Temperature Pyrometer

Well-come to
Suyash F
Suyash amil
Family of Quality Foundr
amily Foundryy Products
Products
CARBON SILICON ANALYSER ®

OPERATION AND MAINTENANCE MANUAL
®
CARBON SILICON ANALYSER
MODEL III
Contents
SPECIFICATIONS ...................................................................... 3
PREPARING CARBON SILICON ANALYSER
MODEL III FOR OPERATION ..................................................... 4
USING CARBON CUPS WITH
CARBON SILICON ANALYSER. ................................................ 6
USING TEMPERATURE TIPS WITH
CARBON SILICON ANALYSER. ................................................ 9
KEYPAD FUNCTIONS ............................................................. 10
Changing Carbon Offset..... ...................................................... 16
SETTING OFFSETS FOR DIFFERENT CHANNELS. ............ 22
PRINTING DATA COLLECTED IN MEMORY. ......................... 25
MAINTENANCE AND TROUBLE SHOOTING. ....................... 26
LIST OF SPARES AND ACCESSORIES ................................. 29
SPECIFICATIONS

1) GENERAL DESCRIPTION :
SUYASH CARBON SILICON ANALYSER is a microprocessor based
device for automatically and rapidly determining %Total Carbon,
%Silicon and %Carbon Equivalent of unalloyed cast iron. The
chemical composition is derived from the cooling curve (specially
Liquidus and Solidus arrest temperatures) by using 'SUYASH
CARBON CUPS'. It also contains inbuilt immersion pyrometer which
gives temperature of a bath by dipping a Pt-PtRh Temperature Tip.
2) POWER REQUIREMENTS :
Voltage : 200 to 250 Volts A.C.
Frequency:50 Hzs./ 60 Hzs.
Power consumption : 30 watts.
Fuse Rating : 0.25 Amps.
3) OPERATING TEMPERATURE :
0°C TO 50°C
4) GENERAL FEATURES :
a) Digital displays for %C.E, %C, %Si. and bath temperature.
b) Bright status indication lamps to indicate the measurement and
computation status.
c) On line temperature indication during the process.
d) Built-in Data storage capacity up to total 96 Records
e) All operations by soft touch keypad.
f) 3 Channels selection for different grades of grey iron.
g) Software for Optional serial port printer attachment for well
organised printed data collection of composition and metal
temperature along with Heat No, Date and time.
h) Offsets for %CE, %C, %Si and Si Slope to satisfy specific needs.
i) Self diagnosis for various errors during process with display of
error codes showing type of error.
3
PREPARING CARBON SILICON ANALYSER MODEL III
FOR OPERATION
LOCATION
CARBON SILICON ANALYSER Should be located such that it is
convenient to the operator but reasonably protected from temperature
extremes, direct radiant heat, vibrations, excessive dust and dirt.
1) Carefully remove CARBON SILICON ANALYSER Model III from the
container.
2) Connect thermocouple compensating wire for cups (proper Red
coloured cromel-allumel compensating cable supplied with the
instrument) at rear of Panel on terminal strip as per the wiring diagram.
Refer Figure no.1 White wire should be connected to positive terminal
and blue wire should connected to the negative terminal. It is important
that these wires has to be connected to the terminal strip marked with
CUP. Tighten the screws firmly.
3) Connect holder for cups mounted on stand to the other end of
Compensating cable maintaining colour code. Refer Figure No. 1
Figure No. 1
Blue wire White

wire
4) Connect thermocouple compensating cable for Tips (proper Green

coloured Copper Constantan compensating cable supplied with the
instrument) at rear panel on terminal strip as per the wiring diagram.
White wire should be connected to positive terminal and blue wire
4
should connected to the negative terminal. It is important that these

wires has to be connected to the terminal strip marked with TIP. Tighten
the screws firmly. Refer Figure No. 2
Blue White
Wire Wire
Blue
White Wire Wire
Figure No. 2
5) Connect 3 pin power cord to 230 volts A.C. supply ensuring that
earthing is properly provided.
It is recommended to use stabiliser if voltage fluctuations are too
much beyond operating range of the instrument.
6) When power is turned on, " POWER ON " L.E.D. will glow and
present offsets to the selected channel Will be displayed
instantaneously showing that the microprocessor is activated followed
by 'CSA' on top display and 'CI', 'SG','MI' at the central display. This
Character "CI" or "SG" or "MI" shows the Selected channel of the
instrument.
7) Allow the unit to stabilise for at least 15 minutes for precise readings.
8) Factory setting for offsets for %CE, %C And %Si is 0.00 and Si slope
is 2.90 for all channels.
9) If required, set various offsets on the instrument by pouring cups to
match results with Spectrometric analysis/Chemical analysis as
described later on.
5
10)Set the real time clock of the instrument as described on page
no. 24.
11) CARBON SILICON ANALYSER is ready for operation now.
13) Measured values remain into the memory (up to total 96 values) even
in case of power failure or another sample is taken. The values can
be retrieved any time later on. It is recommended to keep the unit ON
for at least 15 minutes before taking the reading so that internal
temperature of the unit is maintained at steady state.
USING CARBON CUPS WITH CARBON SILICON ANALYSER.

1) Contact pins of the holder should be thoroughly cleaned once a day
to ensure proper electrical contact between cup and holder.
2) Keep the unit on for at least 15 minutes before using carbon cups.
This is the minimum warm-up time.
3) Confirm that polarity of the compensating lead wires are maintained.
Incorrect polarity of lead wires will not run the instrument.
4) Plug in a SUYASH CARBON CUP® on a stand. Yellow 'READY'
lamp will glow indicating that proper contact of cup is made and
connection between the cup and the instrument is established. Cup
can be mounted on the holder in one position only. The instrument will
ask to feed the heat number. The right digit starts blinking. Increase
the same by pressing "INCREASE" key (Or decrease by pressing
"DECREASE" Key). The left side digit can be selected by pressing
"SHIFT" key. When correct Heat No. is obtained, press "ENTER" so
that the instrument will accept the heat no. fed by you. The instrument
is ready for operation. If new heat number is not entered it will consider
the present heat number as current heat number.
5) Prepare a refractory lined steel spoon or use a graphite crucible
which can contain sufficient quantity of molten metal sample (About
1 Kg. of metal)
6) Preheat the spoon thoroughly by rinsing into the metal. furnace
temperature should be around 1380 to 1400 C while attempting to
pour a cup. The maximum temperature recorded by the cup should
be maintained from 1280oC to 1350oC for S.G.Iron and 1350 to 1400oC
for Malleable Iron. Carefully pour sample of metal into cup slowly but
6
continuously to avoid boiling in the cup. Ensure that metal is poured

into the cup up to the brim. Avoid overflow of metal on the stand. Half
filled cups may not give correct analysis.
7) Yellow lamp will turn off and Amber lamp will glow indicating that the
unit is in the 'Measure' mode. Current temperature of the metal into
the cup will be displayed on the lowermost window of the display, and
the maximum pouring temperature will get automatically latched on
the central display. Pouring temperature should be 80 to 100oC above
the liquidus temperature.
8) 20 to 30 Seconds later %CARBON EQUIVALENT figure will be
displayed and after approximately 45 seconds %TOTAL CARBON
and %SILICON will be displayed on the instrument. Green lamp
showing 'complete ' status will glow.
9) Remove the cup immediately after values are obtained to avoid
damage to the holder.
10)In case of error in measurement Red lamp will glow displaying type of
error.
7
A TYPICAL DISPLAY OF CHEMICAL ANALYSIS
1) WHEN A READING IS COMPLETE, FOLLOWING FIGURE WILL BE

DISPLAYED.
2) PRESS "NEXT" KEY. YOU WILL OBSERVE FOLLOWING FIGURE

WHICH DISPLAYS
T-Maximum, T-Liquidus, T-Solidus
3) PRESS "NEXT" KEY AGAIN. YOU WILL OBSERVE FOLLOWING

FIGURE DISPLAYS
Heat No, Time, Date of sample taken.
8
USING TEMPERATURE TIPS WITH CARBON SILICON

