TECHCON TS8200D Series User manual

1
TS8200D Series
Micro-Meter Mix User Guide
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______________________________________________________________________
______________________________________________________________________
TS8200D Series Micro-Meter Mix
True volumetric measuring, mixing, and dispensing
of 2-component materials

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TS8200D Series
Micro-Meter Mix User Guide
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The TS8200D Series Micro-Meter Mix Pump is our dispensing solution for applications involving
two-component (2K) materials. The pump is comprised of two individual high-quality
progressive cavity (PC) pumps, pulled from our existing PC pump product line, and optimized
for 2K dispensing. PC technology will simplify your dispensing process and improve reliability
by providing high quality and consistent dispensing over many years in operation.
After reading this guide, we hope you develop a solid understanding of the theory of operation,
parts and features, initial set-up and pump integration, assembly and disassembly, product
specifications, and maintenance of the TS8200D Series Micro-Meter Mix pump.
Please spend some time going over the material covered in this guide. This guide was written
by experts who have spent ample time working with the product. Please follow our experts’
recommendations and all provided testing procedures. It is very likely all your questions will be
covered in this guide. Nevertheless, if you need further assistance, please do not hesitate to
contact our Techcon support team. Detailed contact information is provided on the last page
of this document.
From Our Team
Thank you for choosing and putting your trust in our fluid dispensing systems to solve your
dispensing needs. Over the years, we have strived to be the brand of choice for customers
looking to make processes more efficient, improve industrial hygiene, enhance productivity,
and increase/create value. We accomplish this by delivering dispensing solutions that are
smarter, cleaner, and with superior accuracy and durability.
Here at Techcon we value your business and will do everything we can to make you a satisfied
customer.
Please know that no matter the industry, whether it be: aerospace, military, material packaging,
industrial assembly, medical devices, or electronics, you’re supported by a team of expert
engineers who can solve your toughest manufacturing problems. Therefore, if at any time you
experience issues with our product, please do not hesitate to reach us.
We guarantee we will resolve any problems you may encounter to your satisfaction.
We hope to establish a long-lasting relationship.
Thanks again for choosing Techcon

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Contents
1. Introduction ......................................................................................................................................... 4
1.1 Key Features and Benefits ........................................................................................................ 4
1.2 Typical Applications ....................................................................................................................5
1.3 Configuration Options ................................................................................................................5
1.4 Theory of Operation................................................................................................................... 6
1.5 How to Control the Pumps........................................................................................................7
2. Technical Specifications for the Micro-Meter Mix System.................................................. 8
2.1 Pump Dimensions........................................................................................................................ 9
3. Unpacking & Inspection .................................................................................................................10
4. Installation.......................................................................................................................................... 12
4.1 Out of the Box Assembly Instructions ................................................................................ 12
4.2 Mounting the Pumps ................................................................................................................ 16
4.3 Dispense Fluid Set-Up ............................................................................................................. 16
4.4 Final System Layout................................................................................................................. 18
4.5 Venting and Purging the Pumps.......................................................................................... 18
4.6 Calibrating the Pumps............................................................................................................ 22
4.7 Determining Controller Settings and Final Set-Up....................................................... 22
5. Maintenance and Cleaning........................................................................................................... 26
5.1 Preparations Before Disassembly........................................................................................ 27
5.2 Pump Disassembly ................................................................................................................... 28
5.3 Pump Cleaning ........................................................................................................................... 31
5.4 Pump Assembly ........................................................................................................................34
6. Part Numbers and Spare Parts...................................................................................................36
7. Troubleshooting ..............................................................................................................................43
8. Appendix A .......................................................................................................................................44
9. Limited Warranty & Contact Information...............................................................................45

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TS8200D Series
Micro-Meter Mix User Guide
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1. Introduction
The TS8200D Series Micro-Meter Mix is a
precision volumetric mixing and dispensing
system for 2-component material. It
consists of 2 progressive cavity (PC)
pumps integrated in a fluid manifold
connected to the static mixing nozzle. Part
A and part B of the material is precisely fed
by the progressive cavity pump with the
correct ratio into the static mixing nozzle
to provide accurate mixing and dispensing
output. Every component of the pump was
designed to the highest tolerances and
manufactured to the strictest degree of
precision, ensuring world class accuracy
and repeatability.
1.1 Key Features and Benefits
•True Volumetric/Positive
Displacement technology to achieve
+/- 1% variation in dispense output
•High quality mixing to ensure proper
material curing
•Continuous Flow with adjustable flow
rate to provide continuous dispensing
process for efficient operation
•Independent of pressure and viscosity change to ensure accurate and precise
results
•Suckback action to prevent material dripping
•Quick and easy cleaning to reduce down-time

