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493K K-Paq Junior Owner's Manual

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Junior
Owner's Guide

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Summary of Contents for 493K K-Paq Junior

  • Page 1 Junior Owner’s Guide...
  • Page 3 Page No. Title Removal of K-PAQ Junior from packaging Set up of K-PAQ Junior Slave/transmitter Set up of K-PAQ Junior Master/receiver 10-14 K-Kord Software 15-17 Proper use of coolant packs Thermocouples 19-24 Assembly of Get You Started Thermocouples 25-27 Flying Lead Aerial...

  • Page 4: Table Of Contents

    Page No. Title 43-44 Graph Screen 1, 2 45-46 Data Screen 1, 2 47-56 Anatomy of a Rotomoulding Cycle 57-58 Declaration of Conformity Calibration Certificate Contact Information MCM03022016...
  • Page 5 Operation is subject to the following two conditions: (1) this device may not cause interference, and (2) this device must accept any interference, including interference that may cause undesired operation of the device. CAUTION: Changes or modifications not expressly approved by 493K Limited could void the user's authority to operate this equipment. MCM03022016...
  • Page 6 Unpacking the K-PAQ Junior. 1. Remove all lose or unsecured items from the box. 2. Unscrew any fixings holding the insulated canister in place. 3. Ensure the lid is secured correctly with all three toggle clamps then lift the unit using the spring- loaded handle on the lid.
  • Page 7 Set up Of K-PAQ Jr transmitter Insert the single supplied ‘CR AA’ battery into the battery holder of the transmitter ensuring the button end is facing outwards. (Please note that this is a non-standard battery and the button end is of negative polarity.
  • Page 8 BUTTON END BATTERY LIFE SCENARIO 1: 111 Days battery Life K-PAQ Junior transmitter & receiver on & communicating with each other for 8 hours/day and then both switched off for 16 hours/day. SCENARIO 2: 20 Days Battery Life K-PAQ Junior transmitter & receiver on & communicating with each other for 8 hours/day and then only the receiver switched off for 16 hours/day while the transmitter is left on*.
  • Page 9 Flying Lead Aerial 1. Ensure SMA connector is tightly screwed to K-PAQ transmitter face plate. 2. Run the aerial through the small slot on the top of the K-PAQ body along with the thermocouple cables.
  • Page 10 Flying Lead Aerial 3. Ensure the red section of the aerial (A) is outside the K-PAQ Junior metalwork. Section B can be aligned with the silicone sponge seal and Section C should remain inside the K-PAQ Junior . WHITE BLACK...
  • Page 11 Flying Lead Aerial 4. The finished installation position of the flying lead aerial.
  • Page 12 Powering on the K-PAQ Receiver The K-PAQ receiver can be powered by a plug-in 5V 500mA DC adapter (supplied) or with 2x 1.5V ‘D’ Cell batteries. To insert the ‘D’ Cell batteries, twist and remove the cap of the battery holder and insert the batteries with the positive end facing towards the lid.
  • Page 13 Setting up the K-PAQ Transmitter Ensure the unit has the battery inserted and the plastic battery cover securely Switch on the insulated transmitter using the black toggle switch on the fascia lid of the transmitter. The blue LED on the transmitter will come on and begin flashing as soon as it pairs with the receiving station.
  • Page 14 Set up of Receiver to PC The receiver is attached to the PC via the serial communication port, using the RS232 Male-Female pin- to-pin lead. If your PC does not have a serial communications port but has a USB port then you can use a standard serial-to-USB adapter.
  • Page 15 DTR line is held HIGH and, at 2 second intervals, sequentially calls for data from the slaves. The TXR1A units are designed for use with 493K’s unique high temperature slip rings and the K-Kord software package. A photograph of the Model TXR1A is shown below.
  • Page 16 Initial set-up Using the mechanical interface fixtures and the instructions provided with the 493K slip rings, the slave TXR1A units are affixed adjacent to the slip rings on each rotating arm. Insert the K type thermocouple plugs issuing from the slip rings into the appropriate sockets on each slave TXR1A unit.
