Tempsens CALsys 1200BB User manual

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Black body
Temperature
Calibrator
(CALsys
1200BB)
User’s Guide
TEMPSENS INSTRUMENT (I) PVT. LTD UNIT II
A-190 ROAD #5, MIA UDAIPUR, 313003, INDIA
Phone: [phone]
Fax: [phone]
Email: [email protected]
Web: www.tempsens.com

2
Legal Disclaimer
The information contained in this document is the property of TEMPSENS.
TEMSPENS reserves the right to make changes to this document and to the product described herein
without notice. Before installing and using the product, review the latest version of the applicable
documentation, which are available from the Tempsens website at:
http://www.tempsens.com/
© 2021 Tempsens Instrument Pvt. Ltd. All Rights Reserved.
Document Information
NAME
Black Body Temperature Calibrator (CALsys 1200BB) User Manual
DOCUMENT VERSION
1.0
DOCUMENT CODE
TS.CS.001
PUBLISH DATE
Wednesday, November 3, 2021

3
Table of Contents
Preface ................................................................................................................................................5
Safety Information ...................................................................................................................................................5
Electrical Safety........................................................................................................................................................6
Health and Safety Instructions..................................................................................................................................7
Cautions and Preventions......................................................................................................................................... 8
Document Conventions ............................................................................................................................................8
Chapter 1...................................................................................................................................................... 9
Introduction.........................................................................................................................................9
About CALsys 1200BB...............................................................................................................................................9
Basic Working Model of CALsys 1200BB.................................................................................................................. 10
Physical Measurements.......................................................................................................................................... 11
Wiring Diagram ...................................................................................................................................................... 11
Technical Specifications.......................................................................................................................................... 12
Chapter 2.................................................................................................................................................... 13
Setting Up CALsys ...........................................................................................................................13
Installation............................................................................................................................................................. 13
Optimal Environmental Conditions ......................................................................................................................... 13
Unpacking and Initial Inspection ............................................................................................................................. 14
Operating Instructions............................................................................................................................................ 15
Initial Testing.......................................................................................................................................................... 15
Chapter 3.................................................................................................................................................... 17
Operating CALsys 1200BB..................................................................................................................17
Turning On the Unit................................................................................................................................................ 17
Heating Up the Source............................................................................................................................................ 17
Operating Instructions............................................................................................................................................ 18
Cooling Down the Source ....................................................................................................................................... 19

Black body Temperature Calibrator (CALsys 1200BB)
User’s Guide
4
Chapter 4.................................................................................................................................................... 21
Operating Unit Controller ..................................................................................................................21
Front Panel Layout ................................................................................................................................................. 21
The Temperature Controller................................................................................................................................... 21
Altering the Set point ............................................................................................................................................. 21
Monitoring the Controller Status............................................................................................................................ 22
Temperature Units................................................................................................................................................. 22
Chapter 5.................................................................................................................................................... 23
Digital Communication ......................................................................................................................23
Digital Communications Wiring .............................................................................................................................. 23
Digital Communications Parameters....................................................................................................................... 24
Chapter 6.................................................................................................................................................... 25
Software Installation .........................................................................................................................25
Installation............................................................................................................................................................. 25
Parameters on Main Screen ................................................................................................................................... 25
Chapter 7.................................................................................................................................................... 27
Service & Maintenance......................................................................................................................27
Routine service ...................................................................................................................................................... 27
Replacing Controlling Sensor .................................................................................................................................. 27
Replacing Solid State Relay..................................................................................................................................... 27
Chapter 8.................................................................................................................................................... 29
Troubleshooting CALsys 1200BB ........................................................................................................29
CALsys 1200BB unit does not turn on ..................................................................................................................... 29
The CALsys 1200BB unit is not stable...................................................................................................................... 29
The temperature of the Calibrator Unit does not rise.............................................................................................. 29
Appendix A: Calibration Services .......................................................................................................31
In House Calibration Facility............................................................................................................................... 31
On-site Calibration Facility ................................................................................................................................. 32
Fixed-point Calibration Facilities ........................................................................................................................ 32
32
Appendix A: Warranty .......................................................................................................................35
Limit of Liability ................................................................................................................................................. 35
Caution in Using the Product ............................................................................................................................. 35

