A word from the C.E.O.

Dear customer,

Congratulations on becoming the proud owner of world class AJAY SYSCON

product.

On behalf of the company I assure you that this product has been brought to you

with the latest and the best in foundry technology.

As you are aware, our cherished reputation of manufacturing innovative, high

quality electronic instruments like Pyrometer, CE meter and other measuring

instruments for foundry and steel mills speak for themselves.

I assure you the best after sales service from the Ajay Syscon Team.

All the best to you.

Chief Executive Officer

 Warranty Certificate

Ajay Syscon Pvt. Ltd. warrants its product, when properly assembled and
installed as recommended, to be free from defects in material and workmanship,
under normal use and service, fora period of 12 months from the original date of
purchase. However, Ajay Syscon Pvt. Ltd .shall be responsible for the cost of
labour relating to the repairs of any product only for the periodof 365 days from
the date of dispatch from Ajay Syscon premises. After the said 12 months period,
customer will be responsible for the cost of all labour as Ajay Syscon Pvt.Ltd.'s
current charges. Customer is requested to retain the invoice as a proof of the
date of purchase.

This warranty is in lieu of all other warranties, expressed or implied

including the warranties of merchantability and fitness for a particular
purpose. The warranty stated above will not apply to any product which in
Ajay Syscon Pvt. Ltd.'s judgement, has been repaired or altered in any way
so as to affect its reliability nor to any product which has been subject to
damage by fire or accident, misuse, abuse, negligent handling or , use in
excess of its capabilities or lack of periodic inspection.

AJAY SYSCON PVT. LTD.'s obligation under this warranty will be limited
exclusively to the repairs or replacement of any products determined to be
effective by an authorized AJAY SYSCON PVT. LTD. representative ,whose
determination will be final. Any product claimed to be defective shall be returned
to an authorised AJAY SYSCON PVT.LTD. service facility. AJAY SYSCON PVT.
LTD. reserves the right to satisfy its warranty obligation in full by refund of the
purchase price upon return of the defective products if an authorised
representative of AJAY SYSCON PVT. LTD. determines that the nature of the
defect precludes the remedy by replacement or repair. In no event will AJAY
SYSCON PVT. LTD's obligation here under exceed the purchase price.
Purchaser shall bear all cost and expense of transportation of products to and
from an authorised AJAY SYSCON PVT. LTD. service facility, removal and
reinstallation, inspection and testing. In no event shall AJAY SYSCON PVT. LTD.
have any liability whatsoever for incidental or consequential damages arising
from any cause including breach of contract, breach of warranty, strict liability
(In tort or warranty) or negligence.

Note: Before returning the instrument for repair, determine that the
problem is not in the SS lance assembly/metacup stand, by disconnecting
the lance/metacup stand from instrument.

2
 Index

Contents Page No.

ChapterI Use of Instrument 5

Chapter II Operating Control and Indicators 6

Chapter III User Option Selection 6

Chapter IV Thermocouple Selection 7
Chapter V Operating Instructions 8
Chapter VI Functional Description 10
Chapter VII Circuit Description 13
ChapterVIII Importance of Annual Maintenance Contract (AMC) 15
Chapter IX Calibration Procedure 16
Chapter X Maintenance 17
Chapter XI Trouble Shooting 18
ChapterXIII Quick Reference Card 19
ChapterXIV Charging the Tempstick 19

Annexure
i Service Card 23
ii Contact Address 23
iii Test Reports 25
iv Calibration Report 27

3
 Introduction

Ajay Syscon Pvt. Ltd. is a leading company in design and manufacture of

state of the art microprocessor based instruments, for carbon silicon analysis
and temperature measurement. We also manufacture consumables like
metacup and thermocouple tip, of high quality and offer them at competitive
rates. The company was established in 1986 - a joint venture with Syscon
International Inc. USA. An aggressive approach towards the product
development, along with excellent manufacturing facilities has given the
organization an edge over its competitors.

Ajay Syscon is also engaged in microstructure image analysis and vision

system. The microstructure image analysis is useful in Grey Cast Iron foundry,
S.G. Iron foundry for various analysis like documentation of image, perlite, ferrite
percentage, nodular size, nodular counts etc.

We deal with temperature indicators, scanners, data loggers, PID controllers,

data acquisition systems and infrared radiation pyrometers for applications in
industries such as chemical, automobile, cement, etc.

We make various types of thermocouples for single and multi-user in ferrous

and nonferrous industries. Our SYALON thermocouple can be continuously
used in Aluminum metal. These thermocouples are available in various sizes.

These instruments are backed by an independent R&D department and

stringent quality assurance tests like computer based testing, environmental
cycling chambers, burn-in test etc.

4
 Chapter I : Use of Instrument

CHARGING

Before attempting to use the Model 529, first check whether the voltage
indication is gone above 480. If no, then fully charge the unit with the supplied
charger for sixteen hours continuously only.

