TECHCON SYSTEMS DX-500R User manual

TECHCON SYSTEMS
DX-500R
MULTI-PURPOSE
DIGITAL CONTROLLER
User Guide
For English, German, French, Italian, Spanish
Copyright © OK International
TECHCON SYSTEMS
DX-500R
DIGITALES
MEHRZWECK-
KONTROLLIERGERÄT
Benutzerhandbuch
TECHCON SYSTEMS
DX-500R
CONTRÔLEUR
NUMÉRIQUE
POLYVALENT
Guide d’utilisation
TECHCON SYSTEMS
DX-500R
CENTRALINA DI
CONTROLLO
DIGITALE
MULTIUSO
Manuale d’uso
TECHCON SYSTEMS
DX-500R
CONTROLADOR
DIGITAL
MULTIPROPÓSITO
Guía del usuario
2
CONTENTS
Page Number
1. Safety ………………………………………………………………… 2
2. Symbol Definitions ……………………………………………….. 3
3. Specifications ……………………………………………….……….. 3
4. Features …………………………………………………………….. 4
5. Setup Instructions
5.1 To Control Pneumatic Valve ………………………………….. 4
5.2 To Control Spray Valve ……………………………………….. 6
5.3 To Control TS5000 Rotary Pump …………………………….. 8
5.4 To Control TS5000 Rotary Pump with Encoder Motor……….. 10
5.5 Cycle Counter …………………………………………………. 10
5.6 To Change Pressure Unit Display……………………………… 11
5.7 Low Pressure Setting ………………………………………….. 11
6. Troubleshooting ……………………………………………………. 11
7. Maintenance ………………………………………………………… 12
8. Spare Parts and Accessories ……………………………………….. 12
9. Warranty …………………………………………………………….. 12
10. I/O Configuration and End of Cycle Switch ………………………. 12
SAFETY
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.
OK International 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 parts
•Using 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)
•The fluid being dispensed may be toxic and/or hazardous. Refer to Material
Safety Data Sheet for proper handling and safety precautions
•Do not smoke or use open flame when flammable materials are being dispensed
•This equipment is for indoor use only

3
2. SYMBOL DEFINITIONS
Symbol Definition
Power On/Off
Cycle Mode
Timer
3. SPECIFICATIONS
Size 254mm x 191mm x 102mm
(10” X 7.5” X 4.0”)
Weight 2.6 kg (5.8 lbs)
Input Voltage 24VDC
Output Voltage Range 0-24 VDC
Rated Power 15W
Air Input 100 psi (6.9 bars) Max.
Air Output 0-100 Psi (6.9 bar)
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)
Timer 0.008-60.000 seconds
Cycle Mode Timed, Interrupt, Purge
Timing Repeat Tolerance +/- 0.001%
Cycle Rate 900 cycles/min
LCD 20 X 4 display segments
4
4. FEATURES
Figure 1.0
5. SETUP INSTRUCTIONS
5.1 TO CONTROL PNEUMATIC VALVE
CAUTION: A 5-micron filter (TSD800-6) must be installed with the unit to ensure proper
air filtration.
Figure 2.0
Items Description Items Description
1 Power Button 8 Motor Drive Outlet
2 Mode Button 9 Foot Switch Receptacle
3 Set up/Save Button 10 Power Receptacle
4 Display 11 I/O Connection
5 Air Outlet (Unregulated) 12 Air Inlet
6 Air Pressure Regulator 13 Accessory Air Outlet
7 Air Outlet (Regulated)
TO AIR SOURCE
10
8
9
5
7
123
6
4

5
5.1.1 Connecting The Unit: (Refer to Figure 2.0)
1. Connect the power cord, foot switch and air hose to the back of the unit.
Make sure the air inlet pressure is 70 psi (4.8 bar) or higher.
2. Press the Power button (1) to turn on the unit.
3. Connect Valve air hose to Port A.
NOTE: Pressure in Port A can be monitored by the low pressure setting
but is not regulated by the air regulator in the unit. It delivers the same
pressure as the inlet pressure. On the other hand, pressure in Port B is
regulated but it is not linked to the low pressure setting.
4. Press the Mode (2) and Set button (3) simultaneously until “VALVE”
appears on the top right hand corner of the Display as shown in Figure 3.0
Figure 3.0
5.1.2 Program selection
1. Press the Set button (3) to highlight the program number selection.
2. Press the (+) or (-) buttons to select desired program.
3. Press the Set button (3) to exit.
5.1.3 Manual/Purge Dispense Cycle Setting:
1. Press the Mode button (2) until “PURGE” appears on the Display.
2. Press and hold the Foot Switch to activate dispense cycle.
5.1.4 Automatic Dispense Cycle Setting:
1. Push the Mode button (2) to select “TIMED MODE” or “INTERRUPT”.
2. Press and hold the Set button (3) for two seconds to enter set up screen.
The last digit of the dispense time will be highlighted.