  • Page 17 Operation Press the ON button on each TXR1A unit, slaves and master, and confirm the power ON LED is initially illuminated on each unit. The ON LED will illuminate with a SOLID light for approximately 3 seconds to indicate powering on. The MASTER electronics will begin to SEARCH for the slave electronics.
  • Page 18 K-Kord Software Download the operating software K-Kord from the Software section within www.493k.com. Fill in the requested information and click submit. An email will be sent to you which contains a K-KORD download link. Run the K-KORD executable file. By default the software looks at COMS Port 1. Ensure that the USB converter is configured to COM Port 1.
  • Page 19 IF AFTER STARTING K-KORD YOU SEE THE WINDOW BELOW THEN THIS SIGNIFIES THAT YOUR 35 DAY TRIAL OF THE K-KORD SOFTWARE HAS EXPIRED AND YOU MUST REQUEST THE PRODUCT PURCHASE KEY (PPK) FROM 493K LIMITED. THE KEY IS ONLY RELEASED AFTER YOU HAVE BOUGHT THE K-PAQ.
  • Page 20 K-KORD Software: Permanent Installation Entering your Product Purchase Key INSTRUCTIONS: • STEP 1. RUN K-KORD AND WHEN THIS WINDOW APPEARS CLICK ON “Enter Purchase Key”...
  • Page 21 K-KORD Software: Permanent Installation Entering your Product Purchase Key THIS WINDOW WILL APPEAR: STEP 2. HIGHLIGHT THE TEXT UNDER “Your Product Purchase Number” AND THEN COPY & PASTE THE TEXT INTO AN EMAIL AND SEND TO OFFICE@493K.COM.
  • Page 22 K-KORD Software: Permanent Installation Entering your Product Purchase Key • STEP 3. WITHIN 24HRS YOU WILL RECEIVE AN EMAIL IN WHICH WILL BE TYPED A LONG ENCODED NUMBER; THIS IS ‘Your Purchase Key’. COPY AND PASTE ‘Your Purchase Key’ INTO THE TEXT BOX WHERE IT SAYS ‘Your Purchase Key’.
  • Page 23 Proper use of Coolant Packs • Maximum effectiveness of the coolant packs is attained only when they are frozen between -5C (23°F) and -20C (-4°F). A domestic freezer will take you to - 18C (0°F). Do not use in a -40 °C (-40°F) Freezer as the coolant packs will then be too inflexible, and forcing them may result in damage to the unit.
  • Page 24 Proper use of Coolant Packs Standard 2x Cool Pack Arrangement Cool Pack 1 Cool Pack 2 For extending cooling a further cool pack could be fitted to the K-Paq Junior.
  • Page 25 Coolant Pack Area Desiccant Packs • Please Insert Desiccant Packs into the Coolant Pack area to absorb any moisture that might have condensed on the sides of the coolant packs. • Use as Required.
  • Page 26 Thermocouples There are four thermocouple input sockets on the diaphragm of the unit. The plugs should be pushed into the sockets whilst ensuring that the correct polarity of each plug is observed. (The wider blade of the plugs is negative) If the correct polarity is not observed then this will result in erroneous temperature values being recorded and may result in damage to the sockets.
  • Page 27 Assembly of Thermocouple Leads Prior to commencing the procedure please ensure the following: Acquire the appropriate materials to construct the thermocouple leads: - Appropriate lengths of two core thermocouple cable, - High temperature plastic thermocouple connector plug (rated to 220°C), - High temperature silicone (rated to 320°C), Ensure the following tools are to hand: - Small star and blade screwdrivers,...
  • Page 28 Assembly of Get You Started (GYS) Thermocouple Leads To construct the “GYS” Thermocouple Leads, follow the steps outlined below: 1. Start with the high temperature plug connector and the cable.
  • Page 29 Assembly of Get You Started (GYS) Thermocouple Leads 2. Remove the back cover from the plug connector, 3. Strip back the wire to expose 10mm to 15mm of cable,...
  • Page 30 Assembly of Get You Started (GYS) Thermocouple Leads 4. To determine which wire is negative and positive, the negative wire will be magnetic and the positive wire will be non-magnetic 5. Attach to the connector plug using the screw fastening terminals and ensure a firm hold on the wires,...
  • Page 31 Assembly of Get You Started (GYS) Thermocouple Leads 6. Apply the high temperature silicone as a method of potting the cable into the connector plug IMPORTANT - Do not over apply the high temperature silicone as will cause oozing on the sides when fastening the cover onto the connector plug...
