Omega Products PCL10 Installation Manual

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PCL10 / PCL11

Hand-Held Pressure

Indicator-Calibrato

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The information contained in this document is believed to be corrected but OMEGA Engineering Inc. accepts no liability for any errors it

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2

INTRODUCTORY NOTE

This publication contains operating instructions, as well as a description of the principles of operation, of

PCL10 and PCL11 pressure calibrators.

OMEGA has used the best care and efforts in preparing this book and believes the information in this

publication are accurate. The OMEGA products are subjected to continuous improvement, in order to pursue
the technological leadership; these improvements could require changes to the information of this book.
OMEGA reserves the right to change such information without notice.

No part of this document may be stored in a retrieval system, or transmitted in any form, electronic or
mechanical, without prior written permission of OMEGA Engineering Inc.

PCL10 and PCL11 units use sophisticated analogic and digital technologies. Any maintenance operation
must be carried out by qualified personnel

ONLY. We recommend to contact our technicians for any support

requirements.
.
PCL10 and PCL11 is fully tested in conformity with the directive n°89/336/CEE Electromagnetic
Compatibility. OMEGA shall not be liable in any event, technical and publishing error or omissions, for any
incidental and consequential damages, in connection with, or arising out of the use of this book.

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TABLE OF CONTENTS

1 PERFORMANCE.................................................................................................................................. 6

1.1 Specifications................................................................................................................................................... 7

1.1.1 Ranges and resolution ................................................................................................................................ 9

2 GENERAL FEATURES...................................................................................................................... 10

2.1 Input and output flexibility............................................................................................................................... 10

2.2 Self calibration................................................................................................................................................10

2.3 Keyboard........................................................................................................................................................ 10

2.4 Display ...........................................................................................................................................................10

2.5 Digital interface .............................................................................................................................................. 10

2.6 Scale factor function.......................................................................................................................................10

2.7 Square root function....................................................................................................................................... 10

2.8 Pressure measurement damping................................................................................................................... 10

2.9 Case............................................................................................................................................................... 10

3 PHYSICAL DESCRIPTION ................................................................................................................ 11

4 FUNCTIONAL DESCRIPTION........................................................................................................... 12

4.1 Power supply..................................................................................................................................................12

4.2 Operative keyboard........................................................................................................................................ 12

4.3 Pressure Module............................................................................................................................................ 13

4.4 Microcontroller................................................................................................................................................13

4.5 Firmware ........................................................................................................................................................ 13

4.6 Digital display................................................................................................................................................. 13

4.7 Battery charger...............................................................................................................................................13

4.8 Digital interface .............................................................................................................................................. 14

5 UNPACKING ...................................................................................................................................... 15

6 PRE-OPERATIONAL CHECK ........................................................................................................... 16

7 OPERATION & APPLICATIONS ....................................................................................................... 17

7.1 Rechargeable batteries..................................................................................................................................17

7.2 Battery charger...............................................................................................................................................17

7.3 How to maximize the life span of the battery.................................................................................................. 17

7.5 Start-up ..........................................................................................................................................................17

7.6 Instrument Configuration review (Status) ....................................................................................................... 18

7.7 Display contrast and backlight adjustment..................................................................................................... 19

7.8 Normal operative mode.................................................................................................................................. 19

7.9 Zero adjustment ............................................................................................................................................. 20

7.10 Pressure measurement damping ...................................................................................................................20

7.10.1 Averaged Value Calculation Algorythm ..................................................................................................... 21

7.11 Technical unit selection.................................................................................................................................. 22

7.12 Voltage and Current measurements ..............................................................................................................23

7.13 Peak & Valley measurement.......................................................................................................................... 23

7.14 Scale factor program...................................................................................................................................... 23

7.15 Alarm setting and operative mode..................................................................................................................25

7.16 Pressure switch test....................................................................................................................................... 26

7.17 Leak test.........................................................................................................................................................27

7.18 User’s Calibration........................................................................................................................................... 27

8 INSTRUMENT CONFIGURATION..................................................................................................... 29

9 CALPMAN APPLICATION PC SOFTWARE .................................................................................... 30

9.1 Introductory note ............................................................................................................................................ 30

9.2 Software Installation....................................................................................................................................... 30

9.3 General structure of the CalpMan software.................................................................................................... 30

