Heraeus Electro-Nite CasTemp Wireless Parts list manual

5 June 2020 CasTemp Wireless including CasTemp Superheat page I of VII
Instruction and Operating Manual
Description
CasTemp Wireless
including CasTemp
Superheat
CasTemp Wireless software V6 onwards
Document Version: 3.5
Date of Issue: 5 June 2020

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All instrument boards contain electronic components that can be damaged by electrostatic discharge.
These boards should only be handled by qualified personnel. The necessary safety precautions and
security guidelines must be observed during maintenance and service on the instrument.
Trademarks: All brand names and product names included in this manual are trademarks, registered
trademarks, or trade names of their respective holders.
Econ-O-CarbP

P, PosithermP

P, QuiK-CarbP
, CasTemp®and TapTipP 
Pare registered
trademarks of Heraeus Electro-Nite.
© 2015 Heraeus Electro-Nite
This manual is copyrighted by Heraeus Electro-Nite. No part of this document
may be reproduced, transmitted, transcribed, stored in any retrieval system, or
translated into any language by any means without the express written
permission of Heraeus Electro-Nite.
Heraeus Electro-Nite makes no warranties as to the contents of this
documentation and specifically any implied warranties of merchantability or
fitness for any particular purpose.
Heraeus Electro-Nite further reserves the right to alter the specification of the
product without obligation to notify any person or organisation of these
changes.
Improvements or instrument changes added after this document was printed
are to be found on one or more pages enclosed at the end of this manual.
We ask you to take note of these extra sheets.

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Table of contents
1 Safety and Usage Notes.................................................................................................................1
1.1 General.................................................................................................................................... 1
1.2 Qualified Personnel..................................................................................................................1
1.3 Danger Notices ........................................................................................................................1
1.4 Proper Usage...........................................................................................................................2
1.5 Procedures for Maintenance and Repair..................................................................................2
1.6 Guidelines for Handling Electrostatic Discharge ......................................................................2
1.6.1 Electrostatic Discharge......................................................................................................2
1.6.2 Shipping of ESD-Sensitive Modules..................................................................................2
1.7 Looking After the Instrument.................................................................................................... 3
1.7.1 Cleaning Notes..................................................................................................................3
1.8 Packaging the Instrument ........................................................................................................ 3
1.8.1 Packaging Recommendation.............................................................................................3
1.9 Safety Regulations...................................................................................................................3
1.9.1 CE-Declaration of Conformity............................................................................................ 3
1.9.2 Wireless transmitter / receiver module...............................................................................4
1.9.3 Safety ................................................................................................................................4
1.10 RoHS Regulations....................................................................................................................4
1.11 WEEE Regulations...................................................................................................................5
1.12 Recycling ................................................................................................................................. 5
1.13 Residual risks...........................................................................................................................5
2 System overview ............................................................................................................................6
2.1 Introduction .............................................................................................................................. 6
2.2 Benefits....................................................................................................................................6
2.3 Components.............................................................................................................................6
2.3.1 QUBE CTW module...........................................................................................................7
2.3.2 CasTemp Wireless Instrument (CTW)...............................................................................8
2.3.3 CasTemp Wireless User Guide ......................................................................................... 8
3 Installing the system.......................................................................................................................9
3.1 QUBE CTW Module Charging................................................................................................10
3.1.1 Charging on the instrument .............................................................................................10
3.1.2 Charging with the Power Box .......................................................................................... 12
3.2 Critical Safety Information......................................................................................................13
4 Measuring the temperature........................................................................................................... 15
4.1 Measurement screen in standard mode.................................................................................15
4.2 Pairing and unpairing sequences...........................................................................................16
4.2.1 Starting a measurement ..................................................................................................17
4.2.2 Glossary: ......................................................................................................................... 17
4.2.3 Stopping a measurement.................................................................................................24
4.2.4 Prevent unpairing on the instrument................................................................................25
5 Configuration of the system.......................................................................................................... 26
5.1 Configuration possibilities during a measurement.................................................................. 26
5.1.1 Editing the Application Language ....................................................................................27
5.1.2 Separator.........................................................................................................................27
5.1.3 Graph settings ................................................................................................................. 28
5.2 Configuration possibilities when no measurement is ongoing................................................29
5.2.1 Configuring the Temperature parameters........................................................................30
5.2.2 Configuring the CasTemp Wireless instrument parameters ............................................30
5.2.3 SH Prediction Parameters...............................................................................................32

