AST IR-CAST 2C User manual

AST IR-CAST 2C
USER MANUAL
A S Tccurate ensors echnologies
Non-contact Infrared Pyrometers
We measure accurate temperature in extreme conditions
AST - Accurate Sensors Technologies
Misgav Industrial Park
Tel: [phone], Fax: [phone]
Email: [e-mail]
Web: www.accuratesensors.com
, Misgav 20173, Israel

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Index
1. Chapter - 1
General information
2. Chapter - 2 ....................................................................................................................... 2
Introduction
2.1 Application, range and working principle
2.2 Technical specification
2.3 Optics
3. Chapter - 3 ....................................................................................................................... 6
Installation of pyrometer
3.1 Installation
3.1.1 Location selection
3.1.2 Correct positioning of pyrometer
3.1.3 Mounting of pyrometer
3.1.4 Ambient temperature
3.1.5 Atmospheric condition
3.2 Mechanical accessories
3.3 Electrical installation
3.3.1 Connector pin assignment on the back of the pyrometer
3.3.2 USB 2.0 Connection
3.3.3 Converter RS-232 ↔ RS-485
3.3.4 Display instrument
3.3.5 Display & parameterizer
4. Chapter - 4 ....................................................................................................................... 12
Software installation
4.1 Installation
4.2 Parameters in main screen
4.2.1 Communication
` 4.2.2 Temperature
4.2.3 Parameter Setting
4.2.4 Device Information
4.2.5 Record
5. Chapter - 5 ....................................................................................................................... 19
Calculate Spot size
6. Chapter - 6 ....................................................................................................................... 20
Serial communication protocol
....................................................................................................................... 1

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Congratulations on choosing this high quality and highly efficient AST pyrometer for non contact
temperature measurement.
Please read this user manual carefully, step by step, including all notes of security, operation and
maintenance before installing the pyrometer. This manual contains all the necessary instructions for set up and
operation of the pyrometer. This section provides an overview about important safety regulations.
Some Important Safety Regulations Given Below:
1. Safety Precaution :
Each person working with pyrometer must read the user manual before operation. The pyrometer has only to be
used for the purpose described in manual. The pyrometer works only with a potential free low voltage of range
24VDC. This voltage is not harmful for user. The pyrometer may contain harmful material and hence it should not be
disposed of with normal waste.
2. Packaging and Storage :
Always use a shock proof package for shipment of pyrometer. It should be sealed to protect it against humidity. Also
protect the lens of pyrometer with cover. They should be stored at the temperature range from -20°c to 70°c.
3. Limit of Liability and Warranty
All general information and notes for handling, maintenance and cleaning of this instrument are offered according to
the best of our knowledge and experience.
AST reserves the right to revise this document and to make change from time to time in the content hereof without
obligation to notify any person or persons of such revisions or changes
AST instruments have a warranty of two year from the invoice date. This warranty covers manufacturing defects and
faults which arise during operation only if they are the results of defects caused by AST.
AST does not accept liability for any damages or losses which might occur, including consequential damages and
financial losses, as a result of use of the instrument.
4. Copyright
All rights reserved . this document may contain proprietary information and shall be respected as a proprietary
document to AST with permission for review and usage given only to the rightful owner of the instrument with which
this document is associated.
Chapter - 1
General Information

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Chapter-2
Introduction
AST IR-CAST 2C are specially designed highly accurate digital two-color rectangular measuring field IR
pyrometers for non-contact temperature measurement specially used in foundries for molten metal.
2.1 Application, Range and Working Principle
The digital AST IR-CAST 2C pyrometer use ratio method in which 2 adjacent wave lengths are used for
measurement of temperature. They are suitable for high temperature measurement ranging from 700°C to 1700°C.
AST IR-CAST 2C pyrometers are suitable for industrial purpose due to following advantages:
ŸThe pyrometer gives accurate reading even when metal stream moves with in rectangular area.
ŸMeasurement of temperature is not affected by emissivity of object.
ŸMeasurement of object temperature is possible where dust, moisture & other contaminants are present in
surrounding environment.
ŸThe measuring object can be smaller than spot size.
ŸThe pyrometer can be switched between 1-colour & 2-colour mode.
These pyrometers have solid body in stainless steel housing which provides high operation safety even in rough
industrial environment, and large variety of optics with fixed focus which can be easily used in all industrial areas.
AST IR-CAST 2C has a fast response time of 20msec. Pyrometer have RS-232, RS-485 & USB 2.0 outputs.
Response time, emissivity, sub range and peak picker selection can be preset ex works or adjusted through available
software.
The pyrometer temperature measurement method utilizes the fact that objects emit thermal radiation in an
amount that directly corresponds to their own temperature and surface emissivity. Two color pyrometer involves
measuring thermal radiance at two different wavelengths and inferring the temperature from the ratio of these
spectral radiances. Radiance ratio thermometers can be significantly more accurate than single band thermometers
in many applications.
The application in which AST pyrometer can be used is:
Ÿ Molten Metal
If the target is within this rectangular area, it gives an accurate temperature reading even when liquid moves within
this area.
118.00 mm
34.50 mm
Ø49.50 mm
Binder
Connector
AST IR-CAST 2C
14.00 mm
199.00 mm
47.50 mm
Ø 25.00 mm
11.00 mm
Measuring Distance
Measuring Field
Field of View
Metal Stream