CAUTION

USE ONLY SUPPLIED CHARGER TO PREVENT DAMAGE TO THE

UNIT AND THE BATTERIES

The model 529 contains four 1.2 volt rechargeable Nickel Cadmium batteries.
With proper care and maintenance these batteries should last for two years. For
best results the batteries should be charged and then removed from the charger
until they show a need to be recharged. Occasionally the batteries should be
allowed to run completely dead (this can be done by putting Model 529 in
calibration mode where it does not auto shut off) and then fully recharge them.

CAUTION

USE ONLY ASPL SUPPLIED NICKEL CADMIUM BATTERIES TO

PREVENT DAMAGE TO THE UNIT AND THE CHARGER

To charge the Model 529 plugs the charger base into a 230 VAC outlet. Be sure
that the outlet is not switched or turned off at any time. Insert the charger
connector into the front panel jack marked “CHARGER”. When the charger is
installed properly the right most decimal point will light in the display. If this fails to
light check to make sure the outlet is live and all connections are properly made.
To fully charge the unit it should be continuously charged for sixteen hours only.
To check the batteries turn ON the unit and remove the thermocouple from the
stainless steel lance. The Model 529 will display the battery voltage will range
from about 4.80 volts to 5.40 volts. When the thermocouple is reinstalled the
previous reading will be displayed.

CAUTION

OPERATION OF THE UNIT BELOW A BATTERY VOLTAGE OF 4.80

VOLTS WILL GIVE INACCURATE READINGS

5
 Chapter II : OPERATING CONTROL AND INDICATORS

The “POWER” switch is used to turn the model 529 ON. However, the unit will
automatically blank the display after one minute and shut completely off after an
additional minute. The last reading is saved during power off and will be displayed
the next time the unit is turned ON.

The digital display is used to display the results of a measurement and to

report error conditions. Three front panel indicator lights are utilized the operation
mode as follows:

Green Light : Indicates that a good thermocouple is in place.

Yellow Light : Indicates that a measurement is in progress.
Red Light : Indicates the completion of a measurement.

A front panel beeper will produce a sound in conjunction with the red light
to signal the end of the measurement period. Four dip switches enable the user to
select various program options. One bank of four switches each is located on the
processor board just below “POWER” switch (Figure 2 Page 20). These switches
are used to select thermocouple type, calibration mode and output scale
(Fahrenheit or centigrade).

The Model 529 has a built in immersion timer which is fixed at 10

seconds. The immersion timer sets the maximum time that the Model 529 will
attempt to acquire a stable reading before aborting to protect the SS lance
assembly from the damage.

Chapter 3: User Option Selection

GENERAL
For maximum versatility the Model 529 incorporates various user selectable
options, as detailed below. After changing an option selector switch, it is
necessary to let the unit shut itself OFF and then turn it back ON to tell the
instrument to implement the change.

TEMPERATURE SCALE

For centigrade temperature scale, place DIP switch SW2-4 in the on (left) position
(Figure 2 Page 20). Place it in the off (right) position for Fahrenheit.

THERMOCOUPLE TYPE

When the model 529 is switched ON first it shows the PROMPT, which is
dependent on the SW2-1 to SW2-4 switch settings. The switches SW2-1 through
SW2-4 on the processor board (Figure 2 Page 20) selects the thermocouple type in
the following manner:
6
 Chapter IV : Thermocouple Selection

Thermocouple Pt/Pt-Rh IPTS Degress 1 2 3 4 Prompt

Type

S Type 10% 68 Table Fahrenheit OFF OFF ON OFF 110

S Type 10% 68 Table Centigrade OFF OFF ON ON 130

R Type 13% 68 Table Fahrenheit ON OFF ON OFF 111

R Type 13% 68 Table Centigrade ON OFF ON ON 131

B Type 6/30% 68 Table Fahrenheit ON ON ON ON 112

B Type 6/30% 68 Table Centigrade OFF ON ON ON 132

K Type Cr/Al 68 Table Fahrenheit ON OFF OFF OFF 101

K Type Cr/Al 68 Table Centigrade ON OFF OFF ON 121

CAL ON ON ON ON 133

7
 Chapter V : Operating instructions

Operating Instructions

INSTALLATION

A. The system is packed in one piece such as the main instrument in cabinet
assembled with SS lance assembly. Charger, Mini Receptical, Floppies; 2
Nos. and allen key are separately packed in plastic bags and tied to SS lance
assembly.

B. For reassembling the system ( Figure 6 Page 21), insert the SS lance from
the end with cable, into the matching hole on the rear of the instrument. Take
care while inserting the SS lance; of not damaging the electronic package
inside the instrument. The SS lance should be tightened with two align (grub)
screws fixed from the bottom.