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1.2 Typical Applications
• Bonding
• Glob-Top Potting and Encapsulation
• Potting of Electronic Components
• Battery Pack Sealing
• Thermal Paste Dispensing
• Filling
1.3 Configuration Options
Each PC pump is available in three different sizes. The size is determined by the stator
and rotor selection.
-100 Series Stator & Rotor
o0.012 ml/rev per pump
oMinimum dispense volume: 0.012ml per pump
oFlow rate: 0.12 –1.21 ml/min
-200 Series Stator & Rotor
o0.055 ml/rev per pump
oMinimum dispense volume: 0.055ml per pump
oFlow rate: 0.65 –6.90 ml/min
-300 Series Stator & Rotor
o0.080 ml/rev per pump
oMinimum dispense volume: 0.080 ml per pump
oFlow rate: 0.78 –8.12 ml/min

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Note: The TS8200D may be configured in 1 of 6 different pump type configurations.
•TS8200D-100-PS-SYS –Pump A: 100 Series, Pump B: 100 Series
•TS8200D-200-PS-SYS –Pump A: 200 Series, Pump B: 200 Series
•TS8200D-300-PS-SYS –Pump A: 300 Series, Pump B: 300 Series
•TS8200D-2100-PS-SYS –Pump A: 200 Series, Pump B: 100 Series
•TS8200D-3100-PS-SYS –Pump A: 300 Series, Pump B: 100 Series
•TS8200D-3200-PS-SYS –Pump A: 300 Series, Pump B: 200 Series
Tip: Please reference Appendix A for information on flow rate and ratio capabilities
with the different pump type combinations. Other information available: smallest shot
size, combined flow rate references.
1.4 Theory of Operation
The TS8200D Series Micro-Meter Mix pump dispenses fluid with a positive
displacement action using progressive cavity technology. Fluid is introduced into the
pump through the fluid inlet and begins to occupy the empty space that makes up the
upper valve body. The stator and rotor form a perfect seal preventing any material
from flowing beyond there mating point. As the rotor rotates, the fluid is allowed to
flow from one sealed cavity to the next, enabling precise volumetric deposits of
material. During initial set-up, continuously purging of material will be required to fill
the fluid manifold’s fluid path before any actual metering may be performed. Precise
metering quantities of part A and part B will be deposited at the valves output end. A
static mixing nozzle is required to perform the actual mixing of the 2-part material. The
output is driven by a 24 VDC encoder motor. Shearing of the fluid is achieved by
reverse Z-motion (tip retraction).

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1.5 How to Control the Pumps
The TSS8200D Micro-Meter Mix pump must be
integrated with the Techcon TS580D-MM
Series controller. The TS580D-MM allows users
to make the most use out of there dispensing
pump. Controller features include dispensing in
volume, weight, or timed mode, quick and
simple programing to dispense lines, access to
over 50 different memory locations for quick profile change, and remote access &
control of programs via ethernet.
24 VDC encoder
motor
Fluid Inlet
Rotor
Stator
Outlet
Fluid
Manifold
= Process Fluid

