TECHCON SYSTEMS TS6500 User Manual

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Page 1

Techcon Systems

TS6500 CIM Automatic Techkit Mixer

User Guide

English

CONTENTS

Page Number

1. Safety ……………………………………………………..3

2. Description ……………………………………………4

3. Symbol Definition ……………………………………………4

4. Specifications ……………………………………………5

5. Features and Function

5.1 Features …………………………………………...6-8

5.2 Operation Function …………………………………9-10

6. Setup and Operation

6.1 Fuse Installation and Voltage Selection ……………...11

6.2 Turn on the Unit ………………………………….12

6.3 Cartridge Kit Preparation ………………………..13

6.4 Loading the Cartridge Kit ………………………..14

6.5 Spindle Extension Installation ………………………..15

6.6 Mix Cycle Program Setup ………………………..16

6.7 Start the Unit ...…………………………………………16

6.8 Unloading the Cartridge Kit ………………………..16

6.9 Manual Mode ……………………………………………16

7. Speed Control

7.1 For Main Cylinder ………………………………….17

7.2 For Injection Rod ………………………………….17

8. Emergency Stop ……………………………………………17

9. Troubleshooting ……………………………………………18

10. Program Selection ……………………………………………19

11. Cycle Counter Reset ………………………………….19

12. Cartridge Holder Installation ………………………..19

13. Maintenance ……………………………………………21

14. Warranty ……………………………………………………..21

15. Appendix

15.1 Spare Parts and Accessories ………………………..22-24

15.2 Techkit Part Number Chart ………………………..25

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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

• Care must be taken to prevent the ingress of corrosive or

flammable fluid back into the 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.

2 DESCRIPTION

The TS6500CIM Series Automatic Techkit Mixer provides complete automatic mixing of two-component material package in cartridge kits. Equipped with a universal power supply, the TS6500 mixer is immediately usable anywhere in the world. The automatic fluid sensing device makes it very simple for operator to install and setup all cartridge kit sizes. The user friendly firmware provides up to 10 programmable mixing sequences with storage of 10 profiles.

The TS6500CIM Series is available in two versions:

• TS6500CIM-6 for 2.5 (74ml), 6.0 (177ml) and 8.0 oz. (237ml) Kit

• TS6500CIM-20 for 20 oz.(591ml) Kit

The following conversion kits are also available for your conveniences:

• CK6500-6 Conversion kit for 2.5 (74ml), 6.0 (177ml) and 8.0 oz. (237ml) Kit

• CK6500-10 Conversion kit for 1/10 gal.(325ml) Kit

• CK6500-20 Conversion kit for 20 oz.(591ml) Kit

3 SYMBOL DEFINITIONS

Symbol Definition

Power On/Off

Cycle Mode

Setup

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4 SPECIFICATIONS

Size 15.7” (398mm) X 21.2”(538mm) X 40.6”(1032mm) Weight 80lbs (36kg) Input Voltage 120/230 VAC, 50/60 Hz Rated Input Power 200W Rated Input Current 2A @ 120 VAC / 1A@230 VAC Motor Speed 139 RPM Motor Torque 42 in-lb (4.7 Nm) Indoor Use Altitude up to 6,562ft (2,000m) Operating Temperature 32˚F to 122˚F (0˚C to 50˚C) Storage Temperature -10˚C to 60˚C (14˚F to 140˚F)

Max. Relative Humidity

80% for temperature up to 87.8˚F ( 31˚C) Decreasing

linearly to 50% relative humility at 104˚F (40˚C) Air Input 50 to 100psi (3.5 – 6.9 Bar) Display LCD 20 X 4 display segments

4.1 Outside Dimensions

398mm [15.7"]

319mm [12.6"]

380mm [15.0"]

537mm [21.2"]

120mm [4.7"]

1032mm [40.6"]

Figure 1.0 Dimensions

5 FEATURES AND FUNCTIONS

5.1 Features

ITEM DESCRIPTION ITEM DESCRIPTION

1 PlungerBracket 9 AirRegulator

2 CartridgeHolder 10 E‐StopButton

3 GuideBlock 11 LCDDisplay

4 PlungerAirInlet 12 SafetyCover

5 DoorHandle 13 PlungerDisk

6 DriveSpindlewithInjectionRod 14 FluidLevelSensor

7 StartButtons 15 FluidLevelSensorMagnet

8 ControlButtons 16 Plunger

Figure 2.0 Front View

7 7

910

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ITEM DESCRIPTION ITEM DESCRIPTION