C. Remove the top cover (elliptical) of the instrument. Please do not pull it o u t ,
since it is connected by four wires (two wires from the receptacle through SS
lance and two wires from the analog PCB) and 3 wire connected to 9 pin “D”
shell connector.

D. Two wire from electronic assembly are terminated to a connector on this

cover. Two terminals of this connector are marked as + and -. Now
connect the compensating cable coming from the SS lance to theses pins
are follows (Figure 4 Page 20) :

RED wire with Red lug — (+)

BLACK wire with BLUE lug — (-)
This is applicable for type iii receptacle and mini receptacle

In case of mark vii

ORANGE wire with Red lug — (+)
WHITE wire with BLUE lug — (-)

E. Get a thermocouple tip and fix it onto the SS lance at the holder end.

8
INSTRUMENT USE
Prior to taking measurement, the user needs to set the operating parameters for
the instrument. Refer to section 4 page 7 for information on setting switches. As
an exercise in familiarization, the user may wish to hook a millivolt source to the
thermocouple inputs and observe the operation of Model 529.

TAKING MEASUREMENTS
The Model 529 is very easy to use. To read temperature, an appropriate
thermocouple is attached to the probe, which is wired to the thermocouple inputs
on the Model 529. The thermocouple is then immersed in the molten metal. The
immersion light on the Model 529 will go from green to yellow. The Model 529
program is designed to provide more accurate temperature readings with the
shortest acceptable immersion times and with a minimum of unstable readings.
This is accomplished by continuously analyzing the temperature as observed by
the thermocouple and deriving an accurate temperature. As soon as the
observed temperature stabilizes, the lights will go from yellow to red and derived
temperature is displayed. If an acceptable “stable” temperature is not observed
within the specified maximum time (10 seconds in the Model 529) the lights go
from yellow to red and the digital display will indicate “9001”.

MAXIMUM IMMERSION TIME IS 10 SECONDS

Following a “9001” display, the operator can touch the POWER switch to display
the last temperature as observed by the thermocouple.

CAUTION

THIS TEMPERATURE SHOULD NOT BE CONSIDERED AS A VALID

INDICATION OF BATH TEMPERATURE

The Model 529 automatically self tests when not taking measurements. If a
function checks below par, the display will show “9002”. If this message is
displayed the unit will not continue to function.

9
 Chapter VI : Functional Description

A measurement cycle consists of four distinct stages. After power ON, the
Model 529 enters the first stage of the measurement cycle, with the red light ON.
Periodically during this time, it will read the cold end junction temperature and save
the reading for the next measurement period. The Model 529 then continues to look at
the thermocouple input waiting for a closed circuit (thermocouple installed) and a
temperature below 540 degree centigrade.
When these conditions are met, the green light is turned ON, starting the
second stage. The last reading is still retained on the display, since there is no new
information yet. If the instrument is turned ON with a thermocouple on the input, the
first stage will be very short and it will transfer to the second stage almost immediately.
The Model 529 continues to watch the input, but now waits for a temperature reading
above 540 degree centigrade.
A reading above 540 degree centigrade starts the third, or measurement
stage. The yellow light is turned ON, the immersion timer is started and the display is
blanked. The Model 529 samples the thermocouple about seven times per second,
watching the trend of the temperature.
When the temperature has stabilized (or the immersion timer has timed out),
the red light is turned ON, the buzzer sounded and the displayed will depend on the
circumstances. If the stable temperature was reached, the observed temperature will
be displayed. If the stable temperature was reached, the observed temperature will
be displayed. If no acceptable reading was found “9001” will be displayed. The last
temperature reading can be recalled to the display by pressing the “POWER” switch.
At this point, the cycle is completed.
It is possible to take a new reading prior to the thermocouple cooling down to
less than 540 degree centigrade, provided that the last reading was stable. This is
done by reinserting the thermocouple into the bath and immediately pressing the
“POWER” switch. The instrument will go to green light very briefly and then to yellow.
This can be done as often as desired, however, caution should be taken not to over
heat the thermocouple tip or receptacle / holder parts which resides into the SS lance
assembly and consequently damage them.
KEY OPERATIONS FOR TEMPSTICK 529
POWER - To switch on the instrument. In case of K, for peak hold mode as well as for
getting off.
SET - For entering and setting the run number. After setting run number it is
necessary to press it again.
INC - Connection with SET key. Otherwise to see corresponding readings of
existing run number.
DEC/BR - Double mode key - If you directly press this key, the instrument will show
back readings starting from last to first. This key is used to decrease the
run number if used along with INC key. We can also change the furnace
code.
Precaution
Do not press power key in between any operation. However, if you press it by mistake,
do not worry but you should to repeat the whole procedure, again.
Do not set run number when connected to PC.

10
INSTRUMENT TO PC CONNECTION:

Switch off the Computer and the instrument.

Connect the Instrument to the communication Port.

