493K K-Paq Junior, Owner'S Manual

Page 1: ...Owner s Guide Junior...

Page 2: ......

Page 3: ...7 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 Ma...

Page 4: ...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...

Page 5: ...eived including interference that may cause undesired operation Industry Canada IC 5232A 870TR Canada Operation is subject to the following two conditions 1 this device may not cause interference and...

Page 6: ...om 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: ...he 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...

Page 8: ...nsmitter 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 The transmitter will be in the high current...

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 9...

Page 10: ...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 10 RED...

Page 11: ...Flying Lead Aerial 4 The finished installation position of the flying lead aerial 11...

Page 12: ...flash to indicate that it is calling for transmitters Note the status of the light will not change regardless of whether or not it is connected to a transmitter The status of the batteries is shown i...

Page 13: ...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 tur...

Page 14: ...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 In...

Page 15: ...e the 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 sof...

Page 16: ...he CD ROM of the PC and install the K Kord software 4 Run up the K Kord software click the Preferences tab and select the PC serial comport to be used for connection to the master TXR1A unit e g COM1...

Page 17: ...Once the master has been found the slave electronics LED will begin to FLASH for approximately 0 1 second every 2 seconds 4 At the PC click on the Start Recording button located at the top left corner...

Page 18: ...rt 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 ente...

Page 19: ...hase 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 LIM...

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 20...

Page 21: ...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 OF...

Page 22: ...P 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 STE...

Page 23: ...mage to the unit Use the Coolant Bag to transfer the coolant packs from the freezer to the K PAQ This is to ensure that there is minimal frosting on the outside of the coolant packs Wipe the coolant p...

Page 24: ...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 24 Cool Pack 1 Cool Pack 2...

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 25...

Page 26: ...ay 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 position...

Page 27: ...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...

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 28...

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 29...

Page 30: ...e 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 termin...

Page 31: ...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 fa...

Page 32: ...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 10...

Page 33: ...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 moul...

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 34...

Page 35: ...mm 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 To...

Page 36: ...Adjustment Screw If Tension Screw is seized then refer to section entitled Toggle Clamp Greasing Toggle Clamp Maintenance 36...

Page 37: ...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...

Page 38: ...er 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...

Page 39: ...f 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 ma...

Page 40: ...le 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: ...uring 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 cur...

Page 42: ...uired 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...

Page 43: ...meters 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 an...

Page 44: ...ransmitted 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 l...

Page 45: ...tion 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...

Page 46: ...DASHBOARD SCREEN 1 46...

Page 47: ...or 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...

Page 48: ...GRAPH SCREEN 1 48...

Page 49: ...r 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 el...

Page 50: ...DATA SCREEN 1 50...

Page 51: ...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...

Page 52: ...ANATOMY OF A ROTOMOLDING CYCLE 52...

Page 53: ...TYPICAL TEMPERATURE TRACE Ambient temperature outside mold Internal air temperature 53...

Page 54: ...idly 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...

Page 55: ...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...

Page 56: ...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 r...

Page 57: ...t 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...

Page 58: ...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 sta...

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 59...

Page 60: ...DE MOLDING PIAT Internal air temperature drops almost to factory ambient as soon as mold is opened 60...

Page 61: ...COOLING SUMMARY Crystallization solidification FAST initial cooling no release Peak Internal Air SLOW secondary cooling post release Mold opened Ambient air 61...

Page 62: ...ation 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 L...

Page 63: ...tion 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 Lo...

Page 64: ...Electronics Serial Numbers have been calibrated to an accuracy of 4 C Signature Date Position It is recommended that the equipment is calibrated annually to ensure satisfactory operation Please note...

Page 65: ...For all other enquiries you can contact us on Email Office 493k com Telephone 44 0 2893 359922 Contact Information 65...