ANALYSER.
1) Contact pins of the receptacle should be thoroughly cleaned once a
week with smooth emery paper to ensure proper contact between tip
and receptacle.
2) Keep the unit on for at least 15 minutes before using tip. This is the
minimum warm-up time.
Incorrect polarity of lead wires will not run the instrument.
4) Firmly fix a SUYASH TEMPERATURE Tip on the Receptacle. GREEN
'TIP READY' L. E. D. will glow indicating that proper contact of TIP is
made and connection between the tip and the instrument is
established.
5) Remove the slag from the top of the molten metal and dip half length of
"U" tube of the tip into the metal. Ready lamp will turn off and measure
lamp indicating that the unit is in the 'Measure' mode will glow .
Current temperature of the metal sensed by the tip will be displayed
on the lowermost row of the display, and the maximum pouring
temperature will get automatically latched after 5 to 6 seconds along
with heat no. and time of dipping.
6) It is not essential to remove the tip every time. It can be kept plugged
to the lance itself after use.
7) A cup can be fitted and a reading can be taken on cup even if a tip is
fitted to the lance and vice a versa.
8) In case of error in measurement Red lamp will glow displaying type of
error.
9) When a reading is complete, following figure will be displayed.
9
KEYPAD FUNCTIONS
A robust Key-pad is used for various functions such as to change

offsets, to retrieve old readings , to print results, etc.
All keys have been allotted with specific function. Few keys are used
as multiple function key with combinations.
PICTURE OF TYPICAL KEYPAD.
The keypad with 6 keys on the front panel of the CARBON SILICON
ANALYSER® enables the user to control several functions, such as to
program modifications which will make the measurement results more
compatible with existing shop practices, to access the record for last
96 readings etc. The keypad functions are summarised below.
All keypad functions are accessible after use of correct password.
Press FUN key to choose the password. Only last reading can be seen
without password directly. This feature prevents unauthorized tampering
with the Unit, and makes it suitable for the shop floor use.
A SUMMARY OF KEYPAD FUNCTIONS:
ENTER : To accept the alterations made.
SKIP : To skip the alterations made.
10
INCREASE : To increase the programmed values after selecting

the NEXT respective function. ( Increase preset
offsets)
FUN : To select appropriate function
SHIFT : Move cursor to next position for change.
DECREASE : To decrease programmed values after selecting
the PREV respective function. (Decrease preset
offsets.)
You will observe that Key No. FUN, INCREASE and DECREASE
are multiple function keys.
How to use different keys is explained in flow chart for functions
in next section.
11
12
CHANGING OFFSETS.

TO CHANGE OFFSET OF CARBON EQUIVALENT
How to change offsets is explained in this chapter with an example.
If the value of %Carbon equivalent on the instrument is not matching
with the %Carbon equivalent calculated from readings obtained from
Spectrometer or chemical analysis, it can be changed to the desired
value by changing CE offset.( This mainly occurs due to unknown
Phosphorus level) The displayed C.E.VALUE is equal to actual C.E.
value measured by the instrument +/- offset given to the instrument.
This offset is not considered while further calculating %Carbon & %Si in
metal. Once the offset value is set, it should not be changed frequently.
Note that there are three channels on the instrument. Channel "CI"
channel "SG" and channel "MI". If offsets for specific grade of cast iron
are set on channel "CI" Readings by using cup should be taken on channel
"CI" only. Different offsets can be set for three channels.
Procedure to change the value is as follows.
Formula for changing offset.
Displayed C.E. = C.E. Found by instrument + C1 (Constant Offset)
Example: Let us consider that the following results were displayed on
the instrument by pouring a cup.
However, let us assume, that the calculated value of C.E. by

Spectrometric Analysis /Lab analysis was 3.99. That means offset of +
0.07 should be given to C.E. value. To set the desired value on instrument
following procedure should be followed.
13
Changing C.E. Offsets.......
Following Figures will be displayed showing present offsets.
1) The last digit at the bottom will start blinking. Press Key " Incr ( up
arrow) " Till value at the bottom come to " 0.07". ( Desired value)
2) If the offset value is to be reduced, reduce it by pressing key " Dec
(down arrow)". The value at the bottom will reduce showing'-' sign at
the left corner.
3) Following Figures will be displayed.
4) Value at the top shows the previous offset status before the change
and value at the bottom shows the changes made.
5) Press Key No. "ENTER" To enter the changes we have made. {press
Key No. "SKIP" If we want to bypass (Skip) whatever changes we
have made.}
6) Instrument will now enter into %Carbon offset changing mode
automatically. You will find following figure displayed on the instrument
when you come out of % C.E. changing mode.
14
8) If %Carbon and % Silicon are not to be changed press "SKIP" key till
the machine comes out of offset changing state. Procedure to change
%Carbon and % Silicon is explained in next chapter.
CHANGING OFFSETS.
TO CHANGE OFFSET OF %CARBON
If the value of %Carbon on the instrument is not matching with the
%Carbon obtained from Spectrometer or chemical analysis, it can be
changed to the desired value by changing Carbon offset. The displayed
Carbon value is equal to actual Carbon value measured by the
instrument +/- offset given to the instrument. This offset is not
considered while further calculating %Si in metal. Different offsets can
be set for all three channels.
The Basic Process of changing offset for %CARBON is same as that
for %Carbon Equivalent.
Procedure to change the value is as follows...
Formula for changing offset :
Displayed Carbon = %C. Found by instrument + C2 (Constant Offset)
Example: Let us consider the earlier example.
% Carbon displayed by the instrument was 3.30
However let us assume that the value obtained from Spectrometric
Analysis was 3.25. That means offset of '- 0.05 ' should be given to
%Carbon value. To set the desired value on instrument following
procedure should be followed.
15
1) After changing %C.E. offset, the instrument is in the %carbon changing
mode now.
2) Following Figure is appearing on the display after changing %C.E..
CHANGING CARBON OFFSET.....

3) The last digit at the bottom will start blinking. Press Key " DECREASE
" Till value at the bottom come to "- 0. 0 5 ".
4) If the offset value is to be increased, increase it by pressing key
"INCREASE".
Note the -ve sign at the left corner.

7) Press Key No. "ENTER" To enter the changes we have made. {press Key
No. "SKIP" If we want to bypass (Skip) whatever changes we have
made.} If "ENTER" is pressed, %Carbon value will be changed from 3.30
to 3.25. This change will be automatically made applicable to readings
in the memory as well as readings taken in future. It is important to note
that changing %Carbon Offset will not change %C.E. Or %Si.
16
8) Instrument will now enter into %Silicon offset changing mode

when you come out of % Carbon changing mode.
8) If % Silicon are not to be changed press "SKIP" key till the machine
comes out of offset changing state. Procedure to change %Carbon
and % Silicon is explained in next chapter.
TO CHANGE OFFSET OF %SILICON
The Basic Process of changing offset for %SILICON is same as
that for %Carbon Equivalent.
It should be noted that Silicon offset is kept as minimum as possible
and Silicon value is changed by changing Silicon Slope.
If the value of Silicon on the instrument is not matching with the
%Silicon obtained from Spectrometer or chemical analysis, it can be
changed to the desired value by changing Carbon offset. The displayed
Silicon value is equal to actual Silicon value measured by the instrument
+/- offset given to the instrument. Different offsets can be set for all three
channels.
The Basic Process of changing offset for %SILICON is same as
that for %Carbon.
Procedure to change the value is as follows...
Formula for changing offset :
Displayed Silicon = %Si. Found by instrument +
C3 (Constant Offset)
% Silicon displayed by the instrument was 1.86
17
Analysis was 1.90 That means offset of ' 0.04 ' should be given to %Silicon
value. To set the desired value on instrument following procedure
should be followed.
1) After changing %Carbon offset, the instrument is in the %silicon
changing mode now.
Following Figure is appearing on the display after changing %Si.
Changing Silicon Offset.....

