operating range (any value within the allowed range can be selected)
Sensor type (the HW selections” dip-switches must be set manually)
Sensor error action (Up scale, Down scale or frozen output value)
“Reverse” analog output mode.
CJC temperature forced to a fixed value.
Warning: It is not possible to set - at the same time - some configuration parameters through the dip-
switches and some others through the serial line.

5-3
Application Guidelines
The red LED in a fast blinking status (200 ms “on” / 200 ms “off”) indicates a severe internal error. If this
happens frequently, the unit is faulty and is to be returned. If the error disappears, the blinking stops after
one minute.
The red LED in a slow blinking status (2 s “on / 1 s “off”) indicates a problem with the serial line, which
could result from its improper connection or usage. If the error disappears, the blinking stops after 20
seconds.
The red LED in a fixed on status indicates a configuration error, an overload situation or a burn-out
condition. The unit is not faulty. The LED goes off when the error disappears
NOTE: for more details about unit configuration and operating modes a specific “µD Technical Manual”
(109/4B PN. 991165) is available from Elcon on request.

NOTE: when vertically mounted µDin 301 isolators are closely packed in an enclosure or cabinet there is
naturally a reduction in the efficiency of cooling due to the small surface area exposed and limited air flow. If
the forced ventilation is not sufficient a significant temperature rise can occur around the isolators with the
result that a further deviation from the stated nominal accuracy of 0.01%degC can occur due to this thermal
drift. Consideration should be given to providing a space of at least 5mm between modules for beast
ambient temperature stability or when the cooling air flow is restricted.”

5-4
5.2 µ D 321

Functional description
Provides a fully floating supply to power an Intrinsically Safe 2/3 wire transmitter or current source located in
a hazardous area.
The input is repeated as two independent outputs to a safe area load. Output on Ch. 1 is fully floating
(i.e. isolated from supply), and user configurable as sink or source. The isolator is fully compatible with
Smart transmitters allowing bi-directional communications through safe area.
The isolator is fully compatible with Smart transmitters (e.g. HART) and allow bi-directional communications
through safe area output Ch. 1.
Output on Ch. 2 is common to the supply and isolated from input, making it ideal for monitoring
applications. It doesn't support "smart" communication.

Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of section 4.3.

Screw terminal nmbr. Used for

1 Safe area sink / source +, Ch. 1
2 Safe area sink / source -, Ch. 1
4 Safe area source +, Ch. 2
5 Safe area source -, Ch. 2
7 DC supply +
8 DC supply -
3,6,9 not used
11 Hazardous area 2 wire (Smart) TX +
12 Hazardous area common
13 Hazardous area mA transmitter
14,15,16 not used

5-5
Configuration options
The Channel 1 output can be configured as
• source 4-20 mA
• source 1-5 V
• sink 4-20 mA

The Channel 2 output can be configured as

• source 4-20 mA (standard configuration)
• source 1-5 V (factory configuration)

The configuration is performed in the following way:

• lift the plastic protection that covers on the front the device
• set the jumpers according to the figure below

Application Guidelines
The two outputs have different characteristics from the application point of view. Ch. 1 is fully isolated from
the supply and must be used when ground loop should be avoided. Ch.2 on the contrary is not isolated from
the power supply and cannot be used therefore in such an application.
Ch.2 moreover is less precise and the error introduced by the isolator must be kept in mind when using this
channel.
The specified operating range is 4-20 mA, but the unit can operate near 0 mA with reduced accuracy.
Please contact Elcon for more details. You should remember that Ch. 2 can never operate in sink mode. At
the field side, the equivalent circuit (before current limitation) is around 21V/300 Ω.
A separately power current source device can be connected on the 12 & 13 terminals, which in fact act as a
sink input. When considering three-wire transmitter (connection on 11, 12 & 13 ) always check required
supply voltage and current operating range.
An Hand Held Configurator (HHC) for smart transmitters configuration can be connected either at the SA or
at HA side (in this case you need and IS certified HHC). When in SA, a minimum load of 250 Ω must be
present on the current loop and the HHC must be connected across this load. When the PLC/DCS has a low
current sense resistor, you need to insert an external series resistor to get proper communication.

5-6
5.3 µ D 323
Functional description
Provides a fully floating supply to power an Intrinsically Safe 2/3 wire Transmitter or current source located
in a hazardous area. The input is then repeated as an output to a safe area load and is fully floating (i.e.
isolated from supply), and user configurable as sink or source.
The isolator is fully compatible with Smart transmitters and allows bi-directional communications through
safe area output.

Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of section 4.3.

Screw terminal nmbr. Used for

1 Safe area sink / source +
2 Safe area sink / source -
7 DC supply +
8 DC supply -
3,4,5,6,9 not used
11 Hazardous area 2 wire (Smart) TX +
12 Hazardous area common
13 Hazardous area mA transmitter
14,15,16 not used

5-7
Configuration options

The output is fully floating, isolated from input and supply and user configurable as
• source 1-5 V
• source 4-20 mA
• sink 4-20 mA

The sink/source configuration is obtained by positioning the available jumpers as shown in figure.
The configuration is performed in the following way:
• lift the plastic protection that covers on the front the device
• set the jumpers according to the figure below

Application Guidelines
Refer to µD321 guidelines, remembering that Ch. 2 is not available.

5-8
5.4 µ D 325/326

Functional description
Provides a fully floating supply to power an Intrinsically Safe 2 wire Transmitter located in a hazardous area.
Each input is repeated as an independent output to a safe area load. Outputs are isolated from inputs.
Fully compatible with Smart transmitters allowing bi-directional communications through safe area outputs.

5-9
Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of section 4.3.

Mod. 325:

Screw terminal nmbr. Used for

1 Safe area source +
2 Safe area source -
7 DC supply +
8 DC supply -
3,4,5,6,9 not used
11 Hazardous area 2 wire (smart) TX +
12 Hazardous area 2 wire (smart) TX -
13,14,15,16 not used

Mod. 326:

Screw terminal nmbr. Used for

1 Safe area source +, Ch. 1
2 Safe area source -, Ch. 1
4 Safe area source +, Ch. 2
5 Safe area source -, Ch. 2
7 DC supply +
8 DC supply -
3,6,9 not used
11 Hazardous area 2 wire (smart) TX+, Ch. 1
12 Hazardous area 2 wire (smart) TX-, Ch. 1
14 Hazardous area 2 wire (smart) TX+, Ch. 2
15 Hazardous area 2 wire (smart) TX-, Ch. 2
13,16 not used

Configuration options
No user configuration is available for this device, the standard output is source.
The output can be factory configured to 1-5 V output, on request.

Application Guidelines
As for smart communication, please refer to µD321 guidelines. You should remember that the unit can
never operate in sink mode.

5-10
5.5 µ D 333/334
Functional description
Repeats a 4-20 mA input signal from DCS, PLC or other control elements to drive I/P converters,
electrovalve actuators and displays located in a hazardous area. Each channel is loop powered, with only 7
Volts drop , at 20 mA. Designed for high integrity applications, where line fauIts such as open circuit of field
cables are monitored. A field open circuit will present a high impedance (less than 0.8 mA) to the DCS or
control device input to allow alarm conditions to be monitored. Loop power configuration guarantees fail-
safe operation in case of supply or control element failure.

5-11
Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of section 4.3.