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2. Technical Specifications for the Micro-Meter Mix System
Size:
314 mm L x 69 mm W x 34 mm D
12.4” L x 2.7” W x 1.3” D
Weight:
1.24 kg/2.74 lb.
Motor:
24V DC, incremental encoder
Flow rate:
100x100
200x200
300x300
200x100
300x100
300x200
0.24–
2.42ml/min
1.29–
13.80ml/min
1.56–
16.24ml/min
0.77–
8.11ml/min
0.90–
9.33ml/min
1.43–
15.02ml/min
Dispensing Volume Per Revolution per Pump
100x100
200x200
300x300
200x100
300x100
300x200
.012 ml
.047 ml
.08 ml
.012 ml for -100
.047 ml for - 200
.012 ml for -100
.08 ml for -300
.012 ml for -100
.08 ml for -300
Repeatability:
+/- 1% per pump
Dispense Accuracy
> 99%
Fluid inlet pressure Maximum
Up to 2 bar (30 psi) for viscosity of 1,000 cps
or less, up to 5.5 bar (80 psi) for viscosity
greater than 1,000 cps
Fluid inlet type:
1/8” NPT
Mixing Nozzle:
K-type, Standard Bayonet
Mounting:
M4 x 35MM, SHC, S.S
Wetted Parts:
Stator Housing
Anodized Aluminum
Rotor:
Carbide
Stator:
PFE
Flex Coupling:
Stainless Steel, Polyolefin
Shaft Seal Block
Delrin
Manifold Plugs
Delrin
Manifold Gaskets
Viton
Pump O-rings:
BUNA N
Vent seals:
Fluorsilicone
Vent Screws:
Stainless Steel
Fluid inlet fittings
UHMWPE, NYLON
Operating Temperature
10 –40°C (50 - 104°F)
Fluid Temperature
10 –40°C (50 - 104°F)
Storage Conditions
10 –40°C (50 - 104°F)
Fluid Viscosities
1 - 300K Cps (m.Pa.s)

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*2 bar self-sealing is for fluid with viscosity of 1000 Cps or lower. The pump can handle
up to 5.5 bar for 300K Cps viscosity fluid.
**Accuracy measurements are taken for one complete revolution. Absolute deviation
in volumetric dispense accuracy exist for incomplete revolutions and may also occur
for certain dispensing fluid.
2.1 Pump Dimensions
Units = mm

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3. Unpacking & Inspection

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The pump includes the following items:
ITEM
NO.
PART NUMBER
DESCRIPTION
QTY.
1
7000-7300
BOX, 12 X 10.0 X 4.25, METER MIX
1
2
7509-1150
FLUID MANIFOLD,K-TYPE NOZZLE, 1:1
RATIO
1
3
8100-100-002
8100-200-002
8100-300-002
REPLACEMENT STATORS, PC PUMP
*Part Number based on Pump configuration
2
4
7509-1160
LOCKING PLATE, K-TYPE NOZZLE
1
5
8200D-000-001
CALIBRATION ADAPTOR
1
6
7509-1190
PLUG SCREW, FLUID MANIFOLD
2
7
3300-0662
O-RING, 3MM ID X 1MM CS, EPDM
2
8
2800-1027
M3x6mm LG, SHC,S.S. LOW PROFILE
2
9
8100-CLEANKIT-
MMM
CLEANING KIT, MMM, PC PUMP
1
10
TS8200D-
SYBRACKET
SYRINGE BRACKET, METER MIX
1
11
A0100488-2
700 SERIES,30cc RECEIVER HEAD
ASSY
2
12
2800-1031
SCREW, M4 x 35MM, SHC, S.S
2
13
TSD931-81B
ELBOW 90 DEG. WITH LUER LOCK, BLACK
NYLON
2
14
TSD931-96
FEMALE LUER WITH 1/8 NPT THREAD
2
15
TSD931-82B
MALE ADAPTER WITH LUER LOCK,
BLACK NYLON
2
16
7000-7320
USER GUIDE, METER MIX
1
17
7000-7310
QUICK SETUP INSTRUCTIONS SHEET, METER MIX
1
18
7000-4340
LABEL, PACKAGING, VALVE
1
19
4100-0059
LABEL, LEAD FREE RoHS
COMPLIANT(500/ROLL)
1
20
7000-3640-AW
ARTWORK, STANDARD PACKAGE LARGE LABEL
1
21
1400-0280
FOAM, INSERT, METER MIX
1
22
3300-0656
GASKET, 1/2" ID X 5/8" X 1/16 W, VITON
2
23
1400-0187
BAG, 12" x 5", 2 mil POLY BAG
2
24
7509-1460
HOUSING PUMP,MICRO-METER MIX
1
25
2800-1034
M4X70 LG, Stainless Steel Socket
Head Screw
4
26
2800-0543
Washer, M4, Flat, S.S
4
27
2800-0518
WASHER, M4, SPLIT LOCK, S.S
4
28
8100-100-007-MC
REPLACEMENT CABLE ASSEMBLY ,PC
PUMP
2
29
P9500010
BAG, FLAT PE, CLEAR, 6 X 8 X 4 MIL
1
30
1400-0022
BAG,3 X 5,2 MIL,POLYETHYLENE,ZIPLOCK
5
31
7509-9421
7509-9422
7509-9423
ASSEMBLY, PUMP,MICRO-METER MIX
*Part Number Based on Pump Configuration
2
32
8200D-PS
Optimal Pressure Sensor (optional)
1