2) The last digit at the bottom will start blinking. Press Key " INCREASE
" Till value at the bottom come to " 0. 0 4".
3) If the offset value is to be reduced, reduce it by pressing key"
DECREASE ". The value at the bottom will reduce showing '-' sign at
the left corner.
have made.} If "ENTER" is pressed, %Silicon value will be
changed from 1.86 to 1.90 . This change will be automatically made
18
applicable to readings in the memory as well as readings taken in

future. It is important to note that changing %Silicon Offset will not
change %C.E. Or %Carbon.
7) Instrument will now enter into %Silicon Slope changing mode
when you come out of % Silicon offset changing mode.
8) If % Silicon is not to be changed by Silicon slope, press "SKIP" key

till the machine comes out of offset changing state. Procedure to
change % Silicon by silicon slope is explained in next chapter.
TO CHANGE %SILICON SLOPE
If the value of %Si on the instrument is not matching with the %Si
obtained from Spectrometer or chemical analysis, it is always
recommended to change it to the desired value by changing Si Slope
rather than Si offset. This ensures accuracy over entire range of Silicon.
Procedure to calculate silicon slope is as follows.
Formula for changing Slope :
{Desired %Si - C3}
Si Slope =
{Displayed CE - C1} - { Displayed %C - C2}
"Displayed" values should be taken as actual values displayed by
instrument considering offsets. Where
C1 = constant offsets for %CE,
C2 = constant offsets for %C,
C3 = constant offsets for %Si.
19
% Silicon displayed by the instrument was 1.90 after changing silicon

offset.
Analysis was 1.75 .
That means silicon slope should be adjusted such that Si displayed
will be 1.75 .
To Find out slope by calculations we have following data.
{Desired %Si-C3}
OR Si Slope =
{Displayed CE-C1}-{Displayed%C-C2}
"Displayed" values should be taken as actual values displayed
from analysis from cup.
"Desired" value means actual values obtained from chemical
analysis /Spectrometer analysis from sample.
By feeding the values in our example,
1.75 - 0.04
Si Slope = ____________________________ = 2.76
{3.99-0.07}-{3.25-(-0.05)}
Changing Si Slope.....
That means if a slope of 2.76 is set on the instrument, the %Si displayed
by the instrument will be 1.75
To set the desired value ( 2.76 ) on instrument following procedure
should be followed.
1) After changing %Silicon offset, the instrument is in the %silicon
changing mode now.
2) Following Figure is appearing on the display after changing %Si offset.
20
3) The last digit at the bottom will start blinking. Press Key " DECREASE
" Till value at the bottom come to " _ 2. 7 6".
4) If the slope value is to be increased, increase it by pressing key "
INCREASE ".
5) Following Figure will be displayed.
6) Value at the top shows the offset status before the change and value
at the bottom shows the changes made.
have made.} If "ENTER" is pressed, %Silicon value will be
changed from 1.86 to 1.90 . This change will be automatically made
applicable to readings in the memory as well as readings taken in
future. It is important to note that changing %Silicon Offset will not
change %C.E. Or %Carbon.
8) Instrument will now come out of offset changing mode automatically.
You will find following figure displayed on the instrument when you
come out of % Silicon offset changing mode.
21
9) If % Silicon is not to be changed by Silicon slope, press "SKIP" key

and the machine comes out of offset changing state.
10)Now, to confirm that the changes we have made are carried out
correctly, Press "READ" key.
Following figure will be displayed.
11) Observe that values of %C.E., %Carbon and %Si have changed as
per our requirement.
This change will be automatically made applicable to readings in the
memory as well as readings taken in future.
Since the instrument possess self calculating capability, we can change
slope arbitrarily and see the changed value of Si by pressing Key
No. "READ" and again repeating the procedure till the value matches
with actual Si value .
SETTING OFFSETS FOR DIFFERENT CHANNELS.

We may have to give different offset values for various grades of
cast irons to match the results with spectrometer. This can be done by
feeding different offset values on "CI" "SG" and "MI". channels.
22
For example Cast Iron can be kept on channel "CI", S.G.Iron can be kept

on channel "SG" and Malleable Iron on channel "MI".
This avoids repeated offset changing while melting various grades
of cast iron / S.G Iron. It is important to ensure the proper channel is
selected before a cup is poured.
The procedure to change offsets in channel "CI" is explained
earlier. The procedure to change offsets in channel "SG" is same as that
of channel "CI". The method is elaborated as follows.
1) Turn power supply on. Following message will be displayed.
2) Figure `CI ` at the central array indicates Carbon Silicon Analyser

is kept on " CI" channel.
3) To change the channel, press “ FUN” key. Enter password.
4) “CHAn ” is displayed on bottom window
5) Press “ENTER”
6) Earlier selected channel will be displayed on bottom window.
7) Press “NEXT” key to choose desired channel.
8) Press “ENTER”
6) Selected channel will be displayed as shown in the figure
23
8) Set desired offsets for %C.E, %C, %Si and Si Slope for "SG" channel
following the procedure explained for channel "CI"

9) All offsets given for channel "SG" will be considered for calculations
of %C.E., %Carbon & %Si for cups taken on this channel only.
10)To change the channel again to channel "MI",repeat the procedure.
After pressing the Function "FUN " key, enter password to get access
To various options as follows: ( By pressing “NEXT’ key)
CHAn : To select desired channel
Heat : To enter Heat No.
Time : To set /adjust clock
: To see the old records of temperatures in memory.
: To see old records of CE C Si in memory
: To print records in memory
: ** To set the offsets as explained earlier
: To set the functions such as set temp, and heat rate etc.
** access only through password
RETRIEVING /ERASING OLD DATA FROM MEMORY.
SUYASH CARBON SILICON ANALYSER has a unique capability to
store data previously collected from analysis of cups.
In all 96 `Latest` readings can be stored such that sum of readings
on both channels is 96.
97th reading automatically gets erased.
Readings remain in the memory even in the event of power
failure.
The latest analysis is always counted as reading no 1. and second
last reading as reading no 2.
1) Press FUN key and select “ ” function
2) Press key No. "ENTER"
24
Following figure will be displayed

Following procedure should be adapted to proceed further.
i) Press key no "ENTER", You will get the Heat No. of latest analysis,
time and date.
ii) Press "ENTER" again to find Tmax, Tliq, Tsol
iii) Press "ENTER" again to display %C.E., %Carbon & %Si.
iv) Press “ENTER” again to display Under cooling temp. shrinkage area
and degree of recalescence if non Te cup is used.
v) Press “ENTER” again to display Graphite eutectic temp, Tensile
Strength and Brinell Hardness.
iv) Go on pressing Key no "ENTER" for reading no 2, 3 etc.
v) when readings in the memory are over unit will automatically come
out of memory environment.
vi) We can come out of the retrieving mode any time by pressing the
"SKIP" key.
PRINTING DATA COLLECTED IN MEMORY.

Data collected in the memory can be conveniently printed in two ways.
1) On a parallel port printer (which is normally available with computers.)
along with Serial to parallel interface. A printer sharer can also be
used for using only one printer for computer as well as Carbon Silicon
Analyser.
2) On a Serial port printer.
Since data for 96 readings is stored in the memory, it is not necessary
to print the results every time. Data can be printed once or twice a
day so that a systematic data generation is possible.
25
Procedure to take printout is as follows.
1) `Ensure that printer port to the socket provided on instruments as

well as to the printer rear panel Confirm that paper is inserted into
printer.
2) `Press key no "PRN" .
3) " " will be displayed
4) Press "ENTER" to commence printing.
OR
5) Press "SKIP" to abort printing.
6) When printing is finished (Clear Memory?) will be displayed. If
sufficient numbers of printouts on all channels are taken and now
memory is to be erased press Key "ENTER". Otherwise press Key
"SKIP".
7) If the printing is to be stopped in between, turn off the printer as well
as instrument.
MAINTENANCE AND TROUBLE SHOOTING.

This instrument contains no user serviceable parts inside the
instrument. Don't attempt to open the instrument for fault finding.
The external probable faults and corrective action are described
here.
Yellow `Ready`L.E.D. does not glow.
1) Worn or open compensating cable.
2) Resin deposited on Holder terminals.
3) No contact between Cup lead wires and holder terminals.
To confirm that there is external `continuity break` problem, short
compensating cable terminals (+ and -) on connector strip situated at
back side of the panel and see whether the yellow light glows. If it
glows trace back for the open joint.
4) LED has blown off.
26
Yellow `Ready` Lamp blinks when cup is put on .

