Walther 97TS500R User manual

Rev. 1.1
Digital Multi-Purpose Controller 97TS500R
Page 1 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
Telefon: [phone] Telefax: [phone]
http://www.walther-2000.de –[e-mail]
Operating Manual
Digital Multi-Purpose Controller
Article Number: 97TS500R
NOTE
Please read this Operating Manual carefully before first using the device and strictly adhere
to the instructions!
This device may only be worked with and worked on by persons who are familiar with this
Operating Manual and the current regulations for industrial safety and accident prevention.
Keep this Operating Manual at a safe place close to the device!
The instructions must be available at all times!

Rev. 1.1
Digital Multi-Purpose Controller 97TS500R
Page 2 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
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Table of Contents
Page
1EC Declaration of Conformity............................................................................................................................. 4
2Introduction ...................................................................................................................................................... 5
2.1 Target Group of this Manual ................................................................................................................................ 5
2.2 List of Signs and Symbols...................................................................................................................................... 5
3Safety ................................................................................................................................................................ 5
3.1 General Information ............................................................................................................................................. 5
3.2 Dangers from Residual Energies ........................................................................................................................... 5
3.3 Safety Instructions ................................................................................................................................................ 5
3.4 Correct Use ........................................................................................................................................................... 6
3.5 Incorrect Use......................................................................................................................................................... 6
3.6 Warranty............................................................................................................................................................... 6
4Description of Function ..................................................................................................................................... 7
4.1 Explanation of Symbols......................................................................................................................................... 7
4.2 Technical Data ...................................................................................................................................................... 7
5Start-up of Operation ........................................................................................................................................ 8
5.1 Installation Instructions ........................................................................................................................................ 8
5.2 Start-up................................................................................................................................................................. 8
5.3 Description............................................................................................................................................................ 8
6SETUP Instructions............................................................................................................................................. 9
6.1 Control of Air Valve ............................................................................................................................................... 9
6.1.1 Connection of Device (see Fig. 2.0)............................................................................................................. 9
6.1.2 Program Selection ..................................................................................................................................... 10
6.1.3 Setting of Manual /"Purge" Dosing Cycle:................................................................................................. 10
6.1.4 Setting of Automatic Dosing Cycle: ........................................................................................................... 10
6.1.5 Setting the Teach-Mode............................................................................................................................ 10
6.2 Control of Nozzle ................................................................................................................................................ 11
6.2.1 Connecting the Device (see Fig. 4.0)......................................................................................................... 11
6.2.2 Program Selection ..................................................................................................................................... 12
6.2.3 Setting the Manual /"Purge" Dosing Cycle: .............................................................................................. 12
6.2.4 Setting the Automatic Dosing Cycle:......................................................................................................... 12
6.3 Control of Standard TS5000 Rotary Pump .......................................................................................................... 13
6.3.1 Connecting the Device (see Fig. 6.0)......................................................................................................... 13
6.3.2 Program Selection ..................................................................................................................................... 14
6.3.3 Setting the Manual /"Purge" Dosing Cycle: .............................................................................................. 14
6.3.4 Setting the Automatic Dosing Cycle:......................................................................................................... 14
6.4 Control of Spindle Valve with Encoder ................................................................................................................ 15
6.4.1 Connecting the Device (see Fig. 6.0)......................................................................................................... 15
6.4.2 Program Selection ..................................................................................................................................... 15
6.4.3 Setting the Manual /"Purge" Dosing Cycle: .............................................................................................. 15

Rev. 1.1
Digital Multi-Purpose Controller 97TS500R
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Walther Systemtechnik GmbH –D 76726 Germersheim
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6.4.4 Setting the Automatic Dosing Cycle:......................................................................................................... 16
6.4.5 Setting the Repeat Function for Counter of Encoder:............................................................................... 16
6.5 Cycle Counter (see Fig. 9.0) ................................................................................................................................ 16
6.6 Change Display for Pressure Units (see Fig. 9.0)................................................................................................. 17
6.7 Low Pressure Setting (see Fig. 9.0) ..................................................................................................................... 17
6.8 Setting of Multiple Shots: ................................................................................................................................... 17
7Operation ........................................................................................................................................................ 18
7.1 General Information ........................................................................................................................................... 18
8I/O Configuration and Feedback for End of Cycle............................................................................................. 18
9Maintenance and Disposal .............................................................................................................................. 19
9.1 General Information ........................................................................................................................................... 19
9.2 Disposal .............................................................................................................................................................. 19
9.3 Spare Parts and Accessories................................................................................................................................ 19
9.4 Limited Warranty ................................................................................................................................................ 19
10 Troubleshooting .............................................................................................................................................. 20
10.1 General Information ...................................................................................................................................... 20
10.2 Customer Service / Support............................................................................................................................ 20
10.3 Fault Recovery................................................................................................................................................ 20