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TS8200D Series
Micro-Meter Mix User Guide
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4. Installation
4.1 Out of the Box Assembly Instructions
Required tools:
- 8mm (5/16”) wrench or crescent wrench or flat head screwdriver (for mounting
pressure sensors)
- 3.0 mm hex wrench (for manifold screws)
- 2.5 mm hex wrench (for mounting calibration adaptor)
- 2.0 mm hex wrench (for mounting K-type nozzle locking plate)
- Dispensing Fluid (material to be used or cleaning/lubricating fluids)
Warning! Do not dry-assemble the rotor and stator. Excessive friction between dry
components may damage stators and effect pumps performance.
*Do not use water. Using water may damage the pump. Recommend using
conditioning fluid for cleaning.
1. Apply the dispensing fluid or any appropriate lubricant compatible with the
dispensing fluid to the surface of the rotor.
2. Wet the stator opening by squeezing a small amount of the dispensing fluid or
any appropriate lubricant that is compatible with the dispensing fluid.
3. Screw the stator onto the rotor in a clockwise direction, align the 4 tabs of the
stator with the 4 notches of the stator housing, and push in the stator to lock it
into place with the stator housing.

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4. Plug and thread in the motor cables.
5. Insert pump assemblies into the pump housing.
6. Make sure that the high-pressure seals sit and fit properly along the groove
located inside the manifold.
7. Align the manifold with the now-assembled pump and pump housing. The
engraved labels “RESIN” and “HARDENER” should be facing you. Insert and
fasten four (4) 3.0 mm hex screws with lock washers in the order shown in the
image below. Make sure the two now-assembled pumps are vertically
symmetrical and not flaring outwards. Make sure there are no gaps or any visible
light between pump housing and mating parts. If there are issues relieve tension
on the screws and tighten evenly. Reference the image below for recommended
fastening order.

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8. Install fluid inlet fittings.
There are several different fluid inlet fittings available. The fluid inlet fitting
required will depend on the fluid reservoir option you select. In the picture
below, we use 1/8 NPT x luer lock elbow. Reference the “Accessories” section
for information on fluid inlet fittings. It is recommended that Teflon tape be
applied to the thread of the fluid inlet fitting prior to installation.
9. Mount pressure sensors (optional feature)
TS8200D is available with sensors for monitoring dosing
pressure. With this feature you are able to keep closer
track of any output pressure changes caused by factors
other than viscosity, such as premature curing/hardening
of material or obstructions preventing the flow of material.
1
2
3
4

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a. Remove both fluid manifold plug screws and O-rings.
b. Mount sensors. Note: If the sensors are missing O-rings, use the O-rings
from the plugs.
c. Screw the sensors by hand and use 8.0 mm wrench, crescent wrench, or
flat head screwdriver for the final tightening.
Tip: To avoid cable “curling,”do not install sensors to the controller before fastening
the sensors to the pump.
Warning! The surface of the sensors is extremely sensitive. Therefore, take extra
caution when handling these sensors and avoid hitting them against other surfaces.
10. Install Calibration Adaptor
The calibration adaptor is required whenever calibration is performed, when a
new fluid is introduced, when the valve is disassembled & reassembled, or when
the stators or rotors are changed. Connecting calibration adaptor can protect
the TS8200D from having direct contact with the material as it exits the pump.
a. Mount the 1:1/2:1 K-type Nozzle Locking Plate and use a 2.0mm hex
wrench to fasten screws into place.
b. Mount the calibration adaptor and use a 2.5mm hex wrench to fasten
screws into place.
c. Make sure that the calibration adaptor rest evenly against the nozzle
locking plate.

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4.2 Mounting the Pumps
There are two mounting holes for M4x35mm SHCS (screws provided with the pump).
Use a 3.0mm hex wrench to fasten screws into place.
Note: If mounting to a TSR series dispensing robot, you will require 7506-0280
mounting plate. The valve may be mounted using holes marked with a red circle.
4.3 Dispense Fluid Set-Up
Warning/For your safety:
-Follow the safety guidelines outlined by the manufacturer for instructions on
handling the process fluid.
-Do not overtighten fittings. Doing so may damage pump housing components.
-Do not use water for priming or cleaning the pump. Doing so may damage the
pump.
-Do not run the TS8200D without material. Excessive friction between dry
components may lead to pump damage.