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5.2.4 CasTip Parameters..........................................................................................................32
5.2.5 Checkmate ...................................................................................................................... 34
5.2.6 Database parameters......................................................................................................34
5.2.7 LAN 1 & 2 parameters..................................................................................................... 35
5.2.8 Remote Viewer (Meltcontrol Set Up) ...............................................................................36
5.2.9 Level 2 Inputs .................................................................................................................. 37
6 Level 2 communication................................................................................................................. 38
6.1 Telegram composer............................................................................................................... 38
6.2 Implemented protocols........................................................................................................... 43
6.2.1 TCP/IP Client................................................................................................................... 44
6.2.2 TCP-IP Server .................................................................................................................44
6.2.3 Serial port RS232 ............................................................................................................ 45
6.2.4 Profibus ........................................................................................................................... 46
6.2.5 EtherNet IP...................................................................................................................... 46
6.2.6 Implemented Protocols as Physical Devices List.............................................................47
6.2.7 Non standard Protocols................................................................................................... 47
6.3 Bindings between the protocols and the telegrams................................................................ 47
6.3.1 Telegram Output................................................................................................................1
7 Other...............................................................................................................................................1
7.1 Transfer (of Settings) ............................................................................................................... 1
7.1.1 Exporting an Instrument settings ....................................................................................... 2
7.1.2 Importing an Instrument settings........................................................................................2
7.2 Operating System .................................................................................................................... 2
7.2.1 Upgrading Software from ≤V3 to ≥V6.4 or V5.23 to ≥V6.4.................................................3
7.3 Date and Time.......................................................................................................................... 4
7.4 Firmware Upgrade ................................................................................................................... 5
7.5 Download Data......................................................................................................................... 6
7.6 License..................................................................................................................................... 7
7.7 Close Program.........................................................................................................................7
8 Technical Data................................................................................................................................ 8
8.1 Operating Specification............................................................................................................8
8.2 Measurement Specification......................................................................................................8
8.3 Instrument drawings................................................................................................................. 9
8.3.1 Instrument.......................................................................................................................... 9
8.3.2 Mounting Plate...................................................................................................................9
8.3.3 QUBE CTW Module –model 1........................................................................................10
8.3.4 QUBE CTW Module –model 2 - CasTemp Qube module...............................................11
8.4 CasTemp Wireless Instrument Specifications........................................................................12
8.5 QUBE CTW Module –repair..................................................................................................12
9 CasTemp Superheat.....................................................................................................................13
9.1 CasTemp Superheat Introduction ..........................................................................................13
9.2 Screen differences................................................................................................................. 13
9.2.1 CasTemp Wireless Instrument Measurement Screen in standard mode......................... 13
9.2.2 CasTemp Wireless Instrument Measurement Screen in CasTemp Superheat mode......14
9.3 Hardware Requirements........................................................................................................15
9.3.1 CasTip QUBE..................................................................................................................15
9.3.2 Sensor / Probe Holder and Signal Cable (CASTIP LANCE HOLDER)............................15
9.3.3 Lance Handle ..................................................................................................................16
9.3.4 CasTip Sensor.................................................................................................................16
9.4 Level 2 communication ..........................................................................................................17
9.4.1 Communication Protocols for output to plant...................................................................17
9.4.2 Communication Protocols for input to CasTemp Superheat............................................ 17