Switch on the computer.

Insert the floppy (1.44-MB).

Double Click on “My computer”.

Double Click on 3.5 floppy (A). [You will see contents of 3.5 floppy]

Then click on ASPL Term

After a few seconds you will see untitled ASPL terminal

To see communication Settings click A
B

The communication port setting should be as follows:

Baud rate - 9600

Data bits - 8

Stop bit - 1

Echo - Off

Parity - None

Communication Port - As available (Generally comm.2)

If correct click OK.

Then make the communication port open by clicking on the green ball on the tool
bar.

Switch on the instrument. The PC screen should show the address of Ajay
Syscon

Press R to see earlier readings in memory (Capital R).

11
Press D to set date and time in format: DD-MM-YY HRS: MIN: SEC
For example D15-09-00 10:20:30
Press C to cancel, all readings taken previously. After pressing C on keypad of
computer it will automatically cancel all readings. Now, if you press R on
computer keypad to see back readings, the message will be as:
No records stored so far....
We can save all the back readings data by following the procedure of Microsoft
word
For printing the data,
Click the printer diagram of tool bar then click OK to print

FOR SETTING RUN NUMBER:

Switch on the instrument. You will see the prompt and then battery voltage.
If t/c is connected you will see the back reading.
Press set key and hold it for 2 seconds it will show you old run number.
Now to change the numerical number press INC key for increment or BR/DEC
Key for decrement.

TO CHANGE FURNACE CODE:

Switch on the instrument
Press INC key and hold it
Then use BR/DEC key for incrementing furnace code
Press SET again.
The instrument will accept the run no.

TO SEE MEMORY READINGS:

Switch on the instrument
Press BR/DEC key. it will show you back readings with respect to run number
(first you will see run number and then respected temp)
TO SEE SPECIFIC RUN NO AND RELATED TEMPERATURE
Switch on the instrument
First set run no as described above
Press inc key
It will show you respected temp
If there have more than one temp it will be seen in sequence.

12
 Chapter VII : Circuit Description

The Model 529 electronics package consists of three circuit boards.

They are a processor or display board, an analog or power supply board and a
battery board. The three boards are mounted in a stack to back of the front panel.

The processor or display board contains the MCU (Micro Controller

Unit), the charger jack, the configuration switch and the displays. The analog
board has the ADC, the input amplifier and the cold end compensation sensor on
it. Also on the analog board is the power switch circuitry and the negative power
supply generator.

Description of the circuit follows:

AUTO ZERO
In the normal or run mode the MCU will alternately use the auto zero circuit to
check for any drift in the system and then look at the input to measure whatever
temperature signal is present. If there was any drift the MCU subtracts it out
before proceeding.

ANALOG TO DIGITAL CONVERSION

The Model 529 receives its signal from the thermocouple through compensated
lead wires. The signal is amplified by a high quality input amplifier with filtering to
protect against 50/60 Hz noise. The signal is then converted to a digital number
by a 15-bit analog to digital converter.

COLD JUNCTION COMPENSATION

A special temperature-measuring semiconductor is mounted in between where
the thermocouple input wires are attached. This sensor measures the
thermocouple cold end temperature. The cold end temperature is also converted
to a digital number by the ADC. When the digital number from the T/C and the cold
end are added, the result is a temperature number referenced to 32° C (ice point
i.e. 0°C).

LINEARIZER
Since S (Pt/PtRh 10%), R (Pt/PtRh 13%) and B (PtRh 6% / PtRh 30%)
thermocouple types, all have a nonlinear output (millivolts vs temperature) the
digital temperature number must be corrected to obtain an accurate temperature
reading. The MCU takes the digital number from the ADC and uses a digital
linearization algorithm to change the nonlinear temperature input to the correct
temperature reading.

13
FAHRENHEIT AND CENTIGRADE
All internal measurement and linearization is done in Fahrenheit because of its
higher resolution. If a centigrade display is desired, the normal conversion (F- 32
* 5/9) is made before the information is sent to the display.

DISPLAY
The display is four numbers of half-inch high LED seven segment digits, which
can be easily read, even in high ambient light. The display reads temperature in
Fahrenheit or centigrade with a one-digree resolution. The display is used for
system functions such as error messages and for calibration.

TIMER
The Model 529 has an internal timer, which sets the maximum immersion time.
The Model 529 will stop attempting to take a reading if it has not found a stable
reading before the timer runs out. The timer is fixed at ten seconds.

PANEL LIGHTS
The Model 529 has three signal lights on the front lane green, yellow and red. The
green light indicates a ready to measure condition (a cool thermocouple on the
SS lance assembly). The yellow light indicates that the measurement is in
process. The red light indicates the completion of a measurement.

BUZZER
A front panel buzzer sounds at the time the red light comes ON, (for about two
second), as an audible indication of a complete measurement.