Mod. 333:

Screw terminal nmbr. Used for

1 Safe area sink +
2 Safe area sink -
3,4,5,6,7,8,9 not used
11 Hazardous area source +
12 Hazardous area source -
13,14,15,16 not used

Mod. 334:

Screw terminal nmbr. Used for

1 Safe area sink +, Ch. 1
2 Safe area sink -, Ch. 1
4 Safe area sink +, Ch. 2
5 Safe area sink -, Ch. 2
3,6,7,8,9 not used
11 Hazardous area source +, Ch. 1
12 Hazardous area source -, Ch. 1
14 Hazardous area source +, Ch. 2
15 Hazardous area source -, Ch. 2
13,16 not used

Configuration options
No user configuration is available for this device.

Application Guidelines
As any other loop powered isolator, the µD 333/334 has a fail safe behaviour, i.e. if there is a power supply
fault, the isolator output is de-activated.
The two µD334 channels are completely isolated one from the other. This means that single-loop integrity is
preserved also with the two-channel version. A field open circuit can be detected by monitoring the safe
area current ( < 0.8 mA).

5-12
5.6 µ D 337/338
Functional description
Repeats a 4-20 mA input signal from a control system to drive I/P converters, electrovalve actuators and
displays located in a Hazardous Area.
Designed for use with smart I/P and valve positioners, each isolated channel has a low input impedance and
allows complete freedom of connection in the input loop due to the high common mode compliance with
respect to the supply.
A field open circuit presents a high impedance to the control device input.

5-13
Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of section 4.3.

Mod. 337:

Screw terminal nmbr. Used for

1 Safe area sink +
2 Safe area sink -
7 DC supply +
8 DC supply -
3,4,5,6,9 not used
11 Hazardous area source +
12 Hazardous area source -
13,14,15,16 not used

Mod. 338:

Screw terminal nmbr. Used for

1 Safe area sink +, Ch. 1
2 Safe area sink -, Ch. 1
4 Safe area sink +, Ch. 2
5 Safe area sink -, Ch. 2
7 DC supply +
8 DC supply -
3,6,9 not used
11 Hazardous area source +, Ch. 1
12 Hazardous area source -, Ch. 1
14 Hazardous area source +, Ch. 2
15 Hazardous area source -, Ch. 2
13,16 not used

Configuration options
No user configuration is available for this device.

Application Guidelines
The barrier is suitable to drive I/P converters or similar current driven device in Hazardous Area. Due to the
totally isolation and low voltage drop-out inputs, the unit µD 338 is suitable to perform a single input-dual
outputs connection with an external cross wire as shown in figure

An Hand Held Configurator (HHC) for smart driver configuration can be connected either at the SA and at
HA side (in this case you need an IS certified HHC). When in SA, HHC must be connected on input
terminals and must be verified that control device has an HART compatible output characteristic. Otherwise
insert an appropriate filter from valve manufacturer between the control device and the unit.
A field open circuit presents a high impedance to the control device input to allow alarm conditions to be
monitored.

5-14
5.7 µ D 411/412
Functional description
Repeats the status of a voltage free contact or intrinsically safe proximity sensor located in a hazardous
area to a DPDT (Model 411) or 1 SPDT per channel (Model 412) relay output to a safe area.
The DPDT 411 function is obtained by driving in parallel 2 SPDT relays.
Fixed configuration to suit the majority of applications.

(non energised status is shown in both drawings)

5-15
Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of section 4.3.
Mod. 411:
Screw terminal nmbr. Used for
1 Safe area DPDT Relay - open, Out 1
2 Safe area DPDT Relay - common, Out 1
3 Safe area DPDT Relay - closed, Out 1
4 Safe area DPDT Relay - open, Out 2
5 Safe area DPDT Relay - common, Out 2
6 Safe area DPDT Relay - closed, Out 2
7 DC or AC Supply +
8 DC or AC Supply -
9 not used
11 Hazardous area Proximity Sensor / Contact +
12 Hazardous area Proximity Sensor / Contact -
13,14,15,16 not used

Mod. 412:
Screw terminal nmbr. Used for
1 Safe area SPDT Relay - open, Ch. 1
2 Safe area SPDT Relay - common, Ch. 1
3 Safe area SPDT Relay - closed, Ch. 1
4 Safe area SPDT Relay - open, Ch. 2
5 Safe area SPDT Relay - common, Ch. 2
6 Safe area SPDT Relay - closed, Ch. 2
7 DC or AC Supply +
8 DC or AC Supply -
9 not used
11 Hazardous area Proximity Sensor / Contact +, Ch. 1
12 Hazardous area Proximity Sensor / Contact -, Ch. 1
14 Hazardous area Proximity Sensor / Contact +, Ch. 2
15 Hazardous area Proximity Sensor / Contact -, Ch. 2
13,16 not used

Configuration options
No user configuration is available for this device. The input/output relationship is as follows:
Input Output Status LED
switch status: open or
de-energised relay OFF
proximity sensor with target
switch status: closed or
Energised relay ON
proximity sensor without target

Application Guidelines
The units supply the required power to field contact/sensor; no additional power supply is required. A "open"
contact status is equivalent to the status of an object "near" to the proximity sensor. When the input is
"closed", the status LED is "lit" and the output relays are energised, and the converse. To get the desired
normally closed or open output status, select the proper SPDT relay output. On the single-channel unit, the
two output relays are always driven in parallel. The dual channel unit (µD412) is not specified for 50 Hz
mains operation.

5-16
5.8 µ D 421/422 and µ D 421/422 LVAC
Functional description
Repeats the status of a voltage free contact or intrinsically safe proximity sensor in a hazardous area to a
DPDT (Model 421) or 1 SPDT per channel (Model 422) relay output to a safe area.
Additionally the 421 is user configurable for 1 SPDT status output plus 1 SPDT for line fault detection alarm,
with LED indication. The 422 has LED line fault detection indication only.
The DPDT 421 function is obtained by driving in parallel 2 SPDT relays.
The line fault detection feature (primarily used with proximity sensors) de-energises the output relay in case
of line opening or short.

(non energised status is shown in both drawings)

5-17
Connection Information
Please refer to the electrical schematics and to the screw terminal drawing of section 4.3.

Mod. 421:

Screw terminal nmbr. Used for

1 Safe area SPDT Relay - open, status out
2 Safe area SPDT Relay - common, status out
3 Safe area SPDT Relay - closed, status out
4 Safe area SPDT Relay - open, fault out
5 Safe area SPDT Relay - common, fault out
6 Safe area SPDT Relay - closed, fault out
7 DC or AC Supply +
8 DC or AC Supply -
9 Not used
11 Hazardous area Proximity Sensor / Contact +
12 Hazardous area Proximity Sensor / Contact -
13,14,15,16 Not used

Mod. 422:

Screw terminal nmbr. Used for

1 Safe area SPDT Relay - open, Ch. 1
2 Safe area SPDT Relay - common, Ch. 1
3 Safe area SPDT Relay - closed, Ch. 1
4 Safe area SPDT Relay - open, Ch. 2
5 Safe area SPDT Relay - common, Ch. 2
6 Safe area SPDT Relay - closed, Ch. 2
7 DC or AC Supply +
8 DC or AC Supply -
9 Not used
11 Hazardous area Proximity Sensor / Contact +, Ch. 1
12 Hazardous area Proximity Sensor / Contact -, Ch. 1
14 Hazardous area Proximity Sensor / Contact +, Ch. 2
15 Hazardous area Proximity Sensor / Contact -, Ch. 2
13, 16 Not used

