Owner’s Guide
Junior
Page No. Title
5 Removal of K-PAQ Junior from packaging
6-7 Set up of K-PAQ Junior Slave/transmitter
8-9 Set up of K-PAQ Junior Master/receiver
10-14 K-Kord Software
15-17 Proper use of coolant packs
18 Thermocouples
19-24 Assembly of Get You Started Thermocouples
25-27 Flying Lead Aerial
28-29 Mounting to the Mould
30-34 Toggle Clamp Maintenance on K-PAQ Junior
35 Main ways of using K-PAQ Junior
36-38 Fundamental Concepts 1, 2, 3
39 Software Overview
40 PC Specification for use with K-PAQ and K-KORD software
41-42 Dashboard Screen 1, 2
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
59 Calibration Certificate
60 Contact Information
4 MCM03022016
Removal of K-PAQ Junior from
packaging
Check that all Items of Despatched Goods List have been received. You will find this list
inside the box.
Remove the K-PAQ Junior Canister from the box by unscrewing the wing nuts holding it in
place.
LIFTING K-PAQ Junior
When the lid is secured correctly with all three toggle clamps then the unit can be lifted
using the spring-loaded handle on the lid.
5
Set up Of K-PAQ Jr Slave/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. The
internal wiring has been adjusted for this and
the battery should be inserted with the
negative button end facing outwards)
Open the Lid of the K-PAQ and locate the
sealed bag containing the battery cap, battery
cover, O-ring and 2 x screws.
Set the black battery cap on top of the battery
and pushing down, rotate the cap ¼ turn.
Place the black O-Ring over the battery cap.
Place the battery cover over the O-Ring and
secure using the 2 screws provided.
6
Set up Of K-PAQ Junior Transmitter
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.
If the light is solid then it is because it
is looking for the receiver. It will then
turn off after 24 seconds and sleep for
over 2 minutes before waking up to
look for the receiver again.
If the transmitter LED is solid ensure
that the receiver is switched and
flashing and is within range.
Switch
LED
7
Set up of K-PAQ Junior Receiver The receiver comes with a 5v power
adapter. Whenever possible the
receiver should be run on mains
power.
When the receiver is not located
near a mains supply the D cell
batteries can be used to power it.
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.
Switch on the receiver by pressing the
black button. The red LED should now
start to flash and will continue to flash
regardless of whether it is connected to
the transmitter.
8
Set up of K-PAQ Junior Receiver 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. Note which communication port (i.e.
COM1, COM2, etc) the receiver is plugged into as this will be needed to set up the software.
Install the driver software on your PC. The driver can be located in the K-KORD program folder
or it can be downloaded directly by giving Windows the option to search on-line.
TRANSCEIVER
9
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. If not, go to Windows Control Panel
and re-configure the serial-to-USB converter in the
‘Hardware’ section.
You will now have 35 days to enter your Product
Key. (see below on how to request this)
When the software is running, click on the ‘Start
Recording’ button. After ensuring that the
transmitter and receivers are communicating
(signalled by a flashing light on the transmitter) the
data will now be displayed and recorded on screen.
10
K-KORD Software:
Permanent Installation
Entering your Product Purchase Key
• 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.
11
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”
12
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 [email protected].
13
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’.
• STEP 4 . CLICK ON ‘OK’ AND YOU WILL NOW HAVE FULL ACCESS TO YOUR K-KORD SOFTWARE.
14
Proper use of Coolant Packs
• Maximum effectiveness of the coolant packs is attained only when they
are frozen.
• Freeze in a -20 °C (-4 °F). Do not use in a -40 Degrees °C
(-40°F) Freezer as the coolant packs will then be too inflexible.
• Ensure that there is minimal frosting on the outside of the coolant packs.
• Wipe the coolant packs down with a towel before installing them into the
canister. The canister should also contain some desiccant packs to
minimise moisture.
• Once the coolant packs are inserted, close the lid of the K-PAQ as soon
as it is possible to prevent further frosting and/or condensation from
occurring.
15
Proper use of Coolant Packs Standard 2x Cool Pack Arrangement
For extending cooling a further cool pack could be fitted to the K-Paq Junior.
16
Cool Pack 1 Cool Pack 2
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.
17
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.
The thermocouple cable must then be looped downward
and gathered together into a flat bundle to exit via the notch
on the flange of the body. In order to aid positioning an
elastic band may be used to secure the downward loop of
the thermocouple cables to the plug and socket block.
When fitting the lid it is important to ensure that the cables
are held within the notched groove to avoid cutting the wires
with the flange.
Make sure thermocouples are pushed well into the mould
vent pipe by at least 100mm.
100mm
(4”)
18
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,
- Wire strippers,
- Wire cutters,
- Magnet
19
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.
20
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,
21
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,
22
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
23
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. With the connector plug fitted the other end of the cable needs to be
prepared. Strip back the sheathing by 10mm and twisted the two wires
together. Snip the twisted wire to leave a thermocouple junction of 3-5mm.
The point is where the temperature will be measured.
24
Flying Lead Aerial
1. Ensure SMA connector is tightly screwed to K-PAQ Junior
electronics.
2. Run the aerial through the small slot on the top of the K-PAQ Junior body
along with the thermocouple cables.
25
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 .
26
Flying Lead Aerial
The finished position should look like this…
27
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. The holes in the handles are made for
clearance of M8 bolts.