1) Improper or loose contact of cup and holder or compensating cable
and terminal strip.
Clean holder terminals. If problem continues even with back terminal
for compensating cable are short approach manufacturer.
2) Faulty cup.
Put another cup and check.
When Cup is poured Error code "4" is frequently obtained .
To ensure proper solidification, interlock is provided such that if the
difference between T maximum and T liquidus is less than 30oC , %Carbon
Equivalent, %Carbon and %Si are not obtained. In such events pour
another cup at min 50oC above liquidus temperature.
Keypad does not operate.
Use proper password to ensure the smooth key board operation.
2) Few keys does not operate. : Change Keyboard.
ERROR CODES
i) SUYASH CARBON SILICON ANALYSER has a capability of self
diagnosis for various errors during process with display of error
codes showing type of error.
ERROR 1 : Liquidus Temperature found but Solidus not found
a) Half Filled Cup.
b) Low Pouring Temperature.
c) Alloys added are not mixed fully. Allow more time
for mixing.
d) High % of alloying addition like Chromium or Nickel
etc.
27
ERROR 2 : Thermocouple break because of high pouring
Temperature. Contact between cup and holder lost.

a) Pouring Temperature sensed by the cup should be
controlled, should be max 1370°C
b) Loose contact between cup and holder. Clean the
holder or replace if necessary.
ERROR 3 : Liquidus as well as solidus not found.
a) Half Filled Cup.
b) Low Pouring Temperature.
c) Metal is poured in the cup intermittently.
d) High % of alloying addition like Chromium or Nickel
etc.,
e) Very fast cooling rate of cup due to direct wind
blowing on the poured cup.
ERROR 5 : It indicates there is undercooling in cup metal.
a) Inoculated metal is poured in the cup, pour pure
metal(un inoculated metal)in the cup.
ERROR 6 : The analysis made by the equipment is out of the
range of the equipment
a) Low pouring temperature hence correct liquidus
not found. Pour another cup at correct temperature.
b) Half filled cup hence correct liquidus or solidus is
not obtained. Pour another cup at correct
temperature
ERROR 7 : Negative milli volts supplied to the instrument.
a) Check Polarity at holder, cable, and terminal
Strip of the instrument. and maintain the colour
code.
b) White wire should be connected to Positive and blue
wire should be connected to negative terminal.
28
LIST OF SPARES AND ACCESSORIES

Fuse ......... 0.2 Amps.
Compensating Cable ......... Cr-Al Type
Holder ......... Suyash Make
Stand ......... Suyash Make
Keypad ......... Suyash Make
Display Board . ........ Suyash Make
Mother board ......... Suyash Make
Buzzer ......... 230 V.A.C.
MEASUREMENT OF TENSILE STRENGTH AND BRINELL HARDNESS

From the cooling curve, the values of Tensile strength and BHN are
displayed after completion of the reading. These values can be seen by
pressing “NEXT” key.
Note: The values displayed are indicative and are derived from the
cooling pattern of the metal, for a specific cross section. Fluctuations
due to change in cross sectional area, inoculation, alloy additions after
the cup readings, change in knock out timings etc. will affect the
accuracy of the readings to some extent. However, a relatively constant
shift in readings can be adjusted.
CARE TO BE TAKEN WHILE POURING CUPS :-
1. THE CUP SHOULD BE FULLY FILLED UP WITH LIQUID METAL.
2. OVERFLOW OF METAL FROM THE CUP SHOULD BE AVOIDED.
3. INTERRUPTED POURING SHOULD BE AVOIDED.
4. AFTER ANY ALLOY ADDITION(CARBON/SILICON/STEEL) IN BATH
METAL MINIMUM SEVEN MINUTES MUST BE GIVEN, BEFORE
POURING A CUP.
5. THE MINIMUM TEMPERATURE DISPLAYED ON THE CENTRAL
DISPLAY SHOULD BE AS FOLLOWS.
29
6. MINIMUM 1270 DEG.CEL.(1340 DEG.CEL.MAX.) FOR GREY /
S.G.IRON
7. MINIMUM 1350 DEG.CEL.(1380 DEG.CEL.MAX.) FOR MALLEABLE
IRON
8. THE SAMPLE FOR LAB. ANALYSIS MUST BE TAKEN ALONG WITH
THE CUP (FROM THE SAME CRUCIBLE AT THE SAME TIME).
9. REMOVE CUP IMMEDIATELY AFTER GREEN ( COMPLETE ) LAMP
GLOWS.
PRECAUTIONS FOR HOLDER FOR CUPS AND COMPNSATING
CABLE.
1. CLEAN THE CUP HOLDER DAILY.
2. JOINT IN THE COMPENSATING CABLE MAY GIVE WRONG
READINGS.
3. CONTACT OF CUP WIRES WITH THE HOLDER WIRES MUST BE
FIRM OTHERWISE CHANGE THE HOLDER.
4. THE CUP HOLDER MAY BE REPLACED AFTER EVERY THREEE
MONTHS.
5. CHECK THE COMPENSATING CABLE CONDITION PERIODICALLY.
RED OUTER SHEATH CABLE SHOULD BE USED FOR CUPS
GREEN OUTER SHEATH CABLE SHOULD BE USED FOR TIPS
POLARITY- WHITE +VE.
BLUE -VE.
PARTIES ARE REQUESTED TO WRITE THESE POINTS IN
LOCAL
LANGUAGE, IN BOLD LETTERS AND LOCATE IT NEAR TO THE
EQUIPMENT
KINDLY FOLLOW THE ABOVE POINTS TO ENSURE ACCURATE
RESULTS.
30
INSTRUCTIONS AND
MAINTENANCE MANUAL
PORTABLE TEMPERATURE
INDICATOR
MODEL: MICROTEMP HH-106/ HH-136/ HH-630
INDICATOR
Contents
SPECIFICATIONS .................................................................... 33
PREPARING SUYASH MICROTEMP FOR OPERATION ....... 34
ASSEMBLY OF MICROTEMP HH-106/ HH-136
BEFORE USE. .......................................................................... 35
FRONT PLATE L.E.D. INDICATIONS. ..................................... 37
PRECAUTIONS TO BE TAKEN FOR ACCURATE
TEMPERATURE MEASUREMENT .......................................... 39
EQUENTLY ASKED QUESTIONS ........................................... 40

MAINTENANCE: ....................................................................... 42
INDICATOR
LIST OF SPARES. .................................................................... 42

KEY PAD FUNCTIONS ............................................................ 43
TO PUT INSTRUMENT ON AND OFF: .................................... 43
ENTER HEAT NO. ( Htn ) ....................................................... 43
TO SET CLOCK ( RTC ) ........................................................... 44
TO SEE MEMORY : ( MEM ) ................................................... 44
TO SELECT STABLE LATCHING TIME : ( tMr) ....................... 45
TO PRINT DATA ON PC: ( Prn ) ............................................... 45
TO CALIBRATE THE INDICATOR: (CAL)................................ 45
TO SEE BATTERY VOLTAGE: ( VBA ) .................................... 46
TO INTERFACE SUYASH MICROTEMP
TO COMPUTER ........................................................................ 46
SPECIFICATIONS
SUYASH MICROTEMP MODEL MICRO HH-136 is a
MICROPROCESSOR BASED portable electronic instrument operated
at 5 V D.C. for instantly determining the temperature of molten Cast
iron, steel or Non ferrous metals, by using ‘SUYASH TEMPERATURE
TIPS’.
The instrument has many features like very fast and accurate
microprocessor controlled latching, real time clock, memory, and facility
to enter heat numbers and ladle numbers, downloading memory to
computer, software calibration, checking battery voltage etc.
2) POWER REQUIREMENTS FOR INSTRUMENT BATTERY
CHARGER:
INDICATOR
Frequency : 50 Hz./ 60 Hz.
Current : 130 mA output RATING
Batteries : 4 AA size rechargeable, Ni-Cd 1.2V
The instrument works on 4 Ni-Cd rechargeable cells. Never use any
other type of cells than prescribed as these cells may explode and
has a fire hazard if charged.
3) CHARGING TIME: 16 hours for completely discharged battery.
4) DISCHARGE TIME :5 hours of continuous operation.
5) OPERATING AMBIENT TEMPERATURE: 0oC TO 50oC
6) THERMOCOUPLE USED: Pt-PtRh 13% embedded in silica tube
suitable for steel, cast iron, brass, S.G. Iron temperature measurement
up to 1750oC or K type Chromel Alumel for Aluminum and other non
ferrous applications up to 1050oC.
7) Compensating Cables: Copper constantan type compensating cable
must be used for 10% or 13% tips and K type (chromel Alumel)
compensating cable must be used for Chromel Alumel thermocouple.
33
PREPARING SUYASH MICROTEMP FOR OPERATION
Introduction:
There are 3 Parts of the basic Temperature measurement system.
INSTRUMENT: This instrument operates on 4 rechargeable Ni-Cd cells.
Use the charger provided with the instrument for charging the cells when
Lo battery indication appears. A charger socket is provided on front plate
of the instrument.
LANCE AND COMPENSATING CABLE: The instrument is connected
with a lance (stainless steel pipe with a tip holder) for fitting the tip to the
holder. Teflon coated compensating cable runs through the lance. This is
not a normal copper electrical cable and copper cable should not be used
to replace this cable.
Temperature Tips: Temperature tips with type S (Pt-PtRh10%), Type