5
Preface
Welcome to the Black body Temperature Calibrator (CALsys 1200BB) user guide. This guide provides
detailed information about all the product options and features, and explains how to use the product
and configure basic settings to suit your requirements.
This user manual contains information about the product and its proper use and should be kept in a
place where it will be easy to access. This user manual also provides safety precautions in using this
product.
Safety Information
This topic contains important information regarding safety. Ignoring safety precautions may cause
serious personal injury or damage to the unit and/or its components. Use the equipment only as
specified in this manual. Otherwise, the protection provided by the instrument may be impaired.
Refer to the safety information in the Electrical Safety and Health and Safety Instructions sections or
wherever specified in this manual.
The following definitions apply to the terms “Warning” and “Caution”.
“Warning” identifies conditions and actions that may pose hazards to the user.
“Caution” identifies conditions and actions that may damage the instrument being used.
The following safety symbols may appear on CALsys 1200BB unit:
SYMBOL
DESCRIPTION
SYMBOL
DESCRIPTION
Risk of Danger. Important information.
See Manual
Hazardous voltage. Risk of electric shock
Caution, Hot Surface
Protective Earth Ground

Black body Temperature Calibrator (CALsys 1200BB)
User’s Guide
6
Electrical Safety
WARNING:
This equipment must be correctly grounded before use. Make sure the ground conductor
wire (colored green/yellow) in the main power cable is connected to a protective
earth/ground. If the equipment is not properly grounded, the high voltage may flow
through the equipment body (chassis). SEVERE INJURY OR DEATH may result if personnel
fail to observe safety precautions.
Do not remove the panels from the equipment without proper safety measures to avoid
internal main power supply voltage hazard.
To avoid possible electric shock or personal injury, follow these guidelines.
This equipment uses protective earth circuit to ensure that the conductive parts do not store electric
charges or conduct electricity if insulation fails.
Before connecting the equipment to the electricity supply, understand the parts of the calibrator with
the help of operating manual.
Use power cables only with appropriate voltage and power rating, and that are approved for usage in
your country.
Replace the main power cable if the insulation is damaged, or if the insulation shows signs of wear
and tear.
DO NOT put the product at the location where access to the main power is blocked.
DO NOT use an extension cord or adapter plug.
DO NOT use the product if it operates incorrectly.
Make sure the power cord does not touch the hot parts of the product.

Preface
7
Health and Safety Instructions
WARNING: BURN HAZARD - DO NOT touch the well access surface of the unit at high
temperature
To avoid possible health and safety concerns, follow these guidelines.
Wear appropriate protective clothing before using the equipment.
Operators of this equipment should be adequately trained in the handling of hot and cold items and
liquids.
Do not use the apparatus for jobs other than those for which it was designed, that is, the calibration
of thermometers.
Do not handle the apparatus when it is hot (or cold), without wearing the appropriate protective
clothing and having the necessary training.
Do not drill, modify or otherwise change the shape of the apparatus.
Do not use the apparatus outside its recommended temperature range.
After use, do not return the apparatus to its carrying case until the unit has cooled down.
There are no user serviceable parts inside. When required, contact Tempsens agent for repair.
Ensure all materials, especially flammable materials are kept away from the hot parts of the apparatus,
to prevent fire risk.
Do not use the product around explosive gas, vapor, or in damp or wet environments.
Make sure that the space around the product meets minimum space requirements.
DO NOT turn off the unit at temperatures higher than 250°C. This could create a hazardous situation.
Select a set-point less than 250°C and allow the unit to cool before turning it off.
The top sheet metal of the furnace may exhibit extreme temperatures for areas close to the well
access.
Materials used in this furnace may be irritating to skin, eyes, and respiratory tract. Consult the
material manufacturer’s Material Safety Data Sheet (MSDS) to learn about those materials before
using.

Black body Temperature Calibrator (CALsys 1200BB)
User’s Guide
8
Cautions and Preventions
To avoid possible damage to the instrument, follow these guidelines:
Before working inside the equipment, turn the power off and disconnect the power cord.
DO NOT turn the unit upside down with the inserts in place; the inserts will fall out of the unit.
Use of this instrument at HIGH TEMPERATURES for extended periods of time requires caution.
Completely unattended high temperature operation is not recommended for safety reasons.
DO NOT plug the unit into 230 V if the heater switches and fuse holder reads 115 V. This action will
cause the fuses to blow and may damage the instrument.
Components and heater lifetime can be shortened by continuous high temperature operation.
DO NOT use fluids to clean out the well.
Never introduce foreign material into the probe hole of the insert. Fluids and other materials can leak
into the calibrator causing damage.
DO NOT drop or force the probe stems into the well. This type of action can cause a shock to the
sensor and affect the calibration.
Document Conventions
The documentation uses the following conventions.
Note:
Configuration notes
Tip:
Recommendations or suggestions
Important:
Information regarding required or default configuration settings and product limitations
WARNING:
Critical actions and configuration options
WARNING:

9
Chapter 1
Introduction
About CALsys 1200BB
CALsys 1200BB has been designed to provide stable and accurate temperature to enable
professionals to calibrate temperature sensing devices by comparison method. It is designed to be
rugged and easily maintained. This model provides an isothermal cavity in which the pyrometer can
be calibrated against the temperature of the calibrator.
For traceable calibration, a master calibration sensor should be placed into the metal block alongside
the unit under calibration. This method is widely accepted because the calibrator provides very stable
temperature nearing to its controlled point, that is, the Master pyrometer. The controlled point is
calibrated by independent laboratory in compliance to the national standards, and compares the
sensor under calibration.
The CALsys models are part of wide range of portable calibrators designed and made by Tempsens.
Contact Tempsens to learn more about other products by Tempsens.

Black body Temperature Calibrator (CALsys 1200BB)
User’s Guide
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Basic Working Model of CALsys 1200BB
CALsys 1200BB is a transportable unit designed for use on any reasonable flat surface. The target is a
ridged silicon carbide which is having a high emissive material. The target is heated by Kanthal APM
which allows the source to heat up to 1200°C in about 1.5 Hrs and hold it stable at temperature
within ±0.5°C. The heater blockhouses consists a heater & the controller sensor. The temperature
controller to sense the cavity temperature uses this sensor. To obtain the maintain a required
temperature the controller varies the power to the heaters via a solid-state relay(SSR).
Important:
Before using the equipment, read the safety guidelines and operating procedures of the calibrator as
described in the Preface of this user manual.
The basic working model for CALsys 1200BB is as follows:

Introduction
11
Physical Measurements
CALsys 1200BB has the following physical measurements:
Wiring Diagram
Refer to following figure for CALsys 1200BB wiring diagram.

Black body Temperature Calibrator (CALsys 1200BB)
User’s Guide
12
Technical Specifications
CALsys 1200BB has the following technical specifications:
PARAMETER
SPECIFICATION
Temperature range
300°C to 1200°C
Accuracy
±2°C
Stability
±0.2°C at 300°C
±0.3°C at 800°C
±0.5°C at 1200°C
Cavity type
Silicon carbide
External aperture
40mm dia
Cavity diameter
46mm(85mm depth)
Emissivity
0.98(±0.02)
Method of control
Self tuned PID controller
Heating time
1.5 Hrs
Resolution
1°C
Display
LCD, °C or °F user selectable
Size(H x W x D)
590(H) x 450(W)x 530(D)
Weight
50 kg
Power requirements
230VAC, 2.5KW(50 Hz)
Computer interface
RS-232
Calibration
Accredited Calibration certificate provided
Environment operating conditions
0° to 40°C, 0% to 90% RH(non-condensing)
Specification valid in environment conditions
13°C … 33°C

13
Chapter 2
Setting Up CALsys 1200BB
Installation
Place the black body on a flat surface with at least 10 inches of free space around the instrument.
Overhead clearance is required.
DO NOT Place this unit under a cabinet or structure. Plug the power cord into a grounded mains
outlet located on the controlling unit rear panel. Observe that the nominal voltage corresponds to
that indicated in the technical specifications in Technical Specifications in Chapter 1 of this user’s
guide.
Optimal Environmental Conditions
Although the instrument has been designed for optimum durability and trouble-free operation, it
must be handled with care. The instrument should not be operated in an excessively dusty or dirty
environment. Refer to Chapter 7, Service & Maintenance in this user’s manual for routine service and
cleaning recommendations.
The instrument operates safely under the following conditions:
Temperature range: 5 - 50°C (41 - 122°F)
Ambient relative humidity: 15 - 50%
Pressure: 75kPa - 106kPa
Main voltage supply within ± 10% of nominal voltage range
Vibrations in the calibration environment should be minimized
Altitude less than 2000 meters

Black body Temperature Calibrator (CALsys 1200BB)
User’s Guide
14
Unpacking and Initial Inspection
CALsys 1200BB is packed in custom-designed packaging to send out your unit. Unpack the furnace
carefully. Inspect the unit after unpacking for any signs of damage, and confirm that your delivery is
in accordance with the packing note. If you find any damage to the unit or an item is missing, notify
Tempsens immediately.
The following accessories are included in the package:
CALsys 1200BB
Cavity
Collar
Bolts
Insulation Wool
RS 232 cable
Certificates
Manual