Mod. 422

5-18
Configuration options (model 421)
The input/output relationship can be configured and the two relays are normally driven in parallel. If the
supply voltage falls below the minimum, both relays are de-energised.
The input fault-detection capability is available when a proximity sensor or a voltage-free contact is used
with proper termination resistors installed (see Application Guidelines).
The fault sense circuit detects any short-circuit or open-circuit condition of the inputs (hazardous area).
When such a faulty connection is detected, the associated LED is set ON and both relays are de-energised.
Relay 2 can be configured as a fault output (normally energised when no fault is detected).
To configure the module:
• turn the device power off
• do not set the switches to any position other than those specified below
• lift the plastic lid that covers the switches
• choose the feature you wish to set from the table below and set the switches as shown:

Input / Output relationship Output Relay Switch settings

Switch status: open or
energised S1 OFF
proximity sensor with target
Switch status: closed or S2 ON
de-energised
proximity sensor without target
Switch status: closed or
energised S1 ON
proximity sensor without target
Switch status: open or S2 OFF
de-energised
proximity sensor with target

Fault detection Relevant switches Setting

Enabled S3 ON
Disabled S3 OFF

Feature Relevant switches Setting

The two output relays are driven in S4 OFF
parallel and follow the input status S5 ON
S6 OFF
S7 OFF
S8 ON
Relay 1 follows the input status S4 ON
Relay 2 used as fault detection S5 OFF
output S6 OFF
(option to be used only when fault detection S7 ON
enabled) S8 OFF

N.B.: S6 must be always in the OFF status.

5-19
Configuration options (model 422)
The input/output relationship can be configured. If the supply voltage falls below the minimum, both relays
are de-energised.
The input fault-detection capability is available when a proximity sensor or a contact voltage-free is used
with proper termination resistors installed (see Application Guidelines).
The fault sense circuit detects any short-circuit or open-circuit condition of the inputs (hazardous area).
When such a faulty connection is detected, the associated LED is set ON and the related relay is de-
energised.
To configure the module:
• turn the device power off
• do not set the switches to any position other than those specified below
• lift the plastic lid that covers the switches
• choose the feature you wish to set from the table below and set the switches as shown

Input / Output relationship Output Relay Switch settings

Switch status: open or
energised
proximity sensor with target S1/S4 OFF
Switch status: closed or S2/S5 ON
de-energised
proximity sensor without target
Switch status: closed or
energised
proximity sensor without target S1/S4 ON
Switch status: open or S2/S5 OFF
de-energised
proximity sensor with target

Fault detection Relevant switches Setting

Enabled S3/S6 ON
Disabled S3/S6 OFF

Note: S1 / S2 / S3 refer to channel 1, while S4 / S5 / S6 refer to channel 2.

Application Guidelines
A termination resistor of the proper value must be used to end the line in order to implement the fault
detection functionality.
The units supply the required power to field contact/sensor; no additional power supply is required. A "open"
contact status is equivalent to the status of an object "near" to the proximity sensor. When the status LED is
"lit", the output relays are energised. To get the desired normally closed or open output status, select the
proper SPDT relay output. To get the desired input/output relationship, use switches S1 & S2.
On the single-channel unit, when the fault detection is not selected, the two output relays are driven in
parallel. When a fault condition is present, the relays are always put into the de-energised status. To get a
fault-detection capability when the input is a voltage-free (i.e. not a proximitor) contact, use the following
circuit:
Contact fitted with resistors for LFD (typical)

5-20
5.9 µ D 431/432

Functional description
Repeats the status of a voltage free contact or intrinsically safe proximity sensor in a hazardous area to 2
optocoupled Safe Area outputs (Model 431) or 1 optocoupled SA output per channel (Model 432).
Fixed configuration to suit the majority of applications.

5-21
Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of section 4.3.

Mod. 431:

Screw terminal nmbr. Used for

1 Safe area Collector +, Ch1
2 Safe area Emitter -, Ch1
3 Safe area Pull-up, Ch1
4 Safe area Collector +, Ch2
5 Safe area Emitter -, Ch2
6 Safe area Pull-up, Ch2
7 DC or AC Supply +
8 DC or AC Supply -
9 not used
11 Hazardous area Proximity Sensor / Contact +
12 Hazardous area Proximity Sensor / Contact -
13,14,15,16 not used

Mod. 432:

Screw terminal nmbr. Used for

1 Safe area Collector +, Ch1
2 Safe area Emitter -, Ch1
3 Safe area Pull-up, Ch1
4 Safe area Collector +, Ch2
5 Safe area Emitter -, Ch2
6 Safe area Pull-up, Ch2
7 DC or AC Supply +
8 DC or AC Supply -
9 not used
11 Hazardous area Proximity Sensor / Contact +, Ch. 1
12 Hazardous area Proximity Sensor / Contact -, Ch. 1
14 Hazardous area Proximity Sensor / Contact +, Ch. 2
15 Hazardous area Proximity Sensor / Contact -, Ch. 2
13, 16 not used

Configuration options
No user configuration is available for this device. The input/output relationship is as follows:
Input Output Transistor Status LED
switch status : open or Not conducting
OFF
proximity sensor with target (closed status)
switch status : close or Conducting
ON
proximity sensor without target (open status)

Application Guidelines
The units supply the required power to field contact/sensor; no additional power supply is required. A "open"
contact status is equivalent to the status of an object "near" to the proximity sensor. When the input is
"closed", the status LED is "lit" and the output transistors are closed (conducting), and the converse. On the
single-channel unit, the two output transistors are always driven in parallel. The 4K7 internal resistor can be
connected to a +Vdc rail to get a logic level output.

5-22
5.10 µ D 441/442

Functional description
Repeats the status of a voltage free contact or intrinsically safe proximity sensor in a hazardous area to 2
optocoupled Safe Area outputs (Model 441) or 1 optocoupled SA output per channel (Model 442).
Additionally the 441 is user configurable a single optocoupled status output plus a separated optocoupled
output for use as line fault detection alarm. The line fault condition is also shown on the fault LED.
The 442 has LED line fault detection indication only. The line fault detection feature (primarily used with
proximity sensors) opens the optocoupled output in case of line opening or short.