9.4 Pressure gauges test ..................................................................................................................................... 33

9.5 Pressure transmitter test ................................................................................................................................33

9.6 Test result printout from PCL10/11 ................................................................................................................ 34

9.7 Test result printout from PC ........................................................................................................................... 35

10 DIGITAL INTERFACE........................................................................................................................ 36

10.1 Digital output wiring practice .......................................................................................................................... 36

10.2 TTL to RS 232 adapter...................................................................................................................................36

10.2.1 Communication protocol from PCL10/11 to a PC...................................................................................... 37

10.2.2 Computer request for PCL10/11 settings .................................................................................................. 38

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10.2.3 Communication programs ......................................................................................................................... 39

11 MAINTENANCE ................................................................................................................................. 41

11.1 General recommendations............................................................................................................................. 41

11.2 Safety recommendations ............................................................................................................................... 41

11.3 Protection fuses replacement.........................................................................................................................41

11.4 Faulty operating conditions ............................................................................................................................41

11.5 Storage .......................................................................................................................................................... 42

5

1 PERFORMANCE

PCL10/11 is a portable instrument for relative (gauge) and differential pressure measurement.

When connected to an auxiliary device such as a pump, a volume adjuster and a ventilation valve it can be used as a
pressure calibrator.
A complete system testing, measuring and calibrating built in a single, compact portable instrument.
Thanks to its compactness, roughness and user friendly operative mode, PCL10/11 is the ideal instrument for field
measurements, tests and calibrations.
Accurate, compact, rugged, easy to use; the ideal solution to measure and simulate:

• Volts (only measurements)

• milliAmperes (only measurements)

• gauge pressure

• differential pressure

PCL10/11 has been developed using the most advanced microcontroller technique to provide high accuracy on
extended ranges and a powerful operating flexibility.
The calibration uses computerized procedures and the relevant calibration data are memory stored to ensure high
accuracy.
The pressure/differential pressure measurement uses a base piezoresistive sensor individually and fully characterized for
linearity and temperature coefficient.
In addition to pressure measurement the instrument is equipped with a second channel designed for voltage (up to 30 V)
and current (up to 22 mA) measurements.
The selection of operating functions is made on a polycarbonate thermoformed membrane keyboard which assures up to
one million operations per key.
Both pressure and electrical parameter readings are indicated on a high quality LCD dot matrix display equipped with a
backlight device for easy readings also in poor light conditions.
The case, made in shock-resistant ABS, is ergonomically designed for an easy practical use.
The instrument is powered by four Ni-MH rechargeable batteries; an external battery charger is supplied as a standard
accessory.

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1.1 Specifications

• Pressure and ∆P ranges:

see instrument codes

• Vacuum ranges:

-10% of the measuring range
(10 bar and 20 bar ranges only are limited to -0.8 bar)

• Keyboard selectable technical units:

mbar, bar, psi, mmwc (mmH
matm, atm, torr, Lbin

2

, kgm2, kgcm2

• Scale factor and square root:

for direct flow measurement

• Pressure media:

compatible with most common non-corrosive, non-reducing, non-condensing and non explosive gases

• Pressure ports:

1/8” BSPPF

• Accuracy:

Table A = 1 ±(0.1% of reading + 0.03% of f.s.)
Table A = 2 ±(0.05% of reading + 0.02% of f.s.)

The relative accuracy shown above are stated for 90 days and the operative conditions are from +5°C to +45°C.
Outside the above temperature band the temperature drift is ±0.004% rdg/°C

• Position effect:

negligible (excluded 20 mbar range)

• Electrical ranges:

0 to 30.000 V
0 to 22.000 mA

• Electrical ranges accuracy:

± (0.05% of reading + 0.01% of f.s.)

The relative accuracy shown above is stated for 90 days and the operative conditions are from +18°C to +28°C.
Outside the above temperature band the temperature drift is ±0.002% of rdg/°C

• Common mode rejection:

>140 dB at 50/60 Hz ± 1 Hz

• Normal mode rejection:

> 60 dB at 50/60 Hz ± 1 Hz

• Shunt (current channel):

< 110 Ω

• Impedance (voltage channel):

> 1 MΩ

• Maximum voltage input (voltage channel):

50V

• Maximum current input (current channel):

50 mA

• Short-circuit protection (loop power supply):

Fuse + Electronic

• Overcurrent protection (current channel):

Fuse

• Maximum load (passive loop):

900 Ω at 20 mA

• Display:

dot matrix LCD (2 lines of 16 characters each) with backlight device.