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9.4.3 Telegram Requirements..................................................................................................17
9.4.4 Telegram Timings............................................................................................................ 22
9.4.5 Telegram Output................................................................................................................1
9.5 Profibus and Ethernet IP set up ............................................................................................... 1
9.5.1 Profibus Set up..................................................................................................................1
9.5.2 Ethernet IP Set up .............................................................................................................1
9.6 License..................................................................................................................................... 1
9.6.1 License Code..................................................................................................................... 2
9.7 Dual System Set up ................................................................................................................. 4
9.7.1 How to set the IP address of the CasTemp Wireless instrument....................................... 5
9.7.2 How to set the instrument to slave..................................................................................... 6
9.8 How to set up and use the QUBE CasTip................................................................................6
9.8.1 How to change the PAN ID of the Qube CasTip................................................................6
9.8.2 CasTip Safety Mode..........................................................................................................7
9.8.3 Immersion Procedure and Signalisation............................................................................ 7
9.9 Measuring Period.....................................................................................................................8
9.10 Prediction explanation.............................................................................................................. 8
9.11 Superheat Screen Explained .................................................................................................10
9.12 Superheat Trial Set up ........................................................................................................... 11
10 Appendices................................................................................................................................13
10.1 Appendix 1: EC Declaration of Conformity Certificates..........................................................13
10.2 Appendix 2: Safety statement ................................................................................................ 17
10.3 Appendix 3: Remote Client Installation and set up................................................................. 21
10.4 Appendix 4: Profibus and Ethernet IP Module Installation and set up....................................24
10.5 Appendix 5: CasTemp approval form.....................................................................................27
10.6 Appendix 6: QUBE CTW Module Repair Guide.....................................................................28
10.7 Appendix 7: QUBE CasTip Lance Build Guide....................................................................... 29

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Table of Figures
Figure 1: CasTemp Wireless QUBE CTW and instrument Overview....................................................7
Figure 2: QUBE CTW module...............................................................................................................7
Figure 3: CasTemp Wireless instrument (CTW) ...................................................................................8
Figure 4: CTW User Guide....................................................................................................................8
Figure 5: CTW STARTER PACK .......................................................................................................... 9
Figure 6 CTW Starter Pack Assembly Guide........................................................................................ 9
Figure 7: CTW CHARGING CABLE....................................................................................................10
Figure 8: Connecting the CTW CHARGING CABLE to the CTW Instrument......................................10
Figure 9: CTW Instrument and QUBE CTW module in charging position on mounting plate.............. 11
Figure 10: QUBE CTW module with USB-C inlet................................................................................11
Figure 11: Qube CTW Power Box....................................................................................................... 12
Figure 12: Input and Output of Power Box.......................................................................................... 12
Figure 13: Retention clips for input and output leads..........................................................................12
Figure 14: Power Box mounting plate.................................................................................................13
Figure 15: CTW measurement screen................................................................................................ 15
Figure 16: CTW measurement window with large graph ....................................................................16
Figure 17: Incompatible firmware message ........................................................................................ 16
Figure 18: QUBE CTW module........................................................................................................... 20
Figure 19: CTW start-up screen..........................................................................................................20
Figure 20: CasTemp Wireless progress bar........................................................................................20
Figure 21: Scanning location ID’s .......................................................................................................21
Figure 22: CTW instrument in search mode........................................................................................21
Figure 23: Instrument has detected a QUBE CTW module ................................................................21
Figure 24: Confirm the correct measuring place.................................................................................22
Figure 25: Measurement window after pairing.................................................................................... 22
Figure 26: QUBE CTW module after pairing....................................................................................... 23
Figure 27: Another pairing procedure is ongoing ................................................................................ 23
Figure 28: Multiple QUBE CTW modules detected during pairing ......................................................24
Figure 29: Confirmation of the breaking of the pairing ........................................................................24
Figure 30: Detection of open circuit ....................................................................................................25
Figure 31: Configuration window during a measurement....................................................................26
Figure 32: Basic settings window........................................................................................................ 26
Figure 33: Changing the separator settings........................................................................................27
Figure 34: Changing the graph settings.............................................................................................. 28
Figure 35: Home screen with login......................................................................................................29
Figure 36: Menu selection window......................................................................................................29
Figure 37: Temperature type screen................................................................................................... 30
Figure 38: Instrument Settings............................................................................................................ 30
Figure 39: SH Prediction Settings....................................................................................................... 32
Figure 40: CasTip Settings..................................................................................................................33
Figure 41: Database settings..............................................................................................................34
Figure 42: Network settings ................................................................................................................35
Figure 43: Network settings with DHCP unchecked............................................................................ 35
Figure 44: Remote Viewer for Meltcontrol...........................................................................................36
Figure 45: Menu selection window......................................................................................................38
Figure 46: Level 2 configuration window............................................................................................. 39
Figure 47: telegram composer main window.......................................................................................39
Figure 48: new telegram composer..................................................................................................... 40
Figure 49: new telegram added to the list...........................................................................................42
Figure 50: Level 2 configuration window............................................................................................. 43
Figure 51: Physical device options......................................................................................................43
Figure 52: TCP/IP Client configuration................................................................................................44
Figure 53: TCP/IP Server configuration ..............................................................................................44