14
 Chapter
Chapter5: How
VIII to Add Offsets
: Importance of AMC

Calibration cross-checking is needed as electronic components are used in the

instrument. Their properties may differ due to aging effect and due to drastic
ambient temperature variation. Hence it is preferred to ensure the consistency of
measurement results by cross-checking calibration of instrument.

The cross-checking of calibration also helps in….

1 Ensuring results from the instrument are consistent with other

measurements.

2. Determining the accuracy of instrument.

3. Establishing the reliability of the instrument.

4. Calibration process gives us the indication whether particular instrument

is ready for measurement or not.

5. It provides confidence that the instrument has been and is operating to

the manufacturers defined specification

6. Calibration indirectly helps in controlling rejection.

AJAY SYSCON PVT. LTD. has separate service department for

customer complaints and Annual Maintenance Contract.

Customer Care Telephones

Pune +91 (0)9325544412

(0)9325544414
+91 (0)9890919191 (24 HOUR HELPLINE)
Delhi +91( 0)9313746866
Ahmedabad +91 (0)9327050316 / 17
Bangalore +91 (0) 9343706780 / 82
Chennai +91 (0) 9363108393, (0)9894123456
Kolkata +91 (0) 9330909808

15
 Chapter IX : Calibration Procedure

CAUTION

These procedures assume a four and a half digit voltmeter with a ten
microvolt resolution and any accurate calibration potentiometer. Voltage
measurements are referenced to the test point labeled TP3 (ground) on the
analog board (Figure 8 Page 22. For greater accuracy (better resolution)
calibration is in direct digital counts.

1. Warm the unit for thirty minutes

2. Select calibration mode by setting SW2-1, SW2-2, SW2-3 &SW2-4 to the on

position. Press “POWER” to turn the unit ON. In the calibration mode the unit
will NOT automatically shut OFF.

3. Check TP1 (Figure 8 Page 22) for -2.4700 ± 0.0001 volts. Adjust R65 if
required.

4. Supply a 25 millivolts non-compensated input to the thermocouple terminal

block. Adjust R14 to obtain a display of 8750 ± 1 count.

5. Momentarily press “POWER” to call up the cold end sensor reading and
display it. This will display in either degree Fahrenheit or centigrade
depending on the position of Sw2- 4. compare reading to observed ambient
temperature. The unit should display within +/- 2 °F or +/- 1°C. An error larger
than this indicates there is a problem in the unit.

6. Press “POWER” to turn the unit OFF.

7. Return SW2-1 and SW2-2 to their original setting.

8. If desired, supplying a compensated millivolt input and simulating a run can

verify calibration.

THIS CALIBRATION PROCEDURE IS IRRESPECTIVE OF

THERMOCOUPLE TYPE OR IPTS TABLE

16
 Chapter X : Maintenance

GENERAL

Operating experience records show that the most frequent of operating

problems are in the thermocouple hardware used with the unit. Therefore in the
event of a problem, first check the polarity, continuity and insulation resistance of
the thermocouple SS lance and compensating cable. This will normally reveal
the cause of the problem. We also recommend the instrument be checked
against a voltage source such as potentiometer of known calibration at six
months intervals to insure continued accuracy. Recalibration can be done by
following the adjustment instructions or by returning to us.

INTERNAL BATTERIES

The Mode 529 contains four 1.2 volt Nickel Cadmium rechargeable
batteries. Replacement may be necessary in the case of failure. Note the battery
positions before removal to ensure proper polarity of replacement. Cut the cable
ties and remove the battery container from the battery board and simply pull the
batteries out of their sockets and replace them. Replace the cable ties to hold
down the battery container tightly to the battery board. Normal battery life is two
years.

CAUTION

Extreme care should be exercised while performing any internal

maintenance on the Model 529. The circuitry of this unit contains solid-state
devices that are static sensitive. A static free work area and means to drain static
charge build up from the person performing maintenance on the instrument is
essential. Failure to do so may cause permanent damage to this static sensitive
device and void the warranty.

READ NEXT CHAPTERS CAREFULLY BEFORE CARRYING ANY

MAINTENANCE ON THE MODEL 529

17
 Chapter XI : Trouble Shooting Suggestions

1. After turn ON, Model 529 does not operate, some or all panel lamps ON garbage on
display.
a) Disassemble the electronic package as shown in Figure 6 Page 21.
b) Make sure that the supply voltage is above 4.8 volts. (Figure 7 Page 22.)
c) Check the inter-board connections for dust/rust/oxidation. Particularly at power
supply connections.
d)Clean the dust/rust/oxidation present on the pins or solder.
e)See if the Model 529 is getting ON properly. If not send only the electronic package to
us.

