TECHCON SYSTEMS TS550R User manual

TS550R SMART CONTROLLER
FOR
PNEUMATIC VALVES
User Guide
Copyright © OK International

2
CONTENTS
Page Number
1. Safety ………………………………………………………………… 3
2. Symbol Definitions ……………………………………………….. 4
3. Specifications ……………………………………………….……….. 5
4. Features …………………………………………………………….. 5
5. To Controll Pneumatic Valve…………………………………............ 6
5.1 Connecting the unit……..……………………………………… 6
5.1.1 Login …………………………………………………… 7
5.1.2 Pressure Calibration.…………………………………… . 7
5.2 Dispensing ………………..……………………………........ 9
5.2.1 Pressure Adjustment ………………………………….. 9
5.2.2 To Change Pressure Unit Display …………..………... 9
5.2.3 Manual/Purge Dispense Cycle ………………………….. 10
5.2.4 Automatic Dispense Cycle …………………………… 10
5.2.5 Teach Mode Setting …………………………………….. 11
5.2.6 To run in Continuous Mode …………………………….. 11
5.3 Low Pressure Alarm Setting ……………………………….. 13
5.4 Stored Program in Memory Cell …………………………….. 14
5.4.1 To store dispense parameters …………………………… 14
5.4.2 To run in Single Sequence mode ……………………….. 14
5.4.3 To run in Continous Sequence mode …………………… 16
5.5 Cycle Counter ………………………………………………... 16
5.6 To Change Password …………….…………………………… 17
5.7 To Connect to Wi-Fi network ………………………………… 19
6. Internet of Thing (IoT)………………………………………………. 21
7. Software Upgrade …………………………………………………… 27
8. Troubleshooting …………………………………………………….. 29
9. Maintenance ………………………………………………………….30
10. Warranty ……………………………………………………………... 30
11. I/O Configuration and End of Cycle Switch ………………………. 31
31
11. I/O CONFIGURATION AND END OF CYCLE FEEDBACK
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 controller.
7508-0250_A
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

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9. 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 display screen
10. LIMITED WARRANTY
OK International warrants this product to the original purchaser for a period of 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.techconsystems.com. OK International
reserves the right to make engineering product changes without notice.
All returns must be issued with a Returns Authorization number, prior to return.
Send warranty returns to:
Americas
OK International
10800 Valley View Street
Cypress, CA 90630
[phone]
Europe
OK International
Eagle Close Chandler’s Ford Ind Est
Eastleigh, Hampshire
SO53 4NF
United Kingdom
[phone]
Asia
Dover (Shenzhen) Industrial
Equipment Manufacturing Co., LTD.
4th Floor East, Electronic Building
Yanxiang Industrial Zone, High Tech Road
Guangmin New District
Shenzhen, P.R.C
[phone]
www.techconsystems.com
3
1. 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
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

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2. SYMBOL DEFINITIONS
Symbol Description Symbol Description
Run (Activate) Setup
Input Pressure Counter reset
Pressure Port A&B Mac address
Timed mode Accept change
Interrupt mode Pressure calibration
Teach mode Save
Purge mode
Reset time in Teach
mode
Dispense IP address
Login/Logout Cancel
Run Method Sequence Mode
Continous Mode
Sequence Continous
Mode
E-Stop Change Password
Remote Server On line
Off Line
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8. TROUBLESHOOTING
PROBLEM POSSIBLE CAUSE CORRECTION
Display does
not light up No power inputs
Check power cord
connections
Turn on power
System will not
actuate Supplied pressure
dropped below “Low
Pressure” setting
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
System will not
pressurize Insufficient air pressure
Air hoses not plugged
in

Re
g
ulator defective
Increase air supply
pressure
Check connection

Re
p
lace re
g
ulato
r
Inconsistent
dispense Air bubbles in material
Dispense time is too
low
Needle clogge
d
De-air material
Increase dispense time
Replace needle

