ISA MC5 User manual

MULTIFUNCTION CALIBRATOR
User Guide
Applies for Main Firmware version 1.90
Dear user,
We have made every effort to ensure the accuracy of the contents of this manual.
Should any errors be detected, we would greatly appreciate to receive suggestions
to improve the quality of the contents of this manual.
The above not withstanding, we can assume no responsibility for any errors in this
manual or their eventual consequences.
We reserve rights to make modifications to this manual without any further notice.
For more detailed technical data about the MC5 Multifunction Calibrator, please
contact the manufacturer.
© Copyright 1998, 2001, 2002, 2003, 2006
BEAMEX OYAB
Tel
[phone]
Fax
[phone]
E-mail: [email protected]
Internet: http://www.instrumentsolutions.com.au
8822000 / UEMC5 / 000696

Contents
Trademarks
QCAL® is a registered trademark owned by Oy eamex Ab.
HART® is a registered trademark of the HART Communication Foundation.
Any use of the word HART hereafter in
this document implies the registered trademark.
Other trademarks are property of their respective owners.
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Contents
Contents
Part A, General
MC5s Modularity and Options 24
Hardware modules/options .................. 24
Other Connectable devices ............ 25
Firmware options ................................. 25
Safety 26
Certifications and Compliances
(EC Declaration of Conformity) ............ 26
Safety Precautions and Warnings ....... 27
General Warnings .......................... 27
Warnings Concerning the use
of Electrical Modules (E and ET) .... 28
General Warnings Concerning
Pressure Measurement .................. 28
Warnings Concerning
High Pressure ................................ 29
Service 30
Firmware Update ................................. 30
Recalibrating MC5 ............................... 30
The attery Charger ............................ 30
Cleaning MC5 ...................................... 31
Cleaning the Contacts of the
Internal Reference Junction
Module ............................................ 31
Introduction 2
About This Manual ................................. 2
Typographical Conventions .............. 3
Unpacking and Inspection ..................... 3
MC5 Hardware 4
Operational Sections and Connections . 4
The Upper Panel .............................. 5
The Connectors on the
Left Side of MC5 ............................... 6
The Front Panel ................................ 7
Memory ................................................ 10
atteries ............................................... 11
About the Charger and
the Charging Procedure ................. 12
Removing/Replacing the
attery Pack ................................... 13
Support for Table Top Use ................... 14
The Wrist Strap and
the Neck Support Strap ........................ 14
The Optional Carrying Case ................ 14
MC5 irmware 15
General Description ............................. 15
Startup Procedure .......................... 15
asic Mode ..................................... 16
Maintenance ................................... 16
Calibration Mode ............................ 16
Help Function ................................. 17
Printing ........................................... 17
The User Interface ............................... 18
The Status ar ................................ 18
The Function Key ar .................... 19
Menus ............................................. 19
The Display Area ............................ 20
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Contents
Part B, Startup and Basic Operation
Starting MC5 34
Startup Procedure ................................ 34
asic Mode, Defined ............................ 35
Measuring 37
Pressure Measurement........................ 39
Using Internal Modules .................. 39
Using External Modules ................. 39
Zeroing a Pressure Module ............ 40
Current Measurement .......................... 41
External supply ............................... 41
Internal Supply ............................... 41
Voltage Measurement .......................... 42
Measuring Low Voltages ................ 42
Measuring Voltages up to ±50 V .... 43
Resistance Measurement .................... 44
Switch State Sensing ........................... 45
Limit Switch Test .................................. 46
Performing the Limit Switch Test .... 46
Frequency Measurement ..................... 48
Pulse Counting .................................... 49
RTD Measurement (Temperature) ....... 50
Thermocouple Measurement
(Temperature) ...................................... 51
Internal Reference Junction ........... 51
External Reference Junction .......... 51
Special Measurements 53
Mathematical Special Measurements .. 54
Minimum value ............................... 54
Maximum value .............................. 54
Min/Max value ................................ 54
Rate of Change .............................. 54
Special Filtering and Resolution ..... 55
Deviation Measurement ................. 55
Special Measurements Using
Two Ports Simultaneously .................... 56
Difference Measurement ................ 56
Redundant Measurement ............... 57
Generating/Simulating 58
General ................................................ 58
Changing the Value of the
Generated/Simulated Signal .......... 59