2. Green light stays ON with no thermocouple attached.

a) Remove the holder from the lance assembly. Remove the top elliptical cover from
the cabinet. Please do not pull it out, since four wires connect it. Remove the two
wires coming from the lance assembly. Tie up these two wires separately such as they
should not touch each other or the electronic package in any way. Figure 5 Page 31
Check the insulation resistance throughout the receptacle and compensating cable in
the lance assembly by the tester like MEGGER of 500 VDC.

BE SURE THAT THE CABLES COMING FROM THE LANCE ASSEMBLY ARE
REMOVED FROM THE TERMINAL BLOCK AND THEY ARE IN NO WAY
CONNECTED WITH THE ELECTRONIC PACKAGE
BEFORE TAKING THE MEGGER TEST

3. Green light does not comes ON though the thermocouple attached.

a) Remove the holder from the lance assembly and short the receptacle and see if
Green light glows.
b) remove the top elliptical cover from the cabinet. Please do not pull it out, since
it is connected by four wires.
( Figure 4 Page 20.)
Clean the receptacle with the emery paper. Emery paper should be of fine grains such
as it should not scratch the receptacle but should remove oxidation.
c) Check the continuity from the receptacle to the lugs at the terminal block.

BMD T/C TIPS

BIG MULTIPLE DIP THERMOCOUPLE TIPS
It is a sensor to detect the temperature and convert it accurately into equivalent electrical
signal. AJAY SYSCON PRIVATE LIMITED's BMD tip is specially designed to suit the
Model 529 and for accurate results. Each tip can give you 7 to 8 readings in slag free
molten metal.
PRECAUTION
1. The operator should dip a tip upto half part of quartz tube. (Figure 7 Page 22.)
2. Before taking temperature reading slag should be removed.
3. Remove the tip from metal immediately as you hear audio alarm (buzzer) indicating
end of reading.
These precautions will increase life of the tip and receptacle and accuracy will
be maintained.

18
 Chapter XII : Quick Reference Card

When powered ON first shows PROMPT and then shows the last reading.
PROMPT is 131 or R (13%) T/C or 1 30 for S (10%) T/C tips.
Then shows battery voltage if T/C tip is NOT fitted (red LED ON) or last reading
if T/C tip is fitted (green LED ON).
MEASURING THE TEMPERATURE WITH THE TEMPSTICK 529
1. Check that the T/C tip is properly fitted on the lance.
Red LED shuts OFF and green LED glows ON.
2. Dip the T/C tip (only half part of the quartz glass tube) into the slag free molten
metal.
Green LED shuts OFF and yellow LED glows ON.
3. After completion of the measuring cycle buzzer sounds.
Yellow LED shuts OFF and red LED glows ON.
4. If the T/C tip is OK and still on the lance; after the temperature of the T/C tip
goes below 540 degrees centigrade green LED glows.

ERROR
9001 Unstable T/C input (metal or T/C tip not steady)
9002 Hardware problem (return to Ajay Syscon Pvt. Ltd.)
9999 T/C break (over range or T/C break)

Chapter XIII : Charging the Tempstick 529

1. When the T/C is not fitted on the lance; display shows battery voltage..

2. Look for voltage from 480 to 560 (Actual volts multiplied by 100).

3. IF and ONLY IF the voltage goes below 480; you should charge 529.

4. When the 529 is OFF and you put on the charger connected to 529
DECIMAL POINT of the right most digits should glow.

5. Charge the cells at rounds 16 hours only and continuously.

USE 1.2 V NI RE CHARGEABLE CELLS ONLY

USE CHARGER SUPPLIED BY AJAY SYSCON PVT. LTD. ONLY

BEWARE: USE OF OTHER THAN THE ABOVE SPECIFIED MAY

DAMAGED THE TEMPSTICK 529

19
 CALIBRATION POINTS
DIP SWITCH SETTING FOR "R"
TP1 TYPE THERMOCOUPLE
TP3
R14 R65 R
E
R

ELECTRONIC PACKAGE

SW 2

ANALOG BOARD 1

OFF ON

Fig 2

Fig 1

HOLDER & RECEPTACLE

ELIPTICAL PLATE
TYPE III HOLDER

WIRES FROM LANCE ASSEMBLY WIRES FROM ANALOG BOARD

TYPE III RECEPTACLE
+ RED WIRE
- BLACK WIRE
NEGATIVE
(BLUE)

NOTE: FOR MINI & MARK III RECEPTACLE

NEGATIVE + WHITE WIRE WITH YELLOW SLEEVE
(BLUE)
POSITIVE - BLUE WIRE WITH BLUE SLEEVE
(WHITE)

NOTE: FOR MARK VII RECEPTACLE

+ ORANGE WIRE WITH YELLOW SLEEVE
- WHITE WIRE WITH BLUE SLEEVE

Fig 3
Fig 4

20
 MINI RECEPTACL WITH S.S. HOLDER
POSITIVE (WHITE)

MINI HOLDER EBONITE SLEEVE MINI RECEPTACLE

NEGATIVE (BLUE)