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Figure 54: Serial port configuration window........................................................................................45
Figure 55: Serial port configuration settings........................................................................................45
Figure 56: Profibus configuration window........................................................................................... 46
Figure 57: EtherNet IP Configuration window.....................................................................................46
Figure 58: Physical device window after configuring a number of interfaces......................................47
Figure 59: Level 2 configuration window............................................................................................. 47
Figure 60: operation window............................................................................................................... 48
Figure 61: Level 2 configuration window after configuring the telegram and protocol......................... 48
Figure 62: Settings' Menu..................................................................................................................... 1
Figure 63: Transfer of Settings.............................................................................................................. 1
Figure 64: Operating System window................................................................................................... 2
Figure 65: Operating system ipconfig ................................................................................................... 2
Figure 66: Operating system ping.........................................................................................................3
Figure 67: Operating system file explorer.............................................................................................3
Figure 68: date and time seting............................................................................................................. 4
Figure 69: Firmware Update .................................................................................................................5
Figure 70: Firmware update module id confirmed.................................................................................5
Figure 71: Download Data window .......................................................................................................6
Figure 72: License screen.....................................................................................................................7
Figure 73: Standard CasTemp wireless Instrument Screen................................................................ 13
Figure 74: SuperHeat Mode................................................................................................................14
Figure 75: SuperHeat Prediction Mode............................................................................................... 14
Figure 76: Telegram timings for Superheat mode, Flow Sheet........................................................... 22
Figure 77: License Screen....................................................................................................................1
Figure 78: license is active but will expire shortly..................................................................................2
Figure 79: license is expired .................................................................................................................2
Figure 80: license is not yet active........................................................................................................ 2
Figure 81: license file is invalid .............................................................................................................2
Figure 82: license is not yet valid for this instrument............................................................................. 2
Figure 83: license renewal due............................................................................................................. 2
Figure 84: 1st edition model CasTemp Wireless Instrument.................................................................5
Figure 85: 2nd edition model CasTemp Wireless Instrument................................................................ 5
Figure 86: Overview SuperHeat System...............................................................................................9
Figure 87: Superheat Screen Explained.............................................................................................10

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1 Safety and Usage Notes
1.1 General
This manual provides the information required to use the CasTemp Wireless system. This comprises
a CasTemp wireless instrument and a QUBETM CTW Wireless module. It is written for technically
qualified personnel such as engineers, programmers, or maintenance specialists who have been
specially trained and who have the specialised knowledge required in the field of instrumentation and
control.
This manual is an integral part of the instrument even if, for logistical reasons, it has to be ordered
separately. For the sake of clarity, not all details of all versions of the instrument are described, nor
can it cover all conceivable cases regarding installation, operation, and maintenance. If you require
further information or face special problems that have not been dealt with in sufficient detail in this
manual, contact Heraeus Electro-Nite.
We would also point out that the contents of this manual shall not become a part of, or modify, any
prior or existing agreement, commitment, or legal relationship. The Purchase Agreement contains the
complete and exclusive obligations of Heraeus Electro-Nite. Any statements contained in this manual
do not create new warranties or restrict the existing warranty.
1.2 Qualified Personnel
Only qualified personnel should be allowed to work on this instrument. Non-compliance with the
warnings contained in this manual or appearing on the instrument itself can result in severe personal
injury or damage to property. Qualified personnel includes:
•System planning and design engineers who are familiar with the safety concepts of automation
equipment.
•Operating personnel who have been trained to work with automation equipment and are
conversant with the content of the manual in as far as it is connected with the actual operation of
the instrument.
•Commissioning and service personnel who are trained to repair such automation equipment and
who are authorised to energise, de-energise, clear, ground, and tag circuits, equipment, and
systems in accordance with established safety practices.
1.3 Danger Notices
The notices and guidelines that follow are intended to ensure personal safety, as well as protecting
the instrument and connected equipment against damage.
The safety notices are warnings for protection against loss of life (yours or service personnel) or for
protection against damage to property and are highlighted in this manual by the terms and pictograms
defined here. The terms used in this manual and marked on the instrument itself have the following
significance:
Danger: Indicates that death, severe personal injury, or substantial property damage will result if
proper precautions are not taken.
Warning: Indicates that death, severe personal injury, or substantial property damage can result if
proper precautions are not taken.
Caution: Indicates that minor personal injury or property damage can result if proper precautions are
not taken.
Note: Indicates important information about the product, its operation, or a part of the manual to
which special attention is drawn.
Attention: Hints in this documentation to special safety-related guidelines, which equate to the safety
level of Caution and Note.