5-23
Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of section 4.3
Mod. 441:

Screw terminal nmbr. Used for

1 Safe area Collector +, status out
2 Safe area Emitter -, status out
3 Safe area Pull-up, status out
4 Safe area Collector +, fault out
5 Safe area Emitter -, fault out
6 Safe area Pull-up, fault out
7 DC or AC Supply +
8 DC or AC Supply -
9 not used
11 Hazardous area Proximity Sensor / Contact +
12 Hazardous area Proximity Sensor / Contact -
13,14,15,16 not used

Mod. 442:

Screw terminal nmbr. Used for

1 Safe area Collector +, Ch1
2 Safe area Emitter -, Ch1
3 Safe area Pull-up, Ch1
4 Safe area Collector +, Ch2
5 Safe area Emitter -, Ch2
6 Safe area Pull-up, Ch2
7 DC or AC Supply +
8 DC or AC Supply -
9 not used
11 Hazardous area Proximity Sensor / Contact +, Ch. 1
12 Hazardous area Proximity Sensor / Contact -, Ch. 1
14 Hazardous area Proximity Sensor / Contact +, Ch. 2
15 Hazardous area Proximity Sensor / Contact -, Ch. 2
13, 16 not used

Mod. 442

5-24
Configuration options (model 441)
The input/output relationship can be configured and the two optocoupled transistors are normally driven in
parallel. If the supply voltage falls below the minimum, both outputs are not driven.
The input fault-detection capability is available when a proximity sensor or a voltage-free contact is used
with proper termination resistors installed (see Application Guidelines).
The fault sense circuit detects any short-circuit or open-circuit condition of the inputs (hazardous area).
When such a faulty connection is detected, the associated LED is set ON and both outputs are not driven.
The optocoupled transistor 2 can be configured as a fault output (normally driven when no fault is detected).
To configure the module:
• turn the device power off
• do not set the switches to any position other than those specified below
• lift the plastic lid that covers the switches
• choose the feature you wish to set from the table below and set the switches as shown

Input / Output relationship Output Transistors Switch settings

Switch status: open or conducting
proximity sensor with target (closed status) S1 OFF
Switch status: closed or not conducting S2 ON
proximity sensor without target (open status)
Switch status: closed or conducting
proximity sensor without target (closed status) S1 ON
Switch status: open or not conducting S2 OFF
proximity sensor with target (open status)

Fault detection Relevant switches Setting

Enabled S3 ON
Disabled S3 OFF

Feature Relevant switches Setting

Two output transistors driven in S4 OFF
parallel and follow the input status S5 ON
S6 OFF
S7 OFF
S8 ON
Transistor 1 follows the input status S4 ON
S5 OFF
Transistor 2 used as fault det. output S6 OFF
(option to be used only when fault detection S7 ON
is enabled) S8 OFF

N.B.: S6 must be always in the OFF status.

5-25
Configuration options (model 442)
The input/output relationship can be configured. If the supply voltage falls below the minimum, both
optocoupled transistors are not driven.
The input fault-detection capability is available when a proximity sensor or a contact voltage-free is used
with proper termination resistors installed (see Application Guidelines)..
The fault sense circuit detects any short-circuit or open-circuit condition of the inputs (hazardous area).
When such a faulty connection is detected, the associated LED is set ON and the related output is not
driven.
To configure the module:
• turn the device power off
• do not set the switches to any position other than those specified below
• lift the plastic lid that covers the switches
• choose the feature you wish to set from the table below and set the switches as shown

Input / Output relationship Output Transistors Switch settings

Switch status: open or conducting
proximity sensor with target (closed status) S1/S4 OFF
Switch status: closed or not conducting S2/S5 ON
proximity sensor without target (open status)
Switch status: closed or conducting
proximity sensor without target (closed status) S1/S4 ON
Switch status: open or not conducting S2/S5 OFF
proximity sensor with target (open status)

Fault detection Relevant switches Setting

Enabled S3/S6 ON
Disabled S3/S6 OFF

Note: S1 / S2 / S3 refer to channel 1, while S4 / S5 / S6 refer to channel 2.

Application Guidelines
A termination resistor of the proper value must be used to end the line in order to implement the fault
detection functionality.
The units supply the required power to field contact/sensor; no additional power supply is required. A "open"
contact status is equivalent to the status of an object "near" to the proximity sensor. When the status LED is
"lit", the output transistors are closed (conducting). To get the desired normally closed or open output status,
use switches S1 & S2. The 4K7 internal resistor can be connected to a +Vdc rail to get a logic level output.
On the single-channel unit, when the fault detection is not selected the two output transistors are driven in
parallel. To get a fault-detection capability when the input is a voltage-free (i.e. not a proximitor) contact,
use the following circuit:
Contact fitted with resistors for LFD (typical)

5-26
5.11 µ D 471/472

Functional description
Energises intrinsically safe solenoid valves, alarm sounders, displays or LED indicators, in a hazardous area
from a loop powered safe area control signal.
An alternative low current output is available for energising a single LED without installing an external
current limiting resistor. Each channel is loop powered, ensuring high integrity operation and permitting
current monitoring for detection of line fault.
A status LED identifies open field line (LED off with open output).

5-27
Connection Information
Please refer to the electrical schematics above and to the screw terminal drawing of page section 4.3.
When the input power supply is connected, the green PWR LED is ON.
When a load < 10 kΩ is connected to either outputs the yellow STATUS LED is ON.
Mod. 471:

Screw terminal nmbr. Used for

1 Safe area Input +
2 Safe area Input -
3,4,5,6,7,8,9 not used
11 Hazardous area Valve +
12 Hazardous area common -
13 Hazardous area LED +

Mod. 472:

Screw terminal nmbr. Used for

1 Safe area Input +, Ch. 1
2 Safe area Input -, Ch. 1
4 Safe area Input +, Ch. 2
5 Safe area Input -, Ch. 2
3,6,7,8,9 not used
11 Hazardous area Valve +, Ch. 1
12 Hazardous area common -, Ch. 1
13 Hazardous area LED +, Ch. 1
14 Hazardous area Valve +, Ch. 2
15 Hazardous area common -, Ch. 2
16 Hazardous area LED +, Ch. 2

Configuration options
No user configuration is available for this device.
Application Guidelines
The µD 471 module receives as input in the safe area a 24 V dc (nominal) power supply and transfers it to
the hazardous area where it is typically used to drive solenoid valves or audible alarms.
An hazardous area output is also available that can directly drive LED diodes.
The two outputs cannot be used at the same time.
The voltage/current relationship is shown in the picture below. Please note that the output voltage is not
stabilised but it is load-dependent.

5-28
The µ D471 module can, in some operating conditions, transfer to the output an amount of power that is
relevant when compared with the reduced case size. It is therefore required to adopt proper mounting
techniques such as to avoid a too high operating temperature, which can have an impact on reliability and
expected life time. With reference to the above figure, and in function of the output load, the operating area
is to be identified:
• with a normal load (A zone, Rload >300Ω), one must only be careful to keep free from any
obstruction the case venting slits.
• with a high load (B zone Rload<300Ω) the modules must always be mounted using an horizontal
DIN rail.

Mod. 471
The dual channel µ D472 modules can, in some operating conditions, transfer to the output an amount of
power that is relevant when compared with the reduced case size. It is therefore required to adopt proper
mounting techniques such to avoid a too high operating temperature, which can have an impact on
reliability and expected life. With reference to the above figure, and in function of the output load, the
operating area is to be identified:
• with a reduced load (A zone, Rload >900Ω), one must only be careful to keep free from any
obstruction the case venting slits.
• with a normal load (B zone, 300Ω<Rload<900Ω) the modules must always be mounted using an
horizontal DIN rail.
• with a high load, (C zone, Rload <300Ω), besides to the previous cautions, it can be necessary to
space the modules (at least 5 mm), or to alternate the µ D472 with other low-power µD modules
or to adopt a proper forced ventilation within the cabinet (please refer to chapter 4.4 and 4.5).

Mod. 472

The µD 471 isolator is a “loop powered” device which unifies, in a safe area the power supply and the signal
input connections.
The µD 472 comprises two identical and fully independent channels, with the same behaviour described for
the µD 471.
The two µD472 channels are completely isolated one from the other. This means that single-loop integrity is
preserved also with the two-channel version. A field open circuit can be detected by monitoring safe area
current ( < 25 mA).