  • Page 32 Assembly of Get You Started (GYS) Thermocouple Leads 7. When first applied the high temperature silicone leave for 45minutes to allow for a “skin” to form as this helps reduce the amount of oozing caused when replacing the cover on the connector plug 8.
  • Page 33 Mounting to the Mould NUMBER OF FIXTURE POINTS The K-PAQ Junior was designed to be versatile and flexible with two fixing points on each side handle. It is important that when fixing there is at least one fixing point used on EACH side of the canister.
  • Page 34 Using the two angle brackets and the two short straight brackets provided. These can be used to bolt the K-PAQ Junior to the mould wall framework as shown in the pictures.
  • Page 35 Toggle Clamp Maintenance • Tools & materials needed: • 4mm flat blade terminal screwdriver; Catch Claw • Plate High temperature grease; • Pin Hammer Thumb Slider Locking Plate There are three toggle clamps mounted around the K-PAQ Junior insulated transmitter.
  • Page 36 Toggle Clamp Maintenance Adjustment Screw then If Tension Screw is seized refer to section entitled Toggle Clamp Greasing.
  • Page 37 Toggle Clamp Maintenance Toggle Clamp Greasing • The clamps must be greased regularly with appropriate high temperature grease. If the clamps are not greased then extra force will be Point 1 required to close them. This extra force will lead to distortion of the locking plate causing the clamp to be difficult to open and close or to seize.
  • Page 38 Toggle Clamp Maintenance Toggle Clamp Tension Adjustment • These clamps must be regularly checked to ensure that the correct tension is applied to the catch plate; if there is too much tension then the catch plate can become over stressed and through time will become bent open;...
  • Page 39 Toggle Clamp Maintenance Locking Plate Adjustment • To release the Thumb Slide Hook from the Locking Plate the locking plate needs tapped with a light pin hammer downwards away from the clamp. If needed first of all the Thumb Slide hook can be released by pushing it upwards with the small terminal screwdriver.
  • Page 40 MAIN WAYS OF USING K-PAQ Junior • Process set-up whenever changes occur (eg new molds, change of materials) • Trouble-shooting to identify process problems • Simple routine monitoring, using traditional time / temperature criteria to run cycle • Monitoring of cycle, with operator intervention when optimum PIAT is reached •...
  • Page 41 FUNDAMENTAL CONCEPTS - 1 • True process control in rotomolding is not possible without real-time temperature monitoring. • Measuring the temperature of the material inside the mold has practical difficulties, but measuring temperature of the air inside the mold is easier. •...
  • Page 42 • Over multiple cycles, insulation will heat up, so cooling is also required. • In K-PAQ Junior, cooling is provided by gel packs that are frozen & then inserted inside the canister. • Gel packs will provide cooling for a number of cycles, after which they will need to be changed out.
  • Page 43 FUNDAMENTAL CONCEPTS - 3 • Temperature data is collected and transmitted to receiver every 2 seconds. • Up to 3 thermocouple inputs can be used to measure a choice of parameters, including air temperature inside mold, mold wall temperature and ambient air temperature adjacent to mold. •...
  • Page 44 SOFTWARE OVERVIEW • Data is transmitted back to receiver every 2 seconds. • K-KORD software processes data and provides 3 different real-time displays (dashboard, data & graph). • Data can be exported to common spreadsheet formats for off-line analysis and display.
  • Page 45 PC Specification for use with K-PAQ and K-KORD Software Our minimum recommended system specification is: • 2Ghz Intel Core 2 Duo, • 2Gb RAM, • 500mb free disk space, • 1024x768 resolution, • 24-bit colour • Windows XP. •If purchasing a laptop it is strongly recommended that screen resolution of 1400x900 or greater is specified.
  • Page 46 “DASHBOARD” SCREEN - 1...
  • Page 47 “DASHBOARD” SCREEN - 2 • Ideal for operator use • Shows simulated “speedo” type dial read-outs • Adjustable GREEN-AMBER-RED regions indicate under- & over-cook • Indicates read-outs for all 4 thermocouples • Also indicates Internal Air Pressure & Electronics Temperature...