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This pictogram is used in relation to Danger, Warning, and Caution notices.
1.4 Proper Usage
•The instrument or instrument components may only be used for the applications described in the
manual or the technical description, and only in combination with the equipment, components,
and devices of other manufacturers as far as this is recommended or permitted by Heraeus
Electro-Nite.
•The instrument described has been developed, manufactured, tested, and the manual compiled in
keeping with the relevant safety standards. Consequently, if the handling instructions and safety
guidelines described for planning, installation, operation, and maintenance are adhered to, the
instrument, under normal conditions, will not be a source of danger to property or life.
1.5 Procedures for Maintenance and Repair
If measurement or testing work is to be carried out on an active unit, your national accident prevention
rules and regulations must be observed. Use only suitable electrical tools.
Warning:
•Repairs to an item of automation equipment may only be carried out by Heraeus Elec-
tro-Nite service personnel. For replacement purposes, use only parts or components
contained in the spare parts list or listed in the Spare Parts List section of this manual.
Unauthorised opening of equipment and improper repairs can result in loss of life or se-
vere personal injury as well as substantial property damage.
•Only use the fuse types specified in the technical specifications or the maintenance
instructions of this manual.
•Do not throw batteries into an open fire and do not carry out any soldering work on
batteries (danger of explosion). Maximum ambient temperature 85C. Lithium batteries
or batteries containing mercury should not be opened or recharged. Make sure that the
same type is used when replacing batteries.
•Batteries must be disposed of as classified waste.
1.6 Guidelines for Handling Electrostatic Discharge
VLSI chips (MOS technology) are used in practically all Heraeus Electro-Nite electronic modules.
These VLSI components are, by their nature, very sensitive to over voltages and thus to electrostatic
discharge (ESD).
1.6.1 Electrostatic Discharge
This pictogram and warning label is used on cabinets, sub-racks, and packing and suggests
that modules are susceptible to ESD.
Before starting maintenance or installation make sure that you have sufficient protection
against ESD.
Electronic devices can be destroyed by voltage and energy levels that are far below the level
perceptible to human beings. Such voltages can occur when a component or a module is touched by
a person who has not been electrostatically discharged.
In most cases, the components subjected to such over voltages, cannot be immediately detected as
faulty; the fault occurs only after a long period in operation.
1.6.2 Shipping of ESD-Sensitive Modules
Anti-static packing material must always be used when storing and dispatching modules and
components. If the container itself is not conductive, the modules must be wrapped in a conductive

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material such as conductive foam, anti-static plastic bag, aluminium foil, or paper. Normal plastic bags
or foil should not be used under any circumstances. For modules with built-in batteries, ensure that
the conductive packing does not touch or short-circuit the battery connections: if necessary cover the
connections with insulating tape or material.
1.7 Looking After the Instrument
The CasTemp Wireless measurement system requires little maintenance. However, since it is subject
to thermal and mechanical stress, it is recommended you check it once a week to ensure accurate
results.
1.7.1 Cleaning Notes
The instrument can be cleaned with a damp cloth and mild detergent.
1.8 Packaging the Instrument
Since the instrument is a high-quality electronic measurement unit, it should only be dispatched in its
original packing. If the original packing is no longer present, then it is advisable to properly pack the
device in a sufficiently large box lined with a shock-absorbing material such as PUR foam,
polystyrene flakes, or similar. The shock-absorbing layer should have a minimal thickness of 10cm on
all sides. Before packing the instrument, it must be wrapped in paper or plastic film.
1.8.1 Packaging Recommendation
For overseas transportation, the CasTemp Wireless unit should be welded into an air-tight plastic film,
ideally with a desiccant added. These packing recommendations also apply when returning the unit to
the manufacturer.
The QUBE CTW module contains a lithium-ion battery of energy 9.6 Wh. The module should be
packed and labelled in accordance with relevant regulations, noting local variation:
Warning
For air travel the QUBE CTW module must be deactivated.
1.9 Safety Regulations
The unit must be connected in compliance with the VDE 0100 "Regulations for establishing high
voltage equipment with mains voltages below 1000 V".
Warning
Before opening the equipment, it is essential that the mains voltage is
switched off to all channels or that the mains plug is disconnected.
Note that users connected (signalling system, horn) could have their own
power supply, which must also be disconnected. Work on live system
components may only be carried out with the utmost care by skilled
technical personnel.
1.9.1 CE-Declaration of Conformity
The CasTemp Wireless instrument, QUBE CTW module and QUBE CasTip all fulfil the requirements
of the following standards of the EU-directives:
Shipping Mode
Regulations
Air
IATA
Ship
IMDG
Rail
RID
Road
IMDG