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2.2 Technical Specifications
Standard Item supplied with :-
þ
þConnection cable 12-core (length - 5 m)
þDigital cable 3-core (length - 1.5 m)
þUSB cable
þAST software CD
þManual
þCertificate of calibration
AST IR-CAST 2C
AST pyrometer
Measured Temperature Range
(Analog sub range adjustable)
Spectral Range
Emissivity Range
Model AST IR-CAST 2C
700° - 1700°C
single colour (1.0....1.15µm) two colour (0.7 )....1.15µm & 1.0...1.15µm
0.1….1 adjustable (for single color mode)
Emissivity slop 0.75….1.25 slop adjustable (for two color mode)
Response Time
Accuracy
20msec. Adjustable upto 10 sec
± 0.5% +1°C of measured value
Distance to Spot Size Ratio
Digital Output
Analog Output
USB 2.0, RS-232 & RS-485 (Isolated) User Selectable
4-20 mA or 0-20mA or 0-10 V User selectable
Sighting Through the lens sighting (TL)
Operating temperature range 0°C......70°C, 0°C......200°C(with cooling jacket)
Protection class IP 65
Isolation Power supply and digital output and analog output are galvanically
isolated against each other
Operating humidity
Dimensions/Weight
Adjustable Parameters via software
10 - 95% non - condensing conditions
Dia. = Ø49.5 mm; Length = 118 mm / Weight = 0.6 kg
Emissivity, Emissivity Slope, Analog output, Address, Switch off limit,
Response time, Peak picker, Analog output sub range, switches b\w 2-
color or single color
D = 166:1 (V = Vertical)
V
D = 33:1 (H = Horizontal)
H
Power Supply 24V DC
Photodetector Type Si / Si
Repeatability 0.1% of reading in °C +1°C
Power Consumption Max. 2.5 Watt.
Note : 1. After power supply initialization, keep pyrometer under stable temperature condition for 15 Min. to get
above stated accuracy.
2. Pyrometer instrument should be properly earthed before giving the power supply.

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2.3 Optics
has to be measured. This heat radiation is passes through the lens to the sensor and is then converted
to an electrical signal. The farther the measured object is from the pyrometer, the larger the area that will be
measured by the pyrometer. Depending on customer need, the pyrometer is designed with fixed optics.
The pyrometer measure temperature by receiving heat radiation from the object whose temperature
Some fixed optics focus is as below:-
For Installed spot size calculation.
If the pyrometer is not installed at manufactured working distance (WD) then spot size at actual installed
distance should be calculated.
* Manufactured working distance (WD) mentioned on the pyrometer.
Manufactured working distances
WD (mm)
Spot Sizes (mm)
350
1000
Measuring Field
2.1
6
FOV 166:1
V
500 3
700 4.2
10.5
30
15
21
FOV 33:1
H
700° - 1700°C
Aperture (A)
2000 12 60
5000 30
3000 18
150
90
4
Case-I: If installed working distance is greater than manufactured working distance
Case-II: If installed working distance is smaller than manufactured working distance

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For Installed spot size calculation, horizontal & vertical spot size should be calculated separately by putting the
parameters from the fixed optics table.
(A) Vertical Spot Size Calculation
CAST 2C(700° - 1700°C) then spot size is 30mm (as given in table). If user installed this pyrometer at 5000mm then
spot size is not 150mm (as given in table), user should have to calculate as given method.
Installed spot size at 5000mm = (5000/1000) x (6 + 4) - 4 = 46mm
for example, if factory made working distance is 1000mm & pyrometer is AST IR-
(B) Horizontal Spot Size Calculation
IR-CAST 2C(700° - 1700°C) then spot size is 6mm (as given in table). If user installed this pyrometer at 5000mm then
spot size is not 30mm (as given in table), user should have to calculate as given method..
Installed spot size at 5000mm = (5000/1000) x (30 + 4) - 4 = 166mm
Final spot size should be
For example, if factory made working distance is 1000mm & pyrometer is AST
46mm
166mm