Current Generation .............................. 60
Using the ET modules
output terminals .............................. 60
Using the E modules
output terminals .............................. 60
Voltage Generation .............................. 62
Generating Voltages up to ±12 V ... 62
Low Voltage Generation ................. 62
Frequency Generation ......................... 64
Pulse Generation ................................. 65
RTD and Resistance Simulation .......... 66
Thermocouple Simulation .................... 67
Internal Reference Junction ........... 67
External Reference Junction .......... 67
Special Generations 69
Opening the Step or Ramp
Configuration Window ......................... 69
Stepping ............................................... 70
Ramping ............................................... 71
Alarm Limit Settings 73
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Contents
Configuring the Calibrator 76
Settings ................................................ 76
Setting Time and Date ......................... 78
Advanced Utilities 79
Measuring the Environment
Temperature with the ENV Sensor ...... 79
Display Mode Settings ......................... 80
Scaling ............................................ 81
Displaying Values in Percentage .... 82
Displaying Error Values .................. 82
Transmitter/Switch Simulation ............. 83
Transmitter Simulation ................... 84
Switch Simulation ........................... 85
Data Logging ........................................ 86
General ........................................... 86
Configuring ..................................... 86
Starting the Data Log ...................... 87
Viewing the Results ........................ 88
Transferring the Results to
a Personal Computer ..................... 88
Generating Signals Using
External Devices .................................. 89
Controlling the External Device
in asic Mode ................................. 90
Pressure Controller Settings .......... 91
Temperature Controller Settings .... 92
Printing ................................................. 93
Part C, Advanced Operation and Configurations
Additional Information 94
Things to Consider when
Measuring Pressure ............................. 95
General ........................................... 95
Pressure Type ................................ 95
Pressure Modules and their
Naming Conventions ...................... 96
Square Rooting .............................. 96
Thermocouple Measurement/Simulation,
Connections and Troubleshooting ....... 97
Internal Reference Junction ........... 97
External Reference Junction .......... 98
Error situations ............................. 100
Resistance and RTD Measurement,
Connections ....................................... 101
4-wire System ............................... 101
3-wire System ............................... 101
Using a Compensation Loop ........ 102
2-wire System ............................... 102
Current Measurement Parallel to
a Test Diode, Connections ................. 103
Parallel Functions in MC5 .................. 104
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Contents
Part D, Calibration
General 106
Phases of Instrument Calibration ...... 107
As Found Calibration .................... 108
Adjustment ................................... 108
As Left Calibration ........................ 109
Required Modules for Different
Input/Output Signal Combinations ..... 110
Calibrating an Instrument 112
Selecting the Instrument to e Calibrated
112
The Instrument Window ..................... 113
A Calibration Procedure Using MC5 .. 114
About Automatic Calibration ......... 116
About Manual Calibration ............. 116
Autocapture Feature .................... 117
Examples of Instrument Calibration ... 117
Pressure Transmitters
and Sensors ................................. 118
Temperature Sensors ................... 120
Temperature Indicators
and Recorders .............................. 122
Electrical Limit Switches ............... 124
Using External Devices in
Calibration Mode ................................ 126
MC5s Support for Instrument Adjustment
127
Maintaining MC5s Instrument
Database 128
Adding New Instruments .................... 128
Editing Instrument Data ..................... 129
General Data Page ....................... 129
Instrument Input Page .................. 130
Instrument Output Page ............... 130
Calibration Settings Page ............. 131
Calibration Instructions Page ....... 132
Deleting Instruments .......................... 132
Viewing Calibration Results 133
Calibration Result Windows ............... 134
How to Choose Which Calibration
Run is Viewed .............................. 134
Deleting Calibration Results .............. 134
Appendix 1,
User Guide for
MC5 HART Option 136
Appendix 2,
Technical Data 150
Appendix 3,
Quick Guide for the
MC5 Datalog Viewer 156
Appendix 4,
Index 160
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General
Things discussed in Part A:
••
••
•An introduction to what MC5 is
and what the parts of this User
Guide concentrate on.
••
••
•A general description of MC5’s
hardware.
••
••
•A general description of MC5’s
firmware.
••
••
•The modularity and options of
MC5.
••
••
•Safetyprecautionsand warnings.
••
••
•Briefly about how to service MC5.

