Eaton Crouse-hinds series User manual

PCL45USB/PCS45 configurator
January 2016
INM PCS45 rev2
Instruction manual
MTL intrinsic safety solutions
For temperature converters and
pulse isolator modules

INM PCS45
ii

INM PCS45 iii

INM PCS45
iv

INM PCS45 v
CONTENTS
1 INTRODUCTION............................................................1
2 INSTALLATION.............................................................2
3 OPENING SCREEN .........................................................2
3.1 Changing the password .........................................................3
4 OPERATING MODES ........................................................3
4.1 Offline Mode ..................................................................3
4.2 Online........................................................................3
4.3 Demo mode ...................................................................3
4.4 Access Control.................................................................4
4.4.1 Restricted Access. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .4
4.4.2 Full access ....................................................................4
5 CONNECTION TO TARGET MODULE......................................... 4-5
6 SYSTEM TESTING ..........................................................6
6.1 Basic Configuration.............................................................6
6.2 Input Configuration.............................................................6
6.2.1 Module Input Information .......................................................6
6.2.2 Module Output Configuration ....................................................6
6.2.3 Module Alarm Information.......................................................7
7 ONLINE CONFIGURATION .........................................................7
7.1 Basic Configuration...........................................................7/8
7.2 Configuration MTL45/5573 & MTL45/5575 ..........................................8
7.2.1 Input configuration ............................................................8
7.2.2 Input restrictions ..............................................................9
7.2.3 Output configuration ...........................................................9
7.2.4 Alarms Configuration ..........................................................10
7.3 Configuration MTL45/5576-RTD............................................... 10/11
7.4 Configuration MTL45/5576-THC..................................................12
7.5 Configuration MTL45/5532 ...................................................13/14
7.6 Calibration ...................................................................15
8 OFFLINE CONFIGURATION .................................................16
8.1 Configuration.................................................................16
9 DIAGNOSTICS ............................................................17
9.1 Status .......................................................................17
9.2 Monitor......................................................................18
9.3 Data-Logger ..................................................................18
9.4 Set Output ...................................................................19
9.5 Reset........................................................................19
10 PARAMETERS EXPLAINED..................................................20
10.1 Damping and smoothing .......................................................20
10.2 Response time................................................................20
10.3 Output characteristics..........................................................20
10.4 Early Burn-out Detection .......................................................21
10.5 Pulse output..................................................................21
10.6 Leak flow ....................................................................22
11 FAQs ....................................................................23

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NOTE
Much of the information contained within this document and further explanation of some of the features can be
found in the HELP file that is an integral part of the PCS45 software (version 3.11 and later).
Please consult this resource when you have any questions before contacting us. However if you still have any
queries that are not resolved by the HELP file, please contact your local Eaton’s MTL product line representative or
use the product support request facility through the website at www.mtl-inst.com/onlineforms/product.support.

INM PCS45 1
1 INTRODUCTION
The PCS45/PCL45USB configurator enables Eaton’s MTL temperature converters
and pulse isolators, part of Crouse-Hinds series, to be configured from a standard PC
running a Microsoft® Windows® operating system. The configurator comprises PC
software (PCS45) provided on a CD, and an ATEX certified interfacing link (PCL45USB).
Temperature converters and pulse isolators can be configured in the safe area, while
on-line, and the software allows configurations to be saved to disk and printed out when
required.
This manual concentrates on its use with the MTL4500 and MTL5500 range of
products, but the tools may also be used to configure the earlier MTL4000 and
MTL5000 range of products.
PCL45USB hardware
The PCL45USB provides the interfacing link between the converter module and the
personal computer (PC) running the software and connects to the PC using the USB
cable provided. The PCL45USB has a built-in cable fitted with a 3.5mm jackplug to
connect to the ‘Config’ socket on MTL4500 and MTL5500 range of converters. An
adapter cable is also provided to accommodate earlier converters.
PCS45 Configuration software
The software requires only approximately 20Mb of hard disk space and is compatible with
Windows 2000,Windows XP, Windows 7 orWindows 8. Consult Eaton’s MTL product
line for operation with any other operating systems, e.g. Windows Vista™.
CAUTION
The PCL45USB is designed for use only with devices authorised by Eaton
and no responsibility will be accepted for the consequences of its use with
any other device. Authorised devices are either named on the PCL45USB
certificate or compatible devices name the PCL45USB on their individual
data sheet.
Repairs to the PCL45USB are not permitted. The equipment can be used
only in the safe area.