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6. Wait until the system completes the software update from the USB drive
and the first touch-screen calibration is displayed
7. Remove the USB drive from the USB port before proceeding to the next
step
8. Follow the instructions on the display to calibrate the touch screen by
touching the crosshair at five different points. Note: In order to
accurately calibrate the touch screen, it’s recommended that the stylus
pen is used
9. Wait until the system completes the rebooting sequence and the home
screen is displayed
10. Repeat sections 5.1.1 and 5.1.2 to re-calibrate the air pressure
5
TOUCH
SCREEN
AIR OUTPUT B
AIR OUTPUT A WIFI ANTENNA POWER
SWITCH AIR INLET AIR OUTLET UNREGULATED
FOOT
SWITCH
PORT POWER
INLET
IO PORT
INTERNET
PORT
USB PORT GROUNDING
TS560R
3. SPECIFICATIONS
4. FEATURES
Figure 1.0
Size 290mm x 212mm x 98mm
(
11.4” X 8.3” X 3.9”
)
Weight 3.1 kg (6.8lbs)
Input Voltage 24VDC
Output Voltage Range 0-24 VDC
Rated Power 15W
Air Input 100 psi (6.9 bars) Max.
Air Output 0-99.9 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
linearl
y
to 50% relative humidit
y
at 40˚C
(
104˚F
)
Timer 0.008-99.99 seconds
Cycle Mode Timed, Interrupt, Teach, Purge
Timing Repeat Tolerance +/- 0.001%
Cycle Rate 900 cycles/min
Display Touch Screen, Resitive
Meets or exceed CE, TUV and NRTL

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TO AIR SOURCE
1
5
2
3
6
4
TS570R
5. 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
5.1 Connecting the Unit: (Refer to Figure 1.0 and 2.0)
1. Connect the power cord, foot switch to the back of the unit.
2. Connect Valve air hose to either Port A or Port B
3. Press the Power switch to turn on the unit.
Items Description
1 Air Filter
2 Valve (not included)
3 Pressure Pot (not included)
4 Display
5 Power Adapter
6 Foot Switch
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Proceed to make changes
Click “OK” button to save
The new parameters will be displayed on the controller
7. SOFTWARE UPGRADE
Note: For future software upgrade, follow the instructions below.
1. Download the latest software version from Techcon website and copy it to
a blank USB thumb drive. Note: Do not put the software file inside a
folder
2. Make sure that the unit is turned off
3. Insert the USB drive to the USB port located in the back of the unit
4. Turn on the unit
5. Wait while the system is loading the new software. This process can take
a few minutes
“Edit” icon

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6.2 Making Parameters Adjustment from the websever
Go back to the webserver site and click on the “Controllers” menu.
Click on the active controller link
The controller screen will be displayed in the webserver as shown below.
The controller parameters such as pressure and dispense time can be adjusted
from the webserver.
Click on the “Edit” icon
The parameter screen will appear as shown below:
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5.1.1 Login
1. Touch the Login icon to enter the login screen
2. Enter “0000” in Password window
3. Touch the Check Mark icon to save and exit
5.1.2 Pressure Calibration
Note: Pressure calibration must be performed when the unit is activated for
the first time.

8
4. Touch the Setup icon to enter the setup screen
5. Touch the Calibration icon to enter the calibration screen
Note: Make sure the air pressure line is not connected to the unit at this time.
6. Touch the “0” icon to set the pressure to 0
7. Now connect the supplied air pressure line to the back of the unit and turn
up input air pressure to 100 psi
8. Touch the “100” icon to set the pressure to 100
Note: The digital values shown at “0” and “100” icons are for reference only.
The actual calibrated values will be different.
9. Touch the Reboot icon to save the settings and reboot the system
10. Wait until the system completes the rebooting sequence and the home
screen is displayed
The unit is now calibrated and ready to operate
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18. Go to the setup screen of the controller and touch the “Remote Server”
icon
19. Enter the Server IPv4 address recorded in step #11 into Remote IP address box
20. Touch the Check Mark icon to save
21. The controller is now connected to the webserver site.