R (PtPtRh13%), Type B (PtPtRh6% - PtPtRh30%) and K type
INDICATOR
thermocouples can be used with this instrument by calibrating the

instrument with correct option.
Pt-PtRh10%, PtPtRh13% tips are used for temperature measurement
of steel, CI, MCI, FG, CG iron as well as brass copper aluminum etc.
K type temperature tips are used for aluminum.
Type S thermocouples are constructed using one wire of 90% Platinum
and 10% Rhodium and a second wire of Pure platinum. Type S
thermocouples are used up to 1700°C. Type R thermocouples use a
platinum–rhodium alloy containing 13% rhodium for one conductor and
pure platinum for the other conductor. Type R thermocouples are used up
to 1700°C.
In Type B thermocouples, one Arm contains 30% rhodium while the
other Arm contains 6% rhodium. These thermocouples are suited for use
at up to 1800°C.
34
ASSEMBLY OF MICROTEMP HH-106/ HH-136 BEFORE USE.
1) Carefully remove SUYASH MICROTEMP and Lance from the container.
Lance and battery pack is disconnected from instrument before dispatch
for safety during transit.
2) Connect the lance pipe to the instrument with the Allen screws (M6).
Refer Figure no 1
Figure No. 1 Screw
INDICATOR
3) Open the instrument from front. Refer Figure no 2
Remove Remove
the Screw the Screw
Remove Remove
the Screw the Screw
Figure No. 2
4) Connect thermocouple extension wire (Blue/ White) Teflon coated

copper-constantan compensating cable fitted in lance pipe) to 2 free
wires coming out of the instrument by twisting them. Red /BROWN
(+ve) wire coming out of the instrument should be connected to white
35
wire of compensating cable. Black (-ve) wire coming out of the
instrument should be connected to blue wire of compensating cable.
Insulate the wires with sleeve /tape.
Refer Figure no 3
White
Wire
Blue
Wire White Blue
Wire Wire
Figure No. 3
RECEPTACLE
5) Connect 2-pin battery Terminal to battery card.

6) Two more cables are already connected to instrument box. One is for
INDICATOR
buzzer (2 wires) and other for connection to PC (3 wires). (9-pin

connector) Ensure that the connectors are in place.
7) Fit front plate with 4 screws. Refer Figure no 2
8) Charge the battery with battery charger supplied with the instrument
for 8 to 10 hours for the first time.
9) After charging, press "POWER" switch. “Power ON” and "TIP OPEN"
LED will glow.
10)Fit a temperature tip on the receptacle firmly on Lance. "TIP OPEN"
L.E.D will go off.
11) MICROTEMP is ready for operation now.
12) In case of low voltage the "Low Battery "L.E.D. shall glow. Never use
instrument with low voltage, as it will display incorrect reading. Use
Suyash Battery charger with 130mA rating only for optimum life of
batteries and failsafe operation.
13)SUYASH MICROTEMP should be reasonably protected from
temperature extremes, direct radiant heat vibrations and excessive
dust and dirt. Provide a stand at a safe place to avoid falling of
instrument.
36
14)Do not switch off the instrument frequently. It goes to power saving
mode automatically.
FRONT PLATE L.E.D. INDICATIONS.

Refer Figure no 4
Figure No. 4
INDICATOR
POWER ON: Glows when power is on.
MEASURE: When tip is dipped in the metal and instrument starts
temperature measurement.
HOLD: When reading is complete and lance is to be removed from
metal.
OPEN: Temperature Tip is not fitted correctly, cable open or no tip
fitted.
LOW BATTERY: Glow when there is a need to charge cells.
Charging: When charger pin is inserted and charging starts.
Buzzer: When reading is complete or some error occurs.
USING TEMPERATURE TIPS WITH SUYASH MICROTEMP
1) Polarity / colour code of the compensating lead wires must maintained.
Wrong polarity of cable will not latch readings.
2) Ensure that tip is fitted correctly in the holder on the lance. Red L.E.D.
showing 'Tip open' status will go off when tip is fitted correctly. Only
"Power ON" L.E.D. will glow on front plate.
37
3) Earlier reading is automatically erased when the tip is dipped for next
cycle. After power is put on, there is no need to press any button
before dipping the tip.
4) If top of the metal is covered with slag, which is not removable, 'use
and throw' type thermocouples should be used.
A.) For single use (Use and throw) tips, dip the tip in metal. Ensure
that it has passed through the slag.
B.) For Reusable tips, ensure that the metal is free from slag and dip
the "U" tube of the reusable tip into the metal such that half-length
of the "U" tube is immersed into the metal. If top of the metal is
covered with slag, which is not removable, 'use and throw' type
thermocouples should be used.
5) After dipping the tip, L.E.D. showing that the instrument is in
"MEASURE" mode will glow.

6) Within 3 to 6 seconds, when maximum temperature is sensed,
INDICATOR
Temperature will be displayed and will be automatically latched with a

Buzzer alarm. L.E.D. showing 'HOLD' status will glow. After an alarm
is heard, lance should be quickly removed from the metal to achieve
optimum life of the tip/ tip holder.
7) The siren will stop after a few seconds. The latched temperature will
be displayed for approximately 30 seconds and then display will
automatically turn off. The reading can be seen later on from memory
of the instrument.
8) In case of failure of tip while temperature is being measured "Tip Open"
L.E.D. will glow "Err2" will be displayed and siren will sound to alert
the operator to remove the lance immediately.
9) If instrument shows "Low Battery" Indication, charge the instrument
immediately with SUYASH BATTERY CHARGER. Instrument may
give wrong temperature if it is used in such case.
10)For accurate results during temperature measurement, the furnace
power should be switched off so that metal become steady.
38
PRECAUTIONS TO BE TAKEN FOR ACCURATE TEMPERA-
TURE MEASUREMENT
1) There is variety of tips available.Pt-PtRh13% and Pt-PtRh10% and
PtRh6%-PtRh30% ensure the calibration of the instrument is correct
from calibration certificate provided and use the correct type of tip
2) Temperature measurement on hot lance and holder should be avoided.
Allow at least 3 to 4 minutes between two readings to cool the lance if
readings are to be taken continuously for long time.
3) Connection bins in the holder should be kept clean and free from oxides.
4) Correct type of compensating /extension wire must be used inside the
lance. Correct polarity must be maintained while replacing
compensating wire or holder. Worn out/burnt cable must be changed
immediately.
5) Metal surface where tip is dipped must be free from Slag while using
reusable tips for optimum life of tip.
INDICATOR
6) When tip is dipped into the metal hand should be kept steady and tip
should not come out of metal unless siren is heard.
7) Do not remove slag deposited on the tip. It will automatically get
dissolved during next dip.
Error codes-
ERR 1 Reading does not latch

ERR 2 Break in Contact
ERR 7 Reverse Polarity
ERR 8 Steady reading not obtained
Note: ERR 3 to ERR 6 are used for self dignosis
39
FREQUENTLY ASKED QUESTIONS
This instrument contains no user serviceable parts inside the instrument
except battery board. Don't attempt to open the instrument for faultfinding.
The external probable faults and corrective action are described here.
A) Red `Tip Open `L.E.D. glows even when tip is fitted.
1) Tip is not fitted properly. Press the tip firmly on the holder.
2) Oxides deposited on Holder terminals. Clean the holder with em-
ery paper.
3) No contact between Tip lead wires and holder terminals because
of worn out / burnt holder.
4) Break in continuity between tip and instrument.
5) Defective tip.
6) Worn or open compensating cable in the Lance. To confirm whether