  • Page 48: Graph Screen

    “GRAPH” SCREEN - 1...
  • Page 49 “GRAPH” SCREEN - 2 • Ideal for troubleshooting & for process set-up • Enables consecutive process cycles to be compared • Shows temperature vs. time for all 4 thermocouples, plus Internal Air Pressure & Electronics Temperature • Non-critical read-outs can be eliminated from view by simple click boxes...

  • Page 50: Data Screen

    “DATA” SCREEN - 1...
  • Page 51 “DATA” SCREEN - 2 • Ideal for preparing customized displays of process data • Also useful for detailed troubleshooting and process set-up • Simple copy-&-paste operation of data to Microsoft Office Excel or other spreadsheet programs...

  • Page 52: Anatomy Of A Rotomoulding Cycle

    ANATOMY OF A ROTOMOLDING CYCLE...
  • Page 53 TYPICAL TEMPERATURE TRACE Ambient temperature outside mold Internal air temperature...
  • Page 54 HEATING – STAGE 1 Ambient temperature rises rapidly to set point and then settles down Internal air temperature rises much more slowly than oven temperature. During this phase, trace shows a marked degree of scatter, due to the relatively cold powder cooling down the air as it tumbles around .
  • Page 55 HEATING – STAGE 2 Ambient temperature settles around set point Internal air temperature scatter reduces as material starts to lay down and stick to the mold. Curve slope flattens as powder melts due to need to overcome latent heat of melting. Once powder is fully melted, temperature rises more rapidly.
  • Page 56 HEATING – STAGE 3 Ambient temperature drops rapidly as mold exits the oven. Internal air temperature continues to rise, even after mold is withdrawn from oven. Typically, overshoot is 15 – 20 °C. For polyethylene, a Peak Internal Air Temperature (PIAT) of 190 – 220 °C is recommended, in order to ensure correct cure of material.
  • Page 57 COOLING – STAGE 1 Internal air temperature drops from PIAT its peak value as mold is cooled. Cooling rate at this stage is relatively fast, because material is still in contact with mold and conductive heat transfer is possible. Ambient settles down at near to ambient factory temperature.
  • Page 58 COOLING – STAGE 2 PIAT Internal air temperature drop starts to flatten as latent heat of crystallization is released. In the case of semi-crystalline polymers like polyethylene, crystallization is accompanied by shrinkage and material starts to separate from mold wall.
  • Page 59 COOLING – STAGE 3 PIAT Internal air temperature drop slows significantly after release (ie separation) of material from mold wall, because the resultant small air gap reduces heat transfer rate.
  • Page 60 DE-MOLDING PIAT Internal air temperature drops almost to factory ambient as soon as mold is opened.
  • Page 61 COOLING – SUMMARY Peak Internal Air FAST initial cooling – no release Crystallization / solidification SLOW secondary cooling – post release Mold opened Ambient air...

  • Page 62: Declaration Of Conformity

    DECLARATION OF CONFORMITY We the manufacturer: 493K Limited, 23 Watch Hill Road, Ballyclare, BT39 9QW. United Kingdom declare under our sole responsibility that the product :- K-PAQ Master Transmitter/Receiver Model TXR-2A-M/S to which this declaration relates is in conformity with the following...
  • Page 63 DECLARATION OF CONFORMITY We the manufacturer: 493K Limited, 23 Watch Hill Road, Ballyclare, BT39 9QW. United Kingdom declare under our sole responsibility that the product :- K-PAQ Slave Transmitter/Receiver Model TXR03v8c to which this declaration relates is in conformity with the following...

  • Page 64: Calibration Certificate

    Calibration Certificate for K-PAQ Rotational Moulding Temperature Measurement System Valid On: Customer: K-PAQ Electronics Serial Numbers have been calibrated to an accuracy of + / - 4º C. Signature Date: Position It is recommended that the equipment is calibrated annually to ensure satisfactory operation. Please note: Individual thermocouples should undergo similar calibration tests in order to adjust overall system calibration.

  • Page 65: Contact Information

    Contact Information For all other enquiries you can contact us on: Email: Office@493k.com Telephone: +44 (0)2893 359922...