493K K-METRON User manual

K-METRON (FW 3.0.7)
493K THICKNESS MEASUREMENT GAUGE (0-30mm)
WITH RADIO LINK UP AND SOFTWARE RECORDING
USER INSTRUCTIONS (Doc v4.0.0)
RELATING TO FIRMWARE VERSION (FW 3.0.7)
(as displayed on boot-up of the K-METRON)
IMPORTANT
Read all instructions before use
Observe safety precautions
493K Limited
23 Watch Hill Road
Ballyclare, BT39 9QW
United Kingdom
T: [phone]
E: [email protected]

K-METRON Radio User Instructions (Firmware 3.0.4; Doc v4.0)
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1CONTENTS
2GENERAL OPERATION.........................................................................................................3
2.1 Turning the unit ON & OFF..........................................................................................3
2.2 Entering the Configuration Menu. ..............................................................................3
2.3 The Measurement End of the Sensor Head................................................................4
2.4 Coupling the Sensor Head with the Calibrated Magnet. ............................................4
2.5 Loss of Magnetic Coupling. .........................................................................................5
2.6 Tracking the Sensor Head to the Point of Measurement. ..........................................5
2.7 Inserting the Sensor Head in the Dock........................................................................5
2.8 Visual Display Terminology .........................................................................................5
3MEASURING DIFFERENT MATERIALS..................................................................................6
3.1 Materials that can be measured.................................................................................6
3.2 Materials that Cannot be Measured...........................................................................6
3.3 Measuring Non-ferrous Metal Parts. ..........................................................................6
4CALIBRATING THE K-METRON ............................................................................................7
4.1 Entering the Calibration Menu....................................................................................7
4.2 Calibrating the K-METRON..........................................................................................8
4.3 Validating Calibration................................................................................................10
5CHOOSING THE CORRECT MAGNET .................................................................................11
5.1 Selecting the Magnet Type. ......................................................................................12
6POSITIONING OF THE SENSOR HEAD................................................................................13
6.1 Correct Sensor Head Position & Orientation. ...........................................................13
6.2 Measuring an External Radius with K-METRON........................................................14
6.3 Measuring an Internal Radius with K-METRON. .......................................................14
6.4 Sensor Head Care......................................................................................................14
6.5 The Sensor Head Dimensions....................................................................................15
7TAKING A THICKNESS MEASUREMENT.............................................................................16
7.1 Out of Measurable Range Thicknesses. ....................................................................16
7.2 Deleting a Thickness Measurement..........................................................................17
7.3 Indexing Mould ID. ....................................................................................................17
7.4 Units of Measurement ..............................................................................................17
8using the K-METRON’s pc SOFTWARE..............................................................................19

K-METRON Radio User Instructions (Firmware 3.0.4; Doc v4.0)
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8.1 Connecting the K-METRON to the PC & Installing the Communications Driver.......19
8.2 Downloading the K-METRON Software. ...................................................................19
8.3 Setting the Correct Communications Port................................................................19
8.4 Start Recording..........................................................................................................20
8.5 Activating and De-activating the Radio Communication..........................................21
8.6 Recording the Thickness Measurements..................................................................21
8.7 Continuous Internal Database Recording .................................................................22
8.8 Exporting to Excel......................................................................................................23
8.9 Erasing Unwanted Data.............................................................................................24
9K-METRON BATTERY POWER............................................................................................25
9.1 Battery Type ..............................................................................................................25
9.2 Replacing the Battery in K-METRON.........................................................................25
9.3 Battery Life ................................................................................................................25
10 K-METRON - WHAT’S INCLUDED...................................................................................26
11 TECHNICAL SPECIFICATIONS.........................................................................................27
12 DISCLAIMER...................................................................................................................27
13 DECLARATION OF CONFORMITY...................................................................................28

