PIE Practical Instrument Electronics 422, 422 Plus Operating Manual

Model 422

Automated Thermocouple Calibrator

Operating Instructions

Model 422

Automated Thermocouple Calibrator

Operating Instructions

Product Description

• Easy to use

With the PIECAL 422 you can check & calibrate all your
thermocouple instruments and measure thermocouple
sensors.

• Take it with you into the shop, plant or field

Carry it without worry - it comes protected with a rubber
boot and rugged, low profile switches. Easy to operate
even in the dark areas of the plant with the backlit display.

• Calibrate directly in temperature (°C & °F)

Stop carrying around a millivolt source and thermocouple
tables. The PIECAL 422 works with the thermocouples
you use including types J, T, E, K, R, S, B, N, G, C, D, L
(J-DIN), U (T-DIN) and Platinel II. Easily set any value
quickly to within 0.1° with the adjustable digital
potentiometer “DIAL” plus store any three temperatures
for instant recall with the EZ-CHECK™ switch.

• Calibrate quickly with automatic output stepping

Choose between 2, 3, 5, 11 steps and ramp to
automatically increment the output in 100%, 50%, 25%,
10% of span or continuously ramp between span and
zero. Select the step time to match your system from 5, 6,
7, 8, 9, 10, 15, 20, 25, 30 and 60 seconds.

• Compatible with all process instruments

Connect directly to the thermocouple inputs of smart
transmitters, PLCs, DCS and multichannel recorders and
verify their outputs or displays.

• Measure Thermocouple Sensors

Trouble shoot sensor connections and find broken wires. The PIECAL 422 measures the
thermocouple in degrees C or F. Secondary display shows the millivolt value corresponding to
the thermocouple temperature as well as the cold junction temperature measured by the
calibrator.

• Calibration Lab Accurate & Stable

The internal cold junction thermistor is accurate to ±0.05°C and is traceable to NIST. The sensor
is thermally bonded to an isothermal mass which includes brass blocks with screw terminals for
connection of bare thermocouple wires along with a miniature thermocouple connector for fast
connections. The circuitry uses an extremely stable voltage reference and low drift components
which make the PIECAL 422 more accurate than most other handheld and benchtop
thermocouple calibrators.

• Perform Heat Treating Uniformity Surveys and System Accuracy Tests

The PIECAL 422 meets or exceeds the requirement of AMS 2750 as a Field Test Instrument.

82 East Main Street Suite 3.14 • Webster, NY 14580 Tel: [phone] • Fax: [phone] • [e-mail] • www.piecal.com

Practical Instrument Electronics

Copyright © 2015 All rights reserved • 422-9002 - Rev F 3 May 2017

Page 1

Basic Operation

w SOURCE/OFF/READ Switch

Select “SOURCE” to output in °C, °F, or millivolts.
Select “READ” to read a thermocouple sensor
or millivolts. Select “OFF” to turn the unit off.

+

-

22.4°C

T/C

17.332mV

422.1

CALIBRATOR

MAX

READ
MIN

TYPE K

SOURCE

OFF

Push & Turn

Fast Dialing
Push & Hold

Double Click

READ

Store/Step

for Options

°C

for

to

HI

AUTOMATED THERMOCOUPLE

J‐T‐E‐K‐R‐S‐B‐N‐G‐C‐D‐L‐U‐P‐mV

HI

SET

LO

OVERLOAD

q EZ-CHECK™ SWITCH

SOURCE: Instantly output two preset thermocouple

temperatures by moving the EZ-CHECK™ switch to
the “LO” position or “HI” position.
point checks select the “SET” position. The
PIECAL 422 will remember the last “SET”
value, even with the power off.
These values can easily be changed to suit the
calibration requirements. The temperatures stored in
the HI and LO positions are also used for Auto
Stepping.

READ: Slide the switch to the SET position. The
PIECAL 422 will display the current temperature from
the thermocouple sensor. Slide the switch to HI and
the highest temperature measured since turn-on or
reset will be displayed; slide the switch to LO and the
lowest temperature measured since turn-on or reset
will be displayed.

