493K K-METRON User manual

K-METRON (FW 2.3.4)
493K THICKNESS MEASUREMENT GAUGE
WITH RADIO LINK UP AND SOFTWARE RECORDING
USER INSTRUCTIONS (Doc v3.0.0)
RELATING TO FIRMWARE VERSION (FW 2.3.4)
(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 2.3.4; Doc v3.0.0)
1 | P a g e
1OPERATING THE K-METRON...............................................................................................3
1.1 Turning the unit ON & OFF..........................................................................................3
1.2 Coupling the Sensor Head with the Calibrated Magnet. ............................................3
1.3 Loss of Magnetic Coupling. .........................................................................................4
1.4 Tracking the Sensor Head to the Point of Measurement. ..........................................4
1.5 Ensure Correct Sensor Head Orientation....................................................................4
1.6 Measuring an External Radius with K-METRON..........................................................5
1.7 Measuring an Internal Radius with K-METRON. .........................................................5
1.8 The Sensor Head Dimensions......................................................................................6
1.9 Measuring the Thickness.............................................................................................6
1.10 Deleting a Thickness Measurement. .......................................................................6
1.11 Indexing Mould ID. ..................................................................................................6
1.12 Out of Measurable Range Thicknesses....................................................................7
1.13 Choosing which Magnet Type to use. .....................................................................7
1.14 Units of Measurement.............................................................................................7
2THE K-METRON SOFTWARE................................................................................................8
2.1 Connecting the K-METRON to the PC & Installing the Communications Driver.........8
2.2 Downloading the K-METRON Software. .....................................................................8
2.3 Setting the Correct Communications Port..................................................................8
2.4 Recording the Thickness measurements. ...................................................................9
3SAVING THE DATA ............................................................................................................10
3.1 Continuous Internal Database Recording .................................................................10
3.2 Exporting to Excel......................................................................................................10
3.3 Erasing Unwanted Data.............................................................................................11
4POWERING THE K-METRON .............................................................................................12
4.1 Battery Type ..............................................................................................................12
4.2 Replacing the Battery in K-METRON.........................................................................12
4.3 Battery Life ................................................................................................................12
5CALIBRATING THE K-METRON ..........................................................................................13
5.1 Entering Calibration Mode........................................................................................13
5.2 Calibrating the K-METRON........................................................................................13

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
2 | P a g e
5.3 Validating Calibration................................................................................................14
6THE SENSOR HEAD............................................................................................................14
7MEASURING DIFFERENT MATERIALS................................................................................14
7.1 Materials that can be measured...............................................................................15
7.2 Measuring Non-ferrous Metal Parts. ........................................................................15
7.3 Materials that Cannot be Measured.........................................................................15
8WHAT’S INCLUDED ...........................................................................................................15
9TECHNICAL SPECIFICATIONS.............................................................................................16
10 DISCLAIMER...................................................................................................................16
11 DECLARATION OF CONFORMITY...................................................................................17

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
3 | P a g e
1OPERATING THE K-METRON
1.1 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 left-hand POWER LED 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 press the ON/OFF switch on the face of the K-METRON unit the POWER
LED 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 DELETE button; pressing either will only interrupt the auto
power off and will neither ‘transmit’ or ‘delete’ any data.
1.2 Entering the Configuration Menu
To enter the configuration menu, with the K-METRON turned off, hold down the DELETE
button and switch the unit on. While continuing to hold down the DELETE button, the
display will read “Wait … Setup mode”. Once the display reads “M1: Cal Object” release the
DELETE button. The unit is now in the Configuration Menu. To scroll through each menu use
the DELETE button; to select use the Orange Trigger Button.
1.3 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.
Visual Display
Delete Last
Transmitted
Data
Power LED
ON/OFF
Switch
Sensor Head
Sensor Head Dock