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Chapter - 3
Installation of the Pyrometer
3.1 Installation
3.1.1 Location selection
Qualified operating personnel should do the installation. Location should be good enough so that pyrometer
should get continuous infrared radiation.
Pyrometer distance from object is according to below points:-
1.
2. Know your pyrometer spot size according to point 2.3.
3. Pyrometer ambient temperature should be within 0° to 70°C (read 3.1.4).
3.1.2 Correct Positioning of the pyrometer
With through the lens sighting (TL)
In case of through the lens sighting a reticule rectangle marks the position of the measuring area. This
rectangle is true-sided and parallax-free.
Note: The reticule rectangle (TL) is only for indication of measuring area, not exactly shows the measuring
area.
3.1.3 Mounting of pyrometer
To install the pyrometer at the place of measurement a mounting support is supplied as an accessory, after
losing the clamp screws, it can be fastened correctly.
3.1.4 Ambient temperature
The allowed operation temperature for the pyrometer is 0°C to 70°C. Therefore if pyrometer is to be used
above 70°C upto 200°C water cooling jacket with built in air purge unit is used otherwise it may damage the
pyrometer. The ambient temperature is dependent on the temperature and flow rate of cooling water. Details of air
purge & water cooling jacket is given in point 3.2.
3.1.5 Atmospheric conditions
The pyrometer cannot receive the full infrared energy for the measurement if atmospheric conditions like
smoke, dust or steam are present and hence it result in measuring error. An air purge unit can be helpful to avoid
contamination such as dust and humidity on the lens. The air supplied should be at normal temperature with oil &
moisture free. The air purge generates an air stream shaped like a cone and blows particles from the lens area.
The minimum width of the pouring stream must be 33% of the width of the horizontal measuring width.
Measuring Area
Working distance(WD) (mm)
350
500
700
1000
2000
3000
5000
Width of the measuring area (mm)
10.5
15.0
21.0
30.0
60.0
90.0
150.0
Minimum width of the pouring stream (mm)
3.5
5.0
7.0
10.0
20.0
30.0
50.0
Minimum Width of the Pouring Stream
A B C
For Molten Metal pouring

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Air purge unit
(Reference no: 8000-04)
3.2 Mechanical accessories
Water pressure : < 10 bar
Air pressure : < 0.5 bar
Air consumption : 2...3 m³/h
Ambient temperature : < 200°C
Metal : Stainless steel
Weight : 2.75 Kg
Water Cooling Jacket with Adjustable Flange PL
(Reference no: 8000-02)
Water Cooling Jacket with Adjustable Flange TL
(Reference no: 8000-06)
M27 x 0.75
M40 x 1.5
60
48
156
80
287
54 75
18
24.50
M27 x 0.75
M40 x 1.5
175
292
65 80
80
75 48
18
24.50
60
Ø68
Ø63
Ø20
30.60
GRUB SCREW FOR
FIXING PYROMETER
FOR 6 mm INSIDE
DIAMETER HOSE
Adjustable Mounting Stand
(Reference no: 8000-07)
60°
R30
75
60
5
110
60 66
86
3 x M6 THRU AT 120°
Air pressure : < 0.5 bar
Air consumption : 2...3 m³/h
Metal : Aluminium
Weight : 0.15 Kg
Dry, clean air (Oil and dust free)
Metal : Stainless Steel
Weight : 0.9 Kg

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Adjustable mounting support
(Reference no: 8000-05)
3.3. Electrical Accessories
Power supply unit
(Reference no: 9000-02)
AST IR CAST 2C is powered by 24V DC (well stabilized ripple
max 50mV).The input power supply is 110/230v AC check the
polarity before connecting the device.
Device has following specifications
Power supply I/P : 100 - 240VAC, 0.9A
50/60 Hz
Power supply O/P : +24V DC, 1.5 A
3.3.1 Connector pin assignment on the back of the pyrometer
RS-232 Connection
12-Core cable
(Reference no: 7002-02)
110
70
50
70
3
Metal : Stainless Steel
Weight : 0.45 Kg
Pink
Blue
Black
Ref. No.: 9000-01
Temperature Indicator
230V, AC
AST 12-core cable
AST Pyrometer with
Digital Output RS-232
White
Red
Violet
Yellow
GND
+24 V DC
20
4-20 mA(+)
17
(-)
9
10
Female
RS-232 Connector
Computer
AST Digital Cable