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CellaCast®Non-contact temperaturemonitoring systemfor molten metal• Temperature range: 650 – 1700 °C• ATD function

enables automatic detection of in-stream temperaturesdetects and saves the temperature of each cast object

• Rectangular field of view always captures the target, evenwhen the pour stream position varies

• Two-colour ratio technique yields accurate readingsdespite ambient smoke or dust

• Maintenance-free, wear-free system

relay contact S2

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Advantages of non-contacttemperature measurementA pyrometer detects the infrared radiation emitted by anobject’s surface and produces a temperature reading. Fortemperature detection of molten metal, a non-contactmeasurement technique offers foundries many advantagesover an immersion sensor:• The temperature of molten metal is measured at a

crucial point in the casting process: just as it is pouredinto the mould. If high/low temperature limits areexceeded, the foundry operator can react immediatelyand stop the casting process. The foundry can preciselymonitor pour stream temperatures and provide docu-mented evidence of strict compliance with processparameters. Because a thermocouple is immersed intothe molten metal before it is poured, its temperaturereading does not truly represent the metal’s actual tem-perature at the moment the mould is being filled.

• A pyrometer monitors temperatures continously andsaves a reading for each individual mould. In contrast,an immersion thermometer can only be used for spotchecks. This is usually done one time for each ladle priorto the pouring process.

• Because a pyrometer detects the temperature of themolten stream just as it enters the mould, which meansalways at the same point in time, this technique providesmuch higher accuracy and repeatability. When using athermocouple, the accuracy of the temperature read-ing will depend on such factors as the precision of theoperator, the point of immersion and the immersiondepth.

• A pyrometer has no parts subject to wear and tear,therefore a foundry does not incur any operating costsfor expendable parts. The immersion method is subjectto wear on parts. Thermocouple tips require frequentreplacement.

The CellaCast system is based on a two-colour (ratio)pyrometer with high optical resolution. A two-colour pyro-meter yields highly reliable measurement results, even whenthere is a great amount of dust or smoke in the pyrometer’sfield of view. The rectangular field of view ensures that thepour is captured every time, even when its positionfluctuates, thus producing consistently accurate instreamtemperature data. CellaCast features an intelligent ATDfunction (automatic temperature detection) which auto-matically produces a temperature reading for each mould.Thanks to ATD, the pyrometer starts measuring just as theladle starts pouring. Interferences such as flames or moltenmetal drip (as opposed to a pour stream) will not impedethe measurement or impair the signal. The temperaturereading will remain very accurate despite such distur-bances. When the measurement process is finished,CellaCast displays the temperature reading for eachpoured mould. Data is transmitted via analogue output andserial interface. This value can also be viewed at a largeexternal digital display so that the foundry operator caninstantly see the temperature reading. As an option, a visualalarm signal can be connected so that temperature limitviolations can be seen. The temperature data can besaved at a PC or recorded via a data acquisition system.

How the measuring system works

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PyrometerCellaTemp PA 83

Cable VK 02/A

Analogue output 0(4)–20 mA DA 570 Large-ScaleDisplay Unit

PLC for dataacquisition

Centralised data acquisitionand visualisation system

RS 485

PD 830 Control Panel to• select type of cast iron• indicate temperature

CellaMevis Software• displays data online in

graphical format• stores temperature readings

As an option:repeaternecessary when stub line tothe PC is longer than 5 m

USB

Interface adapterRS 485 – USB

Analogue output0(4)–20 mA+ synchronisation signal

RS 485

InterfaceRS 485

Control room monitorfor video camera

Junction box VK 20.23

Relay contact S1

Green indicatorlamp lights upduring themeasurement

Relay contact S2

Red indicator lamplights up whentemperature limitviolations occur

Overview of the CellaCast System

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CellaTemp PA 83 is a two-colour pyrometer which detectsinfrared energy at two different wavelengths and producestemperature readings based on the ratio of these twointensities. Even when dust or smoke obstruct thepyrometer’s field of view, the two-colour or ratio methodproduces accurate temperature data even at signalattenuation of up to 90 %.

CellaTemp PA 83 comes equipped with the sighting optionof your choice: either through-the-lens sighting, lasersighting or a built-in video camera.

With its focusable optics CellaTemp PA 83 can be preciselyfocused to the target object.

Unlike standard pyrometers which focus on a round targetspot, the PA 83 features a rectangular field of view thatcaptures the target every time, even when the pour streamposition varies.