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2 INSTALLATION
Although the software is supplied on a CD the user is strongly advised to check for
the latest revision of the PCS45 application; this is a free download from our website
at:
http://www.mtl-inst.com/product/configuration_tools_and_software/
The site page also provides a USB driver file that must be downloaded and installed on
the target PC to allow the application to communicate with the PCL45USB hardware.
The driver file needs only to be installed once on the machine and is not affected by
subsequent updates to the PCS45 application.
Download and install the USB driver before trying to load and run PCS45.
Unzip the driver files from the downloaded folder and store them in a
location on the hard disc drive of the PC where they can found easily. Refer
to the instruction document related to the installation of the USB driver that
is located with the file on our website. When the PCL45USB equipment is
connected to a USB port on the PC the installation wizard will recognise that
it has found new hardware. At this stage, follow the on-screen instructions
to direct the installation wizard to the location on the hard drive where you
stored the driver files; continue until the USB driver is fully installed. Refer to
the instruction document related to the installation of the USB driver that is
located with the file on our website.
To install the PCS45 software on the PC, extract the file from the compressed
download file and simply run the PCS45_Install_Vxxx.exe application. Again,
an installation wizard will take you through the process and indicate the
required responses.
Do not connect the PCS45USB interface to the isolator module at this stage.
At the initial run of the PCS45 software the Port Selection screen confirms that
the PCL45USB option is the default, and then the password entry screen appears.
Enter ‘MTL’ as the password at this point (password entry is not case sensitive). This
default password can be changed later as explained below.
3 OPENING SCREEN
On first running the application, the main screen will appear.
The top Menu Bar provides access to the main features of PCS45; each of which
is detailed in later sections of this document. The Status Bar at the bottom of the
application window is divided into sections that provide a visual indication of the
operating mode.
Help Field Module type Tag Field Operational mode Access level
Press F1 for help Selected device Configured data Offline restricted access

INM PCS45 3
The software automatically opens a new file when the application is started. This
clears the working database of the tool ready for a new configuration. The screen
shot above shows the status bar for a new file.
The password protects the configuration database. In the absence of a valid
password, access is restricted to read-only (i.e. the user can only view the current
configuration of the isolator). A user wishing to modify any of the details must log in
with the current password.
3.1 Changing the password
As previously stated, the software is shipped with a
default password setting of ‘MTL’, however the user
is free to change this at any time.
Under the Options heading on the Menu Bar, select
Change Password and a dialog box (right) will appear.
Enter the current password and then follow
the instructions.
An incorrect password will leave the user with restricted, i.e. read-only, access.
4 OPERATING MODES
The configuration software supports a number of different operation modes. These
give various levels of access, however the two key modes for configuring isolator
functions are Offline and Online.
4.1 Offline Mode
In Offline mode the application does not require an isolator to be connected, or even
a PCL45USB interface. Offline mode allows a user to create, import or open a stored
configuration file and edit it in readiness for downloading to a module. This process is
explained in more detail later in this manual.
4.2 Online
For Online mode the isolator must be connected, via the PCL45USB, to the PC.
Configuration values are uploaded from the target device to the application database.
Any changes to the values on screen are written to both the database and the
configuration memory of the isolator when the user accepts the values by clicking on
the button provided.
The user can switch between Online and Offline mode via the Menu Bar. Select
Connection and then either Establish or Disconnect options as required.
4.3 Demo mode
This mode is useful for training purposes. It simulates an Online mode, without
a connection to an isolator. The target configuration memory of the isolator is
simulated with local PC memory.
The user can select Demo mode by changing the Port
selection settings. This can be found under the Options
heading of the Menu Bar.
Click on the Demo radio button and click Accept. Then click
on Connection at the Menu Bar and choose the Establish
option. The selection of Demo mode automatically inhibits the
transfer of data to the isolator. The Tag Field of the Status Bar
now displays “DEMO”.
Operating in Demo mode permits all of the configuration
variables of the target isolator type (temperature or pulse) to
be explored.