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•Directive 2014/30/EU concerning electromagnetic compatibility (EMC).
•Radio Equipment Directive 2014/53/EU
Also:
•FCC Title 47 part 15
A copy of the EC Declaration of Conformity certificates can be found in Appendix 1: EC Declaration of
Conformity Certificate.
The operating limits are described in Section 0
Critical Safety Information and Section 0

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Technical Data.
An entire overview of the QUBE CTW module safety statement can be found in Appendix 2: Safety
statement.
1.9.2 Wireless transmitter / receiver module
The Heraeus Electro-Nite CasTemp wireless instruments and QUBE CTW modules work with the
industrial transmitter / receiver module RM024 from Laird Technologies, which is approved worldwide.
There is a 10mW transmitter in both CTW and instrument. The device is transmitting intermittently for
~100mS, so the energy transmitted is small.
1.9.2.1 RM024 transmitter / receiver module
The RM024 Frequency Hopping Spread Spectrum Transceiver Module from Laird Technologies is a
robust and easy to use wireless module. It supports both high data rates and long distances and is
used in many machine-machine applications.
• Frequency range: 2400 - 2483.5 MHz
• Transmission distance: 100m (in-door), 1km (free-field)
• Transmission power: +10 dBs
1.9.3 Safety
• Frequency Hopping Radio Interface (Frequency Hopping Spread Spectrum = FHSS)
• System IDs
• Unique IEEE MAC addresses
• Protected Hardware
• Proof, autonomous transmission / reception protocol
• No conflicts with WLAN or WIFI
1.10 RoHS Regulations
All electrical devices sold in the European market from the 1 July 2006 must fulfil the EU Directive
2002/95/EC Restriction of the use of certain Hazardous Substances in Electrical and Electronic
Equipment (RoHS) as well as the national laws derived from it. According to the definition in Annex IB
of the EU Directive 2002/96/EC WEEE, Heraeus Electro-Nite measuring instruments and analysis
devices belong to category 9 - monitoring and control instruments.
All Heraeus Electro-Nite instruments placed on the market after 1 July 2006 do not contain materials
prohibited according to the RoHS directive.
Affected parts and components are identified and adapted to the statutory requirements and other
substances in those parts and components are utilised where necessary. The quality and usability of
our devices are not affected.
The adaptations are usually not visible, although adapted primary housing parts can show different
surface colour.
1.11 WEEE Regulations
Heraeus Electro-Nite devices are exclusively for commercial use and may not be transferred to
private use. Devices must be disposed of according to the national, statutory regulations for
According to the EU Directive 2002/96/EC Waste Electrical and Electronic Equipment (WEEE),
all electrical devices sold in the European market from the 13 August 2005 must be marked with
a special symbol. This symbol (crossed out waste disposal receptacle with thick black bar
underneath) indicates to the customer that the device must not be placed in household waste,
but must be either deposited at a collection place for commercial scrap or returned to the
manufacturer.

5 June 2020 CasTemp Wireless including CasTemp Superheat Page 6
commercial electrical scrap. You must also follow the EU Directive WEEE regulations and their
national conversion. If in doubt, ask your national importer or Heraeus Electro-Nite.
All old Heraeus Electro-Nite devices can be deposited at Heraeus Electro-Nite premises, free of
charge and using a certificated disposal company. The customer pays only for the carriage.
1.12 Recycling
If the instrument has to be discarded, think about the following recycling issues. The device consists
of several components that can be disposed of separately:
•The electronic cards for electronic recycling.
•The housing for metal recycling.
•The battery for proper disposal
For further recycling information, see section 1.11.
1.13 Residual risks
Risk assessment of the QUBETM CTW module in the tundish environment has identified three
scenarios that could occur when the QUBE CTW module is used outside its operating limits, leading
to module failure, which could impact upon personnel. Appendix 2: Safety statement outlines what
might be expected in failure and how to minimise such exposure.