CellaCast System Modules

Pyrometer CellaTemp PA 83

Temperature range:650 – 1700 °CSensor:photodiodeSpectral range:0.95/1.05 µmFocusing range:

standard lens:400 mm to ∞telephoto lens:1200 mm to ∞wide-angle lens:200 mm to ∞

Distance ratio:Standard lenshorizontal: 45 : 1vertical: 230 : 1Telephoto lenshorizontal: 75 : 1vertical: 375 : 1Wide-angle lenshorizontal: 10 : 1vertical: 55 : 1

Sighting options:• through-the-lens sighting

with rectangular targetmarker

• laser sighting• video camera

2 Analogue outputs:0(4) – 20 mA linear,switchable, scalableLoad:max. 500 Ω2 switching inputs/outputsopen collector 24 V,≤ 30 mAData communication:• USB• RS 485 (integrated

menu-driven user-inter-face to set parametersand transmit data toa PC)

Response time t98:≤ 10 ms (T > 750 °C)ResolutionCurrent output:0.2 K + 0.03 % of selectedrangeTemperature reading:1 KUSB/RS 485:0.1 K in terminal mode

Measurement uncertainty:1 % of temp. reading,at least 4 K(at ε = 1 und Ta = +23 °C)

Technical Data

Repeatability:2 KTemperature coefficient:≤ 0.05 %/Kof temp. reading [°C](deviation to 23 °C)LED display:4-digit (digit height 8 mm)Power requirement:24 V DC +10 %/-20 %current input ≤ 135 mAripple ≤ 200 mVPermissible humidity:95 % r.H. max. (non-condensing)

Ambient temperature:0 – 65 °C (without cooling)Storage temperature:-20 – +80 °CDimensions:Ø 65 x 220 mm(incl. connector)Housing material:stainless steelProtection rating:IP65 according to DIN 40050

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Integrated directly in the electronics of the CellaTemp PA 83, the ATD feature detects the beginning of the pour and automaticallystarts measuring. After each pour, a temperature is computed and displayed for each cast mould. Data is transmitted viaanalogue output and digital interface. The ATD function ensures that interfering factors such as flames or molten metal drip will notinfluence the signal or impair the measurement. When monitoring a continuous molten stream such as at the casting channel orwith extended pouring cycles, the system computes a temperature reading periodically at user-defined intervals and saves thedata.

ATD (Automatic Temperature Detection)

PA 83-001 is a combination of accessories and fittings which offers ideal protection againstdust, smoke and mechanical impact. The cooling jacket, which can be operated witheither water or air, enables pyrometer use at high ambient temperatures.

• Dust stop• Intermediate tube• Air purge• Clamping collar• Cooling jacket• Clamping device

Protective Mounting Assembly

Using the VK 02/A cable, the VK 20.23 junction box links to the pyrometer and supplies it with24 VDC.The junction box features a rugged design, and can thus be installed in severe industrialenvironments. Relays control the signal to the display and trigger alarms when user-definedthresholds are exceeded.The system features simultaneous analogue (0(4) – 20 mA) and digital (RS 485) outputs.

VK 20.23 Junction Box

The PD 830 enables remote configuration from the control station. The user candefine up to 10 data sets, for example to program the specific temperature tolerancelimits for 10 different alloys.

Control panel PD 830

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An optional device which lets the foundry operator view the temperature readingfrom a distance as far as 25 meters away.

DA 570 Large-Scale Display Unit

Red indicator lamp:Functions as an alarm. Lights up when the temperature exceeds user-defined upper/lower limits.

Green indicator lamp:Lights up during measurement.

Indicator Lamps

KELLER’s temperature monitoring software CellaMevis provides onlinegraphic images of measurement data at a PC. An autosave function storesdata at periodic intervals with a timestamp.

Software CellaMevis

As an alternative to temperature monitoring at a PC, data can be transmitted to a PLC-based data acquisition system.

Data Collection at the PLC Level

As an option, CellaTemp PA 83 is available with a built-in video camera. The camera’slight sensitivity adapts dynamically to the brightness of the actual target objectcaptured within the rectangular measurement area. The video camera thus producesa sharp, high-contrast image of the target spot and the surroundings and allows theprocess to be viewed from a control room monitor.

Video monitoring

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The pyrometer continuously monitors temperatures at thecupola furnace, enabling plant operators to react im-mediately to unwanted changes in temperature in order toachieve uniform results.

Points of Non-contactTemperature Measurement

Pyrometers are used at steel mills to check tappingtemperature at blast furnaces. CellaTemp PA 83 features ahigh-resolution telephoto optical system which makes it possibleto detect temperatures from a distance of up to 30 meters.Temperature data is saved to a database by a dataacquisition system for later retrieval and verification.

A pyrometer captures the in-stream temperature of the moltenmetal as it fills the mould – whether poured from the ladle or atfully automated casting lines.

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KELLER HCW GmbHDivision MSRCarl-Keller-Straße 2-1049479 IbbenbürenGermany

www.keller-msr.deTel. +49 (0) 54 51 85 0Fax +49 (0) 54 51 89 73 92info@keller-msr.de

Distribution and Service Centres

Brazilwww.ecil.com.brTel. +55 (15) 32 44 80 00instrumentacao@ecil.com.br

Chinawww.celiangwang.cnTel. +86 (10) 82 86 79 20jhe@germantech.com.cn

Francewww.keller-msr.frTel. +33 (0) 3 66 08 30 05france@keller-msr.de

Indiawww.earthtekniks.comTel. +91 (44) 2746 3747kellermsrindia@gmail.com

Foreign Distributors

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