K-METRON Radio User Instructions (Firmware 3.0.4; Doc v4.0)
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2GENERAL OPERATION
2.1 Turning the unit ON & OFF.
To turn the unit ON momentarily press the ON/OFF switch on the face of the K-METRON
until the Display illuminates. Battery level will be checked each time the unit is turned on,
and if a low battery voltage is detected then a warning will be displayed on start up.
To turn the unit OFF, momentarily press the ON/OFF switch on the face of the K-METRON
until Display goes off.
The unit will auto power off after 3 minutes of inactivity. A warning “PWR OFF” is displayed
after 1 minute of inactivity. The unit can be interrupted from auto power off by pressing
either the orange trigger or the X (or “Delete”) button; pressing either will only interrupt the
auto power off and will neither ‘transmit’ nor ‘delete’ any data.
2.2 Entering the Configuration Menu.
To enter the configuration menu, where Magnet Type, Calibrate, Units, and Radio Menus
are stored, use the following button presses starting from when the K-METRON is in the OFF
state:
1. Hold down the X button (or “Delete” button in older models) and switch the unit on
by pressing the On/Off button.
2. Continue to hold down the X (or “Delete”) button, the display will read “Wait …
Setup mode”.
3. Continue holding down until the display reads “MAG TYPE”then release the X (or
“Delete”) button. (Ensure that the orange trigger is not being mistakenly held down).
4. Once the display reads “MAG TYPE”, the unit is now in the Configuration Menu.
ON/OFF
Switch
Sensor Head
X (or “Delete” button
in older models)
Sensor Head Dock
Visual Display
Power LED

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The Configuration Menu is navigated using the following buttons:
To SCROLL through the Menus, press X (or “Delete”).
To SELECT a Menu item, press the ORANGE TRIGGER.
2.3 The Measurement End of the Sensor Head
The measurement end of the sensor will attract the magnet. Ensure this end of the sensor is
in contact with the surface of the part to be measured.
2.4 Coupling the Sensor Head with the Calibrated Magnet.
Place the Sensor Head on one face of the product that is to be measured. Hold or place the
magnet on the opposite side of the product wall until it couples to the sensor head.
Hollow objects can be measured by inserting the calibrated magnet through a small opening
in the product. The magnet should immediately be coupled with the sensor head positioned
on the outside of the product and adjacent to the aperture. The sensor head can then be
slid over the surface of the product to the desired place of measurement. Movement should
be slow and steady. Care should be taken when moving the sensor head to avoid de-
coupling.
CONFIGURATION MENU
MAG TYPE
Sphere
Cube
10-30mm
CALIBRATE
Confirm Recal
UNITS
Metric
Imperial
RADIO
Radio ON
Radio OFF

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2.5 Loss of Magnetic Coupling.
When magnetic couple of the cube magnet is lost it can be retrieved by retaining the end of
the attached cord and fishing the magnet out of the opening. If the spherical magnet loses
coupling, then it must be retrieved by turning the moulding upside down and allowing the
magnet to fall out or by using a telescopic metal pointer to grab it.
2.6 Tracking the Sensor Head to the Point of Measurement.
The calibrated magnet will automatically couple, orientate and centre itself over the Sensor
Head. Once coupled track the Sensor Head to the point on the part which you wish to
measure, taking care not to remove the sensor head from the face of the work piece. This
may result in the loss of the magnetic coupling. The calibrated magnet will follow the Sensor
Head to the desired point of measurement.
2.7 Inserting the Sensor Head in the Dock.
If the sensor head is difficult to engage in the Sensor Head Dock, then a thin film of grease
should be applied to the O-ring found within the Sensor Head Dock.
2.8 Visual Display Terminology
Displayed Text
Meaning
N/M
No Magnet in range
O/R
Out of Range
Mag type: Cube
Selected Magnet: 10mm Cube
Mag type: Sphere
Selected Magnet: 10mm Sphere
Mag type: 10-30mm
Selected Magnet: 19mm Sphere
PWR OFF
In automatic Power Off Mode

