Description

The MTL 4544AS is a passive,intrinsically safe(IS)analog output module designed to safely split a single 4–20 mA field signal into four independent,isolated outputs for use in hazardous environments classified as Zone 0,1,or Division 1.Manufactured by MTL Instruments(a Cooper Industries/Eaton brand),this compact DIN-rail device requires no external power supply,drawing energy directly from the input loop—making it ideal for retrofitting legacy systems or expanding monitoring without adding power infrastructure.

Engineered for reliability in explosive atmospheres,the 4544AS provides galvanic isolation between channels and robust surge protection,ensuring signal integrity while meeting global safety standards including ATEX,IECEx,FM,and CSA.

Application Scenarios

At a North Sea offshore platform,operators needed to feed a single pressure transmitter signal to four destinations:a local indicator,a DCS analog input,a safety recorder,and a remote HMI—all located in Zone 1 areas.Installing conventional powered splitters would require costly explosion-proof enclosures and additional wiring.Instead,the team deployed the MTL 4544AS,which passively replicated the 4–20 mA signal without external power and maintained full HART communication across all paths.The solution reduced installation costs by 60%,eliminated heat-generating components in confined panels,and passed rigorous DNV-GL safety audits on first inspection.

Parameter

Main Parameters Value/Description

Product Model MTL 4544AS

Manufacturer MTL Instruments(Eaton)

Product Category Passive Intrinsically Safe 4–20 mA Signal Splitter/Output Barrier

Channels 4 isolated outputs from 1 input

Input Signal 4–20 mA(loop-powered),max loop voltage drop:5 V 20 mA

Output Signal 4–20 mA per channel,passive(sinks current)

Power Requirement None–fully loop-powered from input signal

Isolation Galvanic isolation between input and all outputs;>1 kV AC test voltage

HART Compatibility Yes–transparent pass-through on all channels(bandwidth>2.5 kHz)

Hazardous Area Certifications ATEX II 1G Ex ia IIC T6…T4,IECEx,FM,CSA,INMETRO

Operating Temperature-40°C to+70°C

Mounting DIN rail(35 mm),width:50 mm total(12.5 mm per channel)

SIL Suitability SIL2 compliant per IEC 61508(when used in appropriate architecture)

Technical Principles and Innovative Values

Innovation Point 1:True Passive Operation

The 4544AS harvests energy directly from the 4–20 mA loop,eliminating the need for auxiliary power—reducing heat,cost,and failure points in safety-critical zones.

Innovation Point 2:Multi-Channel Intrinsic Safety

Each output is independently certified for Ex ia IIC,allowing direct connection to multiple field devices in Zone 0 without compromising safety integrity.

Innovation Point 3:HART Transparency Across All Paths

Unlike older splitters that filter digital signals,the 4544AS preserves HART FSK modulation,enabling asset management tools(e.g.,AMS Device Manager)to communicate through any output channel.

Innovation Point 4:Ultra-Compact Density

At just 12.5 mm per channel,the 4544AS delivers the highest channel density in its class—critical for space-constrained marshalling cabinets in offshore or skid-mounted systems.

Application Cases and Industry Value

In a U.S.pharmaceutical plant producing sterile injectables,the MTL 4544AS was used to distribute bioreactor temperature signals to a PLC,batch historian,local chart recorder,and alarm annunciator—all within a Class I,Div 1 cleanroom.The passive design prevented electromagnetic interference with sensitive lab equipment,while HART support enabled calibration verification without process interruption.Over three years,the system achieved zero signal drift incidents,supporting FDA 21 CFR Part 11 compliance.

Similarly,an LNG export terminal in Australia replaced active isolators with 4544AS modules across 200+loops.The change eliminated 15+power supplies from hazardous area junction boxes,reducing maintenance workload by 35%and improving MTBF from 48 to over 120 months.

Related Product Combination Solutions

MTL 4511:Single-channel passive IS barrier–ideal for simple point-to-point loops

MTL 5544:Powered version with enhanced diagnostics and higher bandwidth

MTL 4546:4-channel IS input splitter–complementary for multi-receiver analog inputs

ROSEMOUNT 3051:Smart pressure transmitter often paired with 4544AS for HART-enabled distribution

EMERSON DeltaV:DCS system that receives replicated signals from 4544AS for redundant control

HIMA FSC:Safety controller using 4544AS outputs for independent trip monitoring

MTL SURGELOGIX:Surge protection modules installed upstream of 4544AS in lightning-prone areas

MTL FLEXI Panel:Pre-wired enclosure system integrating 4544AS with terminal blocks and labeling

Installation,Maintenance,and Full-Cycle Support

Install the MTL 4544AS on a standard 35 mm DIN rail in a suitable enclosure rated for the hazardous zone.Ensure input loop compliance:maximum source impedance≤500Ωand loop voltage≥12 V at 20 mA.Wiring must follow intrinsic safety segregation rules—keeping IS and non-IS cables separated by≥50 mm or using grounded barriers.

No calibration or configuration is required—simply connect and operate.For maintenance,periodically verify loop voltage drop and inspect terminals for corrosion in humid environments.The 4544AS contains no consumable parts and offers a design life exceeding 15 years under normal conditions.

We supply only factory-original MTL 4544AS units,complete with certification documentation(ATEX/IECEx CoC),and offer 24-month warranty with technical support for system integration.Units are stocked globally with typical lead time of 1–3 days.

Contact us for a customized solution—whether you’re designing a new hazardous area control system,upgrading legacy analog distribution,or ensuring HART transparency across safety and operational networks.The MTL 4544AS delivers certified,zero-power signal integrity where safety,simplicity,and space matter most

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