5-29
6 Servicing

6.1 Maintenance
Introduction
Elcon Instruments µD range isolator modules do not require any particular maintenance under normal
operating conditions. They are designed to operate trouble free and with high stability for long time. Periodic
checks (yearly based) can be scheduled to check their performance over time. If a unit is found not meeting
specifications or in a failure condition then it requires recalibration or servicing.
WARNING.
ANY REPAIR MADE BY UNAUTHORIZED PERSONNEL MAY COMPLETELY INVALIDATE THE SAFETY
CHARACTERISTICS OF THE MODULE. REPAIR NOT MADE BY ELCON INSTRUMENTS IS FULLY AT
USER'S RISK AND RESPONSIBILITY IN ADDITION, THE WARRANTY TERMS OF THE MODULE WILL
BE NULL AND VOID TO ALL EFFECT

6.2 Functional Check & Troubleshooting

General Information
Be careful to perform any measurement with certified testing equipment when operating on hazardous area
environment.
Before going deeper into isolator troubleshooting, check for proper supply connections and values. Also
check for correct input and output connections and loads.
In the following, step by step instructions are provided to check the isolators functional behaviour. This is
both useful as a troubleshooting aid and to enable a straightforward verification of key units specifications.
Current consumption, power dissipation and a few other non critical parameters are not covered by the
procedure (but can anyway be easily tested by the user). The focus is on accuracy and other application-
critical specifications.
When some doubt exist about a faulty unit, please follow the check procedure suggested in this section.
When the problem is confirmed, the unit should be returned for repair to the nearest authorised
representative of Elcon Instruments, clearly specifying which of the procedure verification steps were not
passed.
To carry on the functional check, the following instrumentation is required:
- a stabilised power supply, 0-30 V range, current > 200 mA; the power supply should guarantee an error
lower than 0.1 V (with respect to the specified voltage) measured at the isolator terminals;
- a decade resistor box (or equivalent device), 0-10 K Ω range, 1 Ω resolution;
- 2 41/2 digits multimeters suitable for voltage, current and resistance measurements and such to
guarantee the following accuracy levels: Voltage: 1 mV / Current: 4 µA / Resistance: 1 Ω .
When instrument with a lower accuracy level would be used you should subtract the instruments error from
the measured value before assuming that it exceeds the specified limit.
Always refer to section 5. to properly perform the required connections for the model and channel you wish
to check. Be sure to respect specified polarity, both for voltage (+ or -) and for current (sink or source).
Please note that in the following descriptions, "input" is always referred to the isolator unit and not to the
PLC or DCS device.

Warning: when dealing with mains powered units, be sure to take all required safety precautions.
NOTE: a specific manual (109/GB-PN.991165) is available for the µDin 301 configuration.

6-1
µD 321/3
Ch. 1 - Current output (source):
a) connect the power supply at the unit supply terminals; connect the first multimeter (current mode) at the
input terminals, in series with the resistor box; connect the second multimeter (current mode) at the output
terminals; set the supply at 24 V and switch it on; the power led must go on;
b) set the resistor box to 780 Ω; the input current must be within 19.50 and 20.50 mA; the output current
must be the same, with an error lower than 20 µA;
c) set the resistor box to 5 KΩ; the input current must be within 3.50 and 4.50 mA; the output current must
be the same, with an error lower than 20 µA;
d) set the resistor box to 1500 Ω; the input current must be within 11.50 and 12.50 mA; the output current
must be the same, with an error lower than 20 µA;
e) set the resistor box to 0 Ω; the (short-circuit) input current must be within 23 and 27 mA; the output
current must be the same, with an error lower than 100 µA;
f) disconnect the resistor box ; the (open-circuit) output current must be lower than 0.2 mA;
Ch. 1 - Voltage output:
a) connect the power supply at the unit supply terminals; connect the first multimeter (current mode) at the
input terminals, in series with the resistor box; connect the second multimeter (voltage mode) at the output
terminals; set the supply at 24 V and switch it on; the power led must go on;
b) set the resistor box to 780 Ω; the input current must be within 19.50 and 20.50 mA; the output voltage
must be equal to the input current multiplied by 250 Ω, with an error lower than 10 mV;
c) set the resistor box to 5 KΩ; the input current must be within 3.50 and 4.50 mA; the output voltage must
be equal to the input current multiplied by 250 Ω, with an error lower than 10 mV;
d) set the resistor box to 1500 Ω; the input current must be within 11.50 and 12.50 mA; the output voltage
must be equal to the input current multiplied by 250 Ω, with an error lower than 10 mV;
e) set the resistor box to 0 Ω; the (short-circuit) input current must be within 23 and 27 mA; the output
voltage must be equal to the input current multiplied by 250 Ω, with an error lower than 30 mV;
f) disconnect the resistor box ; the (open-circuit) output voltage must be lower than 50 mV;
Ch. 1 - Current output (sink):
a) connect the power supply at the unit supply terminals; connect the first multimeter (current mode) at the
input terminals, in series with the resistor box; feed the supply voltage to the output terminals, with the
second multimeter (current mode) in series; set the supply at 24 V and switch it on; the power led must go
on;
b) set the resistor box to 780 Ω; the input current must be within 19.50 and 20.50 mA; the output current
must be the same, with an error lower than 20 µA;
c) set the resistor box to 5 KΩ; the input current must be within 3.50 and 4.50 mA; the output current must
be the same, with an error lower than 20 µA;
d) set the resistor box to 1500 Ω; the input current must be within 11.50 and 12.50 mA; the output current
must be the same, with an error lower than 20 µA;
e) set the resistor box to 0 Ω; the (short-circuit) input current must be within 23 and 27 mA; the output
current must be the same, with an error lower than 100 µA;
f) disconnect the resistor box ; the (open-circuit) output current must be lower than 0.2 mA;

6-2
Ch. 2 - Current output:
a) connect the power supply at the unit supply terminals; connect the first multimeter (current mode) at the
input terminals, in series with the resistor box; connect the second multimeter (current mode) at the output
terminals; set the supply at 24 V and switch it on; the power led must go on;
b) set the resistor box to 780 Ω; the input current must be within 19.50 and 20.50 mA; the output current
must be the same, with an error lower than 40 µA;
c) set the resistor box to 5 KΩ; the input current must be within 3.50 and 4.50 mA; the output current must
be the same, with an error lower than 40 µA;
d) set the resistor box to 1500 Ω; the input current must be within 11.50 and 12.50 mA; the output current
must be the same, with an error lower than 40 µA;
e) set the resistor box to 0 Ω; the (short-circuit) input current must be within 23 and 27 mA; the output
current must be the same, with an error lower than 100 µA;
f) disconnect the resistor box ; the (open-circuit) output current must be lower than 0.2 mA;
Ch. 2 - Voltage output:
a) connect the power supply at the unit supply terminals; connect the first multimeter (current mode) at the
input terminals, in series with the resistor box; connect the second multimeter (voltage mode) at the output
terminals; set the supply at 24 V and switch it on; the power led must go on;
b) set the resistor box to 780 Ω; the input current must be within 19.50 and 20.50 mA; the output voltage
must be equal to the input current multiplied by 250 Ω, with an error lower than 15 mV;
c) set the resistor box to 5 KΩ; the input current must be within 3.50 and 4.50 mA; the output voltage must
be equal to the input current multiplied by 250 Ω, with an error lower than 15 mV;
d) set the resistor box to 1500 Ω; the input current must be within 11.50 and 12.50 mA; the output voltage
must be equal to the input current multiplied by 250 Ω, with an error lower than 15 mV;
e) set the resistor box to 0 Ω; the (short-circuit) input current must be within 23 and 27 mA; the output
voltage must be equal to the input current multiplied by 250 Ω, with an error lower than 30 mV;
f) disconnect the resistor box ; the (open-circuit) output voltage must be lower than 50 mV;

