Omega Products CL540 Installation Manual

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TEMPERATURE

Thermocouple, RTD & Thermistor Probes, Connectors, Panels & Assemblies
Wire: Thermocouple, RTD & Thermistor
Calibrators & Ice Point References
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Heating Cable
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MADE IN

User’s Guide

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CL540 SERIES

Thermocouple Simulator

M3979/0603

OMEGAnet®Online Service Internet e-mail

www.omega.com [e-mail]

Servicing North America:

USA:

ISO 9001 Certified

Canada:

One Omega Drive, P.O. Box 4047
Stamford CT 06907-0047
TEL: [phone] FAX: [phone]
e-mail: [e-mail]

976 Bergar
Laval (Quebec) H7L 5A1, Canada
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e-mail: [e-mail]

For immediate technical or application assistance:

USA and Canada:

Mexico:

Sales Service: 1-800-826-6342 / 1-800-TC-OMEGA
Customer Service: 1-800-622-2378 / 1-800-622-BEST
Engineering Service: 1-800-872-9436 / 1-800-USA-WHEN
TELEX: 996404 EASYLINK: 62968934 CABLE: OMEGA

En Espan•ol: [phone]-7803 e-mail: [e-mail]
FAX: [phone] [e-mail]

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Servicing Europe:

Benelux:

Czech Republic:

France:

Germany/Austria:

United Kingdom:

ISO 9002 Certified

It is the policy of OMEGA to comply with all worldwide safety and EMC/EMI regulations that
apply. OMEGA is constantly pursuing certification of its products to the European New Approach
Directives. OMEGA will add the CE mark to every appropriate device upon certification.

The information contained in this document is believed to be correct, but OMEGA Engineering, Inc. accepts
no liability for any errors it contains, and reserves the right to alter specifications without notice.
WARNING: These products are not designed for use in, and should not be used for, human applications.

Postbus 8034, 1180 LA Amstelveen, The Netherlands
TEL: [phone] FAX: [phone]
Toll Free in Benelux: 0800 0993344
e-mail: [e-mail]

Frystatska 184/46, 733 01 Karviná, Czech Republic
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Toll Free: 0800-1-66342 e-mail: [e-mail]

11, rue Jacques Cartier, 78280 Guyancourt, France
TEL: [phone] FAX: [phone]
Toll Free in France: 0800 466 342
e-mail: [e-mail]

Daimlerstrasse 26, D-75392 Deckenpfronn, Germany
TEL: [phone] FAX: [phone]
Toll Free in Germany: 0800 639 7678
e-mail: [e-mail]

One Omega Drive, River Bend Technology Centre
Northbank, Irlam, Manchester
M44 5BD United Kingdom
TEL: [phone] FAX: [phone]
Toll Free in United Kingdom: 0800-488-488
e-mail: [e-mail]

WARRANTY/DISCLAIMER

OMEGA ENGINEERING, INC. warrants this unit to be free of defects in materials and workmanship for a
period of 37 months from date of purchase. OMEGA’s WARRANTY adds an additional one (1) month
grace period to the normal three (3) year product warranty to cover handling and shipping time.
This ensures that OMEGA’s customers receive maximum coverage on each product.

If the unit malfunctions, it must be returned to the factory for evaluation. OMEGA’s Customer Service
Department will issue an Authorized Return (AR) number immediately upon phone or written request.
Upon examination by OMEGA, if the unit is found to be defective, it will be repaired or replaced at no
charge. OMEGA’s WARRANTY does not apply to defects resulting from any action of the purchaser,
including but not limited to mishandling, improper interfacing, operation outside of design limits,
improper repair, or unauthorized modification. This WARRANTY is VOID if the unit shows evidence of
having been tampered with or shows evidence of having been damaged as a result of excessive corrosion;
or current, heat, moisture or vibration; improper specification; misapplication; misuse or other operating
conditions outside of OMEGA’s control. Components which wear are not warranted, including but not
limited to contact points, fuses, and triacs.