• Operative life:

8 hours without printing and without load on 20 mA passive current loop
4 hours without printing and with load on 20 mA passive current loop

O), cmwc (cmH2O), mwc (mH2O), inwc (inH2O), mmHg, mHg, inHg, kPa, hPa,

2

7

• Data memory:

up to 50 group of data

• Working temperature limits:

from -5°C to 50°C

• Storing temperature:

from -20°C to 60°C

• Power supply:

Ni-MH batteries package

• Case:

Injection moulded ABS with internal metal coating in compliance with EMC

• External dimensions:

100 x 60 x 240 mm (without pressure module)
100 x 60 x 285 mm (with pressure module)

• Weights:

net 1 Kg (instrument + pressure module)
gross with packing 1,5 Kg

8

1.1.1 Ranges and resolution

Bar

-0,880 22,000 -12,76 319,08 -8,97 224,34 -8,80 2200,0 -353 8832 -12,76 319,08

-0,880 11,000 -12,76 159,54 -8,97 112,17 -8,80 1100,0 -353 4416 -12,76 159,54

-0,550 5,500 -7,98 79,77 -5,61 56,08 -5,50 550,0 -220,8 2208,1 -7,98 79,77

-0,2200 2,2000 -3,191 31,908 -2,243 22,434 -2,200 220,00 -88,3 883,2 -3,191 31,908

Bar

-0,1100 1,1000 -1,595 15,954 -1,122 11,217 -1,100 110,00 -44,2 441,6 -1,595 15,954

mBar

-55,0 550,0 -0,798 7,977 -56,1 560,8 -5,50 55,00 -22,08 220,81 -0,798 7,977

mBar

-22,00 220,00 -0,3191 3,1908 -224,3 2243,4 -2,200 22,000 -8,83 88,32 -0,3191 3,1908

mBar

-11,00 110,00 -0,1595 1,5954 -112,2 1121,7 -11,00 110,00 -4,42 44,16 -0,1595 1,5954

mBar

-2,200 22,000 -31,91 319,08 -22,43 224,34 -2,200 22,000 -0,883 8,832 -0,0319 0,3191

PSI

PSI

PSI

PSI

PSI

mPSI

mH20 at 4°C kPa

mH20 at 4°C kPa

cmH20 at 4°C kPa

mmH20 at 4°C kPa

mmH20 at 4°C hPa

mmH20 at 4°C hPa

InH20 at 4°C Lb/In2

InH20 at 4°C Lb/In2

InH20 at 4°C Lb/In2

InH20 at 4°C Lb/In2

InH20 at 4°C Lb/In2

InH20 at 4°C Lb/In2

Bar

-0,880 22,000 -0,660 16,501 -660 16501 -0,897 22,434 -0,868 21,712 -25,99 649,7

-0,880 11,000 -0,660 8,251 -660 8251 -0,897 11,217 -0,868 10,856 -25,99 324,83

-0,550 5,500 -0,413 4,125 -413 4125 -0,561 5,608 -0,543 5,428 -16,24 162,42

-0,2200 2,2000 -0,1650 1,6501 -165,0 1650,1 -0,2243 2,2434 -0,2171 2,1712 -6,50 64,97

Bar

-0,1100 1,1000 -82,5 825,1 -82,5 825,1 -0,1122 1,1217 -0,1086 1,0856 -3,248 32,483

mBar

-55,0 550,0 -41,3 412,5 -41,3 412,5 -561 5608 -54,3 542,8 -1,624 16,242

mBar

-22,00 220,00 -16,50 165,01 -16,50 165,01 -224,3 2243,4 -21,71 217,12 -0,650 6,497

mBar

-11,00 110,00 -8,25 82,51 -8,25 82,51 -112,2 1121,7 -10,86 108,56 -0,3248 3,2483

-2,200 22,000 -1,650 16,501 -1,650 16,501 -22,43 224,34 -2,171 21,712 -0,0650 0,6497