µD 325/6
Current output:
a) connect the power supply at the unit supply terminals; connect the first multimeter (current mode) at the
input terminals, in series with the resistor box; connect the second multimeter (current mode) at the output
terminals; set the supply at 24 V and switch it on; the power led must go on;
b) set the resistor box to 780 Ω; the input current must be within 19.50 and 20.50 mA; the output current
must be the same, with an error lower than 20 µA;
c) set the resistor box to 5 KΩ; the input current must be within 3.50 and 4.50 mA; the output current must
be the same, with an error lower than 20 µA;
d) set the resistor box to 1500 Ω; the input current must be within 11.50 and 12.50 mA; the output current
must be the same, with an error lower than 20 µA;
e) set the resistor box to 0 Ω; the (short-circuit) input current must be within 25 and 30 mA; the output
current must be the same, with an error lower than 100 µA;
f) disconnect the resistor box ; the (open-circuit) output current must be lower than 1 mA;

6-3
Voltage output:
a) connect the power supply at the unit supply terminals; connect the first multimeter (current mode) at the
input terminals, in series with the resistor box; connect the second multimeter (voltage mode) at the output
terminals; set the supply at 24 V and switch it on; the power led must go on;
b) set the resistor box to 780 Ω; the input current must be within 19.50 and 20.50 mA; the output voltage
must be equal to the input current multiplied by 250 Ω, with an error lower than 10 mV;
c) set the resistor box to 5 KΩ; the input current must be within 3.50 and 4.50 mA; the output voltage must
be equal to the input current multiplied by 250 Ω, with an error lower than 10 mV;
d) set the resistor box to 1500 Ω; the input current must be within 11.50 and 12.50 mA; the output voltage
must be equal to the input current multiplied by 250 Ω, with an error lower than 10 mV;
e) set the resistor box to 0 Ω; the (short-circuit) input current must be within 25 and 30 mA; the output
voltage must be equal to the input current multiplied by 250 Ω, with an error lower than 30 mV;
f) disconnect the resistor box ; the (open-circuit) output voltage must be lower than 250 mV;

µD 333/4
a) connect the power supply, in series with the first multimeter (current mode) and with the resistor box, at
the input terminals; connect the second multimeter (current mode) at the output terminals; set the supply at
15 V and switch it on;
b) set the resistor box to 400 Ω; the output current must be within 19.50 and 20.50 mA; the input current
must be the same, with an error lower than 20 µA;
c) set the resistor box to 2.5 K Ω; the output current must be within 3 and 5 mA; the input current must be
the same, with an error lower than 20 µA;
d) set the resistor box to 750 Ω; the input current must be within 11 and 13 mA; the output current must be
the same, with an error lower than 20 µA;
e) disconnect the multimeter at the output terminals; the (open-circuit) input current must be lower than 0.8
mA; switch off the supply;
f) connect the power supply, in series with the first multimeter (current mode), at the input terminals;
connect the resistor box, in at the output terminals; set the supply at 17 V and switch it on;
g) set the resistor box to 500 Ω; the input current must be within 19.40 and 20.60 mA (voltage drop test);

µD 337/8
a) connect the power supply at the unit supply terminals; feed the supply voltage, in series with the first
multimeter (current mode) and with the resistor box, at the input terminals; connect the second multimeter
(current mode) at the output terminals; set the supply at 24 V and switch it on; the green power LED must go
on;
b) set the resistor box to 1.1 KΩ; the output current must be within 19.50 and 20.50 mA; the input current
must be the same, with an error lower than 20 µA;
c) set the resistor box to 5.6 KΩ; the output current must be within 3 and 5 mA; the input current must be
the same, with an error lower than 20 µA;
d) set the resistor box to 1.8 KΩ; the input current must be within 11 and 13 mA; the output current must be
the same, with an error lower than 20 µA;
e) disconnect the multimeter at the output terminals; the (open-circuit) input current must be lower than 1.2 mA;

6-4
µD 411/2
a) DC version: set the power supply at 24 V and connect it - in the off status - to the unit supply terminals;
AC version: connect the mains (115 or 230 Vac) to the unit supply terminals, with a suitable series switch
to ensure the off status;
b) connect the resistor box at the input terminals; connect the first multimeter (resistance mode) at the
normally open terminals of the first output relay; connect the second multimeter (resistance mode) at the
normally open terminals of the second output relay; switch the supply on; the power led must go on;
c) set the resistor box to 5 KΩ; the status led must be off; both multimeters (µD411) or the tested channel
multimeter (µD412) must give an "open circuit" reading;
d) set the resistor box to 3 KΩ; the status led must be on; both multimeters (µD411) or the tested channel
multimeter (µD412) must give a "short circuit" reading;

µD 421/2 and µD 421/2 LVAC

For these isolators, the input/output relationship is configurable. Two distinct check procedures are therefore
presented. For simplicity, the "fault detection disabled" mode is not covered by the procedure. Moreover,
the option of using one of the µD421 outputs relays as fault signal is also not considered.
Input closed / output de-energised configuration:
a) for µD422, set the unit configuration switches as: S1= OFF, S2 = ON, S3 = ON, S4= OFF, S5 = ON, S6 = ON;
for µD421, set the unit configuration switches as: S1= OFF, S2 = ON, S3 = ON, S4= OFF, S5 = ON, S6 = OFF,
S7 = OFF, S8 = OFF;
b) DC version: set the power supply at 24 V and connect it - in the off status - to the unit supply terminals;
AC version: connect the mains (115 or 230 Vac) to the unit supply terminals, with a suitable series switch
to ensure the off status;
LVAC version: set the power supply at 24 Vac and connect it - in the off status - to the unit supply
terminals;
c) connect the resistor box at the input terminals; connect the first multimeter (resistance mode) at the
normally open terminals of the first output relay; connect the second multimeter (resistance mode) at the
normally open terminals of the second output relay; switch the supply on; the power led must go on;
d) set the resistor box to 1 KΩ; both the status and the fault led must be off; both multimeters (µD421) or
the tested channel multimeter (µD422) must give a "open circuit" reading;
e) set the resistor box to 10 KΩ; the status led must be on and the fault led must be off; both multimeters
(µD421) or the tested channel multimeter (µD422) must give an "short circuit" reading;
f) set the resistor box to 0 Ω (input short-circuit); the status led must be off and the fault led must be on;
both multimeters (µD421) or the tested channel multimeter (µD422) must give an "open circuit" reading;
g) disconnect the resistor box (input open-circuit); the status led must be off and the fault led must be on;
both multimeters (µD421) or the tested channel multimeter (µD422) must give an "open circuit" reading;
Input closed / output energised configuration:
a) for µD422, set the unit configuration switches as: S1= ON, S2 = OFF, S3 = ON, S4= ON, S5 = OFF, S6 = ON;
for µD421, set the unit configuration switches as: S1= ON, S2 = OFF, S3 = ON, S4= OFF, S5 = ON, S6 = OFF,
S7 = OFF, S8 = OFF;
b) DC version: set the power supply at 24 V and connect it - in the off status - to the unit supply terminals;
AC version: connect the mains (115 or 230 Vac) to the unit supply terminals, with a suitable series switch
to ensure the off status;
LVAC version: set the power supply at 24 Vac and connect it - in the off status - to the unit supply
terminals;
c) connect the resistor box at the input terminals; connect the first multimeter (resistance mode) at the
normally open terminals of the first output relay; connect the second multimeter (resistance mode) at the
normally open terminals of the second output relay; switch the supply on; the power led must go on;