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
4 | P a g e
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.
1.4 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.
1.5 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.
1.6 Ensure Correct Sensor Head Orientation
When measuring flat parts ensure that the sensor head is perpendicular to the surface.
When measuring external radii 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.
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.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
5 | P a g e
An internal radii will return a value for which compensation must be made.
1.7 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.
1.8 Measuring an Internal Radius with K-METRON.
It is straight forward to measure 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.
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
gap
Thickness displayed on the meter
will be the thickness of the
measured part plus the gap
between the sensor head and the
part.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
6 | P a g e
1.9 The Sensor Head Dimensions.
The sensor head is a cylinder of size 27mm diameter x 55mm length.
1.10 Measuring the Thickness.
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 that 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, a ‘TX Error’ will be displayed after holding down
and releasing the 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.
1.11 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 delete button; the display signals
confirmation. The Position Number on the PC will then be reduced by ‘1’.
1.12 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.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
7 | P a g e
The on-screen indication will now show that the Mould Index number has been
incremented.
1.13 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 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.
1.14 Choosing which Magnet Type to use.
The unit comes with two different types of magnet, a cube and a sphere. The desired range
of measurement will be the major factor which determined whether to use the cube or
spherical magnet. The 10mm x 10mm x 10mm cube magnet is best for thick walled parts.
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
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
1.15 Units of Measurement
The measurement can be made in IMPERIAL or METRIC units. To do this hold down the
DELETE button while the K-METRON is off and continue to hold it while switching the unit
on. While continuing to hold down the DELETE button, after a short delay (with Wait …
Setup mode being displayed) the K-METRON will enter the “Configuration menu” and
display “M1: Cal Object”. Release the DELETE button at this point. Pressing the DELETE
button will scroll through the menu. Pressing the DELETE button twice will display “M3:
Units”. To Select or Enter a menu the Orange Trigger button is pulled. Use the DELETE
button to scroll through METRIC/IMPERIAL/EXIT and select the desired Units by pulling the
Orange Trigger Button. The unit will now exit the configuration menu and return to
operational status.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
8 | P a g e
2THE K-METRON SOFTWARE
2.1 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.
2.2 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.
2.3 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 hardward (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)

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
9 | P a g e
To assign the COM number withing the K-METRON software:
•Run K-METRON Software
•Go to options and assign the correct COM Port.
2.4 Recording the Thickness measurements.
Hit the start button to begin receiving and recording data transmitted from the handheld K-
METRON. Received data will be presented on a line per line basis and will record Date, Time,
Mould ID, Position number and Reading.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
10 | P a g e
3SAVING THE DATA
3.1 Continuous Internal Database Recording
The thickness data is stored in the K-METRON’s core database. Unless deleted, all thickness
measurements, even over several days, are saved in a single database. This data can can be
viewed in the database tab in data and time order. A further feature to filter the Mould ID is
available to allow the user to select only the values of a particular mould.
3.2 Exporting to Excel
For more advanced analysis or for report writing the data can be exported to Excel by
clicking on the “Export Excel” button at the top of the screen:

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
11 | P a g e
The entire database will be saved out to an Excel file in the following column format:
<Date>, <Time>, <Mould ID>, <Position>, <Reading>
Example:
Since the user may not want the entire database to be exported to Excel it may be
preferable to delete all data from the database after it has been exported and saved in
Excel, thus leaving a clear database for next use.
The data can also be copied & pasted into other programs using the “Copy Details to
Clipboard” button and then by pasting accordingly. To paste into Excel, use the Text Import
Wizard and the Comma delimited import setting. Only the data that has been selected and
copied will be exported in this case and not the entire database.
3.3 Erasing Unwanted Data.
To erase a single line of unwanted data first select that line with the mouse or by scrolling
up and down with the arrow keys, and then clicking on the “Erase” button.
To erase a block of unwanted data select the first line and then while holding down the shift
key select the last line of the data (using either the mouse or the arrow keys). The click on
the Erase button to delete the entire block of data.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
12 | P a g e
4POWERING THE K-METRON
4.1 Battery Type
K-METRON is designed for use with a single Lithium PP3 9-volt battery. Using a non-lithium
variant of a PP3 9-volt battery, such as an alkaline, will significantly reduce battery life. An
equivalent rechargeable battery may also be used but this may require
4.2 Replacing the Battery in K-METRON
To replace the battery, remove the cover screw. Carefully unclip the spent battery from the
battery cover lid and unclip the battery terminals from the flying power lead. Attach the
terminals on the new battery and ensure they clip on securely. Insert the charged battery
into the clip and remount the cover. Make sure the battery cable is not trapped by the
cover.
4.3 Battery Life
It is recommended that a PP3 lithium battery is used to provide the longest battery life.
When used continually without transmitting data the battery life is in the region of 50 hours
based on transmission of data at a rate of 10 transmissions/hour the estimated battery life
would be in the region of 40 hours.
Battery Cover
Screw
Battery Cover