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3MEASURING DIFFERENT MATERIALS
The unit does not require re-calibration for use with different materials. This equipment will
measure materials of a thickness between 2mm to 20mm where access can be achieved to
both sides of the product being measured.
3.1 Materials that can be measured.
Non-ferrous materials of any density will return an accurate reading within the limits of the
device. Materials that can be measured include all non-ferrous materials such as:
•Plastics of any density or composition
•Foamed materials
•Laminates
•Fibreglass
•Carbon Composites
•Glass
•Aluminium
•Brass and copper
The K-METRON allows the roto moulder to measure the full thickness of MULTI-LAYER
mouldings.
3.2 Materials that Cannot be Measured.
The unit cannot be used to measure any kind of ferrous materials, e.g. steels & irons. The
magnetic attraction found in these materials will affect the accuracy of the reading.
3.3 Measuring Non-ferrous Metal Parts.
When measuring the thickness of non-ferrous metal parts (e.g. aluminium or copper) ensure
that there is no movement of the magnet during the measurement. The figure of 8
movement for these materials should be made to centre the magnet to the sensor head
but should be stopped once centred and before the measurement is taken.

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4CALIBRATING THE K-METRON
The unit may come with calibrated data already recorded for each of the magnets held in
the unit’s memory; this will be confirmed if a Calibration Certificate has been sent with the
unit. The calibrated data associated with each type of magnet will be automatically called on
selection of the magnet from within the configuration menu. After the K-METRON is
calibrated with each type of magnet the values are stored within the K-METRON memory.
Therefore, re-calibration is not necessary when switching between magnets; instead, the
desired magnet is chosen in the configuration menu under the MAG TYPE section.
The K-METRON’s accuracy improves with careful magnetic coupling between the sensor
head and the part face. Measurement accuracy ranges from +/- 0.2mm at the lower end of
the readings and +/- 1mm at the upper end of measurement. This will depend on whether
the spherical magnet or the cube is used.
Although the units are calibrated before leaving 493K re-calibration may be necessary
within your plant. This can be determined by selecting the appropriate magnet and
validating the data as described below in section 4.3 Validating Calibration.
Select a location that is at least 1 metre away from any steel or ironwork which will affect
accuracy of calibration.
Re-calibration is not required for use with differing materials.
4.1 Entering the Calibration Menu.
The Calibrate Menu is found within the configuration menu. Use the following button
presses, starting from when the K-METRON is in the OFF state, to enter the Configuration
menu:
1. Hold down the X button (or “Delete” button in older models) and switch the unit on
by pressing the On/Off button.
2. Continue to hold down the X (or “Delete”) button, the display will read “Wait …
Setup mode”.
3. Continue holding down until the display reads “MAG TYPE” then release the X (or
“Delete”) button. (Ensure that the orange trigger is not being mistakenly held down).
4. Once the display reads “MAG TYPE”, the unit is now in the Configuration Menu.
The Configuration Menu is navigated using the following buttons:
To SCROLL through the Menus press X (or “Delete”).
To SELECT a Menu item, press the ORANGE TRIGGER.
Scroll through the menu using the X (or “Delete”) button and select “Calibrate” by pulling
the orange trigger. The unit will prompt for re-confirmation, and this is acknowledged again
by pulling the orange trigger.

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4.2 Calibrating the K-METRON.
Once in the Calibrate Menu the display should now read NM –no magnet. With no magnet
near the sensor head, the trigger should be depressed and released.
After successfully acknowledging ‘NM – no magnet’ the unit will then request the 20mm
position (+10mm disk for 10-30mm magnet). The magnet should be placed on the
20mm(+10mm disk for 10-30mm magnet) step and the trigger pulled. Confirmation of step
calibration will be provided and then the next step thickness requested, i.e. 19mm. Slide the
magnet onto the next step ensuring that it does not snap onto the next step to avoid
damaging both the magnet and calibration step tool. The next position will be requested,
i.e.18mm, and so on.
The magnet should be placed on each step so that it is in the centre of the step and is not
interfering with the step edge. The sensor head should be centred on the magnet. Ensure
that the magnet is not moving when calibrating as this will affect the calibration values.
The more accurately you can teach the K-METRON the thickness that it is measuring during
calibration, the greater the accuracy of the part thickness measurement in the field.
Continue this step-by-step calibration down to the ‘Zero’ thickness with the magnet directly
on the sensor surface.
If you make a mistake during the calibration sequence, press the X (or “Delete”) button to
go back to the previous position.
For use of 19mm Spherical Magnet to use for the 10mm-30mm measurement range:
Please note that a 10mm aluminium Disk is provided.
The disk features a groove for the sensor head to easily slide into, allowing the operator to
calibrate +10mm in conjunction with the provided calibration step profile.
K-METRON
SENSOR HEAD
+10mm Calibration
Add-on
19mm Sphere
Magnet

