The MTL4581 is a single-channel millivolt/thermocouple isolator engineered to deliver uncompromising accuracy in hazardous industrial environments. Part of Eaton’s MTL4500 series, this intrinsically safe device supports direct connection to thermocouples with external cold-junction compensation, ensuring stable signal transmission in Zone 0/IIC/T4-T6 rated areas . Unlike basic isolators like Pepperl+Fuchs KFD2-UT2-EX1, which rely on fixed configurations, the MTL4581 features dual switches for thermocouple burnout detection and selectable upscale/downscale operation, enabling tailored responses to sensor failures . Its ±0.05% linearity and <2μV/°C temperature drift outperform competitors in maintaining signal integrity across -20°C to +60°C ranges, making it ideal for high-precision applications such as pharmaceutical reactor monitoring and petrochemical process control. The module’s 150μs response time and DC-to-4kHz frequency bandwidth ensure rapid signal stabilization, critical for real-time analytics in fast-changing processes.
Designed for safety-critical systems, the MTL4581 integrates advanced diagnostics to minimize downtime and enhance operational reliability. Its LED status indicators provide real-time feedback on power, loop integrity, and thermocouple health, while the safety drive function can be disabled via a dedicated switch during maintenance or fault conditions . This contrasts with Honeywell’s TC811E1023, which lacks configurable fault responses and relies on manual reset mechanisms. The MTL4581’s 250V RMS galvanic isolation protects against ground loops and electrical interference, ensuring compliance with ATEX, IECEx, and CE standards for explosive atmospheres . With a 600Ω maximum lead resistance tolerance, it accommodates long cable runs in offshore platforms or large-scale refineries, reducing installation complexity compared to RTD-based solutions. The module’s 0.7W typical power consumption also aligns with energy-efficient automation trends, lowering lifecycle costs in energy-intensive industries.
Built to withstand extreme conditions, the MTL4581 excels in environments with high electromagnetic noise or wide temperature fluctuations. Its reinforced housing and -50°C to +85°C storage capability ensure resilience in arctic or desert settings, while the non-condensing humidity tolerance (0–90%) prevents corrosion in coastal or humid industrial zones . Unlike Yokogawa’s SLIO series, which requires additional surge protection, the MTL4581 incorporates intrinsic short-circuit and reverse-polarity safeguards, eliminating the need for external fusing. The module’s field-replaceable screw terminals simplify wiring changes, reducing maintenance time by 40% compared to soldered alternatives. With a 10-year lifecycle guarantee and global technical support, the MTL4581 balances upfront investment with long-term dependability, making it a preferred choice for applications demanding SIL2/3 compliance, such as chemical processing and nuclear facilities. By combining precision signal conditioning with ruggedized design, it redefines the standard for hazardous-area isolation in modern industrial automation.
| Attribute | Description |
| Product Model | MTL4581 – Single-Channel Millivolt/Thermocouple Isolator with Burnout Detection. |
| Manufacturer | Eaton (MTL Instruments). |
| Category | Intrinsic Safety Isolator, Signal Conditioner, Temperature Measurement. |
| Safety Certifications | - ATEX/IECEx: Zone 0/IIC/T4-T6 (hazardous area protection).
- FM/CSA: Class I, Division 1, Groups A-D (pending confirmation via MTL datasheet).
- SIL2/3 Compliance: Configurable for safety instrumented systems (HFT=1). |
| Signal Handling | - Input: Direct thermocouple (Type J, K, T, E, R, S, B, N) or millivolt signals (0-20mV, 0-50mV, 0-100mV).
- Output: Isolated 4-20mA, 0-20mA, or 1-5V proportional to input.
- Cold-Junction Compensation: External (requires separate CJC module).
- Burnout Detection: Configurable upscale/downscale via dual switches. |
| Key Features | - Isolation: 250V RMS galvanic isolation between input/output/power.
- Diagnostics: LED indicators for power, output current, and burnout status.
- Accuracy: ±0.05% linearity, <2μV/°C temperature drift.
- Response Time: <150μs for 90% step response.
- Bandwidth: DC to 4kHz (-3dB). |
| Physical Specs | - Dimensions: 16.5mm (W) x 104.8mm (H) x 118.8mm (D) (estimated from MTL4500 series).
- Weight: 0.2kg (approximate).
- Mounting: Backplane-compatible with MTL4500 series or DIN rail. |
| Environmental Range | - Operating Temp: -20°C to +60°C.
- Storage Temp: -50°C to +85°C.
- Humidity: 0-90% non-condensing. |
| Technical Performance | - Input Impedance: >10MΩ for thermocouple inputs.
- Output Load: 0-600Ω for 4-20mA output.
- Power Supply: 20-35V DC, 0.7W typical consumption.
- Common-Mode Rejection: >120dB at 50/60Hz. |
| Applications | - Hazardous industries: Oil/gas, chemical, pharmaceutical.
- Temperature monitoring in reactors, furnaces, and pipelines.
- SIL-rated safety loops requiring precise thermocouple signal isolation. |
| Compliance | - EMC: IEC 61000-4-4 (electrical fast transient immunity).
- RoHS compliant.
- CE marked, CCS2 certified (China Classification Society). |
| Installation | - Hot-swappable design with field-replaceable screw terminals.
- Compatible with MTL4500 series backplanes for modular expansions. |
| Documentation & Support | - Resources: Datasheet, installation guide, safety manual (available via Eaton’s portal).
- Warranty: 2-year standard coverage. |
Packaging & Shipping
Company Information
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