Setting Up CALsys 1200BB
15
Operating Instructions
1. Open the carrying case carefully and takeout the operating manual from the box and read carefully.
2. Take out the Temperature Calibrator unit carefully and keep it at suitable place.
3. Connect the power cable to the rear power entry and the power plug to the main power outlet.
4. Turn the switch on, and observe the display on the controller. The display shows that the calibrator is
ready for use.
5. Keep the switch in the ON position.
6. Ensure the metal INSERT is properly inserted in the bath.
7. Keep the fan in ON position.
8. If the fan is running and temperature of the furnace is rising, the bath is in healthy condition.
Note:
The unit must be correctly connected to the electricity supply.
The unit must be correctly grounded.
The unit’s ON/OFF switch is located on the power inlet. DO NOT switch OFF the unit when it is hot.
Keep the unit running until cooled.
Initial Testing
This unit is fully tested before dispatching. However, verify its operation as follows:
1. After connecting the CALsys 1200BB to the electricity supply, the temperature controller display
should show the temperature of the chamber, and the last set-point value. The fan on the back
should be heard running.
2. Change the set-point to 250°C and observe that the block temperature rises and settles to this
value.
3. If the unit performs as expected, the unit can now be used for calibration.
If any problems or faults arise during the test, contact Tempsens immediately for help and advice.

Black body Temperature Calibrator (CALsys 1200BB)
User’s Guide
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17
Chapter 3
Operating CALsys 1200BB
Turning On the Unit
1. Before plugging the unit to main power outlet, ensure that the voltage, frequency and current
from the main power outlet are within the recommended rages (typically: 230 VAC±10, 50/60 Hz).
2. Plug the black main power cord into main outlet.
3. Turn the controller on using the switch located on the controlling section, and set the
temperature value in the controller. The Calibrator will turn on and begin to heat the previously
programmed temperature set-point.
Heating Up the Source
Press “UP” or “DOWN” key of controller to change the set-point value. The controller switches the
calibrator heater to ON or OFF to raise or lower the temperature. The displayed temperature will
gradually change until it reaches the set-point temperature.
The Calibrator may require 50 to 60 minutes to reach the set-point depending on the span. The unit
takes 20 to 30 minutes more to stabilize the bath temperature within ± 0.5°C of the set-point.

Black body Temperature Calibrator (CALsys 1200BB)
User’s Guide
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Note:
All other controller parameters are set to default, and are locked. It is recommended not to change
these parameters.
Important:
When the source is operated at any temperature above ambient temperature, the front face and plate
become hot.
Always put the fan in "ON" condition and do not switch off the main power supply directly. Before
tuning the unit off, set the controller to 0°C, and then wait until the temperature drops below 100°C.
Operating Instructions
1) Remove the front with the help of screw driver, as shown in the image given below
2) The chamber will look like the image given below:

Operating CALsys 1200BB
19
3) Next step is to insert the cavity in the chamber.
4) Now, attach the collar with the help of screw driver as shown in the image below.
5) With the use of bolt and screw, reattach the front sheet follow instruction on page no. 18 to
attach the front sheet.
6) After the complete installation.
7) Connect the 'CALsys 1200BB' to a suitable power supply. ON the Mains switch located at back side
with power entry.
8) Set the desire temperature value in PID by using UP & Down key.
9) Aim the reference (Master) standard infrared temperature sensor to the target area.
10) PV (Present value) display in controller will gradually rise until it reaches the set point
temperature. The controller takes some time to reach the set-point depending on the span.
Furnace is stable when PV is equal to SV (Set Value).

Black body Temperature Calibrator (CALsys 1200BB)
User’s Guide
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11) Master sensor takes some time to reach the set point temperature and stable at
temperature near about controller set temperature.
12) When temperature of the master and UUC (Unit under calibration) are stable record the
readings of master sensor.
13) Compare the UUC reading with the master's reading & find out the error by comparison
method.
14) Reset the controller and / or repeat the calibration for another calibration point or for
another sensor.
15) When the calibration is complete, reset the controller to 0°C & wait until the unit has
cooled to below 300°C, before moving the 'CALsys 1200BB to new location the 'CALsys 1200BB'
must be cooled below 300°C before it can be put back into its carrying case.
Note:
Plan the calibration point by gradually increasing temperature, then set the controller
accordingly. This method will save the time.
Cooling Down the Source
Before transporting the metal block, ensure that the temperature of bath has cooled
sufficiently.
If you require metal block to cool quickly, set the temperature to the room temperature
(ambient temperature).
Always cool the heated instrument to ambient temperature before disconnecting it from the
mains, switching it OFF, or removing the temperature sensor or test item.
Always keep the heated instrument supervised and under observation until it cools down
sufficiently.