TECHCON SYSTEMS TS5440 User manual

Techcon Systems
TS5440
Microshot Needle Valve
User Guide

2
CONTENTS
Pagenumber
1. Specifications ………………………………………………………………………………3
2. Unpacking and Inspection ………………………………………………………………4
3. Description ………………………………………………………………………………4
4. Theory of Operation ………………………………………………………………………4
5. Setup Instructions ………………………………………………………………………5
6. Typical System Setup ………………………………………………………………………6
7. Troubleshooting ………………………………………………………………………7
8. Maintenance and Cleaning ………………………………………………………………8
9. Spare Parts and Accessories ………………………………………………………………9
10. Warranty ………………………………………………………………………………11

3
1. SPECIFICATIONS
Size: 5.0” (127mm) long; 1.1”(28.5mm) diameter
Weight: 0.5 lb (227g)
Fluid inlet port: 1/8” NPT female
Fluid outlet port: Male luer lock
Air inlet port: 10-32 UNF
Mounting port: 10-32 UNF
Maximum fluid pressure: 100 psi (6.9 bars)
Minimum air pressure required: 70 psi (4.8 bars)
Wetted parts: 303 stainless steel, Teflon®
Operating frequency: Exceeds 400 cycles/min.
Flow rate at 100 psi (water): 900 ml/min.
Material viscosity range: Up to100,000 Cps.
Dimensions are in inches [mm]
Figure 1.0
4.44
10-32 UNF
MOUNTING PORT
[112.78]
4.75-5.00
[120.65-127.00]
10-32 UNF
AIR INLET PORT
Ø1.00[25.4]
TS5440
FAR SIDE FLUID INLET PORT
1/8 NPT

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2. UNPACKING AND INSPECTION
Carefully unpack the valve and examine the items contained in the carton.
These will include:
•Valve Assembly
•Valve bracket
•Sample Needle Kit and fluid line
•Valve Air Hose
•User guide
3. DESCRIPTION
The TS5440 Microshot Needle valve is designed to dispense low to medium viscosity material with very
precise deposits over a wide range of shot and bead sizes down to a fraction of a micro liter. An internal
spring return makes the valve fully adaptable for use with Techcon Systems time/pressure controllers. A
short opening stroke provides extremely fast, positive shut-off. An external stroke control adjustment
makes it easy for the operator to fine tune shot sizes. The TS5440’s compact design allows for
mounting flexibility and easy integration into automated applications.
4. THEORY OF OPERATION
The TS5440 is a normally closed, adjustable opening, needle and seat valve. Inlet air pressure through
port (1) retracts the needle assembly (2) from the seat inside the dispensing tip (3) allowing material to
flow from the valve material inlet (4) to the dispensing tip (5). Relieving the input air pressure allows
the spring (6) to return the needle back to its position to close the material path.
Figure 2.0
OPEN POSITION CLOSED POSITION
1
4
2
6
5
3

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5. SETUP INSTRUCTIONS
Refer to Figure 3.0
NOTE: This installation uses luer lock adapters shipped with the valve. Any approved material
line with 1/8” NPT connections will work.
1. If desired, mount the valve to the bracket included (1).
2. Connect fluid feed line to valve inlet port (2).
3. Insert the open end of the air hose to air inlet fitting (3) then connect the other end to an
approved valve controller.
4. Set the fluid reservoir pressure. Do not exceed 100 psi (6.9 bars)
5. Install desired dispense tip (4) to the valve outlet and secure it with the retaining ring (5)
NOTE: Recommended dispense tip size is 22-gauge or smaller. Use larger than 22-gauge
dispense tip may results in valve leakage.
6. Make sure all connections are tight
7. Place container under the valve outlet and activate the valve until the fluid flows steady.
The amount of fluid that flows through the valve is determined by:
•Flow control adjustment - Turn end cap counterclockwise to increase material flow rate.
•Length of actuation, set at controller (Valve open time).
•Fluid reservoir pressure
•Dispensing tip size
Figure 3.0
3
2
4
5
1

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6. TYPICAL SYSTEM SETUP
TECHCON SYSTEMS TS5130
CONTROLLER OR EQUIVALENT FLUID FEED SYSTEM
TS5440
NEEDLE VALVE
PLANT AIR MUST BE PROPERLY
FILTERED AND DRY. IF NOT, SPECIFY
A 5-MICRON FILTER REGULATOR.
MATERIAL
CONSTANT AIR
PULSED AIR
TS5440
XXXX
Figure 4.0