K-METRON Radio User Instructions (Firmware 3.0.4; Doc v4.0)
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THE CUBE AND SPHERICAL MAGNETS ARE NOT INTERCHANGEABLE AND DOING SO WILL
RESULT IN INACCURATE READINGS. THE MAGNET TYPE MUST BE SET IN THE
CONFIGURATION MENU BEFORE USING THE K-METRON. IT IS ADVISABLE TO STORE ANY
UNUSED MAGNETS IN THE K-METRON CASE TO AVOID MISTAKENLY LOSING OR USING THE
WRONG MAGNET.

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4.3 Validating Calibration.
After calibration is complete the measured data should be validated. To do this position the
calibrated magnet once more on each step and ensure the K-METRON’s measured and
displayed value is that of the actual step thickness (note the measurement tolerances as per
the table above apply).
Magnet Used
Mag Type
Calibration Range
10mm Sphere
Sphere
0mm - 20mm
10mm Cube
Cube
0mm - 20mm
19mm Sphere
10-30mm
10mm –30mm
10mm Cube and 10mm Sphere Validating Calibration
19mm Sphere Validating Calibration –use the provided +10mm disk to measure units
over 20mm.
+10mm Calibration
Add-on

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5CHOOSING THE CORRECT MAGNET
The unit comes with three different types of magnets, a cube, a 10mm sphere, and a 19mm
sphere. The desired range of measurement will be the major factor which will determine
whether to use the cube or spherical magnet. The 10mm x 10mm x 10mm cube magnet is
best for thick-walled parts (> 4mm). Since thick-walled parts are usually large a cord is
supplied to help retrieve the magnet should it become de-coupled from the sensor head.
The 10mm spherical magnet is best for thinner parts when tight radii are to be measured.
The measurement specifications for each of the magnets are shown in the Table below.
MEASUREMENT SPECIFICATIONS FOR CUBE AND SPHERICAL MAGNETS
METRIC
Part thickness
Accuracy
10mm cube
magnet
4mm –20mm
4mm-17mm: +/- 0.2mm of reading
17mm +: +/- 1.0mm of reading
Factory Set
10mm sphere
magnet
2mm-20mm
2mm-13mm: +/- 0.2mm of reading
13mm: +/- 1.0mm of reading
19mm sphere
magnet
10mm -30mm
10mm –20mm: +/- 0.2mm of reading
21mm: +/- 1.0mm of reading
IMPERIAL
Part thickness
Accuracy
0.39” cube
magnet
0.157” – 0.787”
0.157” – 0.669”: +/- 0.008” of reading
0.669”: +/- 0.039” of reading
Factory Set
0.39” sphere
magnet
0.079” – 0.787”
0.079” –0.512”: +/- 0.008” of reading
0.512”: +/- 0.039” of reading
0.75” sphere
magnet
0.39” – 1.1811”
0.39” –0.787”: +/- 0.008” of reading
0.787”: +/- 0.039” of reading