For fast three

e EZ-DIAL™ KNOB

SOURCE: Turn the knob to adjust the output
level. Turn clockwise to increase the output,
counter clockwise to decrease the output in 0.1°
steps at a time. Push down and turn the
EZ-DIAL knob for faster dialing.

Press and hold the knob for two seconds to store
desired EZ-Check™ HI/LO points in SOURCE
mode. Continue to press and hold the knob for
two more seconds to start the automatic
stepping or ramping.

READ: Press and hold to transfer the current
temperature into the EZ-Check™ HI/LO points.
This clears the HI/LO temperature readings
which will update as the temperature changes.

Double click the knob to get into the PIECAL 422
Configuration Mode. Use configuration to select
°C or °F, T/C Type, Backlight On/Off, Step Size,
Step Time and Auto Off On/Off, CJC & mV.

CHANGING BATTERIES

Low battery is indicated by “BAT” on the display.
Approximately one to four hours of typical
operation remain before the PIECAL 422 will
automatically turn off. To change the batteries;
remove the rubber boot, remove the battery door
from the back of the unit by sliding the door
downward. This allows access to the battery
compartment. Replace with four (4) “AA” 1.5V
batteries being careful to check the polarity.
Replace the battery door and replace the boot. All
stored configuration options (T/C Type,
EZ-CHECK Memories, etc.,) are reset to factory
settings when the batteries are removed.

Note: Alkaline batteries are supplied and
recommended. Purchase the optional Ni-MH
rechargeable batteries for maximum battery life.

Connections

Simulating or reading thermocouples requires
the use of thermocouple or extension grade
thermocouple wire.
Plug thermocouple wires into the miniature
thermocouple jack or place bare thermocouple
wires onto the brass block under the screws.

The PIECAL 422 has two banana jacks mounted
in the top end of the housing. These are not
temperature compensated and are to be used
only for millivolt signals.

Practical Instrument Electronics

82 East Main Street Suite 3.14 • Webster, NY 14580 Tel: [phone] • Fax: [phone] • [e-mail] • www.piecal.com

Page 2

Configuration

Configure the Calibrator

Move w POWER SWITCH to “SOURCE” or
“READ”.

DOUBLE CLICK

EZ-DIAL KNOB

V#.##

Setup

Double click the
unit is on and the following displays will appear
for 15 seconds:
Turn the e DIAL KNOB to move through the
three pages of menus. Press the e DIAL KNOB
to toggle between OFF and ON or to scroll
through the settings.

MAIN

> EXIT (1/3)
FUNCTION T/C V
UNITS °C °F
T/C TYPE
COLD JUNC ON OFF

T/C DISPLAY

> EXIT (2/3)
DISPLAY mV ON OFF
DISPLAY CJ ON OFF

FEATURES
> EXIT (3/3)
AUTO OFF ON OFF
BACKLIGHT ON OFF
STEPS/RAMP 2 3 5 11 RAMP
STEP/RAMP TIME 5 6 7 8 9 10 15 20 25 30 60

EXIT - exits this menu immediately and saves

any changes. Menu will automatically exit after
15 seconds of inactivity).

UNITS - pressing the knob will toggle between
°C and °F.

FUNCTION - pressing the knob will toggle
between T/C and V. Select T/C for thermocouple
or V for the -13.000 to 80.000 mV range.

T/C TYPE - pressing the knob will cycle through
T/C types J, K, E, T, R, S, B, N, L (J-DIN),
U (T-DIN), G (W), C (W5), D (W3) and
P (Platinel II).

FOR CONFIGURATION

e DIAL KNOB at any time the

J K E T R S B N L U G C D P

COLD JUNC - Automatic COLD JUNCTION
(Cold Junction Compensation) may be turned
on or off. It is recommended that CJC be left on
(default). CJC should only be turned off if an
external cold junction compensator or ice bath is
used with the PIECAL 422.

DISPLAY mV - If DISPLAY mV is ON the mV
value corresponding to the sourced or measured
temperature is displayed.

DISPLAY CJ - If DISPLAY CJ is ON the cold
junction temperature measured by the PIECAL
422 will be displayed.

AUTO OFF - If AUTO OFF is ON, the unit will
turn off after 30 minutes of inactivity to save
battery life. If AUTO OFF is OFF the unit will stay
on until the POWER SWITCH is moved to the off
position.