3. Press the Set button (3) to move the cursor to the next position.
4. Press the (+) or (-) button to set the time
5. Press and hold the Set button (3) for two seconds to save the data.
6. If the unit is in “TIMED MODE” mode, press and release the Foot Switch
to activate the timed dispense cycle.
7. If the unit is in “INTERRUPT”, press and hold the Foot Switch until the
dispense cycle is completed. The dispense cycle can be disrupted if the
Foot Switch is released and resumed when the Foot Switch is depressed
again.
Items Description Items Description
1 Power Button 6 Air pressure regulator knob
2 Mode Button 7 Footswitch
3 Set Button 8 Pneumatic Valve (not included)
4 LCD Display 9 Fluid Reservoir (not included)
5 Power Adapter 10 Air Filter
Cycle Mode
Dispense
Time
Program #
Valve Pressure Port
Pressure Port B
Regulated
Counter
Control Type
1
0.100S A: 70 PSI
B: 70 PSI
P1 TIMED MODE VALVE
6
5.1.5 Teach Mode Setting
In the teach mode, the dispense time will be accumulated as long as the
foot switch is depressed. This is helpful in determining required dispense
time when dispense output is unknown.
1. Push the Mode button (2) to select “INTERRUPT”.
2. Press and hold the Set button (3) to enter the teach mode. The time will
show “0.000” in the LCD.
3. Press and hold down Foot switch. Dispense time will be accumulated.
4. Release Foot Switch when desired amount of fluid is dispensed.
5. Press and hold the Set button (3) for two seconds to save the data.
6. Press the Mode button (2) to switch the “TIMED MODE” mode.
7. The dispenser is now set to repeat this timed cycle.
5.2 TO CONTROL SPRAY VALVE
CAUTION: A 5-micron filter (TSD800-6) must be installed with the unit to ensure proper
air filtration.
Figure 4.0
Items Description Items Description
1 Power Button 6 Air pressure regulator knob
2 Mode Button 7 Foot Switch
3 Set Button 8 Pneumatic Valve (not included)
4 LCD Display 9 Fluid Reservoir (not included)
5 Power Adapter 10 Air Filter
TO AIR SOURCE
10
5
8
9
7
4
3
21
6

7
5.2.1 Connecting The Unit: (Refer to Figure 4.0)
1. Connect the power cord, foot switch and air hose to the back of the unit.
Make sure the air inlet pressure is 70 psi (4.8 bars) or higher.
2. Press the Power button (1) to turn on the unit.
3. Connect Valve air hose to Port A and Atomize air hose to Port B.
4. Press the Mode (2) and Set up button (3) simultaneously until “SPRAY”
appears on the top right hand corner of the Display.
Figure 5.0
5.2.2 Program selection
Follow step 1 to 4 in Section 5.1.2
5.2.3 Manual/Purge Dispense Cycle Setting:
Note: A complete spray cycle consists of: Pre-Spray, Spray and Post-Spray
1. Press the Mode button (2) until “PURGE” appears on the Display.
2. Press and hold the Set button (3) for two seconds to enter set up screen.
The last digit of the Pre-Spray time (PRE) will be highlighted.
3. Press the (+) or (-) button to set the time.
4. Press and hold the Set button (3) for two seconds to move the cursor to the
Post-Spray time (POST).
5. Press the Set button (3) to move the cursor to the next position.
6. Press the (+) or (-) button to set the time.
7. Press and hold the Set button (3) for two seconds to save the data.
8. Turn up the Atomized air pressure by rotating the Air pressure regulator
knob (6) until the desired pressure is indicated on the Display.
Note: Pressure in Port A can be monitored by the low pressure setting
but is not regulated by the air regulator in the unit. It delivers the same
pressure as the inlet pressure. On the other hand, pressure in Port B is
regulated but it is not linked to the low pressure setting.
9. Press and hold the Foot Switch to activate spray cycle.
5.2.4 Automatic Dispense Cycle Setting:
1.Push the Mode button (2) to select “TIMED MODE” or “INTERRUPT”
mode.
2.Press and hold the Set button (3) for two seconds to enter set up screen.
The last digit of the Spray time/Dispense time (DISP) will be highlighted.
3.Press the (+) or (-) button to set the time
4.Press and hold the Set button (3) for two seconds to move the cursor to the
Pre-Spray time (PRE) and repeat this step to go to Post-Spray time (POST).
5.Press the Set button (3) to move the cursor to the next position.