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13. Go to any computer and open any web browser
14. Type in: http://localhost:8090/ then press the enter button
You are now in the webserver site. The below screen will be displayed:
15. Click the “Login” button
16. Enter “admin” in the Login box
17. Enter “1001” in the Password box
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5.2 DISPENSING
5.2.1 Pressure Adjustment
Note: Pressure in Port A and Port B delivers the same output pressure.
This pressure is to activate the valve. Make sure the supplied pressure is set
at least 70 psi (4.8 bar)
1. Touch the “Pressure A.B” icon to enter the pressure setup screen
2. Touch the Up and Down arrows to set valve activation pressure (70 psi
minimum)
3. Touch the Check Mark icon to save and exit
5.2.2 To Change Pressure Unit Display
Note: The default pressure unit is PSI. To change pressure unit to BAR,
follow the instructions below.
1. Touch the Setup icon to enter the setup screen

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2. Press the “BAR” icon to change pressure unit to BAR
3. Touch the X icon to save and exit
5.2.3 Manual/Purge Dispense Cycle Setting:
1. Touch the Purge icon to select the purge cycle.
The Purge icon will turn to green color.
2. Press and hold down the foot switch to activate the purge dispense cycle.
Alternately, touch and hold the Run icon on the display to activate the
purge dispense cycle.
5.2.4 Automatic Dispense Cycle Setting
1. Touch the “Timed” mode icon to set the dispense cycle in pre-set dispense
time. The icon should turn to green color.
2. Touch the Dispense icon to enter the setup screen
3. Touch the Up and Down arrows to set the desired dispense time.
Note: The minimum activation time is 0.008 second
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9. Type: “set ZONEINFO=C:\iot\timezone.zip” then press the “Enter” button
10. Type: “ipconfig” then press the “Enter” button
11. Record the Server IPv4 address show in the “IPv4 Address” line on the above
screen; For this example, the Server IP address is: 172.16.40.91
This address will be entered in the controller screen later.
12. Type: “.\portal” then press the Enter button

22
7. Type: “cd :\iot” then press the “Enter” button
8. Type: “set OKI_IOT_PREFIX=MyPrefix” then press the “Enter” button
11
4. Touch the Check Mark icon to save and exit
5. Press the foot switch to activate the “Timed” dispense cycle.
Alternately, touch the run icon on the display to activate the “Timed”
dispense cycle.
Note: The unit has an “Interrupt” mode feature. In this mode, the
“Timed” dispense cycle can be disrupted if the foot switch is released and
resumed when the Foot Switch is depressed again.
6. Touch the “Interrupt” icon to activate “Interrupt” mode. The icon should
turn to green color.
5.2.5 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 the required
dispense time when the dispense output is known.
1. Touch the “Teach” icon to enter the teach mode
2. Touch the “Time Reset” icon to set timer to zero
3. Press and hold down the foot switch, the dispense time will be accumulated
4. Release the foot switch when the desired amount of fluid has dispensed
5. Touch the “Timed” icon to transfer the accumulated dispense time to
“Timed” mode
6. The unit is now set to repeat this “Timed” cycle
5.2.6 To run in Continous Mode
The controller can be setup to repeat the run continuously.
1. Touch the Setup icon to enter the setup screen

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2. Touch the “Run Method” icon
3. Enter the delay time (ex. 5000 ms)
4. Touch the “Countinous Run” icon
5. Touch the Check Mark icon to save
6. Touch the X icon to exit
The screen will look similarly to the screen below:
Note: If the controller is set to activate memory cell 1 and the delay time is
set at 5000 ms, the controller will activate memory 1 continuously with
5000 ms delay between each activation.
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6. INTERNET of Thing (IoT)
6.1 Setup webserver on the computer
1. Go to Techcon Website (www.techconsystems.com) and download the
following files to your computer:
a. The “portal.exe” file
b. The “timezone.zip” file
2. Create a new folder and name “IoT” or any desired name
3. Copy the “portal.exe” file and the “timezone.zip” file in the “IoT” folder
4. Click on the “Windows” start icon
5. Type: “cmd” in the box (as show below)
6. Press the “Enter” button
The screen should appear as shown below