BACKLIGHT - If BACKLIGHT is ON the
backlight will light all the time the unit is powered
up. For maximum battery life turn the backlight
off when using the calibrator in areas with
enough ambient light to read the display.

STEPS/RAMP - pressing the knob will cycle
through 2, 3, 5, 11 and RAMP. The endpoints of
the steps or ramp are based on the values
stored in the HI and LO EZ-CHECK outputs.

2 steps will automatically switch between the
values stored in the HI & LO EZ-CHECK (0 &
100%).

3 steps between the HI, Midpoint and LO
EZ-CHECK (0, 50 & 100%).

5 steps between the HI and LO EZ-CHECK
in 25% increments (0, 25, 50, 75 & 100%).

11 steps between the HI and LO EZ-CHECK
in 10% increments (0, 10, 20...80, 90 &100%).

RAMP continuously ramps up and down
between the HI and LO EZ-CHECK outputs.

STEP/RAMP TIME - pressing the knob will cycle
through 5, 6, 7, 8, 9, 10, 15, 20, 25, 30 and 60
seconds.

Note: All settings are remembered even with the
power off. Removing the batteries resets the
values to factory defaults.

Practical Instrument Electronics

82 East Main Street Suite 3.14 • Webster, NY 14580 Tel: [phone] • Fax: [phone] • [e-mail] • www.piecal.com

Page 3

Sourcing Thermocouple

SOURCE

Choose this function to provide a simulated thermocouple signal into controllers, temperature
transmitters, indicators or any input devices that measure thermocouple sensors.

1) Disconnect the thermocouple sensor from the
device to be calibrated.

2) Select “SOURCE” with slide switch

w.

3) Connect a thermocouple wire (matching the type
of wire to sensor being simulated) with miniature
male T/C connector or bare leads under the
brass screws to the inputs of the device being
calibrated, making sure to check polarity. Millivolt
outputs (without cold junction) may be connect­ed with a copper (white) miniature T/C connector
or the banana jacks with copper wire.

The output is adjusted in 0.1° (or 0.001 mV)
increments by turning the knob

e while the

EZ-CHECK™ switch q is in the “HI”, “LO” or “SET”
position. Press and turn the knob for faster dialing

22.4°C

17.332mV

HI

AUTOMATED THERMOCOUPLE

J‐T‐E‐K‐R‐S‐B‐N‐G‐C‐D‐L‐U‐P‐mV

HI

SET

LO

OVERLOAD

422.1

TYPE K

CALIBRATOR

MAX

READ
MIN

-

T/C

SOURCE

OFF

Push & Turn

Fast Dialing
Push & Hold

Double Click

READ

Store/Step

for Options

+

°C

for

to

with 10° (or 0.100 mV) increments.

The OVERLOAD indicator will light if excessive
voltage or current is detected by the calibrator.

Reading Thermocouple Sensors

READ

Choose this function to measure temperatures with a thermocouple probe or sensor.

1) Disconnect the thermocouple sensor from any other device.

2) Select “READ” with slide switch

3) Place the EZ-CHECK switch into the READ position.

4) Connect a thermocouple probe (matching the type of wire to sensor being measured) with min­iature male T/C connector or bare wire under the brass screws to the sensor. Millivolt outputs
(without cold junction) are connected with a copper (white) miniature thermocouple connector or
to the banana jacks with cooper wire.

The PIECAL 422 measures the temperature signal and constantly updates the display with the
current temperature reading. Move the EZ-CHECK switch to MAX to see the highest temperature
reading and to MIN to see the lowest temperature reading. Press and hold the knob
MAX and MIN readings.

The OVERLOAD indicator will light if excessive voltage or current is detected by the calibrator.

w.

e to clear the

Warranty

Our equipment is warranted against defective material and workmanship (excluding batteries) for a
period of three years from the date of shipment. Claims under warranty can be made by returning
the equipment prepaid to our factory. The equipment will be repaired, replaced or adjusted at our
option. The liability of Practical Instrument Electronics (PIE) is restricted to that given under our
warranty. No responsibility is accepted for damage, loss or other expense incurred through sale or
use of our equipment. Under no condition shall Practical Instrument Electronics, Inc. be liable for any
special, incidental or consequential damage.