2
General
Introduction
Congratulations for selecting the ultimate calibration tool!
MC5 is a documenting All-In-One Multifunction Calibrator with cali-
brationcapabilityof pressure, temperature, electrical and frequency
signals.As a member of Beamex’s QCALQuality Calibration family
it is of course able to communicate with the available QCAL calibra-
tion software. MC5’s modularity allows customized construction. If
requirementsincreasein the future, new functionality may beadded
by getting additional modules, e.g. adding temperature and/or elec-
trical modules to an MC5 that previously only included pressure
modules.
Thanks to the logical user interface MC5 is very easy to use. The
largebacklitgraphicaldisplayguidestheuser in differentlanguages
and it displays results both numerically and graphically.
MC5 performs automatic calibration of pressure, electrical and tem-
perature process instruments. It is capable of communicating with
external devices such as pressure controllers. MC5 also communi-
cates with HART field instruments.
MC5 represents the state of the art in accuracy, adaptability and all-
round usability.
About This Manual
This User Guide is divided in four parts: A, B, C and D.
•PartAdiscussesgeneralmatters.Thereis also a chapterabout
safety.
•Part B describes the basic use of MC5 such as measuring
and generating signals.
•Part C handles configuration level usage, some optional
software utilities and also offers some additional information
concerning pressure measurement, RTD and T/C measure-
ment/simulation.
•Part D concentrates on calibration and matters related to
calibration like handling instrument data.
The even page header displays the title of the active part. The odd
page header displays the main subject (Heading level 1).
Theheaderofeach oddpagealsoindicatesthe active partas shown
in the adjacent picture (with Part B
active). Use the information pro-
vided in the headers as a quick
guide when searching for a particular subject.

3
Typographical Conventions
All examples of user interface texts are printed using 8 pt Arial
Black, e.g.
Selected port: ET: TCi(mea)
All front panel texts (fixed texts on MC5’s cover) are printed using
8 pt Eurostile, e.g.
Connectors marked T/C, Low V
Function and Menu keys are often referred to using both the key
name in 8 pt Eurostile and the corresponding text (function) dis-
played on the screen in 8 pt Arial Black, e.g.
Function key D/Menu
Unpacking and Inspection
At the factory each new MC5 passes a careful inspection. It should
be free of scrapes and scratches and in proper operation order
upon receipt. The receiver should, however, inspect the unit for any
damage that may have occurred during transit. If there are signs of
obvious mechanical damage, package contents are incomplete, or
the instrument does not operate according to specifications, con-
tact the purchasing sales office as soon as possible. The standard
accessories are as follows:
•Calibration Certificate
•This User Guide
•Warranty Card
•Battery Pack, NiMH
•Charger for the Battery Pack
•Computer communication cable
•If any internal pressure modules are present:
A pressure hose set
•If the E module is present: Two test leads and clips
•If the ET module is present: Four additional test leads and
two clips
For a description of available hardware and software options, see
MC5’s Modularity and Options on page 24.
If you have to return the instrument to the factory for any reason,
use the original packing whenever possible. Include a detailed de-
scription of the reason for the return.
Warning!
The accessory polyurethane hose supplied with the calibrator
is rated to the maximum pressure of 20 bar at 21°C (290 psi at
70°F). Applying higher pressure can be hazardous.
Introduction