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2 System overview
2.1 Introduction
The CasTemp Wireless system is an instrument for continuous temperature measurements in
continuous casting tundishes and other applications.
Continuous steel casting is a process based on the solidification of steel. A well-controlled steel
solidification is the precondition for high quality cast products and caster throughput. Therefore, a
real-time temperature is recognised as a key factor in strand quality and casting speed related to the
cast steel grade.
The CasTemp Wireless system uses the wireless QUBE CTW module to send real time measurement
data from the CasTemp sensor to the CasTemp Wireless instrument mounted nearby..
The CasTemp Wireless instrument then has the possibility to send the results to the plant level 2
computer systems using different interface possibilities.
This means that the:
•Conti-Lab E instrument is replaced by CasTemp Wireless instrument
•Hot- or cold-zone compensation cabling is replaced by the QUBE CTW module
•Other than these changes, all sections in the CasTemp manual still apply
•CasTemp Wireless User Guide describes:
oAll the necessary information to ensure safe operation of the system at all times
oMounting of the QUBE CTW module,
ofitting to the CasTemp sensor.
2.2 Benefits
The benefits of using the CasTemp Wireless system are:
•Simple to install and set up
•Economical: no cable runs to the tundish
•Operate the system in gloved hands with a simple, one-button operation
•Reliable data capture
•Easy-to-read display
•Long battery life with simple battery charging
•No additional complexity of global or local positioning systems
•Same accuracy as the wired CasTemp system
•Modular customizable system
2.3 Components
To allow a customer to begin wireless continuous temperature measurement a minimum number of
components are necessary:
•QUBE CTW Module
oA robust and easy-to-use wireless module connected to a CasTemp sensor
oContains a rechargeable Lithium Iron Phosphate battery
•CasTemp Wireless instrument:
oContains the receiver, monitors QUBE CTW module output, and can connect to
existing plant level 2 systems.
•Charging system for the rechargeable battery
•CasTemp Wireless User Guide
Figure 1: CasTemp Wireless QUBE CTW and instrument Overview shows a schematic of the
CasTemp Wireless system in operation

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Figure 1: CasTemp Wireless QUBE CTW and instrument Overview
2.3.1 QUBE CTW module
The QUBE CTW module, Figure 2: QUBE CTW module, transceiver unit plugs directly on to the
CasTemp sensor and has the following features:
•Compatibility with CasTemp and other Heraeus continuous temperature sensors
•Robust construction for stable operation in environments -200C to 600C
•Can be operated with gloved hands
•LED status indication (closed circuit, broadcast, battery, over temperature)
•Programmable data capture rate
•ITS 90 type B thermocouple calibration
•Wireless Interface: 2.4GHz communication
•Rechargeable battery via dedicated USB port connection on the QUBE CTW module
•Long battery life (depends on data capture rate)
•Standard lengths of 1.5m, 3m and 4m are available
•A straight or right angled head (90o) are available
Figure 2: QUBE CTW module

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2.3.2 CasTemp Wireless Instrument (CTW)
The CasTemp Wireless instrument, Figure 3: CasTemp Wireless instrument (CTW), controls the
QUBE CTW module and displays the liquid steel temperature:
•Wall-mounted in an IP67 housing
•Easy-to-read wide field of view TFT display
•1:1 pairing protocol: only one QUBE CTW module can be linked to one instrument at a time to
maintain location identity (ID) control
•One-button operation
•TCP/IP Ethernet, USB, Serial output ports
oOptional Profibus and Ethernet IP ports
•Setup and programming of the QUBE CTW module and the CasTemp Wireless instrument
using an external keyboard and mouse
•Data storage and download capability via USB
•Remote Viewer capability via TCP/IP Ethernet (with data download functionality)
•Separate power outlet for attaching a dedicated cable for recharging the QUBE CTW module
Figure 3: CasTemp Wireless instrument (CTW)
Figure 4: CTW User Guide
2.3.3 CasTemp Wireless User Guide
The CasTemp Wireless User Guide (Figure 4: CTW User Guide) contains all relevant information for
safe system operation:
•Preparation
•Location ID
•Critical Safety Information
•Pairing Conditions
•Measurement Conditions
•Alerts
•Troubleshooting
•Glossary