Practical Instrument Electronics

82 East Main Street Suite 3.14 • Webster, NY 14580 Tel: [phone] • Fax: [phone] • [e-mail] • www.piecal.com

Page 4

Storing EZ-CHECK Outputs

STORING HI and LO EZ-CHECK Outputs

Choose this function to provide a simulated thermocouple signal into controllers, temperature
transmitters, indicators or any other input device that measure thermocouple sensors.

1) Store your high (SPAN) output temperature by moving the EZ-CHECK switch to the HI position
and turn the
EZ-Dial knob until STORED appears to store the value. Release the EZ-Dial knob.

2) Store your low (ZERO) output temperature by moving the EZ-CHECK switch to the LO position
and turn the
EZ-Dial knob until STORED appears to store the value. Release the EZ-Dial knob.

3) Instantly output your SPAN and ZERO temperature outputs by moving the EZ-CHECK switch
between HI and LO. You may also select any third temperature output (such as mid-range) using
the SET position on the EZ-CHECK switch.

e EZ-Dial knob until the desired temperature is on the display. Press and hold the

e EZ-Dial knob until the desired temperature is on the display. Press and hold the

Automatic Stepping

To change the Automatic Stepping settings

Double click the e DIAL KNOB at any time the unit is on and the menu will appear for 15 seconds.

Turn the e DIAL KNOB to move through down
to the third (FEATURES) menu. Press the e
DIAL KNOB to toggle between OFF and ON or
to change the STEPS and the STEP TIME
settings. These settings are remembered even
with the power off.

EXIT MENU - exits this menu immediately and saves any changes. Menu will automatically exit after
15 seconds of inactivity.

STEPS - pressing the knob will cycle through 2, 3, 5 and 11 then reverse direction. The endpoints of
the steps are based on the values stored in the HI and LO EZ-CHECK outputs.

2 steps will automatically switch between the values stored in the HI & LO EZ-CHECK (0 &
100%).

3 steps between the HI, Midpoint and LO EZ-CHECK (0, 50 & 100%).

5 steps between the HI and LO EZ-CHECK in 25% increments (0, 25, 50, 75 & 100%).

11 steps between the HI and LO EZ-CHECK in 10% increments (0, 10, 20...80, 90 &100%).

RAMP continuously between the HI and LO EZ-CHECK.

FEATURES

> EXIT (3/3)
AUTO OFF ON OFF
BACKLIGHT ON OFF
STEPS/RAMP 2
STEP/RAMP TIME 5 6 7 8 9 10 15 20 25 30 60

3 5 11 RAMP

STEP TIME - pressing the knob will cycle through 5, 6, 7, 8, 9, 10, 15, 20, 25, 30 and 60 seconds.

To start the Automatic Stepping

Start automatic stepping or ramping by placing the EZ-CHECK Switch into the HI or LO position
then press and hold the
after 3 seconds and continue to press the DIAL KNOB) until the word STEPPING appears on the
display. The word STEPPING will appear on the display anytime the selected automatic function is
running. Stop the stepping by again pressing and holding the

e DIAL KNOB for 6 seconds (the word STORE will appear on the display

e DIAL KNOB for 3 seconds.

Practical Instrument Electronics

82 East Main Street Suite 3.14 • Webster, NY 14580 Tel: [phone] • Fax: [phone] • [e-mail] • www.piecal.com

Page 5

Thermocouple Ranges & Accuracies

Based on ≤ ± (0.008 % of Reading + 0.006 mV)