6.Press the (+) or (-) button to set the time
7.Press and hold the Set button (3) for two seconds to save the data.
8.If the unit is in “TIMED MODE” mode, press and release the Foot Switch
to activate the timed spray cycle.
Cycle Mode
Pre-Spray
Time
Spray Time
Program #
Atomized Pressure Port B
Regulated
Valve Pressure Port A
Counter
Control Type
1
0.100S A: 70 PSI
0.050S B: 40 PSI
P1 TIMED MODE SPRAY
8
9.If the unit is in “INTERRUPT” mode, press and hold the Foot Switch until
the dispense cycle is completed. The dispense cycle can be disrupted if the
Foot Switch is released and resumed when the Foot Switch is depressed
again.
5.3 TO CONTROL STANDARD TS5000 ROTARY PUMP
CAUTION: A 5-micron filter (TSD800-6) must be installed with the unit to ensure proper air
filtration
Figure 6.0
5.3.1 Connecting The Unit: (Refer to Figure 6.0 for detail)
1. Connect the power cord, foot switch and air hose to the back of the unit.
2. Connect Motor Cable to Port C.
3. Connect syringe air hose to Port B (regulated, pulsed air signal)
If constant air pressure is required, connect syringe air hose to accessory
air outlet port located in the rear of the unit, port #13 in figure 1.0
4. Press the Power button (1) to turn on the unit.
5. Press the Mode (2) and Set up button (3) simultaneously until “PUMP”
appears on the top right hand corner of the Display.
Items Description Items Description
1 Power Button 6 Air pressure regulator knob
2 Mode Button 7 Foot Switch
3 Set Button 8 TS5000 Rotary Pump (not included)
4 LCD Display 9 Air Filter
5 Power Adapter 10 Material reservoir (Not included)
Figure 6.0
TO AIR SOURCE
58
10
7
321
64
9

9
Figure 7.0
5.3.2 Program selection:
Follow step 1 to 4 in Section 5.1.2
5.3.3 Manual/Purge Dispense Cycle Setting:
1. Turn up the air pressure by rotating the Air pressure regulator knob (6)
until the desired pressure is indicated on Display.
2. Press the Mode button (2) until “PURGE” appears on the Display.
3. Press and hold the Foot Switch to activate Manual cycle.
Follow instructions below to set motor reverse time and output voltage:
4. Press and hold the Set button (3) for two seconds to enter set up screen.
The motor reverse time will be highlighted.
5. Press the (+) or (-) button to set the motor reverse time.
6. Press and hold the Set button (3) for two seconds to move the cursor to the
output voltage.
7. Press the (+) or (-) button to change the voltage value.
8. Press and hold the Set button (3) for two seconds to save the data.
9. Press and hold the Foot Switch to activate Manual cycle.
5.3.4 Automatic Dispense Cycle Setting:
1. Push the Mode button (2) to select “TIMED MODE” or “INTERRUPT”
mode.
2. Press and hold the Set button (3) for two seconds to enter set up screen.
The dispense time (DISP) will be highlighted.
3. Press the (+) or (-) button to set the time.
4. Press and hold the Set button (3) for two seconds to move the cursor to the
reverse time.
5. Press the (+) or (-) button to set reverse time.
6. Press the Set button (3) to move the cursor to the next position.
7. Press and hold the Set button (3) for two seconds to move the cursor to the
output voltage.
8. Press the (+) or (-) button to change the voltage value.
9. Press and hold the Set button (3) for two seconds to save the data.
10. If the unit is in “TIMED MODE” mode, press and release the Foot Switch
to activate the timed dispense cycle.
11. If the unit is in “INTERRUPT” mode, press and hold the Foot Switch until
the dispense cycle is completed. The dispense cycle can be disrupted if
the Foot Switch is released and resumed when the Foot Switch is
depressed again.
20.000V 1
P1 TIMED MODE PUMP
Cycle Mode
Input Voltage
Reverse Time
Dispense Time
Program #
Pressure Port B
Regulated
Counter
Control Type
0.050S B: 15 PSI
0.100S A: 15 PSI Pressure Port A (not use)
10
5.4 TO CONTROL ROTARY PUMP WITH ENCODER MOTOR
Procedures to control the Rotary Pump with encoder motor are very similar to
procedures to control the standard Rotary Pump. The encoder count values is
ranging from 1 to 60,000 counts.
5.4.1 Connecting The Unit: Refer to Figure 6.0 for details
1. Connect the power cord, foot switch and air hose to the back of the unit.
2. Connect Encoder Motor Cable to Port C.
Note: Encoder motor cable, DX-ECABLE, must be purchased
separately.
