Metcal DX-250 User manual

Metcal
DX-250 / 255
Precision Dispensers
User Guide
English, German, French, Italian and Spanish version
Copyright © Metcal
DX-250 / 255
Präzsions-Dosiergeräte
Benutzerhandbuch
DX-250 / 255
Doseurs de
précision
G
Guide de
l'utilisateur
DX-250 / 255
Dosatore di
precisione
Manuale dell’utente
DX-250 / 255
Dosificadores de
precisión
Guía del usuario
2
CONTENTS
Page Number
1. Safety ……………………………………………………………2
2. Symbol Definitions …………………………………………………3
3. Specifications ……………………………………………….…………...3
4. Features ……………………………………………………………4
5. Connecting the Unit ……………………….…….………..…………5
6. Setup Instructions …………………………………………………5
7. Troubleshooting …………………………………………………6
8. Maintenance ……………………………………………………………7
9. Spare Parts and Accessories ………………………………………7
10. Warranty ……………………………………………………………7
11. I/O Configuration and End of Cycle Switch ……………………….…...8
1SAFETY
1.1 Intended Use:
WARNING: Use of this equipment in ways other than those described in this User
Guide may result in injury to persons or damage to property. Use this equipment
only as described in this User Guide.
Metcal cannot be responsible for injuries or damages resulting from unintended
applications of its equipment. Unintended uses may result form taking the following
actions:
•Making changes to equipment that has not been recommended in the User
Guide
•Using incompatible or damaged replacement partsUsing unapproved
accessories or auxiliary equipment
1.2 Safety Precautions:
•Do not operate this unit in excess of maximum ratings/settings
•Always wear appropriate personal protective clothing or apparel
•Use only the following power adaptor models: PSA15R-240P(ZJ) or
PW118RA2403B01, PW118RA2403H01, PW118RA2403M01,
PW118RA2403G01
•Care must be taken to prevent the ingress of corrosive or flammable fluid back
into the unit. If corrosive or flammable fluids are used, an inline filter (881-
000-000), not included, must be installed on the dispenser to help prevent the
fluids from being sucked back into the unit
•The fluid being dispensed may be toxic and/or hazardous. Refer to Material
Safety Data Sheet for proper handling and safety precautions
•If a piston is not used with the barrel, an inline filter (881-000-000), not
included, and must be installed on the receiver head to help prevent fluids from

3
being sucked back into the unit. Also do not overfill the barrel and to lay the
barrel on its side
•Do not smoke or use open flame when flammable materials are being dispensed
•This equipment is for indoor use only
2SYMBOL DEFINITIONS
Symbol
Definition
Power On/Off
Cycle Mode
Timer
Vacuum
Pressure
3SPECIFICATIONS
Size
152mm X 165mm X 178mm
(6” X 6.5” X 7”)
Weight
1.2 kg (2.6lbs)
Input Voltage
24 VDC
Rated Power
10 W
Air Input
100 psi (6.9 bar) Max.
Pollution Degree
II
Installation Category
I
Indoor Use
Altitude up to 2,000m (6,562ft)
Operating Temperature
0˚C to 50˚C (32˚F to 122˚F)
Storage Temperature
-10˚C to 60˚C (14˚F to 140˚F)
Max. Relative Humidity
80% for temperature up to 31˚C (87.8˚F) Decreasing
linearly to 50% relative humility at 40˚C (104˚F)
Air Output
DX-250 = 0-100 psi (0- 6.9 bar)
DX-255 = 0-15 psi (0-1.03 bar)
Vacuum
406mm (16”) of Hg
Timer
0.020-60.000 seconds
Cycle Mode
PURGE, TIMED
Timing Repeat Tolerance
+/-0.001%
Cycle Rate
600 cycles/min
LCD
16 X 2 display segments
4
4FEATURES
Figure 1.0
Items
Description
1
Power Button
2
Mode Button
3
Counter Reset Button
4
Display
5
Air Pressure Gauge
6
Air Pressure Regulator
7
Pulsed Air Outlet
8
Vacuum Control
9
Time Control Knob
10
Receiver head air hose holder
11
Foot Switch Receptacle
12
Power Receptacle
13
I/O Connection
14
Exhaust Port
15
Air Inlet
16
Cord Lock