T/C

Type

Degrees C

Range

J -200.0 to -180.0 ±0.3° -328.0 to -292.0 ±0.5° +Iron

-180.0 to -50.0 ±0.2° -292.0 to -58.0 ±0.4°

-50.0 to 500.0 ±0.1° -58.0 to 932.0 ±0.2°

500.0 to 1200,0 ±0.2° 932.0 to 2192.0 ±0.4°

Accuracy Degrees F

Range

Accuracy T/C

Material

-Connstantan
Jacket

ISA/ANSI

Color

White

Red

Black

K -230.0 to -100.0 ±0.6° -382.0 to -148.0 ±1.1° + Chromel®

-100.0 to 1050.0 ±0.2° -148.0 to 1922.0 ±0.4°

1050.0 to 1371.1 ±0.3° 1922.0 to 2500.0 ±0.5°

T -260.0 to -200.0 ±1.0° -436.0 to -328.0 ±1.8° +Copper

-200.0 to -50.0 ±0.5° -328.0 to -58.0 ±0.9°

-50.0 to 0.0 ±0.2° -58.0 to 32.0 ±0.4°

0.0 to 400.0 ±0.1° 32.0 to 752.0 ±0.2°

E -240.0 to -200.0 ±0.4° -400.0 to -328.0 ±0.7° +Chromel

-200.0 to -100.0 ±0.2° -328.0 to -148.0 ±0.4°

-100.0 to 850.0 ±0.1° -148.0 to 1562.0 ±0.2°

850.0 to 1000.0 ±0.2° 1562.0 to 1832.0 ±0.4°

R -18.3 to 250.0 ±1.2° -1.0 to 482.0 ±2.2° +Pt/13Rh

250.0 to 750.0 ±0.6° 482.0 to 1382.0 ±1.1°

750.0 to 1600.0 ±0.5° 1382.0 to 2192.0 ±0.9°

1600.0 to 1767.8 ±0.6° 2192.0 to 3214.0 ±1.1°

S -18.3 to 100.0 ±1.2° -1.0 to 212.0 ±2.1° +Pt/10Rh

100.0 to 400.0 ±0.8° 212.0 to 752.0 ±1.4°

400.0 to 1700.0 ±0.6° 752.0 to 3092.0 ±1.1°

1700.0 to 1767.8 ±0.7° 3092.0 to 3214.0 ±1.3°

-Alumel®
Jacket

-Constantan
Jacket

-Constantan
Jacket

-Platinum
Jacket

-Platinum
Jackrt

Yellow

Red

Yellow

Blue

Red

Blue

Purple

Red

Purple

Black

Red

Green

Black

Red

Green

B 315.6 to 550.0 ±1.8° 600 to 1022.0 ±3.2° +Pt/30Rh

550.0 to 900.0 ±1.1° 1022.0 to 1652.0 ±2.0°

900.0 to 1150.0 ±0.7° 1652.0 to 2102.0 ±1.3°

1150.0 to 1820.0 ±0.6° 2102.0 to 3308.0 ±1.1°

Note: Doesn’t include cold junction error of ±0.05°C

-Pt/6Rh
Jacket

Grey

Red

Grey

Practical Instrument Electronics

82 East Main Street Suite 3.14 • Webster, NY 14580 Tel: [phone] • Fax: [phone] • [e-mail] • www.piecal.com

Page 6

Thermocouple Ranges & Accuracies

Based on ≤ ± (0.008 % of Reading + 0.006 mV)

T/C

Type

(W)

(W5)

(W3)