Rev. 1.1
Digital Multi-Purpose Controller 97TS500R
Page 4 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
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http://www.walther-2000.de –[e-mail]
1 EC Declaration of Conformity
in accordance with the EC Machinery Directive 2006/42/EC of May 17th, 2006, Annex II A
We herewith declare that the design and construction of the machine marketed by us as described
below corresponds with the safety requirements of the EC Directive 2006/42/EC. If the machine is
modified without our consent, this declaration loses its validity.
Manufacturer Walther Systemtechnik GmbH
Hockenheimer Straße 3
D- 76726 Germersheim
Description
Digital Multi-Purpose Controller, Article Number 97TS500R
We declare that the product is in accordance with the following relevant regulations:
EMC Directive 2014/30/EU, dated 26 February 2014
The following harmonized European Standards have been applied:
DIN EN ISO 12100 Safety of machinery; basic concepts, general
principles for design –Risk Assessment and Risk
Reduction (ISO 12100:2000)
Other applied technical standards and specifications:
Authorized Representative for Technical Documentation:
Stefan Hirl, Hockenheimer Straße 3, D- 76726 Germersheim
Germersheim, 18 April 2016
(Place, Date) (Stefan Hirl, Management)

Rev. 1.1
Digital Multi-Purpose Controller 97TS500R
Page 5 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
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2 Introduction
2.1 Target Group of this Manual
Operating Personnel
Maintenance Personnel
2.2 List of Signs and Symbols
This operating manual warns users of operations which may put their health at risk. The warnings are
indicated by combinations of text and symbols as follows:
WARNING
Signals a possible dangerous situation.
Death or severe injuries can follow, if you do not avoid this situation.
CAUTION
Signals a possible dangerous situation.
Slight or minor injuries can follow, if you do not avoid this situation. This sign is also
used where damage to property is possible.
IMPORTANT
Indicates tips for usage and other particularly useful information.
No dangerous situation.
3 Safety
3.1 General Information
The construction of this device is according to the latest technology and is absolutely reliable. The individual
components as well as the complete device are continuously checked by our quality management.
3.2 Dangers from Residual Energies
Please instruct the operating personnel on the respective measures to be taken against the occurrence of
mechanical, hydraulic, pneumatic and electric / electronic residual energies.
3.3 Safety Instructions
Walther Systemtechnik cannot be made liable for damages to persons or property resulting from incorrect
use of devices.

Rev. 1.1
Digital Multi-Purpose Controller 97TS500R
Page 6 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
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OBSERVE
Please observe the following safety advice in order to avoid dangerous situations!
A safe and secure operation of the device depends on a careful transport and storage, and a work-
manlike installation and mounting.
Keep in mind that an unqualified operation with power and current can cause pain, or severe health
damages or even death.
This operating manual requires a technical qualification for operating and working with electrical
equipment. Contact your local certified electrician if you do not have this special qualification!
Rules and regulations quoted in this manual are binding for all EC countries. If the device is operated
in a non-EU country, their binding national regulations apply.
Do not operate the device with other than the authorized nominal power/settings.
3.4 Correct Use
This device will not be operated by other than qualified personnel, nor installed, configurated or pa-
rameterized.
The personnel actually operating the device will be trained by qualified technical personnel.
This device is for use in confined spaces only.
WARNING!
An incorrect use for purposes other than described in this manual can lead to damages
to persons or property. Only use the device as described herein.
3.5 Incorrect Use
Operating the device with insufficient knowledge about the operation, maintenance and care of the
device.
Making changes, extensions or alterations on the device that may hamper its safety without the prior
consent of Walther Systemtechnik GmbH.
Operating the device with defective safety installations or not properly attached or malfunctioning
safety devices,
Using unsuitable materials and media.
3.6 Warranty
According to the conditions laid down by the German Engineering Federation (VDMA), Walther
Systemtechnik GmbH has a guarantee of 12 months under normal European operating conditions on its own
parts (spare parts are excluded); or according to the conditions of the manufacturer.
This guarantee can only be granted by Walther Systemtechnik GmbH, if:
the user has thorough knowledge of the content of this operating manual;
the user follows the instructions and notes contained in this operating manual;
the user does not rebuild or make changes on parts of the device without prior consent of WST
Systemtechnik GmbH.

Rev. 1.1
Digital Multi-Purpose Controller 97TS500R
Page 7 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
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4 Description of Function
4.1 Explanation of Symbols
Symbol
Explanation
On / Off
Cycle operation
Timer
4.2 Technical Data
General Data
Dimensions (LxWxH)
ca. 254mm x 191mm x 102mm (10” x 7.5” x 4.0”)
Weight
2.6 kg (5.8 lbs)
Input voltage
24 V DC
Output voltage range
0-24 VDC
Nominal power
15 W
Compressed air inlet
100 psi (6.9 bar) max.
Compressed air outlet
0-100 psi (6.9 bar)
Degree of contamination
II
Installation category
I
Use in internal space
Set-up height up to 2.0 m (6.562 ft)
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 temperatures up to 31°C (87.8°F) linearly drop-
ping to 50% relative humidity at 40°C (104°F)
Timer
0.008-60.000 seconds
Cycle operation
Timer-operated, step-operation, rinsing
Repeat tolerance
+/- 0.001%
Cycle speed
900 cycles/minute
LCD
20 x 4 display segments