mHg at 0°C torr

mmHg at 0°C torr

mmHg at 0°C torr

mmHg at 0°C torr

mmHg at 0°C torr

Kg/cm2

Kg/cm2

Kg/m2

Kg/m2

Kg/m2

Atm

Atm

mAtm

mAtm

mAtm

InHg at 0°C

InHg at 0°C

InHg at 0°C

InHg at 0°C

InHg at 0°C

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2 GENERAL FEATURES

2.1 Input and output flexibility

An advanced flexibility of performance has been achieved using the microcontroller technique. Each instrument, through

a menu-driven procedure, allows simultaneous measurement of pressure (gauge or ∆P) and of the typical loop signal in

current (up to 22 mA) or voltage (up to 30 V). The microcontroller performs linearization and temperature compensation
of the piezoresistive pressure sensor using the characterization data stored in the pressure module memory.

2.2 Self calibration

The hardware-firmware design allows the automatic calibration of the instrument. The calibration procedure is protected
by a security code.

2.3 Keyboard

A thermoformed metal-click tactile polycarbonate membrane keyboard, with a working life of one million operations per
key, seals the internal electronics from the surrounding environment. The contact closure of membrane keys is
acknowledged, as a coded signal, directly by the microprocessor.

2.4 Display

The high contrast alphanumeric LCD display with dot matrix (7x5 dots per character-16 characters ), in the normal
operative mode, simultaneously indicates pressure symbol and value, current or voltage symbol and value.
It is also used for operator’s messages, instrument configuration set-up, special operative modes, etc.
It is equipped with a backlight device to allow easy readings even in poor light conditions.
The method to adjust the display contrast is described in par. 8.7.

2.5 Digital interface

A digital interface with TTL logic levels is available as a standard for communication with external units. A serial data port
provides a communication capability at a logic level of 0-5 V (four wires: Tx, Rx, GND, Vcc). A TTL to RS 232 adapter is
available as an option.

2.6 Scale factor function

Easy menu-driven set-up to read or simulate electrical signal values in terms of engineering units. Four programmable
alphanumeric characters are available on the display to show the symbol of the parameter (i.e. mbar, etc.). The display
will indicate the scaled input value.

2.7 Square root function

It can be programmed during the set-up procedure to obtain direct readings of flow from a dP transmitter signal. The
display limits are -9999 and +30000.

2.8 Pressure measurement damping

To allow measurement of unstable input signals using a special algorithm based on a combination of working band and
average weight.

2.9 Case

The case is designed for an easy hand held operation and transportation. The body is injection molded, shock-resistant
ABS with internal metal coating. An ABS case for instrument + printer + pumps + accessories is available on request.

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3 PHYSICAL DESCRIPTION

The PCL10/11 palm-top indicator consists of a rugged and compact case, a replaceable pressure module, a mother
board with all basic functions, a daughter board for the auxiliary functions (mA and V readings), a tactile membrane
keyboard, a LCD display and a group of four nickel-metalhydride rechargeable batteries.
The internal surface of the case is metal coated to improve compliance with EMC.
The battery package is located on the lower back part of the case, and is accessible through a cover fastened by a
metal screw.
The two sections of the case are joined together by four metal screws located on the back side.
The optional leather case, with shoulder strap, assures a better protection of the instrument against mechanical knocks
or scratches.

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4 FUNCTIONAL DESCRIPTION

The PCL10/11 portable calibrator block diagram is shown below.

• power supply

• reference voltage signal

Reference
Voltage

Pressure sensor
Module + Memory

Power
Supply

Microcontroller LCD Display

Analog to Digital
Converter

Multiplexer

External
Battery Charger

Operator
Keyboard

Digital
Interface

Auxiliary Voltage &
Current Input

• microcontroller (central unit + memory)

• input circuit

• LCD display

• operative keyboard

• replaceable pressure module with characterisation data memory

4.1 Power supply

The instrument is powered by four internal batteries that can be recharged through an external charger module supplied
as a standard accessory. The internal batteries are Ni-MH rechargeable AA type with a nominal voltage of 1.25 V.
The voltage of the four batteries in series (approximately 5 V) is connected to the input of a switching circuit to generate
the voltages for the pressure transducer, the analog and digital circuits. The power supply circuit, is also configured as a
voltage multiplier to generate a voltage of 24 Vdc for the final output stage operating both into active or passive loops.

The above voltage levels are required to work with an external load up to 900Ω to supply the external current loop (see

par. 7.8).