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7. TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTION
Fluid pressure too low Increase fluid pressure
Operating pressure too low Increase air pressure to 70 psi (4.8 bars)
Dispense tip clogged or damaged Replaced tip
Fluid cured in valve chamber Clean valve thoroughly
No fluid flow
The stroke adjustment closed Open stroke adjustment counterclockwise
Fluid pressure fluctuating Make sure fluid pressure is constant
Valve operating pressure is too
low Increased valve pressure to 70 psi (4.8 bars)
Valve open time is not consistent Check to make sure the valve controller
is providing a consistent output
Inconsistent
fluid flow
Air trapped in fluid housing Purge valve
Fluid drools after the valve
closes, eventually stopping Air trapped in fluid housing Purge valve
Fluid leaks at needle hub Defective dispense needle Replace needle. Make sure to use TE
series needle only

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8. MAINTENANCE AND CLEANING:
Tool required: 7/64” hex wrench; 7/16” open-end wrench; Snap ring pliers, O-ring tool.
Normally, purging the valve with appropriate flush material or solvent after use is sufficient for
cleaning. However some material may cause a buildup in the valve chamber, in this case periodic and
thorough cleaning will be required.
NOTE:
•To replace seals, please order seal kit part number: 5440-SEALKIT
•To repair valve, please order valve kit part number: 5440-VALVEKIT
CAUTION: Make sure the fluid pressure is released before disassemble the valve.
Refer to figure 5.0
1) Release fluid pressure.
2) Disconnect fluid line.
3) Disconnect valve air hose.
4) Unscrew retaining cap (1) and remove the dispense needle.
5) Remove the three mounting screw (17).
6) Pull the fluid housing (4) away from the air cylinder (11).
7) Remove the luer adapter assembly (2) from the fluid housing (4).
8) Clean and inspect the needle assembly (8), luer adapter assembly (2) for wear and
damage. Replace parts as necessary.
9) Replace O-ring (7) if necessary. Make sure to lubricate new O-ring with approved
lubricant.
10)Reinstall the luer adapter assembly (2) to the fluid housing (4).
11)Align the fluid housing (4) to the air cylinder (11) and reinstall the three mounting
screws. (Alternately tighten the screws a little at a time until they are secure.
13 14
3465789101112 1 2
1615 17
TS5440
XXXX
Figure 5.0

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9. SPARE PARTS AND ACCESSORIES
9.1Spare Parts: The seal replacement kit, part number = 5440-SEALKIT, includes:
FLUID INLET FITTING
O-RING (5)
O-RING (8)
MYLAR WASHER (16)
O-RING (10)
NYLON WASHER (9)
CUP SEAL (27)
O-RING (11)
5440-SEALKIT
REPAIR KIT, NEEDLE VALVE
The valve repair kit, part number = 5440-VALVEKIT, includes:
5440-VALVEKIT
REPAIR KIT, NEEDLE VALVE
FLUID INLET FITTING
LUER ADAPTER (2)
RETAINING RING (10)
NEEDLE ASSEMBLY (4)
RETAINING RING (6)
SEALKIT
MOUNTING SCREWS (17)
Figure 6.0

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9.2 Standard Accessories:
9.3 Optional Accessories:
The flowing three components are needed to make a bench mounting stand:
PART NUMBER DESCRIPTION
918-033-000 Production master stand
918-000-012 Rod Clamp
5620-000-008 Mounting rod
PART NUMBER DESCRIPTION
918-000-048 Bracket
9000-000-112 Sample needles kit
TSD126-360BK Black fluid line
TE SERIES NEEDLE
PART NUMBER Gauge Hub Color ID(in)
TE722050PK 22 Blue .016
TE723050PK 23 Orange .013
TE725050PK 25 Red .010
TE727050PK 27 Clear .008
TE730050PK 30 Lavender .006
TE732025PK 32 Yellow .004

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10. LIMITED WARRANTY
Manufacturer warrants this product to the original purchaser for a period of one (1) year from date of
purchase to be free from defects in material and workmanship, but not against damages by misuse,
negligence, accident, faulty installations and instructions. Manufacturer will repair or replace (at
factory’s option), free of charge, any component of the equipment thus found to be defective, on return
of the component, “PREPAID” to the factory during the warranty period. In no event shall any liability
or obligation of the Manufacturer arising from this warranty exceed the purchase price of the equipment.
This warranty is only valid if the defective product is returned as a complete assembly without physical
damage. The Manufacturer’s liability, as stated herein, cannot be altered or enlarged except by a written
statement signed by an officer of the company. In no event shall the Manufacturer be liable for
consequential or incidental damages. A return authorization is required from Techcon Systems prior to
shipping a defective unit to the factory.
Manufacturer reserves the right to make engineering product modifications without notice.
Send warranty returns to:
OK International
Garden Grove Division
12151 Monarch Street
Garden Grove, Ca 92841
Teflon is a registered trademark of E.I. DuPont. T1000168-B