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4.4 Access Control
To avoid unauthorised access a user is required to enter a password before being
permitted to change any parameters.
4.4.1 Restricted Access
This provides read-only access. Details of the current configuration can be viewed or
printed.
4.4.2 Full access
This provides both read and write operations. The user is permitted to edit or create
new configuration files.
5 CONNECTION TO TARGET MODULE
Provide DC power to the isolator module, then insert the jack plug from the
PCL45USB and connect its USB lead to the PC to establish a logical connection
between PCS45 software and the target’s microprocessor.
(Remember that the jack plug connector on the end of the PCL45USB cable is for
use only with the MTL4500/5500 ranges modules. Use the extension adaptor cable
for older temperature converters such as MTL4073 and MTL5074).
Click on Connection on the Menu Bar and then the Establish option. The software
will then attempt to communicate with the isolator. If PCS45 has already been used
during this session then the database may already contain data.
The software will automatically prompt the user with a pop-up window when
this occurs.
At this stage the data in the database is likely to be meaningless for the current task.
Click OK and wait as the software establishes a connection and copies the isolator’s
configuration into the database.
If there is a problem with the connection, the software will report an error message.

INM PCS45 5
The fault shown indicates a serious failure of the serial communications. If this
occurs, the user should check the physical connection, (i.e. the cables between the
PC, PCL45USB and the isolator). Another reason for this fault is the
incorrectselection of a serial port for the application.
Once the user has established a connection with the isolator the Status Bar
will be updated.
The screen shows an example of successful connection.
• Module Type = MTL4573/MTL5573
• Tag Field = ANDY 73 (This is simply the last TAG setting that was stored.)
• Operational Mode = Online.
• Access Level = full access.

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6 DISPLAYING THE CURRENT CONFIGURATION
In Online mode PCS45 automatically uploads the current configuration from
the isolator. The user can view the current settings via the Display menu of the
Menu Bar.
The configuration data is segmented into different categories that reflect the
feature-set of the target isolator. The examples shown here are for an MTL4575
temperature converter.
6.1 Basic Configuration
The upper half of the window displays the predefined
manufacturer’s settings by MTL that describe the target
device and its revision level, while the lower half displays
the user configurable settings.
Remember that at this stage you can view only the
configuration data. There is a different procedure for
modifying the configuration.
6.2 Module Configuration
Details of the operational parameters of the module are
grouped in the three ‘tabs’ of the Module Configuration
window.
6.2.1 Module Input Information
This window displays the current settings of the module
input parameters that have been configured by the user.
See the later sections of this manual for the parameter
selections that can be made.
6.2.2 Module Output Information
This window displays the current settings of the user
configurable output parameters for the specific module.
See the later sections of this manual for the parameter
selections that can be made.

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6.2.3 Module Alarm Information
This window displays the relevant alarm parameters
currently set for the module.
As before, see the later sections of this manual for the
parameter selections that can be made.
7 ONLINE CONFIGURATION
In Online mode the user can directly modify
the configuration of the isolator. This is done via
the Device Data menu of the Menu Bar. The
configuration data is segmented into different
categories, just like those of the Display menu.
New configurations can be set up by selecting the
File menu of the Menu Bar and choosing New.
The selection screen for the module type to be
configured shows the valid options for this version
of PCS45.
7.1 Basic Configuration
The upper half of the window displays the
predefined manufacturer’s settings, while the
lower half displays the user configurable settings.
The Tag Name and Descriptor fields are
straightforward text entries. The Tag name and
Descriptor have maximum character lengths of
8 and 16 characters respectively. All lower case
letters in these fields are converted to upper case
automatically and illegal characters are suppressed.
The date format is dd/mm/yyyy.
The date can be set automatically by clicking the
Today button, which synchronises the date with
that of the PC. Alternatively the user can either
type the required date directly, or use the drop-
down calendar, (available via the
down arrow).