there is an external `continuity break` problem, short compensat-
INDICATOR
ing cable terminals (Red and Black) coming out of the instrument
and see whether the red L.E.D. goes off. If it goes off, trace back
where the contact is open at compensating cable or holder.
B) When a tip is dipped instrument does not show reading and does not
latch temperature.
1) Compensating wire polarity is not maintained either at Instrument
side or at receptacle side. Blue wire from compensating cable
should be connected to blue wire coming out of the receptacle.
White wire from compensating cable should be connected and
white wire coming out of the receptacle.
C) BATTERY DOES NOT CHARGE /BATTERY CHARGING L.E.D. does
not glow.
1) Check voltage across the charger pin. It should between 20 to 35
VDC
2) Non standard Charger is used.
3) Verify contacts at charger socket.
D) Data does not get transferred to PC:
1. Check wiring as per table provided on page no. 47
40
2. Ensure that Btl.txt file is in delimited text format only. Otherwise
rename the btl.xls file and transfer data again. Now Btl.xls file be
regenerated.
3. If line drivers are provided, check the power and voltages of line
driver supply.
4. If the instrument is “Power saving” mode, switch ON. The power
ON LED should glow during data transfer.
E) When tip is dipped "Err 1" is displayed by instrument. "Error 1" indicated
that no arrest was observed till the instrument sensed less than 1000°C.
This happens if the tip is removed before the reading is latched.
F) Instrument shows "Err 2" when tip is dipped. Error 2 indicates contact
between tip and the instrument is lost. The probable reasons are....
1. Loose contact between tip and holder
2. Oxides deposited on holder
3. Loose contact between cable and holder
INDICATOR
G) When tip dipped instrument shows "Err 7"
Error 7 indicates instrument sensed negative mili volts from Instrument.
The reasons could be as follows...
1. Compensating wire polarity is not maintained either at instrument
side or at receptacle side. On instrument side, White wire of com-
pensating cable should be connected to Red wire coming out from
the instrument. Blue wire of compensating cable should be con-
nected to black wire coming out of the instrument.
On holder side, Blue wire of receptacle should be connected blue wire
of compensating cable and white wire of receptacle should be
connected to white wire of compensating cable.
H) When the tip is dipped instrument displays "Err 8"
Error 8 indicates that the steady peak temperature is not sensed by
instrument. The probable reason is
1. The furnace is not put off while temperature measurement
2. Tip removed before siren is heard.
41
MAINTENANCE:
No circuit level maintenance is suggested on site. Do not add, remove
or replace any component or part on the PCB, as it may affect the
performance. Most of the problems are solved by changing compensating
cable, tip holder, charging sockets, charger and battery board.
It is necessary to train maintenance personnel to train about colour
codes of compensating wire. While changing holder, white compensating
lead wire must be connected to white wire of holder and Blue wire must
be connected to blue wire of holder.
It is necessary to train user about removing tip from metal as soon as
buzzer is heard. If tip is burning, it should not be kept on lance.
If the wire melts in the lance and sticks to pipe, it has to be removed by
heating the lance, absolutely keeping safety in mind about hot pipe.
If the tip drops off the holder while dipping in the metal, it is necessary
INDICATOR
to change the holder
LIST OF SPARES.
BUZZER ... D.C. PIEZO ELECTRIC- 1 no
BATTERY CHARGER ... SUYASH MAKE 24VDC 130 mA. –1No
LANCE ... SUYASH MAKE- 1No
RECEPTACLE (HOLDER) ...SUYASH MAKE- 5 No
COMPENSATING CABLE... Teflon coated COPPER –
CONSTANTAN cable- 10 Mtrs
CHARGER SOCKET(PAIR)... 2 No.
FRONT PLATE WITH SOCKET... Suyash make 1 NO
RECHARGEBLE BATTERY CARD ... Suyash make 1 NO
42
KEY PAD FUNCTIONS
Entire functions are operated with 2 keys, Increment key () and
Enter key ( ). Following functions ARE performed with the key board
1. Htn : Heat No. and ladle no.
2. Rtc : Real time clock
3. Mem: memory
4. Tmr : Time setting
5. Prn : Printing
6. CAL : Calibration
7. V Bat: Battery voltage
8. To make the instrument ON and OFF.
TO PUT INSTRUMENT ON AND OFF:
1. Press “ ” and “” key simultaneously to switch off instrument.
INDICATOR
Everytime it is not necessary to put off instrument manually. It has an
auto shut-off provision.
2. Press “Power ON” to make the instrument ON.
ENTER HEAT NO. ( )

1. Press Power switch on the instrument.
2. Press Inc switch to display Htn on screen
3. Press .
4. Earlier Heat No. Will be displayed on screen.
5. Four digits can be increased with the help of key
6. After each digit is selected press “ ” to shift the cursor to next digit.
7. After setting Heat No. ”L” will be displayed (ladle number). Set Ladle
No. by “” and “ ” key
8. Heat No. can not be changed after the reading is obtained.
9. Earlier heat number will be retained till it is manually changed.
43
TO SET CLOCK ( RTC )
1. Press "power".
2. Press "" and then " " key to display "rtc"
3. Press " " to select "rtc" function (clock). Year will be displayed. (Yr00)
4. Press "" to increment in year. There is no decrement key after '99'
again '00" will be displayed.
5. Press, " " when correct year is displayed. The instrument will now
display month. (mn01)
6. PRess "inc" to increment in month. There is no decrement key, after
'12' again '1' will be displayed.
7. Press, " " when correct month is displayed. The instrument will now
display Date. Repeat the steps from 6 and 7 for changing date, hour,
minutes and seconds. Now the instrument shall return to its original
status. (btL)
INDICATOR
TO SEE MEMORY : ( ME )
1) Press "" followed by “" key to display "r tc ".
2) Press "" key to display "MEM"
3) Press "" key to select the function. After pressing “" year will be
displayed.
4) After pressing "" key month will be displayed.
5) By pressing "" key again Date will be displayed.
6) By pressing "" key again hours will be displayed.
7) By pressing "" key again minutes will be displayed.
8) By pressing "" key again temperature will be displayed. Keep on
pressing "" key till desired readings are seen. Press "" key to come
out of the function. The instrument can store last 100 readings in
memory.
44
TO SELECT STABLE LATCHING TIME : ( TM)
1) Press "" and "" key to display "rtc ".
2) Press "" key to display "MEM"
3) Press "" key to display "tMR"
4) Press "" key to select the function.
5) Provide the password. Press "" key to increase timing. The factory
setting for timer is 1.5 seconds and should not be changed.
6) Press "" to select proper value, now the instrument will display
"AG"(i.e. again/ repeat)).
7) By pressing "" key set the same timing as that of "tmr". If the value of
"tmr" is not equal "AG" the machine will not accept the change made in
"tmr".
8) Press "" to select the value selected and come out.
9) 1000/600 will be displayed. This is the temperature where the instrument
INDICATOR
will start scanning the temperature. Set 600 for non ferrous and 1000
for rest all type of metals like steel, iron.
10)Press enter to select the value. Enter the same value for AG.
11) Hd 15 will be displayed. This is the time between 2 readings. Minimum
15 sec should be set for all types except Aluminum. For Aluminum set
60 sec.
TO PRINT DATA ON PC: ( PR )

Although it is advisable to transfer data on PC and then print, data
could be printed directly from instrument on printer. For this a serial to
parallel converter is required and should be kept near PC.
1. Press “: key to display “Prn ”
2. Press to start printing
3. After printing is over, select Y/N for erasing data in memory.
TO CALIBRATE THE INDICATOR: (CAL)

The calibration of the instrument is by software. Do not move any
potentiometers to calibrate the instrument.
45
1. Press “” key to display “CAL”
2. Press to select
3. the password provided
4. “Zero” will be seen for some time and some number (count) will be
seen on screen. Feed 00.00 mV to the instrument and press “ ”.
5. “Span” will be seen on the screen and some no. (count) will be displayed.
For PT PT RH 13 % feed 18.84 mV And for PT PT RH 10% feed 16.75
mV and press “Enter”.
6. Rt (room temperature) will be displayed on screen Provide correct room
temperature with Inc key and press “ ”.
7. The instrument is now calibrated.
8. It is recommended to get the instrument calibrated by authorised
Suyash engineer only.
TO SEE BATTERY VOLTAGE: ( VBA )

INDICATOR
Current battery voltage can be seen in percentage. 100% is fully

charged battery and 0 % is discharged battery.
1. Press key to select “Vba t” and press .
2. Remainiong battery voltage will be shown in percentage.
3. Charge the battery when “LO BAT” indicator glows
TO INTERFACE SUYASH MICROTEMP TO COMPUTER