POSITIVE
(WHITE)

NEGATIVE
(BLUE) Fig 5

CABINET ASSEMBLY
R ATTACH RED WIRE FROM ANALOG BOARD TO + VE SIDE
OF THE TERMINAL BLOCK AND BLACK WIRE TO - VE SIDE
E
R

D C B A

SCREW IN UNTILL IT ELECTRONIC PACKAGE

SET DIP SWITCH
TIGHTENS ON THE
BEFORE MOUNTING IN
SS LANCE ASSEMBLY ELECTRONIC PACKAGE
CASTING
A : MS FRONT PLATE WITH MYLAR PAD
B : PROCESSOR DISPLAY BOARD.
C : ANALOG BOARD
D : BATTREY BOARD
E : TOP ELLIPTICAL COVER.
R : REMOVE THE SCREWS TO OPEN THE ELLIPTICAL COVER. Fig 6

21
 INCORRECT WAY OF DIPPING BMD TIP

LADDLE

CORRECT WAY OF DIPPING BMD TIP

(ONLY HALF PORTION OF "U"
TUBE SHOULD BE DIPPED INTO
MOLTEN METAL.)

BMD TIP

SLAG FREE MOLTEN METAL

Fig 7

ANALOG BOARD
RED WIRE WITH RED BLACK WIRE WITH
LUG BLUE LUG

R14R65
TP3 TP1

TC+ TC-

IC 7660

PIN NO. 8

PIN NO. 5

RED WIRE
BLACK WIRE Fig 8
22
 Service Card

Name of Customer :

Instrument : TEMPSTICK 529

Accessories :

Date of installation :

Installation done by :

Warranty period valid up to :

Date Parts Name and Signature

of Visit Nature of Problem Replaced FOR ASPL CUSTOMER

Contact Address
If you have any queries please contact: ajaysyscon@vsnl.net
or call us on 24 HOUR HELPLINE: 09890919191

AJAY SYSCON PVT. LTD

Works:
Survey No 147/1&2, Shembekar Industrial Compound, Chinchwad, Pune- 411 019.
Tel. + 91 20 2744 0460 / 61 / 62 Fax: +91 20 2747 2743

Administrative Office:
8/20 Erandwana, Off Karve Road, Pune - 411 004, India
Tel: +91 20 2543 9582 / 3, 2546 0819, 2543 4937 Fax: +91 20 2543 9581
 Test Report

Name of the Instrument: TEMPSTICK 529 Date:

Serial Number:
No. Checking Points Specified Ranges / Observations Observed
1 Myler Key Pad Appearance Clean (see LED circles)
2 Solder Joints on PCB's No dry Solder / No Shot
3 Board Stamping and Held Secure Fitting & Screw Painting
(Brass spacers should not be tapped)
4 Serial No. tag Pasted Inside with Model No.& Serial Number
5 Calibration Sticker On top of Instrument with details
6 Cabinet Hardware & Mechanical Fittings Yes
7 Potentiometer Sealing Yes
8 Power ON Switch Normally open / Short when pressed
9 LED Alignment & it’s Sequence Ready-Green, Measure-Yellow, Complete - Red
10 Buzzer Sound Compared with standard buzzer
11 Clock Operation Connected with computer. Check
time by switching off for 10 minutes
12 Auto Switch Off Period 2 Minutes for S, R, B & 10 minutes for K type
13 Battery Charging Indication Right Most Decimal point glow
14 Battery Voltage Above 5 volt
15 Working Voltage i.e. 500 to 560 indication on display
16 Full Load Current 55 to 70 mA
17 Current in Stand by Mode 28 to 38 mA
18 Quincent Current (Off State Current) less than 1 mA
19 Voltage between Pin No. 2 & 5
of 9 Pin D Connector (Cabinet End) -8 to -12 volt
20 Back Reading Indication By pressing BR Key
21 Back Reading Proof Enclosed on Separate sheet
22 Reference Voltage between -2.4700 ± 0.0001
Ground & Tp2
23 Calibration ADC count shown by instrument after
applying 25 mV (STD 8750 ± 4)
Check for temperature tolerance ± 1°C
24 Thermocouple Continuity (S,R,B & K) Good & Easy Contact
25 Rubber (Foam) for PCB safety See in cabinet, top plate, front plate
26 Brightness of 7 Seg. Display Ok
27 Use lock clip for screws See on top plate screws
28 Lance Assembly I +ve
Comp. Cable (White) to outer Dia. of
Receptacle & - ve Comp. Cable (Blue)
to inner dia of Receptacle
II Insulation test between +ve & -ve
III Insulation test between Cable & Lance body
29 Response of NF Probe (K Type) Between 15 to 30 seconds
30 16 Hours Instrument Charging Report
Reference & Date
31 Specific History of Instrument