4.2 Operative keyboard

The front panel is a tactile polycarbonate membrane keyboard, and has a working life of one million operations per key.
The contact closure of the membrane keyboard is acknowledged as a coded signal by the microprocessor that
recognizes the operator’s instructions .
Keys are interconnected on a 4 x 3 matrix; the microprocessor identifies the active key directly.

The values of the <▲> and <▼> keys ( membrane slidewires ) are acknowledged through the converters built in the

microprocessor chip.

<ON> Power ON switch
<OFF> Power OFF switch
<Lamp> Switches -On- the LCD back-light display

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<PAGE> Scrolls display/menu pages
<PRINT> Enables printout of data

<▲> <▼> Data selection

<STATUS> Instrument configuration review and set-up data storage
<ZERO> Pressure channel zero reset
<HOLD> To freeze and temporary memory store data
<DAMP> Pressure measurement signal damping
<STORE> Memory load / Operator’s message acknowledgements
<SET-UP> Instrument configuration
<PEAK> Maximum value identification and measurement
<VALLEY> Minimum value identification and measurement
<CONV> Convert displayed data to electrical data (scale factor only)
<LCD-> Adjust the LCD contrast
<LEAK> Leak test procedure to allow the test of leak in terms of pressure decay over time
<ALARM RESET> Switch -Off- the acoustic alarm
<ENTER> Memory load key

4.3 Pressure Module

The replaceable Pressure Module incorporates a fully characterised piezoresistive sensor and communicates with basic
unit via a 15 pin connector.
Temperature/pressure characterisation data are stored in a non volatile EEPROM, resident in the replaceable module.
An extended number of Pressure Module units are available in a wide variety of pressure measurement ranges (see
table B Par. 1.1).
Any Pressure Module can be used in any basic unit and the measurement system will provide measurement accuracy in
conformance with the declared specifications.

4.4 Microcontroller

The microcontroller handles all the logic functions of the instrument, performs the linearization for pressure transducers,
compensates for the reference junction temperature, drives the digital display and acknowledges all the operator’s
instructions.
The core of the circuit is a single-chip microcomputer that utilises HCMOS technology to provide the low power
characteristics and high noise immunity of CMOS plus the high speed operation of HMOS.
The microcomputer provides highly sophisticated, on- chip peripheral functions including: 256 bytes of static RAM, an 8
channel analog to digital (A/D) converter (used to read the battery package voltage, the analog keyboard, the battery
charger, the short-circuit and the overload on the external current loop), a serial communication interface (SCI)
subsystem, and a serial peripheral interface (SPI) subsystem.
The microprocessor works with an 8/16 bit communication bus to EPROM and EEPROM memories and is interfaced
with a decoder, a latch of address and an inverter-driver.

4.5 Firmware

The operating system firmware handles all logic instructions to the internal peripheral circuits and performs the
computation of the linearization equations.
The application system firmware is resident on the non-volatile memory (EEPROM) of the microprocessor chip.
It is used to store the installation parameters (autocalibration data, program data, etc.)

4.6 Digital display

The digital display, mounted on an auxiliary board, uses high contrast LCD technology (STN liquid ).
The character generation is made by a secondary dedicated microprocessor driven by two integrated circuits with signal
input from the bus of the main microprocessor.
The 16 characters are displayed with a 7x5 dot matrix.

PCL10/11 is standard equipped with a backlight device for easy readings in poor light conditions.

4.7 Battery charger

The auxiliary module, supplied as a standard accessory, allows operations from 100-120 Vac or 230-240 Vac 50/60 Hz.
The calibrator, if needed, can be operated directly from a line source through the charger.
The plastic case of the battery charger incorporates the line voltage plug and a cable with a connector for interconnection
to the instrument.

13

The charger circuit is designed with an insulating transformer and a voltage stabiliser circuit. The step-down transformer
reduces the power line (100, 115 or 230 Vac nominal) to a value of 10 Vac. The above voltage is full wave rectified,
filtered and stabilised. The output voltage of 6,66 V is the ideal value to recharge the internal Ni-MH batteries.

4.8 Digital interface

The digital interface circuit is essentially based on the serial communication interface subsystem (SCI) on the chip of the
microprocessor at 0 up to +5V level.
An adapter to convert TTL to RS 232 voltage levels can be obtained on request.

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