The Temperature indicator has a memory storage capacity of more
than 700 readings. Each reading is stored with Heat No, Ladle No. , year,
month, date time etc.
1. If the distance between PC and instrument is less than 20 mtr,data
can be directly transferred by using he cable provided. If the distance
is large (about 100 mtr )the data has to be transferred using additional
line drivers. However once connections are made, the procedure for
data transfer with or without line drivers is same.
2. Make a directory name SUYASH on your hard disk. Copy the software
BTLXLS??.exe (?? Is revision number)provided by SUYASH in this
directory. Run the program. 4 files with suffix 01,02,03,04 will be
46
generated. Select BTLXLS01.exe for com port 1 (serial port 1), Select
BTLXLS02.exe for com port 2, and so on.
3. To connect the instrument to PC for data transfer, a 9-pin D type
connector is provided. One end of the cable is to be connected to 9-
pin connector of the instrument. Where as the other end of the cable
is connected to 9 pin serial port of the PC. The data can also be
transferred with a 25 pin connector at PC end.
4. To transfer the data to PC from the instrument, GO TO SUYASH
directory. Run BTLXLS?.exe program.(? denotes latest rev No.)The
program will take you to transfer, erase or quit mode. It is advisable to
erase the data after successfully downloading to PC. This will avoid
repetition of readings.
5. After download is complete, a file “BTL.xls” will be created automatically.
This file could be opened in excel directly. Remember, the file generate
is in delimited text mode and should never be edited/ converted in
excel work sheet mode. Instead, you can create a new file and copy
INDICATOR
the contents.
6. If it is observed that garbage is being transferred to btl.xls file, transfer the
data by switching on PC in command prompt only. This will avoid conflict
in 2 serial ports, if any. A typical layout of BTL.xls file is as shown below:
Take this table in Excel format
HEAT LADLE DATE TIME TEMP TOTAL
1404 1 1-May-02 10.02 1510
1408 11 1-May-02 13.02 1489 002
If the distance between instrument and PC is more than 20 mtr., it is
advisable to transfer data through line drivers.
For connecting 9 pin serial port to PC:
Connect pin no. 2 to G ( Black wire )
connect pin no. 3 to E ( Red wire )
connect pin no. 5 5o F ( Green wire )
The connections between 2 line drivers should be A -- A,
B -- B, C -- C and D -- D.
47
connections of second line driver near PC are as follows:
Connect E to pin no. 2 of PC ( Red wire )
connect F to pin no. 5 of PC ( Green wire )
connect G to pin No. 3 of PC ( Black wire )
Voltages between pins 2,5 and 3,5 should fluctuate when data is being
transferred.
Connecting 25 pin serial port to PC:
Connect pin no. 2 to G ( Black wire )
connect pin no. 3 to E ( Red wire )
connect pin no. 5 5o F ( Green wire )
The connections between 2 line drivers should be A -- A,
B -- B, C -- C and D -- D.
INDICATOR
connections of second line driver near PC are as follows:

Connect E to pin no. 3 of PC ( Black wire )
connect F to pin no. 7 of PC ( Green wire )
connect G to pin No. 2 of PC ( Red wire )
Voltage across pin "2 and 5 " and "3 and 5 " should be -9 V DC on
instrument side.
Voltage across pin " 2 and 7 " and " 3 and 7 " should be -9 V DC on
computer side.
Voltages should fluctuate when data is being transferred.
48
INSTRUCTIONS AND MAINTENANCE
MANUAL
TEMPERATURE INDICATOR
(MAINS)
MODEL MICRO MHD -136
(MAINS)
Contents
SPECIFICATIONS .................................................................... 50
PREPARING SUYASH DIGITEMP
FOR OPERATION ..................................................................... 51
USING TEMPERATURE TIPS WITH
SUYASH DIGITEMP. ................................................................. 53
PRECAUTIONS TO BE TAKEN FOR
ACCURATE TEMPERATURE MEASUREMENT ..................... 54
MAINTENANCE AND TROUBLE SHOOTING. ....................... 55
LIST OF SPARES. .................................................................... 56
CALIBRATION .......................................................................... 56
KEY PAD FUNCTIONS ............................................................ 57
TO SET CLOCK : ...................................................................... 59
(MAINS)
SPECIFICATIONS
SUYASH DIGITEMP is a Microprocessor based electronic instrument
operated on 230 V A.C. for instantly determining the temperature
of molten Cast iron, steel or Non ferrous metals, by using 'SUYASH
TEMPERATURE MEASUREMENT TIPS '.
The instrument is rugged and specially manufactured to withstand
adverse foundry conditions.
2) POWER REQUIREMENTS FOR MAINS OPERATED UNIT :
Frequency: 50/60 Hzs.
Power consumption : 15 watts.
3) OPERATING AMBIENT TEMPERATURE :
0°C TO 50°C
4) THERMOCOUPLE USED :
Usually Pt-PtRh13% type embedded in silica tube.
(MAINS)
51
PREPARING SUYASH DIGITEMP FOR OPERATION
LOCATION
SUYASH DIGITEMP Should be located such a that it is convenient
for the operator to see the temperature but reasonably protected from
temperature extremes, direct radiant heat , vibrations and excessive dust
and dirt.
1) Carefully remove SUYASH DIGITEMP from the container .
2) Connect thermocouple extension wire (proper copper-constantan
compensating cable supplied with the instrument) at the right hand
side of case on terminal strip marked as tip. Refer Figure no 1.
White wire should be connected to positive terminal and blue wire
should connected to the negative terminal. Tighten the screws firmly.
3) Connect receptacle mounted on Lance to the other end of
compensating cable maintaining colour code. Usually this cable is
fitted to holder before dispatch. Refer Figure no 1.
White
Wire
Blue
Wire
White Blue
Wire Wire
(MAINS)
Figure No. 1 RECEPTACLE
4) Connect 3 pin power cord to 230 volts A.C. supply ensuring that
earthing is properly provided.
It is recommended to use stabiliser if voltage fluctuations are beyond
operating range of the instrument. (210 V to 240 V AC)
52
5) Fit a temperature measuring tip on the receptacle firmly on
Lance. "- - - -" will be displayed on the instrument.
6) Allow the unit to stabilize for at least 15 minutes for precise readings.
7) Connect a parallel port printer to 25 pin D type connector if data printing
is desired. Take care to put off the printer and instrument while
connecting printer to avoid damage to I.C. s.
8) Connect optional Jumbo display to instrument. Refer Figure no 2
Insert Figure ( DISP )
Figure No. 2
(MAINS)
9) DIGITEMP is ready for operation now.
53
USING TEMPERATURE TIPS WITH SUYASH DIGITEMP.
Incorrect polarity of lead wires will give 'Error code 8'.
2) Keep the unit on for at least 15 minutes before using tips. This is the
minimum warm-up time.
3) Ensure that tip is fitted correctly in the holder on the lance. Yellow
L.E.D. showing 'Tip Ready' status will glow with an audio signal when
tip is fitted correctly.
4) Confirm that the metal is free from slag and dip the "U" tube of the
reusable tip into the metal such that half length of the "U" tube is
immersed into the metal. If top of the metal is covered with slag
which is not removable, 'use and throw' type thermocouples should
be used.
5) After dipping Amber L.E.D. showing that the instrument is in
"MEASURE" mode will glow.
6) 3 to 6 seconds later temperature will be displayed and will be
automatically latched with an audio alarm. Green lamp showing
'LOCK' status will glow. After an alarm is heard by the operator,
lance should be quickly removed from the metal to achieve optimum
life of the tip.
7) The siren will stop after few seconds but The latched temperature
will be continuously displayed untill next reading is taken.
8) In case of failure of tip while temperature is being measured, Red
L.E.D. will glow, 'ERR 2' will be displayed and siren will sound to alert
the operator to remove the lance immediately.

(MAINS)
54
PRECAUTIONS TO BE TAKEN FOR ACCURATE TEMPERA-
TURE MEASUREMENT
1) There are two types of tips available. Pt-PtRh13% and Pt-PtRh10%.
Ensure that correct type of tip is used for temperature measurement.
2) Metal surface where tip is dipped must be free from slag while using
reusable tips for optimum readings.
3) Temperature measurement on hot lance and holder should be
avoided to enhance accuracy. Allow at least 3 to 4 minutes in
between two readings to cool the lance if readings are to be taken
continuously.
4) Connection pins in the holder should be kept clean and free from
oxides.
5) Proper Compensating cable for Pt-PtRh thermocouple must be used.
The outer sheath of correct type of compensating cable is Green in
colour. Correct polarity must be maintained while replacing
compensating wire or holder. Do not use more than 10 Meters of
compensating cable. Worn out or burnt cable must be replaced
immediately.
6) Do not run the compensating cable parallel to the electrical wires.
7) When tip is dipped into the metal hand should be kept steady and tip
should not come out of metal unless siren is heard.
8) Do not remove slag deposited on the tip. It will automatically get
dissolved during next dip.
Error codes-
(MAINS)
ERR 1 Reading does not latch

ERR 2 Break in Contact
ERR 7 Reverse Polarity
ERR 8 Steady reading not obtained
Note: ERR 3 to ERR 6 are used for self dignosis
55
MAINTENANCE AND TROUBLE SHOOTING.
This instrument contains no user serviceable parts inside the
instrument. Don't attempt to open the instrument for fault finding.
The instrument has error diagnosis capability. The external probable
faults and corrective action are described here.
Red `Tip Ready' L.E.D. does not glow even when tip is fitted.
1) Tip is not fitted properly. Press the tip firmly on the holder.
2) Oxides deposited on Holder terminals.
3) No contact in between Tip lead wires and holder terminals because of
worn out holder.
4) Continuity break between tip and instrument.
5) Defective tip.
6) Worn out or open compensating cable.
To confirm whether there is external `continuity break` problem, short
compensating cable terminals (probe + and -) on connector strip situated
at side of the instrument Refer Figure no--- and see whether the red LED
glows. If so, trace back where the contact is open at cable and holder
side.
When tip is dipped "Err 1" is displayed by instrument.
"Error 1" indicates that no arrest was observed till the equipment
sensed less than 1000 deg C. This happens if the tip is removed before
the reading is latched.
Instrument shows "ERR 2" when tip is dipped.