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
13 | P a g e
5CALIBRATING THE K-METRON
After the K-METRON is calibrated with each type of magnet the values are stored within the
K-METRON memory. There re-calibration is not necessary when switching between
magnets; instead the desired magnet is chosen in the configuration menu.
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.
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.
5.1 Entering Calibration Mode.
With the unit turned OFF hold down the DELETE button. While still holding the DELETE
button down (in one hand) turn the unit on (with the other hand). Therefore on switch on,
when the display lights up, release the ON/OFF button but continue to hold down the
DELETE button for a few seconds when “M1: Cal Object is displayed then immediately
release the DELETE button while waiting the display will read “Wait … Setup mode”. This is
an instantaneous press holding for an extended period will result in the unit turning off!
The K-METRON is now in the configuration menu. Scroll through the menu using the
DELETE button and select “M2: Calibrate” by pulling the orange trigger. The unit will
prompt for re-confirmation and this is acknowledged with the orange trigger.
5.2 Calibrating the K-METRON.
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. The magnet should be placed on the 20mm 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
down. 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.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
14 | P a g e
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 DELETE button to go back
to the previous position.
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.
5.3 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).
6THE SENSOR HEAD
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 above.
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
to ensure its continued performance is maintained. 493K offer a return carriage paid
service, calibration and inspection.
7MEASURING DIFFERENT MATERIALS
No calibration is required for use with differing 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.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
15 | P a g e
7.1 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
7.2 Measuring Non-ferrous Metal Parts.
When measuring the thickness of non-ferrous metal parts 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.
7.3 Materials that Cannot be Measured.
The unit cannot be used to measure any kind of ferrous materials, e.g. steels & irons.
8WHAT’S INCLUDED
The system comprises:
1. A portable display unit containing the measurement electronics;
2. A Lithium PP3 9volt battery;
3. Sensor Head with lead attached to the display unit;
4. 2 x spherical 10mm magnets;
5. 1 x 10mm cube magnet with retrieval cord;
6. Magnetic telescopic pick up tool;
7. 1mm - 20mm Calibration Steps;
8. Instruction Manual;
9. K-METRON Software (downloaded via link supplied);
10. 493K carry bag.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
16 | P a g e
9TECHNICAL SPECIFICATIONS
Range: 2 to 20mm (magnet dependent)
Resolution: 0.1mm
Accuracy: +/- 0.2mm or +/- 1mm depending on calibration type
Range error: Better than +/- 0.3mm
Temperature: 5°C to 35°C (41°F to 95°F)
Calibration: @ 20°C (68°F)
Minimum radius measured: (10mm Cube): 20mm
(10mm Spherical): 5mm
Power Supply: 1 x Lithium PP3 9volt battery (recommended)
1 x Alkaline PP3 9volt battery (although the K-METRON will
work with Alkaline batteries there will be a significantly
reduced battery life)
10 DISCLAIMER
Use of this instrument is at the operators’ risk and 493K Limited will not be held liable for
any claims for damage to other equipment occasioned by its use or any consequential
claims related to the instrument’s accuracy. See also limitations as to use.

K-METRON Radio User Instructions (Firmware 2.3.4; Doc v3.0.0)
17 | P a g e
11 DECLARATION OF CONFORMITY
We the manufacturer 493K Limited
23 Watch Hill Road
Ballyclare
Co. Antrim
BT39 9QW
United Kingdom
declare under our sole responsibility that the product :-
K-METRON, Model No. 2.0
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 :-
EC EMC 2004/108/EC.
Place of issue 493K Limited
23 Watch Hill Road
Ballyclare
Co. Antrim
BT39 9QW
United Kingdom
Date of issue 30 Nov 2016
Signature
Name Dr Gareth W. G. McDowell
Position Managing Director