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3 Installing the system
In order to achieve a successful installation, all of the necessary components can be obtained in one
CTW STARTER PACK (Figure 5: CTW STARTER PACK). This provides all parts and accessories to
allow a customer to begin a wireless continuous temperature measurement. The CTW STARTER
PACK comprises:
•x2 QUBE CTW Modules.
•x1 CasTemp Wireless instrument:
•1 QUBE CTW INST. ACCESSORIES. Associated mounting and fixing accessories pack.
ocontains the instrument mounting plate and all necessary fixings
othe CasTemp Wireless User Guide
oCASTEMP SHORTING TOOL
oCTW CHARGING CABLE
Figure 5: CTW STARTER PACK
Variants of the starter pack are possible based on the length of QUBE CTW module and whether a
straight or right handed head is required, see Section 8.3.3 QUBE CTW Module.
A CTW STARTER PACK Assembly Guide (Figure 6 CTW Starter Pack Assembly Guide) and User
Guide (Figure 4) are provided with each CTW STARTER PACK.
Personnel training and awareness are critical to ensure ongoing safe and reliable operation.
Figure 6 CTW Starter Pack Assembly Guide

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3.1 QUBE CTW Module Charging
Charging of the QUBE CTW module can be performed in two ways; using the dedicated power outlet
on the CasTemp Wireless instrument or by use of an external QUBE CTW Power Box.
3.1.1 Charging on the instrument
In order to charge the QUBE CTW module battery the following steps are required:
•Ensure QUBE CTW module is not measuring (or alternatively not showing continuity).
•Ensure CasTemp Wireless Instrument charge socket is clean and undamaged.
•Plug in the CTW CHARGING CABLE (Figure 7) as supplied into the dedicated (5V) charging
port socket on the underside of CasTemp Wireless instrument (highlighted yellow circle) as
shown in Figure 8: Connecting the CTW CHARGING CABLE to the CTW Instrument
Figure 7: CTW CHARGING CABLE
•NOTE: USB-A Port is for DATA and communications only.
Figure 8: Connecting the CTW CHARGING CABLE to the CTW Instrument

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3.1.1.1 QUBE CTW module with USB-A inlet
•Lift up the Harting cover but DO NOT remove.
•Ensure QUBE CTW module charge socket is clean and undamaged.
•Plug in the USB plug end of the CTW CHARGING CABLE into the dedicated USB charging
port socket on the QUBE CTW module
Figure 9 shows the assembled instrument mounting
plate, CasTemp Wireless instrument and QUBE CTW
module in charging position on the mounting plate.
3.1.1.2 QUBE CTW module with USB-C inlet
•Lift up the retaining flap on the QUBE CTW module but DO NOT remove.
•Plug in the USB plug end of the CTW CHARGING CABLE into the dedicated USB charging
port socket on the QUBE CTW module as shown in Figure 10
NOTE: For both QUBE CTW module USB-A and USB-C variants:
•No lights will be indicated on the QUBE CTW module unless the button (shown in Figure 18)
is pressed however the battery will be charging.
•If the button is pressed then the battery and measurement LED’s are shown as in sections
4.2.2.4 and 4.2.2.4
•The cable can be left connected when the charge level reaches 100%. The software will
ensure that the charging circuit is protected and battery level remains topped up.
Figure 9: CTW Instrument and QUBE CTW
module in charging position on mounting plate
Figure 10: QUBE CTW module with USB-C inlet

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3.1.2 Charging with the Power Box
A separate charging option is available for the QUBE CTW module which allows charging to be done
without the CasTemp Wireless Instrument. Both QUBE CTW module USB-A and USB-C variants can
be charged when using the appropriate CTW CHARGING CABLE with the QUBE CTW Power Box
Figure 11: Qube CTW Power Box
Figure 12: Input and Output of Power Box
The power box requires a mains supply of 100-240VAC, 300mA mac, 50/60Hz. The input lead will
need to be prepared with the connector supplied in the kit. The output is identical to that of the
charging output on the CasTemp Wireless Instrument, meaning the same charging cable can be
used. Input and output leads are held in place using retention clips.
Ensure that connectors on both leads and on the power box are clean and undamaged before
connecting up.
Figure 13: Retention clips for input and output leads