POSITIONING OF TELEMETRY PATH
When mounting the transmitter in the mould’s frame work it is important that the
aerial is pointing away from the central point of the mould and in general is not
shielded by excessive amounts of metal framework or mould.
28
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.
29
• Tools & materials needed:
• 4mm flat blade terminal screwdriver;
• High temperature grease;
• Pin Hammer
There are three toggle clamps mounted
around the K-PAQ Junior insulated
transmitter.
Claw
Thumb Slider
Catch Plate
Locking Plate
Toggle Clamp Maintenance
30
Adjustment Screw
If Tension Screw is seized then
refer to section entitled Toggle Clamp Greasing.
Toggle Clamp Maintenance
31
• The clamps must be greased regularly with
appropriate high temperature grease. If the
clamps are not greased then extra force will
be 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. (see section entitled
Locking Plate Adjustment)
• The clamps are to be greased at three
points:
• Point 1:Outside Thumb Slider
• Point 2:Behind Thumb Slider
• Point 3:Tension Screw Thread
Point 1
Point 2
Point 3
Toggle Clamp Maintenance
Toggle Clamp Greasing
32
• 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; if there is too little tension then the
clamp will be loose and there will be the risk that it does not maintain a grip on the
catch plate. The excessive compression on the silicone sponge will also cause
deformation in this seal and may allow moisture and heat to more easily enter the
inner workings of the electronics.
• The tension on the clamp can be adjusted to ensure a reasonable grip on the catch
plate. Turning the screw with the terminal screwdriver will adjust the tension. Too
much tension will cause the catch plate to bend when the clamp is closed. If this
occurs then the clamp should be loosened. Too little tension and the claw will rattle
on the catch plate. If this occurs then the clamp should be tightened. The tension
should be such that the clamp can be closed easily between finger and thumb without
having to strike the clamp or use excess force.
• Clockwise adjustment: tightens clamp
• Anti-clockwise adjustment: loosens clamp
Toggle Clamp Tension Adjustment.
Toggle Clamp Maintenance
33
• 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.
• If the Thumb slide hook is not engaging in the locking plate then the Lock Plate may
need to be tapped lightly downward with a light pin hammer as shown in the photo
below:
Locking Plate Adjustment
Toggle Clamp Maintenance
34
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
• Using voltage outputs generated by K-KORD software as inputs to
machine PLC to initiate automatic actions
35
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.
• Temperature of air inside the mold closely tracks temperature of
material and identifies all the key events during a cycle (eg melting,
correct cure, release of material during cooling).
• K-PAQ overcomes practical difficulties in measuring temperature during
rotomolding (biaxial rotation), using insulated and cooled canister to
contain sensitive electronics.
36
FUNDAMENTAL CONCEPTS - 2
• Sophisticated insulation provides an excellent heat barrier in a compact
unit.
• 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. This simple operation can be accomplished
within the normal servicing time (unloading / loading) of the mold.
• Change-out is typically necessary twice per 8-hour shift.
37
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.
• Temperature of sensitive electronics inside the transmitter is
continuously monitored and data is transmitted back to receiver
every 2 seconds.
• Temperature and pressure data is displayed on a PC; a variety of
formats are available (dashboard, data & graph).
38
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.
39
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.
•Netbooks should be avoided if possible, due to considerably lower specification.
40
“DASHBOARD” SCREEN - 1
41
“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
42
“GRAPH” SCREEN - 1
43
“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
44
“DATA” SCREEN - 1
45
“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
46
ANATOMY OF A
ROTOMOLDING CYCLE
47
TYPICAL TEMPERATURE TRACE
Ambient temperature outside mold
Internal air temperature
48
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 .
49
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.
50
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.
51
COOLING – STAGE 1
PIAT
Ambient settles down at near to
ambient factory temperature.
Internal air temperature drops from
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.
52
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.
53
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.
54
DE-MOLDING
PIAT
Internal air temperature
drops almost to factory
ambient as soon as
mold is opened.
55
COOLING – SUMMARY
Crystallization / solidification
FAST initial cooling – no release
Peak Internal Air
SLOW secondary cooling – post release
Mold opened
Ambient air
56
57
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
standard(s) or other normative document(s) :-
EN55022 : 1988 Class B, EN50082-1, IEC 801-2 : 1991, IEC 801-3 : 1984, IEC 801-4 : 1988
following the provisions of :-
the Low Voltage Directive 73/23/EEC
and the EMC Directive 89/336/EEC.
Place of issue:
493K Limited, 23 Watch Hill Road, Ballyclare, BT39 9QW. United Kingdom
Date of issue 01 December 2015
Signature
Name Dr Gareth W.G. McDowell
Position Managing Director
58
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
standard(s) or other normative document(s) :-
EN55022 : 1988 Class B, EN50082-1, IEC 801-2 : 1991, IEC 801-3 : 1984, IEC 801-4 : 1988
following the provisions of :-
the Low Voltage Directive 73/23/EEC
and the EMC Directive 89/336/EEC.
Place of issue:
493K Limited, 23 Watch Hill Road, Ballyclare, BT39 9QW. United Kingdom
Date of issue : 01 December 2015
Signature
Name Dr Gareth W.G. McDowell
Position Managing Director
59
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.
For all other enquiries you can contact us on:
Email: [email protected]
Telephone: +44 (0)2893 359922
Contact Information
60