6-5
d) set the resistor box to 1 KΩ; the status led must be on and the fault led must be off; both multimeters
(µD421) or the tested channel multimeter (µD422) must give an "short circuit" reading;
e) set the resistor box to 10 KΩ; both the status and the fault led must be off; both multimeters (µD421) or
the tested channel multimeter (µD422) must give a "open circuit" reading;
f) set the resistor box to 0 Ω (input short-circuit); the status led must be off and the fault led must be on;
both multimeters (µD421) or the tested channel multimeter (µD422) must give an "open circuit" reading;
g) disconnect the resistor box (input open-circuit); the status led must be off and the fault led must be on;
both multimeters (µD421) or the tested channel multimeter (µD422) must give an "open circuit" reading;

µD 431/2
a) DC version: set the power supply at 24 V and connect it - in the off status - to the unit supply terminals;
AC version: connect the mains (115 or 230 Vac) to the unit supply terminals, with a suitable series switch
to ensure the off status; set the power supply at 24 V (required for output transistors polarisation);
b) connect the resistor box at the input terminals; connect the "pull-up" terminal of the 2 output transistors to
the "+" of the power supply, end the "emitter" terminal to the "-" of the power supply;
c) connect the first multimeter (voltage mode) between the "collector" terminal of the first output transistor
and the "-" of the power supply; connect the second multimeter (voltage mode) between the "collector"
terminal of the second output transistor and the "-" of the power supply; switch the supply on; the power led
must go on;
d) set the resistor box to 5 KΩ; the status led must be off; both multimeters (µD411) or the tested channel
multimeter (µD412) must give a "24 V" reading;
e) set the resistor box to 3 KΩ; the status led must be on; both multimeters (µD411) or the tested channel
multimeter (µD412) must give a "<1 V" reading;

µD 441/2
For these isolators, the input/output relationship is configurable. Two distinct check procedures are therefore
presented. For simplicity, the "fault detection disabled" mode is not covered by the procedure. Moreover,
the option of using one of the µD441 outputs transistors as fault signal is also not considered.
Input closed / output de-energised configuration:
a) for µD442, set the unit configuration switches as: S1= OFF, S2 = ON, S3 = ON, S4= OFF, S5 = ON, S6 = ON;
for µD441, set the unit configuration switches as: S1= OFF, S2 = ON, S3 = ON, S4= OFF, S5 = ON, S6 = OFF,
S7 = OFF, S8 = OFF;
b) DC version: set the power supply at 24 V and connect it - in the off status - to the unit supply terminals;
AC version: connect the mains (115 or 230 Vac) to the unit supply terminals, with a suitable series switch
to ensure the off status; set the power supply at 24 V (required for output transistors polarisation);
c) connect the resistor box at the input terminals; connect the "pull-up" terminal of the 2 output transistors to
the "+" of the power supply, end the "emitter" terminal to the "-" of the power supply;
d) connect the first multimeter (voltage mode) between the "collector" terminal of the first output transistor
and the "-" of the power supply; connect the second multimeter (voltage mode) between the "collector"
terminal of the second output transistor and the "-" of the power supply; switch the supply on; the power led
must go on;
e) set the resistor box to 1 KΩ; both the status and the fault led must be off; both multimeters (µD441) or the
tested channel multimeter (µD442) must give a "24 V" reading;
f) set the resistor box to 10 KΩ; the status led must be on and the fault led must be off; both multimeters
(µD441) or the tested channel multimeter (µD442) must give a ">1 V" reading;
g) set the resistor box to 0 Ω (input short-circuit); the status led must be off and the fault led must be on;
both multimeters (µD421) or the tested channel multimeter (µD422) must give a "24 V" reading;
h) disconnect the resistor box (input open-circuit); the status led must be off and the fault led must be on;
both multimeters (µD421) or the tested channel multimeter (µD422) must give a "24 V" reading;

6-6
Input closed / output energised configuration:
a) for µD442, set the unit configuration switches as: S1= ON, S2 = OFF, S3 = ON, S4= ON, S5 = OFF, S6 = ON;
for µD441, set the unit configuration switches as: S1= ON, S2 = OFF, S3 = ON, S4= OFF, S5 = ON, S6 = OFF,
S7 = OFF, S8 = OFF;
b) DC version: set the power supply at 24 V and connect it - in the off status - to the unit supply terminals;
AC version: connect the mains (115 or 230 Vac) to the unit supply terminals, with a suitable series switch
to ensure the off status; set the power supply at 24 V (required for output transistors polarisation);
c) connect the resistor box at the input terminals; connect the "pull-up" terminal of the 2 output transistors to
the "+" of the power supply, end the "emitter" terminal to the "-" of the power supply;
d) connect the first multimeter (voltage mode) between the "collector" terminal of the first output transistor
and the "-" of the power supply; connect the second multimeter (voltage mode) between the "collector"
terminal of the second output transistor and the "-" of the power supply; switch the supply on; the power led
must go on;
e) set the resistor box to 1 KΩ; the status led must be on and the fault led must be off; both multimeters
(µD441) or the tested channel multimeter (µD442) must give a "<1 V" reading;
f) set the resistor box to 10 KΩ; both the status and the fault led must be off; both multimeters (µD441) or
the tested channel multimeter (µD442) must give a "24 V" reading;
g) set the resistor box to 0 Ω (input short-circuit); the status led must be off and the fault led must be on;
both multimeters (µD421) or the tested channel multimeter (µD422) must give a "24 V" reading;
h) disconnect the resistor box (input open-circuit); the status led must be off and the fault led must be on;
both multimeters (µD421) or the tested channel multimeter (µD422) must give a "24 V" reading;

µD 471/2
a) connect the power supply to the unit input terminals; connect a multimeter (current mode), in series with
the resistor box, at the "valve" output terminals; set the supply at 24 V and switch it on;
b) set the resistor box to 300 Ω; the output current must be within 40 and 42 mA; the output voltage must
be within 12 and 13 V; the power and status led must be on;
c) set the resistor box to 10 KΩ; the power led must be on and status led must be off;
d) connect the multimeter (current mode), in series with the resistor box, at the "led" output terminals;
e) set the resistor box to 0 Ω; the output current must be within 18 and 24 mA; the power and status led
must be on;

6-7
6.3 Warranty
Elcon offers an extended period of warranty assistance performed at their factory. Each instrument to be
repaired is thoroughly analyzed to locate the cause and mode of possible faults and correlate them with the
initial, intermediate, and final testing documentation.
This allows Elcon to trace with more accuracy the fault causes, thus obtaining valuable indications, reliability
statistics, and qualitative evaluation for the purpose of maintaining the quality and reliability of the products
under strict control.