Rev. 1.1
Digital Multi-Purpose Controller 97TS500R
Page 8 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
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5 Start-up of Operation
5.1 Installation Instructions
Please read the installation instructions carefully and observe all steps when installing the device. If you do
not adhere to the installation instructions, there can be functional errors, or the required AMV guidelines may
be violated, or the EC conformity is lost.
Before connecting the device and starting operation, please make sure that the operating voltage and the
required operating voltage conditions of the device match those on site (see type label and technical data).
Take the respective measures if necessary.
The device will be powered by a separate power line.
This operating manual does not list all regulations and standards etc. which have to be observed when oper-
ating the device in conjunction with larger systems. These regulations and standards etc. have to be gath-
ered and observed by the operator of the device for the individual operation.
5.2 Start-up
Check the following before starting to operate the device:
Do the type label data match the data of your order?
The supply voltage has to be identical with the voltage information on the type label.
The nominal power of the connected consumer will not exceed the power indication on the type label
(ohmic load).
5.3 Description
Fig. 1.0
Positions
Description
Positions
Description
1
ON/OFF button
8
Outlet for engine drive
2
Mode button
9
Foot switch bushing
3
Setup-/Memory button
10
Main socket
4
Display
11
I/O connection
5
Air outlet (uncontrolled)
12
Compressed air inlet
6
Compressed air controller
13
Additional compressed air outlet
7
Air outlet (controlled)

Rev. 1.1
Digital Multi-Purpose Controller 97TS500R
Page 9 of 20
Walther Systemtechnik GmbH –D 76726 Germersheim
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6 SETUP Instructions
6.1 Control of Air Valve
IMPORTANT!
Use a 5-micron filter (97TSD800-6) in order to guarantee a correct filtering of the air.
Fig. 2.0
Positions
Description
Positions
Description
1
ON/OFF button
6
Outlet for engine drive
2
Mode button
7
Foot switch bushing
3
Setup-/Memory button
8
Main socket
4
Display
9
I/O connection
5
Air outlet (uncontrolled)
10
Compressed air inlet
6.1.1 Connection of Device (see Fig. 2.0)
1. Connect main power cable, foot switch and air hose to back of device. Make sure that the incoming air
pressure is at 70 psi (4.8 bar) or more.
2. Press ON/OFF button (1) to turn on the device.
3. Connect valve air hose to connection A.
IMPORTANT!
The pressure in connection A can be controlled through the setting of the low pressure,
but it will not be controlled by the compressed air controller in the device. It will supply
the identical pressure as the incoming pressure. The pressure in connection B is con-
trolled separately and is not related to the setting of the low pressure.
4. Press mode button (2) and button "Set" (3) at the same time until "VALVE" is displayed in the upper
right corner of the display, as shown in Fig. 3.0.
Fig. 3.0

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6.1.2 Program Selection
1. Press the button "Set" (3) in order to mark the selected program number.
2. Select the desired program with the (+) or (-) button.
3. Press the "Set" button (3) to end.
6.1.3 Setting of Manual /"Purge" Dosing Cycle:
1. Press the mode button (2), until “PURGE” is displayed.
2. Hold down the foot switch in order to activate the dosing cycle.
6.1.4 Setting of Automatic Dosing Cycle:
1. Press the mode button (2) and select between the modes "TIMED MODE" (time-controlled) and “IN-
TERRUPT”(step-operation).
2. Hold the “Set” button (3) for two seconds in order to change into the Setup-display. The last number of
dosing time will be marked.
3. Move the cursor to the next position by using the “Set” button (3).
4. Use the buttons (+) and (-) to set the time.
5. Hold the “Set” button (3) for two seconds if you want to save the data.
6. If the device operates in "TIMED MODE" (time-controlled), push foot switch and let go in order to acti-
vate the time-controlled dosing cycle.
7. If the device is in "INTERRUPT" mode (step-operation), push foot switch and hold until dosing cycle has
finished. Let foot switch go in order to interrupt the dosing cycle and push again in order to reactivate.
6.1.5 Setting the Teach-Mode
The Teach-Mode will sum up the time as long as the foot switch is operated. This is helpful for determining
the required dosing time or when the actual dosing capacity is not known.
1. Change into the “INTERRUPT” mode (step-operation) by using the mode button (2).
2. Hold the “Set” button (3) to activate the Teach-Mode. The LCD-display will show “0.000” for time.
3. Push the foot switch and hold it. The dosing time will be added up.
4. Let the foot switch go once the respective dosing quantity has been dispensed.
5. Hold the “Set” button (3) for two seconds if you want to save the data.
6. Use the mode button (2) to get into the “TIMED MODE”.
7. The dosing device has now been set for a repetition of the time cycle.