OMEGA is pleased to offer suggestions on the use of its various products. However,
OMEGA neither assumes responsibility for any omissions or errors nor assumes liability for any
damages that result from the use of its products in accordance with information provided by
OMEGA, either verbal or written. OMEGA warrants only that the parts manufactured by it will be
as specified and free of defects. OMEGA MAKES NO OTHER WARRANTIES OR
REPRESENTATIONS OF ANY KIND WHATSOEVER, EXPRESS OR IMPLIED, EXCEPT THAT OF TITLE,
AND ALL IMPLIED WARRANTIES INCLUDING ANY WARRANTY OF MERCHANTABILITY AND
FITNESS FOR A PARTICULAR PURPOSE ARE HEREBY DISCLAIMED. LIMITATION OF
LIABILITY: The remedies of purchaser set forth herein are exclusive, and the total liability of
OMEGA with respect to this order, whether based on contract, warranty, negligence,
indemnification, strict liability or otherwise, shall not exceed the purchase price of the
component upon which liability is based. In no event shall OMEGA be liable for
consequential, incidental or special damages.

CONDITIONS: Equipment sold by OMEGA is not intended to be used, nor shall it be used: (1) as a “Basic
Component” under 10 CFR 21 (NRC), used in or with any nuclear installation or activity; or (2) in medical
applications or used on humans. Should any Product(s) be used in or with any nuclear installation or
activity, medical application, used on humans, or misused in any way, OMEGA assumes no responsibility
as set forth in our basic WARRANTY/ DISCLAIMER language, and, additionally, purchaser will indemnify
OMEGA and hold OMEGA harmless from any liability or damage whatsoever arising out of the use of the
Product(s) in such a manner.

RETURN REQUESTS/INQUIRIES

Direct all warranty and repair requests/inquiries to the OMEGA Customer Service Department. BEFORE
RETURNING ANY PRODUCT(S) TO OMEGA, PURCHASER MUST OBTAIN AN AUTHORIZED RETURN
(AR) NUMBER FROM OMEGA’S CUSTOMER SERVICE DEPARTMENT (IN ORDER TO AVOID
PROCESSING DELAYS). The assigned AR number should then be marked on the outside of the return
package and on any correspondence.

The purchaser is responsible for shipping charges, freight, insurance and proper packaging to prevent
breakage in transit.

FOR W

ARRANTY RETURNS, please have the

following information available BEFORE
contacting OMEGA:

1. Purchase Order number under which the product
was PURCHASED,

2. Model and serial number of the product under
warranty, and

3. Repair instructions and/or specific problems
relative to the product.

OMEGA’s policy is to make running changes, not model changes, whenever an improvement is possible. This affords
our customers the latest in technology and engineering.

OMEGA is a registered trademark of OMEGA ENGINEERING, INC.
© Copyright 2003 OMEGA ENGINEERING, INC. All rights reserved. This document may not be copied, photocopied,

reproduced, translated, or reduced to any electronic medium or machine-readable form, in whole or in part, without the
prior written consent of OMEGA ENGINEERING, INC.

FOR NON-WARRANTY REPAIRS,
for current repair charges. Have the following
information available BEFORE contacting OMEGA:

1. Purchase Order number to cover the COST
of the repair,

consult OMEGA

2. Model and serial number of the product, and

3. Repair instructions and/or specific problems
relative to the product.

CL540 Field Calibration Procedure Continued

CL540 Series Operating Instructions

Basic Keypad Operations

Cold Junction Calibration:

Double click the EZ-Dial knob to enter the Cold Junction Calibration mode. Cal CJ will appear on
the top left of the LCD.

1. Connect the Thermistor probe to the + side of the T/C connector.

2. Connect the other side of the Thermistor probe to the OHM meter.

3. Let the temperature settle for 15minutes.

4. Check the Cold Junction Temperature on the top right of the LCD with the
temperature reading of the Thermistor probe.

5. If the reading is out of Specification then dial the EZ-Dial to the temperature reading
from the Thermistor probe.

6. Press the EZ-Dial Knob down.

7. The display will flash STORED to confirm that the value was stored.

8. Verify the UUT (top right side of the LCD) Cold Junction Temperature is tracking with
the temperature reading of the Thermistor probe.

If using and ice bath or ice point calibrator to measure the junction voltage with a Voltage meter,
follow the steps below.