WARRANTY CONDITIONS.
Elcon Instruments certifies that all the instruments of their manufacture are immune from defects or loss of
essential quality, and whenever they are apparatus, Elcon also guarantees proper operation. The duration of
the warranty period is clearly indicated in the order confirmation and starts from the date of delivery or on
site test (if required). Unless otherwise specified the warranty is for 12 months, from delivery date.
The warranty does not cover consumable items.

TERMS - CONDITIONS- WARRANTY LIMITS.

1. Form of report
The action due to the customer for vices, defects, or loss of quality is subject to the terms of articles
1495,1497 C.C. (Italian Civil Code).
The denunciation of the, defect or quality loss must be made by the customer by registered mail, telex,
fax, or equivalent written form to be sent to the main office of Elcon Instruments.

2. Limit - burden - obligation of the customer to conserve the warranty

a) The warranty is limited to repairing and substitution, FOB Elcon Instruments factory, of the useless
parts, for a confirmed defect of materials and/or workmanship, free of charge, and the remaining,
shipping, dismounting and mounting expenses (operations that in any case must be done in
accordance with the supplier), at the customer's charge.
In no case Elcon Instruments will be held responsible for expenses, for loss of profit and/or damage,
direct or indirect, that can be incurred by the customer due to a fault or defect of the material.
b) The warranty ends for instruments or materials damaged by:
− shipment
− storage non conforming to the instruction manual specifications
− incorrect installation
− loss of adequate protection for the type of installation (mechanical, climatic, etc.)
− incorrect application of power supply voltage
− erroneous wiring of the power supply line (applied on input or output measuring circuits)
c) The warranty ends for instruments or materials if repaired, modified, or simply tampered with, even if
only in part, by personnel not authorized by Elcon Instruments and also ends if used in improper way
and/or not conforming with the given instructions.
d) The warranty is valid only if payment has been received from the customer in a timely fashion, as per
the original agreement; otherwise it is void.
e) All parts that are subject to normal wear and inevitable deterioration are excluded from this warranty.
f) In case of having to return the instrument to one of the Elcon Instruments authorized labs for repair,
the customer shall obtain a written authorization with shipping instructions from Elcon Instruments.
Shipment expenses, all the concerned burdens, and the risk of loss or damage of the returned
instrument are exclusively born by the customer.
The same rules apply also when the instrument needs to be replaced.
g) During the warranty period, the customer will allow any personnel appointed by Elcon Instruments ex-
ecute control of the instruments and materials.

6-8
 h) The customer cannot require cancellation of the contract in reason of vices or defects, but only their
elimination or, when they cannot be repaired, the replacement of the instruments, if available on the
market. In case the replacement is for any reason impossible, Elcon Instruments has the faculty to
offer instruments of the same or equivalent type, quality and efficiency, suitable to the same use.
If the customer refuses such offer without justified motivation he is entitled to reimbursement of the
money already paid or a refund of the real incurred expenses.
i) For items subsupplied by Elcon Instruments the standard warranty terms as given by the original ma-
nufacturer are applicable.
j) The warranty must be considered for material repaired, substituted on ex works basis.

Such warranty replaces and supersedes any other declared or implicit warranty.

6-9
7 Glossary
Acronym Description
A/D Analog to Digital
AC Alternating Current
ADC Analog to Digital Converter
Ch. Channel
D/A Digital to Analog
DAC Digital to Analog Converter
DC Direct Current
DCS Distributed (or Digital) Control System
DIN rail A mounting solution based on a rail that
complies with DIN standards
DPDT Dual Pole Dual Through switch

EMC Electro Magnetic Compatibility

HHC Hand Held Configurator
PLC Programmable Logic Controller
Sink The terminal that receives a current flow
Source The terminal that forces a current flow
SPDT Single Pole Dual Through switch

SPST Single Pole Single Through switch

Supply The device that applies a voltage (supply

voltage) to two terminals
Top hat rail A mounting device (rail) with two folds on
both sides that makes it look like a top hat.
Tx Transmitter

7-1
8 Index

A
accuracy ..............................................................................................................................................1-1; 5-1; 5-2; 6-8
Accuracy............................................................................................................................................................2-7; 2-8
ANSI/ISA RP.............................................................................................................................................................3-1

B
Burn out....................................................................................................................................................................2-7

C
connections...............................................................................................................................................................4-3

D
DPDT...................................................................................................................................................... 2-1; 5-15; 5-17
dual channel .............................................................................................................................................................1-1

F
Frequency response.......................................................................................................................2-9; 2-10; 2-11; 2-13

G
galvanic isolation ...............................................................................................................................................1-1; 3-2
ground loop problems ...............................................................................................................................................1-1
grounding..................................................................................................................................................................3-2
Grounding.................................................................................................................................................................3-2

H
hazardous area ................................................................................................... 1-2; 5-15; 5-17; 5-21; 5-23; 5-27; 5-28
Hazardous area.........................................................................................................................................................1-2
Hazardous Area ........................................................................................................................................................1-1

I
Intrinsic Safety ............................................................................................................................................ 1-1; 2-2; 3-1
isolation .............................................................................................................................................................1-1; 3-2

J
jumpers..............................................................................................................................................................5-6; 5-8

L
line fault alarm ..........................................................................................................................................................1-1
loop powered ..........................................................................................................................................1-1; 5-12; 5-27
Loop powered .........................................................................................................................................................2-18
Loop Powered........................................................................................................................................................... 2-1

M
microprocessor ..................................................................................................................................................1-1; 5-1
mounting.....................................................................................................................................................1-1; 6-8; 7-1
mV..............................................................................................................................1-1; 2-7; 2-9; 2-10; 2-11; 5-1; 5-2

8-1
 O
open field ................................................................................................................................................................5-27

P
Power dissipation......................................................................................................................... 2-14; 2-16; 2-17; 2-18
proximity sensor..................................................................... 2-17; 5-15; 5-16; 5-17; 5-19; 5-21; 5-22; 5-23; 5-25; 5-26

R
range ...................................................................................................................................................1-1; 5-2; 5-3; 6-1
Range................................................................................................................................................................2-5; 2-8
Relative humidity ......................................................................................................................................................2-6
relay ........................................................................................................................................1-1; 2-1; 5-15; 5-17; 5-20
Relay ........................................................................................................................................... 2-14; 2-15; 5-19; 5-25
RTD............................................................................................................................................................2-7; 5-1; 5-2

S
sink........................................................................................................... 1-1; 2-9; 2-10; 5-5; 5-6; 5-7; 5-10; 5-12; 5-14
source....................................................................................................................1-1; 2-9; 2-10; 5-2; 5-5; 5-6; 5-7; 5-8
SPDT...................................................................................................................................................... 2-1; 5-15; 5-17
switch status ..................................................................................................................................................5-16; 5-22

T
TC ............................................................................................................................................................................5-1
temperature ................................................................................................................................................1-1; 5-1; 5-3
Temperature ........................................................................................................... 2-8; 2-9; 2-10; 2-11; 2-12; 2-13; 3-1
Temperature drift ......................................................................................................................................................2-8
Thermocouple ...........................................................................................................................................................5-1

8-2
 ELCON REPRESENTATIVE & DISTRIBUTOR:

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