4
General
MC5 Hardware
General features:
•IP65 water/dust proof case (EN60529)
Battery pack IP30.
•Integrated impact protectors
•Both a wrist strap and a neck support strap
•A support for using the calibrator on the table
•Operating temperature: -10 … +50 °C (14 … 122 °F).
+10 … +40 °C (50 … 104 °F) when charging the batteries.
•Storage temperature: -20 … +60 °C (-4 … 140 °F).
Note: The stickers and the batteries may be affected when
storing longer periods in extreme conditions.
•Humidity: 0 … 80 %RH
More comprehensive specifications are available in Appendix 2.
Operational Sections and Connections
I n t e r n a l
P r e s s u r e
M o d u l e s
E x t e r n a l
P r e s s u r e
M o d u l e s
E n v i r o n m e n t
T e m p e r a t u r e
S e n s o r I n t e r f a c e
A u x i l i a r y
I n s t r u m e n t
I n t e r f a c e
C o m p u t e r /
P r i n t e r
I n t e r f a c e
E l e c t r i c a l a n d
T e m p e r a t u r e M o d u l e
( E T M o d u l e )
e f e r e n c e
J u n c t i o n M o d u l e
( J M o d u l e )
E l e c t r i c a l
M o d u l e
( E M o d u l e )
T h e
U p p e r
P a n e l
T h e
L e f t
S i d e
T h e
Front
P a n e
l
All sections and connections are presented in detail on the next
pages.
Note.
Keep in mind that the previous picture (as well as all pictures of
MC5 in this manual) has an example configuration of modules. The
configuration of your MC5 may vary significantly from the one in the
picture.

5
The Upper Panel
The upper panel has 5 places for the following modules/connec-
tors:
External Pressure Modules
MC5 has a connector for External Pressure Modules (EXTs). The
connector is located on the right hand side of the upper panel and
is marked with PX1 in a sticker on the upper panel.
Internal Pressure Modules
Up to three Internal Pressure Modules may be installed in MC5.
One of them may be an internal barometric module. Although the
BarometricModulereservesthe spaceallocated foraninternalpres-
sure module it does not need a connector in the upper panel, so the
space reserved for the connector may be used for, e.g. a connector
for an External Pressure Module.
The connectors for Internal Pressure modules start from the sec-
ond connector on the left. The possible Barometric Module is al-
ways located as second from right and it measures the barometric
pressure through a connection in the back panel of MC5. Normally
nothing need to connected to the barometric pressure module’s
connector.
Internal pressure modules are marked with P1 … P3. The Baro-
metric Module does not have an abbreviation. The whole name is
written on the module.
The recommended pressure medium for all internal pressure mod-
ules is clean air. Clean non-corrosive liquids may optionally be used
in modules with a measuring range of 20 bar/300 psi or more.Avoid
spilling liquid on MC5 when connecting/disconnecting pressure
hoses to/from pressure modules.
To avoid damaging the calibrator, use hand tightening only when
connecting the pressure measurement hoses (max. torque 5 Nm,
approx. 3.6 lbf ft). If the use of tools is required to secure the con-
nection (typically pressure modules with a pressure range higher
than 20 bar), apply the counterforce with a spanner on the connec-
tor body’s hexagonal part.
The overpressure protection of the internal pressure modules vents
to the back of the calibrator. Remember to be cautious when work-
ing with pressure and pressure modules. See also chapters Safety
on page 26 and Safety Precautions and Warnings on page 27.
MC5 Hardware

6
General
The Connectors on the Left Side of MC5
The left side of MC5 (front view) has three connectors as follows:
Environment Temperature Interface
This connector is for an optional temperature measurement sen-
sor. This sensor is only meant for environment temperature mea-
surement. It should not be used as a reference sensor when cali-
brating temperature instruments.
Computer/Printer Interface
The COMP/PRT connector may be used when connecting to a se-
rial port in a PC.The PC may have a calibration software capable of
communicating with MC5 or, e.g. a software that reads data logging
results in MC5 and transfers them to a PC.
The same connector can be used when MC5 is connected to an
optional portable printer. The printer may be used for printouts of
user interface screens (e.g. calibrations results).
Warning!
Use only cables provided by Beamex when connecting MC5 to
a PC or a printer.
Auxiliary Instrument Interface
The AUX connector is used when connecting pressure controllers,
temperature baths/dry blocks etc. to MC5.
Using auxiliary instruments is described in Part C of this manual.