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You will need the following items:
-Phillips head screwdriver (not included)
-Fluid supply components and fluid inlet fittings
-Process Fluids
1. Prepare process fluids and fluid supply. The fluid supply may be either syringes
or a fluid reservoir. Reference “Accessories” section for information on available
fluid supply solutions.
Tip: “Degassing” the fluid is recommended. Trapped air will contribute to dispense
volume variations.
Warning! Do not pressurize the fluid supply at this time!
2. Inspect and confirm fluid vent screws are present and well fastened on both the
front and back of the pumps.
Tip: Avoid over tightening vent screws. Over tightening may lead to tears to the vent
seal O-ring.
3. Connect the fluid supply to the fluid inlet of the pump. If using a fluid reservoir,
reference the “Accessories” Section for information on compatible fluid lines.
Make sure the resin is connected to the pump with the “RESIN” label and the
hardener is connected to the pump with the “HARDENER” label.
Warning! Do not pressurize the fluid supply at this time!
4. If the pump is not already mounted or placed in the “up-right” vertical position,
please do so at this time.
5. Install any fluid supply accessories. Reference “Accessories” section for
information on fluid supply accessories.
6. Install the TS580D dispensing controller.

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4.4 Final System Layout
1. Air Filter, 2. Pump, 3. Pressure Tank, 4. Pressure Tank
4.5 Venting and Purging the Pumps
Venting and purging the pumps is recommended before placing them into operation.
Failure to vent and purge during the initial setup may lead to dispensing issues.
a. Begin to pressurize the fluid supply.
Warning! Make sure the fluid supply pressure is set very low. A good rule is to begin
pressurizing the fluid starting from 0 psi. Reason: Higher pressures may cause low
viscosity fluids to spray from the output when purging or from the pump housing if
the pump is incorrectly assembled.
b. Set the fluid pressure to around 0.3 bar (5 psi). The fluid pressure will
depend on the viscosity of the material. For this sample setup, we are
assuming low viscosity less than 1000 cps (mPa-s) is being used on both
the left and right pump.
Tips: Low viscosity (1 –2000 cps) Pressure range 1 –10psi
Medium viscosity (2000 –30,000 cps) Pressure range 10 –20 psi
High viscosity (30,000 cps + ) Pressure range 20 –80 psi
Using Fluid Reservoir
Using Syringes

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c. Inspect the seals for leaking
From top to bottom inspect:
1. Front and back vent port seals
2. Stator housing top seal
3. Fluid inlet fitting seal
4. Pump housing top seal
5. Pump housing bottom seal
6. Pump output seal
If there is any leakage, adjust the tension on the screws and inspect the O-ring seals.
Reference disassembly section of user guide for additional information.
d. Purging and Venting “RESIN” –Pump 1
i. Place a clean towel or a container under the pump.
Tip: Never use the same cleaning towel for both process fluids. Mixing the fluids may
lead to undesired chemical reactions.
ii. To purge the resin though the manifold:
1. Navigate to the Home page.
2. Unlock the unit by clicking lock icon.
Default password = 0000.
3. Select the Purge Pump 1 icon.
1
2
3
4
5
6

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Note: Purge Pump 1 icon will dispense the resin at a safe speed for initial priming of
the pump.
4. Press the foot switch.
5. Allow the fluid to flow from the manifold until a steady
stream of air free material is observed.
6. Release the foot switch.
7. We are now done purging pump 1.
iii. To vent the resin:
1. Have a cleaning towel or container under the pump ready
to catch material
2. Using a Phillips head screwdriver, loosen front vent screw
by turning in the counterclockwise direction. Loosen screw
in 1 revolution increments. At around the 6th –7th revolution,
you should begin to see material seep out. Allow material to
escape until no more air bubbles are observed.
Warning: Do not loosen to more than 8 complete revolutions. Doing so will
unfasten the screw allowing pressurized material to spray out.
3. Fasten the venting screw. Avoid over tightening the screw.
Over tightening may lead to tearing of the vent seal O-ring.
e. Purging and Venting “HARDENER” –Pump 2
i. Place a clean towel or a container under the pump
Tip: Never use the same cleaning towel for both process fluids. Mixing the fluids
may lead to undesired chemical reactions.