Error 2 indicates contact in between tip and the instrument is lost.
(MAINS)
The probable reasons are ...

1) Loose contact between tip and Holder
2) Oxides deposited on holder
3) Loose contact between cable and holder
When a tip is dipped instrument shows "Err 7"
56
Error 7 indicates instrument sensed negative milli volts from
instrument The reasons could be as follows.
1) Compensating wire polarity is not maintained either at instrument
side or at receptacle side.
Blue wire should be connected Blue wire coming out of the receptacle.
White wire should be connected to White wire coming out of the
receptacle.
"When the tip is dipped instrument displays "Err 8"
Error 8 indicates that the steady peak temperature is not sensed by
instrument. The probable reasons are as follows
1) Earthing not provided.
2) Earthing is improper.
3) The furnace is not put off while temperature measurement.
LIST OF SPARES.
LANCE ........... SUYASH MAKE
RECEPTACLE(HOLDER) ........... SUYASH MAKE
COMPENSATING CABLE ........... COPPER - CONSTANTAN
CALIBRATION
Usually instrument is checked for calibration with 4 1/2 digit milli Volt
meter. If calibration is found drifted, it has a provision of Calibrating it by
software.
Calibration procedure shall be carried by trained person only. The
(MAINS)
procedure is as follows:
Press “FUN” key
“ ” Shall be displayed
Press “INCR” key till “ ” is displayed
Provide the password
57
Select tip type( 10% or 13% )with “INCR” key
00.00 will be displayed followed by some count.
Provide 00.00 mV to the instrument and press “FUN” key.
For 13% tips 18.84 or for 10% tips 16.77 will be displayed followed
with some count on the display.
Provide correct value of displayed mV to instrument and press “FUN”
key “ ” will be displayed. With “INCR” or “DECR” key set correct room
Temperature on Deg C. Press “FUN” key. The instrument is now
calibrated. Check the calibration with mV source.
KEY PAD FUNCTIONS

FOR HEAT NO, MEMORY, PRINTING, CLOCK, TIMER.
Entire functions are operated by 3 keys only.
1) “FUN” key ( Function )
2) “INCR” ( Increase )
3) “DECR” ( Decrease )
To Select Heat Number. :
Press key marked "FUN" to display " ".
Press "FUN" key again, to display the earlier Heat Number.
Press “FUN” key to shift the curser to required digit.
Press "INCR" or "DECR" repeatedly to go forward or backward to

select the desired heat number.
(MAINS)
Press "FUN" to accept the selected heat number.

Repeat the procedure to enter all 4 digits.
After heat no Ladle no can be entered.
58
To see readings in Memory :
Press key marked "FUN" to display " ".
Press key marked "INCR" till " " is be displayed.
Press key marked "FUN" to select.
Press "DECR" or "INCR" repeatedly to go backward or forward to see
the reading in memory.
After pressing "INCR" laddle number shall be displayed followed by
Year, month, date , time & temperature shall be displayed.
Keep on pressing "INCR" key till desired readings are seen.
Press key marked "FUN" to come out.
For Printing on parallel port printer:
Press key marked "INCR" till " " is displayed.
Press key marked "FUN" to select printing.
Printing will start.
If printer is not connected instrument will display “ ”
And will keep searching printer for 1 minute & will skip printing.
After printing is over " " will be displayed & subsequently
" " will be displayed.
Press "INCR" to toggle between " " and " ".
If " " is selected the memory shall be erased. If " " is selected
the memory shall not be erased.
Press "FUN" to select " " or " " & come out.
(MAINS)
59
TO SET CLOCK :
1. Press "FUN" to disp " ".
2. Press "INCR" to disp " ".
3. Press "FUN" to disp " ".
4. Press "FUN" to select. ( year will be displayed.)
5. Press "INCR" for increment in year. Press "DECR" for decrement
in year.
6. Press "FUN" when proper year is displayed. month will be displayed.
7. Press "INCR" or "DECR" for increment or decrement in month.
8. Press "FUN" when correct month is displayed.
Repeat the steps from 7 and 8 for changing Date, Hour, Minutes,
Seconds.
Now, the Instrument shall return to original status.
(MAINS)
60

Temperature Pyrometer

Uploaded by

Document Information

Copyright

Available Formats

Share this document

Share or Embed Document

Sharing Options

Did you find this document useful?

Is this content inappropriate?

Copyright:

Available Formats

Temperature Pyrometer

Uploaded by

Copyright:

Available Formats

Well-come to

CARBON SILICON ANALYSER ®

CARBON SILICON ANALYSER ®

Blue wire White

4) Connect thermocouple compensating cable for Tips (proper Green

CARBON SILICON ANALYSER ®

USING CARBON CUPS WITH CARBON SILICON ANALYSER.

CARBON SILICON ANALYSER ®

1) WHEN A READING IS COMPLETE, FOLLOWING FIGURE WILL BE

2) PRESS "NEXT" KEY. YOU WILL OBSERVE FOLLOWING FIGURE

3) PRESS "NEXT" KEY AGAIN. YOU WILL OBSERVE FOLLOWING

CARBON SILICON ANALYSER ®

A robust Key-pad is used for various functions such as to change

CARBON SILICON ANALYSER ®

CARBON SILICON ANALYSER ®

However, let us assume, that the calculated value of C.E. by

Following Figures will be displayed showing present offsets.

CHANGING CARBON OFFSET.....

Note the -ve sign at the left corner.

CARBON SILICON ANALYSER ®

Changing Silicon Offset.....

CARBON SILICON ANALYSER ®

8) If % Silicon is not to be changed by Silicon slope, press "SKIP" key

% Silicon displayed by the instrument was 1.90 after changing silicon

9) If % Silicon is not to be changed by Silicon slope, press "SKIP" key

SETTING OFFSETS FOR DIFFERENT CHANNELS.

CARBON SILICON ANALYSER ®

2) Figure `CI ` at the central array indicates Carbon Silicon Analyser

6) Selected channel will be displayed as shown in the figure

following the procedure explained for channel "CI"

CARBON SILICON ANALYSER ®

PRINTING DATA COLLECTED IN MEMORY.

1) `Ensure that printer port to the socket provided on instruments as

MAINTENANCE AND TROUBLE SHOOTING.

CARBON SILICON ANALYSER ®

Temperature. Contact between cup and holder lost.

CARBON SILICON ANALYSER ®

MEASUREMENT OF TENSILE STRENGTH AND BRINELL HARDNESS

EQUENTLY ASKED QUESTIONS ........................................... 40

LIST OF SPARES. .................................................................... 42

Temperature Tips: Temperature tips with type S (Pt-PtRh10%), Type

thermocouples can be used with this instrument by calibrating the

4) Connect thermocouple extension wire (Blue/ White) Teflon coated

5) Connect 2-pin battery Terminal to battery card.

buzzer (2 wires) and other for connection to PC (3 wires). (9-pin

FRONT PLATE L.E.D. INDICATIONS.

"MEASURE" mode will glow.

Temperature will be displayed and will be automatically latched with a

ERR 1 Reading does not latch

Note: ERR 3 to ERR 6 are used for self dignosis

6) Worn or open compensating cable in the Lance. To confirm whether

to change the holder

ENTER HEAT NO. ( )

TO PRINT DATA ON PC: ( PR )

TO CALIBRATE THE INDICATOR: (CAL)

TO SEE BATTERY VOLTAGE: ( VBA )

Current battery voltage can be seen in percentage. 100% is fully

TO INTERFACE SUYASH MICROTEMP TO COMPUTER

connections of second line driver near PC are as follows:

MODEL MICRO MHD -136

Figure No. 1 RECEPTACLE

Insert Figure ( DISP )

9) DIGITEMP is ready for operation now.

the operator to remove the lance immediately.