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The current month is displayed automatically with
today’s date circled in red. The user is free to click
through the pages (using the arrows either side of the
month name) and to click on any date.
On completion the configuration needs to be download
to the module (because, so far, these changes
have taken place only in the database on the PC).
Click on the Accept button to transfer the modified
configuration to the configuration memory of the
isolator. A loading bar should move from left to right- in
the grey window at the bottom- as the download takes
place.
7.2 Configuration MTL45/5573 & MTL45/5575
The signal parameters of the MTL45/5573 and MTL45/5575 single channel
temperature converters are configured through different tabs of the Module Config.
screen. Click on the Device Data menu and choose from “Input”, “Output” or
“Alarms” configuration.
Input tab dialogue box MTLx573 and MTLx575
7.2.1 Input configuration
From the “Input” tab of the ‘Configure module data screen the first selection to be made
is for the input type; thermocouple/mV –THC, or resistance temperature detector/ohms –
RTD.
After making this selection the relevant options for the parameters of each type of input
can be entered. Select the particular input variant, the process units, linearization and filter
frequency options by clicking on the appropriate ‘radio button’ in the boxes. For RTD inputs
the field wiring arrangement (2-, 3-, or-4 wires) must be selected and forTHC inputs the
cold-junction compensation can be enabled if linearization has been selected.
The range of measurement for the sensor to be reflected in the analogue output current
is entered as numeric values of the process units selected. Note also that the operation of
the output current can be reversed simply by swapping the values assigned to the 4mA
and 20mA points.

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7.2.2 Input restrictions
Some settings in this dialog box can appear to be unavailable (“greyed out”) because some
options depend upon what others have been chosen. For example, CJ compensation is not
available for RTD and mV inputs, because it is not applicable to the input type.
The table below indicates the available options appropriate to the input type chosen.
The shaded cells indicate where there is no choice, i.e. the options have been limited
by previous choices.
Input Type Linearisa-
tion
Cold Junction Compensation Process Units
THC
types
B, E, J, K, N, R, S, T, XK On Optional- on or off °C, °F, °R, K or mV
Off Off only mV
mV Off only Off only mV
RTD
types 2-wire, 3-wire or 4-wire On Off only °C, °F, °R, K or Ohms
Off Off only Ohms
7.2.3 Output configuration
The upper portion of the dialog box contains the
damping and smoothing parameter fields for
filtering the output current.
For an explanation of some of the terms used
for these screens please see section 10 of this
document.
The lower portion contains the selection for the
output characteristic to follow either the Eaton’s
MTL standard or for the NAMUR NE43 type.
Simply type in the required values, select the
required options and click Accept. The loading bar
will pan from left to right during the download.
For the MTL45/5575 a response time can be
selected to reflect the needs of the process, but
it is strongly recommended to leave the module
on the ‘slow’ default value to achieve the best
accuracy of measurement. See section 10.2 for
details.
As for the input configuration parameters, the
software automatically restricts the configurable
parameters. The output configuration options
reflect the associated Input Type and its units of
measure.
Output tab dialogue box MTLx573
Output tab dialogue box MTLx575

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7.2.4 Alarms Configuration
The alarm parameters that can be set are changed dependent upon the input
type selected and the base model being configured.
In addition to the standard alarms for transmitter, cold-junction and line condition,
an Early Burnout Detection can be enabled for thermocouple sensors
Finally, the MTL45/5575 includes an alarm monitoring relay which, when enabled,
requires the trip point and hysteresis to be set.
7.3 Configuration MTL45/5576-RTD
The MTL4576 and MTL5576 are 2-channel temperature converters. They can be
supplied either with standard field-terminal connectors for use with resistance
temperature sensors (-RTDs) or with connectors that have integral cold-junction
sensors for use with thermocouple sensors (-THCs). The basic electronic interface
module is the same but must be configured to suit the sensor type.
The input and output configuration settings for the MTLx576 appear as two tabs on
the same screen. See the following Input and Output tab dialog boxes.
Alarms tab dialogue box MTLx575Alarms tab dialogue box MTLx573
Input tab dialogue box MTLx576-RTD

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The module has two modes of operation, available from the drop-down box at the
top of the Input dialog box.
• 2 inputs – 2 outputs = two separate input/output channels
• 1 input – 2 outputs = one input driving both outputs
This selection should be made first.
For the RTD model, select the ‘Input’ tab and choose RTD as the ‘Input type’ (top
left), then select the channel options as required, i.e. RTD type, Process units,
Linearisation and wiring (2- or 3-wire).
The range settings at the bottom of the screen define the portion of the sensor
characteristic that will be used for the analogue output. Note that these are entered
using the process units that have been chosen for that channel. Range reversal is
simply a matter of swapping the values assigned to the 4mA and 20mA points.
See section 10 for an explanation of some of the terms used on the ‘Output’ tab
dialog box. For additional assistance, refer to the Help file (F1 key) provided with the
PCS45 software.
Output tab dialogue box MTLx576