20
6. If the selected network is an unsecured network (not password protected),
touch “Connect” tab to connect
7. Once the unit is successfully connected to the Wi-Fi network, the
“Connect” tab will change to “Disconnect” and the online symbol will
change to green
8. If the selected network is a secured network (password protected), first
create a text file and type the network’s password, then save the file as
“password.txt”
9. Copy the “password.txt” file to a blank USB thumb drive. Note: Do not
put the “password.txt” file inside a folder
10. Insert the USB drive to the USB port located in the back of the unit
11. Touch “Connect” tab to connect. Once the unit is successufully connected
to the Wi-Fi network, remove the USB drive from the USB port
12. Touch X icon to save and exit
13. Touch the IP Address icon and the unit will show an IP address
Note: Once the unit is turned off, the Wi-Fi connection is lost. To re-connect
the unit back to the same network after the unit is turned on, repeat steps 1-4
and touch the “Default” tab.
13
5.3 Low Pressure Alarm Setting
Note: This controller is equipped with an adjustable “Low Pressure” alarm
function. If the set pressure dropped below the “Low Pressure” setting, the
controller will not activate. 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. The “Low Pressure” setting can be adjusted. Follow
the instructions below.
1. Touch the Setup icon to enter setup screen
2. Touch the Low Pressure (LP) icon to set the desired low pressure
3. Slide the pressure scale to set the desired low pressure threashold
4. Touch the X icon to save and exit

14
5.4 Stored Program in Memory cell
The unit has 50 memory cells to store all dispense parameters. The controller can
activate all memory cells in sequence mode.
5.4.1 To store dispense parameters
1. Touch the forward or backward arrow to select the
desired memory cell.
2. Enter all the desired dispense parameters then touch the
“Save” icon to save the data
5.4.2 To run in Single Sequence Mode
1. Touch the “Run Method” icon to enter sequence mode setup
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5.7 To Connect to Wi-Fi network.
1. Connect the antenna to the Wi-Fi connector located in the back of the unit
2. Touch the Setup icon to enter the setup screen
3. Touch the Wi-Fi icon to enter the network setup screen
4. Touch the “Scan” tab to scan for all available networks
5. Touch the Up and Down arrows to select the desired network

18
2. Touch the change “Password” icon
3. Enter the old password, then enter the new password
4. Touch the Check Mark icon to save
5. Touch the X icon to exit
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2. Enter number of memory to be run in sequence (ex. 1 to 3)
3. Touch the “Sequence Mode” icon
4. Touch the Check Mark icon to save
5. Touch the X icon to exit
The screen will look similarly to the screen below:
Notes:
A. If there is no delay time entered in the setting, the operator has
to press the foot switch or touch the Run icon after each
memory cell is completed to activate the next memory cell.
B. If delay time is entered in the setting, the controller will activate
the next memory cell in sequence automatically.

16
5.4.3 To run in Continuous Sequence Mode
1. Follow steps 1 to 2 above and enter the waiting time “delay time” between
each activation.
2. Touch the “Sequence Mode” icon
3. Touch the “Continuous Mode” icon
4. Touch the Check Mark icon to save
5. Touch the X icon to exit
The screen will look similarly to the screen below:
Note: If the sequence mode is set to activate memory cells 1 – 3 and the
delay time is set at 5000 ms, the controller will activate memory 1 to 3
continuously with 5000 ms delay between each activation.
5.5 Cycle Counter
The cycle counter records the numbers of automatic dispense cycle being
activated. Up to 999,999 cycles can be recorded. To reset the counter, follow
steps below:
1. Touch the Setup icon to enter the setup screen
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2. Touch the Counter Reset icon to reset the counter
3. Touch the Check Mark icon to confirm
4. Touch the X icon to exit
5.6 To Change Password
Note: The default password is “0000”. To change the password, follow the
instructions below.
1. Touch the Login icon to enter the login screen