1. Connect the CL540 as shown in Figure 1.

2. Let the temperature settle for 15 minutes.

3. Check the Cold Junction Temperature on the top right of the LCD to the Voltage
reading on the DVM and T/C chart.

4. If the reading is out of Specification then dial the EZ-Dial to the correct reading form
the DVM and T/C chart.

5. Press the EZ-Dial Knob down.

6. The display will flash STORED to confirm that the value was stored.

7. Verify the UUT (top right side of the LCD) Cold Junction Temperature is tracking with
the temperature reading of the DVM and T/C Table.

Figure 1

J

Cu

Cu

+

3

_

V

_

Cu

Cu

+

J

4

_

Voltmeter

Isothermal

(same temperature)

Block

Completion of Calibration:

Turn the CL540 off. Next time the unit is turned on the CL540 will be Calibrated and in normal
operational mode.

Ice Bath / Ice Point

EZ-Check Switch

Slide the switch to select from three user stored
values for the desired calibration points.
The User can select HI, DIAL and LO positions.
These values can easily be changed to suit the
calibration requirements.

ON/OFF Switch

Slide the ON/OFF Switch to turn the CL540
on or off.

EZ-Dial Knob

The EZ-Dial Knob has two adjustment
speeds. Simply turning the EZ-Dial Knob will
select fine adjustments. While pressing down
and turning the EZ-Dial Knob will make
course adjustments.

Note: When the EZ-Check Switch is in the
HI or LO position, pressing and holding the EZ-
Dial Knob without turning
or LO values.

will store new HI

CL540 Configuration

Instructions for Enabling and Disabling the Configuration Options

1. Turn the CL540 on with the ON/OFF Switch .

2. Press the EZ-Dial Knob while the PRESS EZ-DIAL KNOB FOR
CONFIGURATION message is displayed.

3. Select options by turning the EZ-Dial Knob until the arrow points
to the desired option.

4. The option can be enabled or disabled by pressing the EZ-Dial
Knob.

The CL540 configuration menu will exit automatically after 5 seconds of
inactivity and go to normal operation with the options selected. These
options are recalled at turn on until they are changed again.

+

CL540 Configuration Menu

Auto Off ON (default)/OFF

If Auto Off is ON, the unit will turn off after 30 minutes to save battery life, if there is no user activity. If
Auto Off is OFF the unit will stay on until it is turned off from the keypad. This is typically useful for
manual loading or continuous use.

Display Units °C (default)/°F
Pressing the EZ-Dial Knob to toggles between °C or °F

TC {tc type}
Model CL540: The T/C type is fixed as

ordered from the factory and cannot be
changed.

Model CL540Z: To change T/C type, press
the EZ-Dial Knob. Turn the EZ-Dial
Knob to scroll through the list of available
types. Press again to save and return to
the configuration menu.

CL540 Configuration

{tc type} is one of:

B, E, J, K, N, R, S, T, or mV

{tc type} is any of:

B, E, J, K, N, R, S, T, or mV

PRESS EZ-DIAL KNOB
FOR CONFIGURATION

AUTO OFF ON
DISPLAY UNITS °C
TC TYPE K

EZ-Dial  K nob

Turning the EZ-Dial Knob to adjust the output up or down. Fine adjustments can be made by turning the
EZ-Dial Knob. Coarse adjustments can be made by pressing and turning the EZ-Dial. New values can
be stored into the HI and LO EZ-Check positions by pressing down on the EZ-Dial Knob until STORED
is indicated on the display.

EZ-Check Switch

The EZ-Check Switch has three positions: HI, DIAL, and LO. Its position is shown at the left edge of the
display with HI and LO indicators. The output is adjustable in all three positions. The EZ-Check
Switch allows user-selected values to be stored in the HI and LO positions when used in combination with
the EZ-Dial Knob.

To store new EZ-Check value(s):

1. Dial the display to match the desired stored outputs for the HI or LO positions.

2. Press down on the EZ-Dial Knob until the confirmation message STORED appears.

3. Recall the values by moving the switch between HI, DIAL, and LO.

Operational description: When returning to previously set EZ-Check positions, the DIAL position always
recalls the last output value it was dialed to. The HI and LO positions will recall the last STORED value,
NOT the last output value it was last dialed to.

Hint: For faster calibrations, the product has been designed so the position of the switch can be felt. This
tactile feature allows continuous monitoring of the device being calibrated without looking back at the
CL540 display. This is also useful in poor lighting or under difficult operating conditions.

