junior - 493k · assembly of thermocouple leads ... run the aerial through the small slot on the...

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

http://www.493k.com/

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:



INSTRUCTIONS:

• STEP 1. RUN K-KORD AND WHEN THIS WINDOW APPEARS CLICK ON “Enter

Purchase Key”

12

K-KORD Software:



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

mailto:[email protected]

K-KORD Software:



• 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


Thermocouple Leads 2. Remove the back cover from the plug connector,

3. Strip back the wire to expose 10mm to 15mm of cable,

21


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


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


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.


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 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.


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


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:


Date of issue 01 December 2015

Signature

Name Dr Gareth W.G. McDowell

Position Managing Director

58

DECLARATION OF CONFORMITY

We the manufacturer:


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:


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

mailto:[email protected]

junior - 493k · assembly of thermocouple leads ... run the aerial through the small slot on the...

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