493K K-Paq Junior User manual

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
4MCM03022016

MCM03022016 5
Compliance.
FCC ID: SDM870TR
This device complies with Part 15 of the FCC Rules. Operation is subject to the following two conditions: (1) this device may not cause
harmful interference, and (2) this device must accept any interference received, 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 (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.

Unpacking the K-PAQ Junior.
6
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.
4. Check that all Items of Despatched Goods List have been received.

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. 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.
7

BATTERY TYPE
Use only a Lithium Manganese 3V CR AA, with reverse Polarity: Button end is –ve. Do not use any other Lithium battery.
8
K-PAQ JUNIOR BATTERY TYPE & EXPECTED LIFE
+_
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*.
*The transmitter will be in the high current repetitive listen mode searching for a receiver signal call - 24 seconds listening & 120 seconds
sleep for 16 hours/days.
SCENARIO 3:
16 Days Battery Life
K-PAQ Junior transmitter is on for 24 hours/day with the receiver switched off 24 hours/day*.
*The transmitter will be in the high current repetitive listen mode searching for a receiver signal call - 24 seconds listening &
120 seconds sleep for 16 hours/days.

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

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 .
10
RED
WHITE
BLACK

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

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.
If there is a mains power cut then the batteries will automatically respond
as a battery back-up and the unit will continue to operate.
Switch on the receiver by pressing the black button, shown in the photo
below. The red LED should now start to 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 in the K-KORD software. When this
display indicates that a battery set is no longer “Good”, the batteries
should be replaced as soon as convenient.
With normal usage, the batteries would be expected to last in excess of
3.5 months in a master unit.
Should the receiver lock-up or cease responding to the pushing of the
ON/OFF switch first of all perform a ‘hard reset’ by removing the batteries
for a period of approximately 15 seconds. If the unit is still not responding
then replace the batteries or test with the external power supply.
12

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.
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
13

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. 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
14

MCM03022016 15
General Description
The K-Kontrol Data Relay Unit is a battery powered radio telemetry transceiver (914.5MHz –USA; 869.85MHz –European; 433.92 MHz –
Rest of the World) that processes the signals acquired from four type K-type thermocouples and, on receipt of master command, transmits
the temperature data to a master unit which, via an RS232 serial output, passes the data to a computer for display, analysis and storage.
The unit can serve as a master or a slave. A unit connected to a computer via an RS232 serial cable automatically adopts the role of master
once 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 software package.
A photograph of the Model TXR1A is shown below.
The unit is contained in an ABS plastic enclosure 160 x 120 x 90mm.
Power is provided by two 1.5 volt, D size, alkaline batteries retained in a cylindrical battery holder mounted in the base section of the
enclosure.
Access to the thermocouple, RS232 and external power connectors is provided by slots/holes in the sides of the lid.
A power ON/OFF push switch and a power ON light emitting diode (LED) indicator are sited on the top facia of the unit.
The transmit/receive aerial is contained within the enclosure

MCM03022016 16
Initial set-up
1. 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.
2. Insert the K type thermocouple plugs issuing from the slip rings into the appropriate sockets on each slave
TXR1A unit.
3. Place the K-Kord disc into the 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, COM2, COM3 or COM4.
5. Any problems allocating the correct comport, once K-Kord is installed, click the Tools drop down menu on the
toolbar and select “Automatic COM port Detection Wizard” and follow the step by step instructions.
6. Site the master TXR1A unit adjacent to the PC and connect the RS232 serial cable between the master and the
selected comport of the PC.

MCM03022016 17
Operation
1. 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.
2. The MASTER electronics will begin to SEARCH for the slave electronics. This is indicated by the constant
flashing LED light. The master will not go to sleep it will constantly search for any slave electronics.
3. The SLAVE electronics will initially SEARCH for the master which is indicated by the LED remaining solid for 24
seconds. After this period the SLAVE electronics will turn to SLEEP mode for 170 seconds. It will continue this
cycle until the master has been found. 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 of the K-Kord window.
5. As each slave TXR1A unit “finds and locks on” to the master, its power ON LED will change to flash on for
approximately 0.1 seconds every 2 seconds.
6. The received temperature data can be viewed in tabular or graphical form on K-Kord software and is
automatically saved to a default directory file.
7. When the Stop Recording button on the K-Kord window is pressed, the master and the slaves will remain paired
with each other as the power ON LEDs on the master and slave units will continue to flash
8. When the Start Recording button is pressed within K-Kord the temperature measurement data will be displayed
in an instant as the paired master and slave units are constantly connected with each other.

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.
18

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.
19

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
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