Connection Diagram

THERMOCOUPLE WIRE

Two Wire Connection to Transmitter

Specifications

General Specifications:

(Unless otherwise indicated all specifications are rated from a nominal 23 °C, 70 % RH for 1 year from calibration)

Temperature Range -25 to 60 °C (-10 to 140 °F)

Relative Humidity Range 10 % RH 90 % (0 to 35 °C), Non-condensing

Size 4.9 X 3.15 X 1.82 inches (125.5 X 80 X 46.2 mm)

Weight 7.2 oz (204 grams)

Battery 9V Alkaline provides 45 hours of continuous use

Miscellaneous Low battery indication with nominal 1 hour of operation left

Source Thermocouple Specifications (ITS-90 Curves):

Millivolt Uncertainty

Temperature Coefficient of mV Source

Output Noise

Output Impedance

Cold Junction Uncertainty

Cold Junction Sensor Temperature Coefficient

General Temperature Accuracy ±(0.015% of mV setting + 0.009mV) ± 0.25°C (0.5°F)

Output Dial Adjustment Resolution 0.1°C or °F for Model 521/1°C or °F for Model 520

Span -13.000 - 80.000 mV

T/C Type B 594  1820° C (1101.2  3308.0°F)

T/C Type E -260 - 1000° C (-436.0  1832.0°F)

T/C Type J -210  1200° C (-346.0  2192.0 °F)

T/C Type K -245 - 1372° C (-409.0  2501.6°F)

T/C Type N -229 - 1300°C (-380.2  2372.0° F)

T/C Type R 24 - 1768° C (75.2  3214.4°F)

T/C Type S 21 - 1768° C (69.8  3214.4°F)

T/C Type T -251 - 400° C (-419.8  752.0°F)

10 % RH 70 % (35 to 60 °C), Non-condensing

Overload Protected to 60V for 30 seconds or less

High contrast graphic liquid crystal display with 0.357 (9.07 mm) high digits

±(0.015% of mV Setting + 0.009 mV)

±0.005mV/°C Ambient

±5µVpp from 0.1 Hz to 10 Hz

0.2W

±0.25°C (0.5°F)

±0.05°/° in ambient temperature (°C or °F)

RED

TRANSMITTER
OR RECEIVER

CL540 Field Calibration Procedure

Suggested Equipment:

1. Precision Voltage Meter with an accuracy of 0.0066% at 80.000mV

2. Precision Thermistor probe with accuracy of ± 0.063°C or

better (YSI 46046 ±0.05°C)

OR

3. A stable ice bath or Thermocouple ice point calibrator and a NIST traceable thermocouple

wire stable to within ±0.063°C.

We recommend using a direct junction temperature measurement technique for the most accurate and
reliable calibrations of our equipment. This technique uses accurate RTD or Thermistor probes to
measure the reference junction (cold junction) temperature. While measuring the junction voltage with a
DVM and ice bath technique will work. This method is less reliable due to complexity and is generally less
accurate due to cumulative errors.

Precautions:

Avoid touching thermocouple connections, as this will cause temperature errors in calibration. It is
recommended that the CL540 be handled as little as possible during calibration to reduce errors.
The heat from your body may cause uneven heating of temperature sensitive components.

Enabling Calibration:

Install a fresh battery and allow 15 minutes for the CL540 to stabilize to ambient temperature. Remove
the EZ-Dial Knob, battery cover and the four black Phillips head screws. While holding the CL540 face
down in one hand, carefully separate the top and bottom of the housing. Place the unit into calibration
mode by shorting the calibration via located on the bottom left side on the PCB with tweezers and turning
the UUT on. Verify the CL540 is in Calibration mode by viewing the top Left of the LCD for the word CAL.

Source mV Calibration:

LO Calibration:

1. Connect the CL540 terminals to a Voltage meter.

2. Slide the EZ-Check switch to the LO Position indicated by displaying a LO on the
left side of the display.

3. Dial the CL540 so the meter reads 0.000 mV.

4. Press the EZ-Dial Knob down.

5. The display will flash STORED to confirm that the value was stored.

HI Calibration:

1. Slide the EZ-Check switch to the HI Position indicated by displaying a HI on the left
side of the display.

2. Dial the CL540 so the meter reads 80.000 mV.

3. Press the EZ-Dial Knob down.

4. The display will flash STORED to confirm that the value was stored.