Degrees C

Range

N -230.0 to -180.0 ±1.0° -382.0 to -292.0 ±1.8° +Nicrosil

-180.0 to -50.0 ±0.5° -292.0 to -58.0 ±0.9°

-50.0 to 1100.0 ±0.2° -58.0 to 2012.0 ±0.4°

1100.0 to 1300.0 ±0.3° 2012.0 to 2372.0 ±0.5°

G

100.0 to 150.0 ±1.2° 212.0 to 302.0 ±2.2° +Tungsten

150.0 to 400.0 ±0.8° 302.0 to 752.0 ±1.4°

400.0 to 1700.0 ±0.4° 752.0 to 3092.0 ±0.7°

1700.0 to 2320.0 ±0.7° 3092.0 to 4208.0 ±1.3°

C

-1.1 to 1500 ±0.5° 30.0 to 2372.0 ±0.9° +W5/Re

1500 to 1900 ±0.6° 2372.0 to 3452.0 ±101°

1900.0 to 2100.0 ±0.7° 3452.0 to 3812.0 ±1.3°

2100.0 to 2320.0 ±0.9° 3812.0 to 4208.0 ±1.6°

D

-1.1 to 50.0 ±0.6° 30.0 to 122.0 ±1.1° +W3/Re

50.0 to 1400.0 ±0.4° 122.0 to 2552.0 ±0.7°

1400.0 to 1800.0 ±0.5° 2552.0 to 3272.0 ±0.9°

1800.0 to 2320.0 ±0.9° 3272.0 to 4208.0 ±1.6°

Accuracy Degrees F

Range

Accuracy T/C

Material

-Nisil
Jacket

-W26/Re
Jacket

-W26/Re
Jacket

-W25/Re
Jacket

ISA/ANSI

Color

Orange

Red

Orange

White

Red

White/Blue

White

Red

White/Red

White

Red

White/Yellow

0.0 to 1000.0 ±0.2° 32.0 to 1832.0 ±0.4°

P

Platinel®

1000.0 to 1395.0 ±0.3° 1832.0 to 2543.0 ±0.5°

DIN Colors

L

-200.0 to -50.0 ±0.2° -328.0 to -58.0 ±0.4° +Iron

J-DIN

T-DIN

-50.0 to 500.0 ±0.1° -58.0 to 932.0 ±0.2°

500.0 to 900.0 ±0.2° 932.0 to 1652.0 ±0.4°

U

-200.0 to -75.0 ±0.3° -328.0 to -103.0 ±0.5° +Copper

-75.0 to 100.0 ±0.2° -103.0 to 212.0 ±0.4°

100.0 to 600.0 ±0.1° 212.0 to 1112.0 ±0.2°

Note: Doesn’t include cold junction error of ±0.05°C

+Pd55/Pt31/Au14

-Au65/Pd35
Jacket

-Connstantan
Jacket

-Constantan
Jacket

Yellow

Red

Black

Red
Blue
Blue

Red
Brown
Brown

Practical Instrument Electronics

82 East Main Street Suite 3.14 • Webster, NY 14580 Tel: [phone] • Fax: [phone] • [e-mail] • www.piecal.com

Page 7

Thermocouple Ranges & Accuracies

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

General

Accuracy ±(0.008% of Reading + 0.006 mV)

Cold Junction Compensation

Millivolt Range -13.000 to 80.000 mV

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

Temperature Effect ≤ ±50 ppm/°C; Cold Junction Sensor ≤ ±25 ppm/°C

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

Size L=5.63 x W=3.00 x H=1.60 inches

Weight 12.1 ounces (including boot & batteries)

Batteries Four “AA” Alkaline 1.5V (LR6)

Battery Life 50 Hours

Optional NiMh

Low Battery Low battery indication with nominal 1 hour of life left

Protection against misconnection Over-voltage protection to 60 V dc (rated for 30 seconds)

Display High contrast graphic liquid crystal display. LED backlighting

Read

Input Impedance

Open Thermocouple

Threshold
Pulse

Normal Mode Rejection 50/60 Hz, 50 dB

Common Mode Rejection 50/60 Hz, 120 dB

Rechargeable battery kit

± 0.09°F (±0.05 °C) - Thermistor traceable to NIST for 11 years

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

120 VAC for North America Only; charger, four
batteries, AC & DC cords [Part # 020-0103]

for use in low lit areas.

> 10 Megohms

10,000 Ohms nominal
< 10 microamp pulse for 400 milliseconds

NiMh

Source

Output Impedance < 0.3 Ohms

Source Current > 20 mA (drives 80 mV into 10 Ohms)

Noise ≤ 4 microvolts p-p for frequencies of 10 Hz or below

Accessories

Optional: T/C Wire Kit 1 for Types J, K, T & E Part No. 020-0202
Optional: T/C Wire Kit 2 for Types B, R/S & N Part No. 020-0203
Three feet (1 meter) of T/C extension wire, stripped on one end with a miniature T/C
male connector on the other end.
Standard Test Leads (Included with calibrator) Part No. 020-0207
Optional Ni-MH 1 Hour Charger w/4 Ni-MH AA Batteries Part No. 020-0103
(100-120 V AC input for North America Only)
Optional Magnet Strap Part No. 020-0236

Practical Instrument Electronics

82 East Main Street Suite 3.14 • Webster, NY 14580 Tel: [phone] • Fax: [phone] • [e-mail] • www.piecal.com

Page 8