3. Connect syringe air hose to Port B (regulated, pulsed air signal).
If constant air pressure is required, connect syringe air hose to accessory
air outlet port located in the rear of the unit, port #13 in figure 1.0
4. Press the Power button (1) to turn on the unit.
5. Press the Mode (2) and Set up button (3) simultaneously until “PUMP-E”
appears on the top right hand corner of the Display.
Figure 8.0
5.4.2 Program Selection: Follow steps in Section 5.3.2
5.4.3 Manual/Purge Dispense Cycle: Follow steps in Section 5.3.3
5.4.4 Automatic Dispense Cycle Setting: Follow steps in Section 5.3.4
5.5 CYCLE COUNTER (Refer to Figure 9.0)
The cycle counter records the numbers of automatic dispense cycle being
activated. Up to 60,000 cycles can be recorded. To reset the counter, follow
steps below:
1. Press and hold Set button (3) for two seconds to enter setup screen.
2. Press and hold both Set button (3) and Mode button (2) simultaneously to
clear the counter.
3. Press and hold Set button (3) for two seconds to exit setup screen.
Figure 9.0
1P 15 PSI
P1 TIMED MODE PUMP-E
20.000V 1
Control Type
Encoder Count
Reverse
Encoder Count
Input Voltage
Program # Cycle Mode
Pressure Port B
Regulated
Counter
10000P 15 PSI Pressure Port A (not use)

11
5.6 TO CHANGE PRESSURE UNIT DISPLAY (Refer to Figure 9.0)
The default pressure unit display is “psi”. To change pressure unit display to
“bar” follow steps below:
1. Press and hold Set button (3) for two seconds to enter setup screen.
2. Press both (+) and (-) button simultaneously two times. The unit “psi” will
be flashing.
3. Press both Set button (3) and (+) button simultaneously to change unit
display to “bar”. Repeat this step to change unit display back to “psi”
4. Press and hold Set button (3) for two seconds to exit setup screen.
5.7 LOW PRESSURE SETTING (Refer to Figure 9.0)
The low-pressure setting is pre-set at the factory to 70 Psi (4.8 bars). When the
supplied pressure drops below 70 Psi (4.8 bars) the unit will not function. To
change the low pressure set point, follow steps below:
1. Set the dispense cycle in “TIMED MODE” mode.
2. Press and hold the Set button (3) for two seconds to enter the setup screen.
3. Press (+) and (-) button simultaneously, the low pressure set point will appear
on display as shown on figure 6.0.
4. Press the Set button (3) and (+) button simultaneously to increase the set point.
5. Press the Set button (3) and (-) button simultaneously to decrease the set point.
6. Press and hold the Set button (3) for two seconds to save the data.
Figure 10.0
6. TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTION
LCD does not
light •No power input
•Check power cord
connections
•Turn on power
System will not
actuate •Supplied pressure
dropped below set
pressure
•Foot switch not plugged
in or improperly
plugged in
•Defective foot switch
•Broken wire or loose
connection inside unit
•Defective solenoid
•Defective PC board
•Increase supplied
pressure
•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
DISP: 0.100 70 psi Low pressure
set point
P1 TIMED MODE VALVE
12
System will not
pressurize •Insufficient air pressure
•Air hoses not plugged
in
•Regulator defective
•Increase air supply
pressure
•Check connection
•Replace regulator
No Motor
Response •Foot switch connection
is loose
•Motor cable connection
is loose
•Input Voltage is too
low
•Dispense time is too
low
•Check Foot switch
connection
•Check Motor cable
connection
•Increase input voltage
•Increase dispense time
Inconsistent
dispensing •Air bubbles in adhesive
•Dispense time is too
low
•Dispense needle started
to clog
•De-air material
•Increase dispensing time
•Replace needle
7. MAINTENANCE
The dispenser is designed and built to be relatively maintenance free. To assure
trouble free operation, please follow below steps:
1. Make certain air supply is clean and dry.
2. Avoid connecting the unit to excessive moisture or solvent saturation.
3. Avoid connecting air supply exceeding 100 psi (6.9 bars).
4. Use only Amyl Alcohol to clean outside surface of the main housing.
5. Use only soft cloth to clean the LCD.
8. SPARE PARTS AND ACCESSORIES
For DX-500R spare parts and accessories information
9. LIMITED WARRANTY
OK International warrants this product to the original purchaser for a period of two (2)
years 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 OK
International's option) free of charge. Customer with defective product under warranty
must contact the nearest OK International office or distributor to secure a return
authorization prior to shipping the product to the assigned OK International authorized
service center. For nearest OK International office or distributor contact information,
please visit www.okinternational.com. OK International reserves the right to make
engineering product changes without notice.
10. I/O CONFIGURATION AND END OF CYCLE FEEDBACK
For DX500R I/O Configuration and End of Cycle Switch information