Inspected by Approved by
 Test Report (copy)

Name of the Instrument: TEMPSTICK 529 Date:

Serial Number:
No. Checking Points Specified Ranges / Observations Observed
1 Myler Key Pad Appearance Clean (see LED circles)
2 Solder Joints on PCB's No dry Solder / No Shot
3 Board Stamping and Held Secure Fitting & Screw Painting
(Brass spacers should not be tapped)
4 Serial No. tag Pasted Inside with Model No.& Serial Number
5 Calibration Sticker On top of Instrument with details
6 Cabinet Hardware & Mechanical Fittings Yes
7 Potentiometer Sealing Yes
8 Power ON Switch Normally open / Short when pressed
9 LED Alignment & it’s Sequence Ready-Green, Measure-Yellow, Complete - Red
10 Buzzer Sound Compared with standard buzzer
11 Clock Operation Connected with computer. Check
time by switching off for 10 minutes
12 Auto Switch Off Period 2 Minutes for S, R, B & 10 minutes for K type
13 Battery Charging Indication Right Most Decimal point glow
14 Battery Voltage Above 5 volt
15 Working Voltage i.e. 500 to 560 indication on display
16 Full Load Current 55 to 70 mA
17 Current in Stand by Mode 28 to 38 mA
18 Quincent Current (Off State Current) less than 1 mA
19 Voltage between Pin No. 2 & 5
of 9 Pin D Connector (Cabinet End) -8 to -12 volt
20 Back Reading Indication By pressing BR Key
21 Back Reading Proof Enclosed on Separate sheet
22 Reference Voltage between -2.4700 ± 0.0001
Ground & Tp2
23 Calibration ADC count shown by instrument after
applying 25 mV (STD 8750 ± 4)
Check for temperature tolerance ± 1°C
24 Thermocouple Continuity (S,R,B & K) Good & Easy Contact
25 Rubber (Foam) for PCB safety See in cabinet, top plate, front plate
26 Brightness of 7 Seg. Display Ok
27 Use lock clip for screws See on top plate screws
28 Lance Assembly I +ve
Comp. Cable (White) to outer Dia. of
Receptacle & - ve Comp. Cable (Blue)
to inner dia of Receptacle
II Insulation test between +ve & -ve
III Insulation test between Cable & Lance body
29 Response of NF Probe (K Type) Between 15 to 30 seconds
30 16 Hours Instrument Charging Report
Reference & Date
31 Specific History of Instrument

Inspected by Approved by
 Calibration Report

Supplied to:
Address:
Name of the Instrument: TEMPSTICK 529 TYPE
Sr. No. Date:
Ambient Temperature

No. Expected temperature °C CorrespondingCompensated mV Show Temp.°C

1
2
3
4
5
6
7
8

Millivolts as per IPTS - 68 Standards

Next Calibration Due on

Note:- Simulator / Indicator or Multimeter used for Calibration is traceable to national standards.
These equipments are duly calibrated at:
Yenkay Instruments and Controls Pvt. Ltd.
(NABL Accredited Lab in Pressure and Electrotechnical Measurements)

Description & Identification of Instrument used

Nomenclature
Type / Model No.
Sr. No.
Report No.
Next Calibration Due on

Encl.: Xerox of above

Inspected by Approved by
 Calibration Report (copy)

Supplied to:
Address:
Name of the Instrument: TEMPSTICK 529 TYPE
Sr. No. Date:
Ambient Temperature

No. Expected temperature °C CorrespondingCompensated mV Show Temp.°C

1
2
3
4
5
6
7
8

Millivolts as per IPTS - 68 Standards

Next Calibration Due on

Note:- Simulator / Indicator or Multimeter used for Calibration is traceable to national standards.
These equipments are duly calibrated at:
Yenkay Instruments and Controls Pvt. Ltd.
(NABL Accredited Lab in Pressure and Electrotechnical Measurements)

Description & Identification of Instrument used

Nomenclature
Type / Model No.
Sr. No.
Report No.
Next Calibration Due on

Encl.: Xerox of above

Inspected by Approved by
1 y
W1
ear Warranty
WARRANTY REGISTRATION CARD
(Customer’s Copy)
TEMPSTICK 529

Name of Customer:

Invoice No. and Date:

Sr. No. Unit:

Address:

Signature & Stamp

1 y
W1
ear Warranty
WARRANTY REGISTRATION CARD
(Dealer’s Copy)
TEMPSTICK 529

Name of Customer:

Invoice No. and Date:

Sr. No. Unit:

Address:

Signature & Stamp

1 y
W1
ear Warranty
WARRANTY REGISTRATION CARD
(Company Copy)
TEMPSTICK 529

Name of Customer:

Invoice No. and Date:

Sr. No. Unit:

Address:

Signature & Stamp