7
The Front Panel
The front panel has several sections. Some of them are pointed out
with a callout in the picture of Operational Sections and Connec-
tions, and some of them not (e.g. display and keyboard). The ones
with a callout are discussed first in the following paragraphs.
Electrical Module (E module)
The E module can measure the following quantities: voltage, cur-
rent and frequency. It can also be used when counting pulses or
detecting the state of a switch. Additionally there is a possibility to
generate current and supply an instrument with a 24 VDC power
supply.
The E module also includes the optional HARTmodem. This allows
communication with an instrument with HART capabilities. When
HART is used in conjunction with MC5’s power supply, an internal
270 ohm resistor
needed for HART com-
municationisautomati-
cally included.
Additional information
on calibrating HARTin-
struments is in Appen-
dix 1.
Electrical and Temperature Module (ET module)
The ET module is specially designed for temperature instrument
calibration needs. It is not however restricted to only temperature
instrument use because it can also generate voltage, current, fre-
quency and pulses.
Measuring capabilities:
•Low Voltage measurement and T/C measurement using ei-
ther the internal reference junction or the Low Voltage connec-
tors.
•Resistance and RTD measurement.
Generation/simulation capabilities:
•T/C simulation using either the internal reference junction or
the Low Voltage
connectors.
•Resistance and
RTD simulation.
•Voltage, current,
frequency and
pulse generation
T / C , L o w V
4 - w m e a s
R , R T D
3 & 4 - w m e a s
V ,
1
,+ 2 4 V
1
m e a s / s i n k
L o w V
H A R T
®
T / C I N T . R
T / C O R E X T
W I R E S O N L Y
2 - w x m t r
V , ,
M E A S U R E
O U T P U TS E N S O R M E A S U R E & S I M U L A T E
E T E
M a x i n p u t :
6 0 V D C / 3 0 V A C
T / C , L o w V
4 - w m e a s
R , R T D
3 & 4 - w m e a s
V ,
1
,+ 2 4 V
1
m e a s / s i n k
L o w V
H A R T
®
T / C I N T . R
T / C O R E X T
W I R E S O N L Y
2 - w x m t r
V , ,
M E A S U R E
O U T P U TS E N S O R M E A S U R E & S I M U L A T E
E T E
M a x i n p u t :
6 0 V D C / 3 0 V A C
MC5 Hardware

8
General
Reference Junction Module
The T/C measurement/simulation internal reference junction is an
optional addition to the ET module. It is specially designed for MC5
andthereforebestsuitedforreferencejunction compensation when
calibrating thermocouples or instruments connected to a thermo-
couple.
The Reference Junc-
tionModuleissuited for
all standard T/C plugs
and stripped wires.
Open the fixing screw
on the left side of MC5
before connecting the
wires/plug to the Reference Junction Module. Make sure to con-
nect the wires/plug as the polarity is indicated on the Reference
Junction Module. Remember to tighten the fastening screw when
the wires/plug are connected. Hand tightening is adequate. Do not
pull out the wires/plug without first opening the fixing screw. Other-
wise you might damage the contact surface of the connectors.
T/C measurement and simulation may also be done without the
internal reference junction by using the Low Voltage terminals in
the ET module. Then the reference junction arrangements have to
be done outside MC5 and the correct reference junction settings as
well as the reference junction temperature have to be informed to
MC5.
Part B of this manual describes in detail what kind of reference
junction settings are available.
Display MC5 has a backlit transreflective display. The resolution of the dis-
play is 240 x 320 pixels.
To quickly tune the contrast of the display:
•Press and hold the light button down.
•Use the up and down arrow keys to change the contrast.
To quickly tune the backlight brightness:
•Press and hold the light button down.
•Use the left and right arrow keys to change the backlight
brightness.
The changed settings are automatically saved as default settings.
T / C , L o w V
4 - w m e a s
R , R T D
3 & 4 - w m e a s
V ,
1
,+ 2 4 V
1
m e a s / s i n k
L o w V
H A R T
®
T / C I N T . R
T / C O R E X T
W I R E S O N L Y
2 - w x m t r
V , ,
M E A S U R E
O U T P U TS E N S O R M E A S U R E & S I M U L A T E
E T E
M a x i n p u t :
6 0 V D C / 3 0 V A C

9
Keyboard The keys on the MC5’s keyboard are grouped according to their
function as follows:
The Cursor Keys and the Enter Key
The Cursor keys and the Enter key are located close to the upper
left corner of the display. The Cursor keys are used when moving
the cursor on the screen. They also have several special functions
in certain situations, e.g. when tuning the contrast of the display.
The Enter key finishes the entering of values.
The Keys Above the Display
The Light key toggles the back light of the display on and off. It is
also used when setting the contrast and the brightness of the dis-
play(seechapterDisplay onpage 8)andwhen printing screenshots
(see chapter Printing on page 17).
The Help key displays case sensitive help.
The On/Off key switches MC5 on and off. Press the On/Off key for
abouthalf-a-secondtoswitchon/off.This delayed function prevents
accidental on/off switching of MC5.
MC5 Hardware