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5.1 Selecting the Magnet Type.
To select the type of magnet to measure with, enter the Configuration Menu (Chapter 2.2)
and select “MAG TYPE”; then scroll through until the desired Magnet type and select using
the Orange Trigger. There are three types of Magnets to choose from:
Type of Magnet
Measurement Range
•Sphere
0mm - 20mm
•Cube
0mm - 20mm
•10-30mm
10mm –30mm
The data for each of the magnets is calibrated via the “Calibrate” menu.
Magnet selection map, press X(“Delete” for older version) button to cycle between the
three magnet types:
To SCROLL through the Menus, press X (or “Delete”).
To SELECT a Menu item, press the ORANGE TRIGGER.
CONFIGURATION MENU
MAG TYPE
Sphere
Cube
10-30mm
CALIBRATE
Confirm Recal
UNITS
Metric
Imperial
RADIO
Radio ON
Radio OFF

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6POSITIONING OF THE SENSOR HEAD
The correct position and orientation of the sensor head on the part surface is essential to
ensure an accurate reading is taken.
6.1 Correct Sensor Head Position & Orientation.
When measuring flat parts ensure that the sensor head is perpendicular to the surface.
When measuring external radius, it is important to ensure that the sensor head is
perpendicular to the surface of the part being measured.
Incorrect Sensor Head Orientation: a non-perpendicular orientation will result in an
erroneous measurement.
An internal radius will return a value for which compensation must be made.
Thickness displayed on the
meter will be the thickness
of the measured part.
Thickness displayed on the
meter will be the thickness of
the measured part.
Thickness displayed on the meter will
be the thickness of the measured
part plus the gap between the sensor
head and the part.
gap
Thickness displayed on the meter
will be the thickness of the
measured part plus the gap
between the sensor head and the
part.

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6.2 Measuring an External Radius with K-METRON.
It is straight forward to measure external radii down to 5mm. Place the sensor head on the
surface of the part located at external radius to be measured. Ensure that the sensor head is
perpendicular to the tangent of the radius to make an accurate reading.
6.3 Measuring an Internal Radius with K-METRON.
It is straight forward to measure an external radius down to 5mm. At radii less than this the
main difficulty is with access to the surface. When measuring thickness of internal radii, the
correct measurement often requires compensation for the gap distance as shown below.
6.4 Sensor Head Care
DO NOT ALLOW THE TRANSDUCER MAGNET TO ‘SNAP’ TO THE FACE OF THE SENSOR –
SEVERE DAMAGE MAY OCCUR TO THE DEVICE SENSOR AND MAGNET.
Keep the Sensor Head and magnet away from computer displays or any product which is
sensitive to strong magnetic fields. Permanent damage may occur to such devices.
The Sensor is highly sensitive to magnetic fields and temperature. High temperature
environments may also affect the accuracy of readings.
The instrument has been factory calibrated to accuracies shown in the table below.
Regular checks should be made to ensure the instrument is operating within its capabilities
and it is recommended that the unit is returned to 493K Limited for an annual recalibration
A minimum external radius of 5mm
(3/16”) can be measured using the
supplied 10mm diameter magnetic
sphere.
A minimum external radius of 3.3mm
(0.1229”) can be measured using a 6.6mm
diameter magnetic sphere (contact for
supply).
minimum external
radius
gap
A minimum internal radius of
25mm (1”) can be measured before
it becomes impractical and difficult
to compensate for gap distances.
Radii less than 25mm also tend to
allow the magnetic force to pull
the magnet to the side of the part.
minimum external
radius

K-METRON Radio User Instructions (Firmware 3.0.4; Doc v4.0)
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to ensure its continued performance is maintained. 493K offer a return carriage paid
service, calibration, and inspection.
6.5 The Sensor Head Dimensions.
The sensor head is a cylinder of size 28mm diameter x 55mm length.
Diameter of sensor head. Length of sensor head.
Ø28mm
55mm