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7.4 Configuration MTL45/5576-THC
The configuration for the THC version is very similar to the RTD model explained
above.
For the THC model, select the ‘Input’ tab and choose THC as the ‘Input type’ (top left),
then select the channel options as required, i.e. THC type, Process units, Linearisation
and Cold Junction.
Refer to section 10 for an explanation of some of the terms used on the ‘Output’ tab
dialog box. For additional assistance, refer to the Help file (F1 key) provided with the
PCS45 software.
Configuration of the output and alarm parameters is essentially the same for both forms
of the MTL45/5576, with the available options being determined by the type of sensor
already selected.
The representation of the User Sensor configuration screen is included here for
completeness, but please contact your Eaton’s MTL product line representative for
advice on the use of this facility before any attempt is made to generate your own
sensor profile. It is primarily intended for the adjustment of thermocouple sensor
characteristics to suit local material variances rather than the origination of completely
new thermocouple types.
Input tab dialogue box MTLx576-THC
Alarms tab dialogue box MTLx576

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7.5 Configuration MTL45/5532
The MTLx532 pulse isolator and converter offers the option of an analogue output
signal that can be scaled to represent the frequency of the input signal. To obtain this
type of output, DIP switches at the side of the module must be pre-configured. See
the instruction manual (INM4500 or INM5500) for details of these settings.
To enable the configurable parameters of the MTL45/5532 module to be set, SW4
must be “ON”.
In providing an analogue representation of the input
frequency there are several aspects of the intended
application to consider and then configure. The basic
settings allow the assignment of the output type
(0-20, 4-20, NE43) and the frequency to use for the
4mA bottom of range and the 20mA top of range.
As well as the primary scaling that this defines it is
possible to set small adjustments as a percentage
of the span – for example when driving an analogue
indicator the calibration may need adjusting to
compensate for the (in)accuracy of the indicator.
OFF position
ON position
1 2 3 4
SW1 SW2 SW3 SW4
Vsp Vsp LFD Mode
Switches located on the edge of the module define the mode of operation
Input tab dialogue box MTLx532
User Sensor tab dialogue box MTLx576

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The leak-flow parameters enable a threshold to be set
which effectively ignores inputs below the set value. This
facility is used, for example, when there is the possibility
of a small residual trickle flow in either direction of
material flow and this should not be included in the
totalised values. By setting the leak-flow threshold to,
say, 2% then a flow of greater than this value is required
before the output starts to change.
Once the type of input signal has been set, the transfer
function to create the output pulse form can be defined.
The pulse output can be suppressed if the requirement is
only for an analogue output (see reference above to DIP
switch settings). Note that in the simple fixed-function
mode of the product, all the input types are essentially
connected in parallel and it is the user choice as to
which signal is connected. When using the configurable
functions of the product then the type of input signal
must be defined since features such as line-fault-
detection (LFD) only apply to the switch/prox input type
and not to the voltage/current input types.
Output pulses can be associated on a 1:1 basis related
to the input, i.e. 1 pulse out for 1 pulse in, or a frequency
divider option can be applied offering a divisor from 1 to
65534, but with an output frequency limit of 1kHz. The
format of the output pulses can also be set such that it
simply ‘toggles’ (i.e. changes state), or produces a pulse
of fixed duration, based on the input pulse count and the
division setting. See Section 10.5 for more details.
Finally the alarm output can be configured. There are three ways to make use of this
option. One use of this relay output channel can be to signal the LFD status if the input
type is a switch or proximity detector. Next, the output can be set for a simple trip
operation where the output is triggered based upon the threshold value and hysteresis
values selected.
Finally there is a ‘window’ trip mode where the alarm output is determined with
reference to two trip points that define a lower and an upper value. The alarm can be
defined to occur while the signal sits between the two trip points, or ‘inverted’ to alarm
when the signal goes outside of the trip point window. An example of the use of this
alarm feature is for the monitoring of fan or conveyor speed where a certain minimum
value is required and yet a maximum value must also be set. Note that although two
trip points can be assigned there is only one relay output, which is why we use the
Output tab MTLx532
Digital Functions tab MTLx532