10
General
Pressing the +/- key toggles the sign of the entered numeric value.
Note. The +/- key is applicable only in numeric fields.
The Decimal key adds the decimal point to the numeric value that
is currently edited.
The Function Keys
The Function Keys are located below the display. The meaning of
each Function Key varies depending on the situation. The lower
part of the display indicates what the Function Key stands for at the
moment.
The Numeric Keys
The Numeric keys are not only used when entering numbers:
•Keys 1 to 7 are used as menu selector keys.
•Keys 0 and 8 are used to scroll through several pages of menu
options. They may also be used when browsing through op-
tions in a pop-up list.
•Key 9 can be used when accepting a selection or when finish-
ing a data entry. The functionality of the 9 key is almost similar
to the key, except for one situation: When entering num-
bers, the 9 key produces the number 9. To finish entering a
number, you will have to use the key or use the D/OK
Function Key when available.
Memory
MC5 has a dynamic memory allocation system. This means that
there is not a specific area of memory reserved for, e.g. instrument
data.All free memory may be used for anything that requires more
memory. Thus there is no exact limit for the number of instruments
that MC5 can maintain in its memory. It all depends on how much
memory is allocated by other data.

11
Batteries
MC5 supports the use of both rechargeable batteries and alkaline
batteries. When using alkaline batteries, you need a Dry Battery
Cartridge. MC5 automatically detects the battery type.
The alkaline batteries to be used are:
- Cell Voltage: 1.5 V
- Amount: 6
- Type: AA
The charger for rechargeable batteries operates in the following
environments:
- Voltage: 100 … 240 VAC,
- Frequency: 50/60 Hz
The charging electronics is in the Battery Pack. Therefore the bat-
teries may be charged although the Battery Pack is disconnected
from MC5’s Base Unit. If you have two sets of rechargeable batter-
ies you may charge the disconnected Battery Pack while at the
same time use MC5 with the connected Battery Pack.
The maximum operating time without recharging varies depending
on the usage and brightness setting of the display light. Also the
generated output current and the usage of the 24V transmitter sup-
ply affect the maximum operating time. Even with constant maxi-
mum load, the standard rechargeable batteries should last for 6
hours. A good average operating time is 10 hours.
If alkaline batteries are in use, the maximum operating time also
depends on the quality of the batteries. An average operating time
is approximately 4 hours.
The upper left corner of MC5’s display shows a picture of a battery.
The whiter the picture is, the more acute is the need for recharging
(or changing of the alkaline batteries).
Notes.
MC5’smemoryandtheinternalclock/calendaruses a small amount
ofpoweralthoughthecalibratorisswitched off.Remembertocheck
the capacity of the batteries from time to time although MC5 is not
in use.
Do not leave MC5 without a Battery Pack or a Dry Battery Cartridge
for a long time. MC5 may loose its settings if it is left without a
support voltage for an extended period.
Full batteries:
Empty batteries:
MC5 Hardware

12
General
About the Charger and the Charging Procedure
The charger is connected to the charger connector at the bottom of
MC5. The charging electronics informs you of the phases of the
charging procedure with the help of the charge status light.
When connecting the charger, the charging electronics first checks
the charge level of the batteries. At this stage, no light is visible in
the charge status light.
When the charge status light is red, a recharging is either starting
(blinking red light) or in progress (constant red light). MC5 may be
usedduringtherechargingphase.Empty batteries are fullycharged
in approx. 2½ hours.
When the charge status light is green, the batteries are charged.At
this stage the charging electronics provide a support voltage that
prevents the batteries from discharging
Warnings!
USEONLYTHE CHARGERPROVIDED WITH THECALIBRATOR.
The charger accepts input voltages from 100 to 240 VAC.
The charger should only be used indoors and the temperature
should not exceed 40 °C (104 °F).
C h a r g e r c o n n e c t o r
C h a r g e s t a t u s l i g h t