5
5CONNECTING THE UNIT
CAUTION: A 5-micron filter (TSD800-6), not included, must be installed with the unit to
ensure proper air filtration.
Figure 2.0
6SETUP INSTRUCTIONS
Refer to Figure 1.0
6.1 Manual Dispense Cycle Setting:
1. Turn on the unit by pressing the Power button (1)
2. Press the Mode button (2) until “PURGE” appears on the Display.
3. Turn up the air pressure by rotating the Air pressure regulator knob (6) until
the desired pressure is indicated on the Air pressure gauge (5)
4. After filling the barrel or using pre-packaged adhesive, attach syringe to
receiver head assembly. Make certain that the syringe locks into place.
5. Connect the plug end of the receiver head assembly to one of the air
dispense outlet (7)
6. If vacuum “suck back” is needed, rotate the Vacuum regulator (8) counter
clockwise until the desired vacuum pressure is obtained
7. Press and hold the Foot switch to activate dispensed cycle. (The
Purge/Manual Mode is now activated)
6.2 Automatic Dispense Cycle Setting:
1. Push the Mode button (2) to select “TIMED” mode
2. Rotate the Time control knob (9) to set desired dispense time
3. Repeat step 3 to 6 in Section 6.1
4. Depress Foot switch to activate timed dispensed cycle
Items
Description
1
To Air Source
2
Air Filter (Not included)
3
Power Adapter
4
Foot Switch
6
6.3 Cycle Counter
The cycle counter records the numbers of dispense cycle being activated. Up
to 65,535 cycles can be recorded. This number is shown at the lower right
hand corner of the LCD. Press the Counter Reset button (3) to clear the
counter.
7TROUBLESHOOTING
PROBLEM
POSSIBLE CAUSE
CORRECTION
LCD does not
light
•No power input
•Check power cord
connections
•Turn on power
System will not
actuate
•Foot switch not
plugged in or
improperly plugged
in
•Defective foot
switch
•Broken wire or loose
connection inside
unit
•Defective solenoid
•Defective PC board
•Check foot switch
connection
•Foot switch needs to be
repaired or replaced
•Unplug power cord and
disconnect air supply.
Remove cover and check
for broken wires or loose
connections
•Replace solenoid
•Replace PC board
System will not
pressurize
•Insufficient air
pressure
•Air hoses not
plugged in
•Regulator defective
•Increase air supply
pressure
•Check connection
•Replace regulator
System will not
pull vacuum
•Vacuum setting is
too low
•Defective solenoid
•Defective vacuum
venturi
•Defective vacuum
needle valve
•Increase vacuum setting
•Replace solenoid valve
•Replace venture
•Replace needle valve
Inconsistent
dispensing
•Air bubbles in
adhesive
•Dispense time is too
low
•Dispense needle
started to clog
•Reduce vacuum setting
•Increase dispensing time
•Replace needle
8MAINTENANCE

7
The dispenser is designed and built to be relatively maintenance free. To assure
trouble free operation, the following recommendations should be followed:
1. Make certain air supply is clean and dry.
2. Avoid turning barrels upside down or laying barrel so that material may
run through air line to internal components.
3. Avoid connecting the unit to excessive moisture or solvent saturation.
4. Avoid connecting air supply exceeding 100 psi (6.9 bar) for the DX-250
and 15 psi (1.03 bar) for the DX-255.
5. Use only Amyl Alcohol to clean outside surface of the main housing.
6. Use only soft cloth to clean the LCD.
9SPARE PARTS AND ACCESSORIES
For DX-3xx/2xx spare parts and accessories information, please visit the DX-
3xx/2xx User Guide webpage at http://www.metcal.com
10 LIMITED WARRANTY
Metcal warrants this product to the original purchaser for a period of one (1) year
from date of purchase to be free from material and workmanship defects but not
normal wear-and-tear, abuse and faulty installation. Defective product or
subassembly and components under warranty will be repaired or replaced
(at Metcal's option) free of charge. Customer with defective product under warranty
must contact the nearest Metcal office or distributor to secure a return authorization
prior to shipping the product to the assigned Metcal authorized service center. For
nearest Metcal office or distributor contact information, please visit
www.metcal.com. Metcal reserves the right to make engineering product changes
without notice.
11 I/O Configuration and End of Cycle Switch
8
During a dispense cycle, an open collector circuit closes and remains closed while
the valve is dispensing.Pin 3 and 4 can be as feedback signal to synchronize with
other devices. Power from an external source is allowed to pass through the circuit
to operate a 5 to 24 VDC load. Power consumption must not exceed 250 mA. The
load could be a relay, solenoid, counter, LED, or any device that will operate within
a 5 to 24 VDC range and a maximum of 250 mA.
Note:
During the dispense cycle, pin 3 will be grounded. Please make sure the
external device (your machine that controls the dispenser/controller) has the
same ground as the DX-250/255 controller.
Pin 7, 8, and 9 = Available
Chasis Ground
To initiate a dispense cycle with
contact closure
When low pressure alarm is triggered, Pin 4 is grounded (-)
When low pressure alarm is turned off,
Pin 4 is not connected (opened)
End of Cycle Feedback
During dispensing cycle, Pin 3 is grounded (-)
End of dispensing cycle,
Pin 3 is not connected (opened)
To initiate a dispense cycle with voltage
Pin 1 (+)
Pin 2 (-)
Pin 3
Pin 4
Pin 5
Pin 6
Pin 5