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7TAKING A THICKNESS MEASUREMENT
When the sensor head is at the desired measuring point pull and hold the orange trigger
and make small figure of eight movements of the Sensor Head to ensure the Transducer
Magnet is centrally located on the Sensor Head. Centring of the calibrated magnet will easily
occur on materials up to 20mm (0.78”) thick but will also depend on the surface finish of the
material being measured.
On releasing the trigger, the unit will display and transmit the minimum value measured to
the receiver.The data that are sent to the PC are the Date, Time, Mould Identification
Number, the Mould Position Number and the Thickness Reading.
If the receiver is not connected to the PC or the handheld transmitter is out of radio range
of the receiver then a ‘TX Error’ will be displayed on pulling the Orange Trigger. The unit is
still operational and can be used to display on-screen readings without the receiver being
connected to the PC, however users should be aware that a 'TX Error' indicates that the
reading is not saved on the PC. If it is not the intention to use the radio link this facility can
be turned off in the Configuration Menu in the “Radio” selection.
7.1 Out of Measurable Range Thicknesses.
During the calibration of a spherical or cube magnet the unit will determine at which
maximum thickness the sensor magnets become out of range and then will display O/R for
‘out of range’ when appropriate. The O/R limit is reached whenever the effect of the
magnet on the sensor head is too small to provide a useful measurement. It is also seen
when no magnet is present, such as would happen when the magnet becomes de-coupled.
For a limit where the thickness decreases to zero and the measurement is out of range,
“LOW” will be displayed.

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7.2 Deleting a Thickness Measurement.
If an erroneous thickness measurement has been made and transmitted to the PC then it
can be remotely deleted from the PC. To do this press the X (or “Delete”) button; the display
signals confirmation. The Position Number on the PC will then be reduced by ‘1’.
7.3 Indexing Mould ID.
After the thickness measurements on a particular mould are completed the user has the
option to increment the Mould Identification number. This number is used as a guide to
indicate which moulds are being measured and recorded.
To increment the Mould Index number, complete the following two steps:
Step 1. Move the magnet away from the sensor head so that O/R (‘out of range’) is
displayed on-screen;
Step 2: Hold the trigger down for 7 seconds.
The on-screen indication will now show that the Mould Index number has been
incremented.
7.4 Units of Measurement
Measurements can be made using IMPERIAL or METRIC units. Units are changed in the
Configuration Menu under the “Units” section. To enter the Configuration Menu:
1. Hold down the X button (or “Delete” button in older models) and switch the unit on
by pressing the On/Off button.
2. Continue to hold down the X (or “Delete”) button, the display will read “Wait …
Setup mode”.
3. Continue holding down until the display reads “MAG TYPE” then release the X (or
“Delete”) button. (Ensure that the orange trigger is not being mistakenly held down).
4. Once the display reads “MAG TYPE”, the unit is now in the Configuration Menu.
The Configuration Menu is navigated using the following buttons:
To SCROLL through the Menus press X (or “Delete”).
To SELECT a Menu item, press the ORANGE TRIGGER.
Scroll through the menu section and select the “Units”; then scroll through
METRIC/IMPERIAL/EXIT and select the desired Units. The unit will now exit the configuration
menu and return to operational status ready to measure using the units of measurement
chosen.

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CONFIGURATION MENU
MAG TYPE
Sphere
Cube
10-30mm
CALIBRATE
Confirm Recal
UNITS
Metric
Imperial
RADIO
Radio ON
Radio OFF

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8USING THE K-METRON’S PC SOFTWARE
8.1 Connecting the K-METRON to the PC & Installing the
Communications Driver.
Connect the K-METRON receiver unit to the PC using the attached USB flying lead. Allow
Windows to automatically connect to the internet for the latest communication driver. It
will do this automatically upon plugging in the USB flying lead.
8.2 Downloading the K-METRON Software.
Download and install the K-METRON software from the link supplied by 493K. If you do not
have this link it can be found at www.493k.com under the Software heading.
8.3 Setting the Correct Communications Port.
Ensure that the K-METRON software is set to look at the correct communications port that
has been assigned by Windows for the receiver hardware (when the radio receiver was
connected and the driver installed, Windows will have auto-assigned this number).
To determine the communication port number that Windows has assigned go to:
•Windows Control Panel
•Device Manager
•Under Ports (COM & LPT) the USB Serial Port will show the COM number that has
been allocated by Windows e.g.
(in this case Windows has assigned the COM number 18)