17 FlowControl,MainCylinder

21 AirFilter

18 FlowControl,InjectionRod

22

Wrench

19 VoltageSelectSwitch

23

AccessoriesBracket

20 PowerInputSocketwithFusebox

24

CartridgeHolderBracket

Figure 4.0 Partial Side View

Figure 3. Back View

Figure 5.0 Buttons and Screen Identification

MIX CYCLE

SET

PROGRAM # MODE PRESSURE

TOTAL MIX

TIME

SAFE TO

RUN

POWER/

(-) CYCLE

BUTTON

MODE/

(+) CYCLE

BUTTON

SETUP/

SAVE

BUTTON

CYCLE

COUNTER

Figure 6.0 Setup Screen Identification

PROGRAM # MODE PRESSURE

MIX CYCLE

SET

CYCLE

COUNTER

TOTAL MIX

TIME

DELAY TIME AT UP STROKE

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5.2 Operation Function

DESCRIPTION FUNCTION

1 Plunger Bracket

• Holds plunger assembly when not in use

2 Cartridge Holder

• Holds cartridge kit

• Operates with the plunger assembly and

guide block to drive the cartridge up and down for mixing

3 Guide Block

• Operates with the plunger assembly and cartridge holder to drive the cartridge up and down for mixing

4 Air Plunger Inlet

• Provides air to plunger

5 Door Handle

• Secures cover and disengages door

Drive Spindle with Injection Rod

• Rotates mix rods during mix cycle

• Injects the hardener into the resin

Start Buttons (Green)

• Starts the unit

• Press green buttons simultaneously to

start

8 Control Buttons

• Input buttons (see Fig. 5)

9 Air Regulator

• Regulate the air pressure to the unit

Emergency Stop button (Red)

• Stops the Unit in an Emergency

• Press to Engage

• “E-Stop!” will be displayed,

• To reset, rotate the E-Stop knob a

quarter turn clockwise

11 LCD Display

• Displays unit status, operation and error messages.

Protective (Safety) Cover

• Protect operators when machine in use

13 Plunger Disk

• Part or Plunger Assembly

14 Fluid Level Sensor

• Senses the fluid level at the top of the cartridge

Fluid Level Magnet

• Work with Fluid Level Sensor

16 Plunger Assembly

• Locks cartridge in place

• Applies steady pressure to prevent air

entrapment

Flow Control; Main Cylinder

• Controls the speed of the Main Cylinder

• Rotate the flow control screw clockwise

to increase the speed.

• Rotate the flow control screw counterclockwise to decrease the speed

Flow Control; Injection Rod

• Controls the speed of the injection rod

• Rotate the flow control screw clockwise

to increase the speed.

• Rotate the flow control screw counterclockwise to decrease the speed

Voltage Select Switch

• Select 115V or 230V

Power Input Socket with Fuse Box

• Input power connection

21 Air Filter

• Provide air filtration

22 Wrench

• Use to install Air filter assembly and Drive spindle assembly

Accessories Bracket

• To hold wrench or other accessories

Cartridge Holder Bracket

• To hold extra Cartridge Holder

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6 SETUP AND OPERATION

NOTE: To ensure proper voltage setting, units shipped from the factory will not have the fuse installed. Refer to Section 6.1 to install proper fuse and select proper voltage.

6.1 Fuse Installation/Voltage Selection

1. Remove the fuse holder by using a flat head screw driver to pry it open.

2. Insert proper fuse into the fuse box, refer to table below

3. Re-install the fuse holder into the unit

4. Select the proper voltage by sliding the voltage switch up or down.

Voltage Range Voltage Setting Fuse Rating

100V – 120V 115V 2 Amp, Type F 220V – 240V 230V 1 Amp, Type F

Figure 7.0 Fuse Installation

Voltage Selector Switch

Fuse Holder

Screw Driver

Fuse Holder with Fuse installed

Fuse

Fuse Holder

6.2 Turn On the Unit

1. Insert the power cord to the power socket (Fig. 3, 20).

Caution: Make sure the proper fuse has been installed and correct voltage has been set. Refer to section 6.1 for instructions.

2. Connect the air filter assembly to the air inlet (Fig. 3, 21).

3. Connect the air hose to the air filter assembly

Caution: The air filter assembly (7091-9080), supplied with the unit, must be installed to ensure proper air filtration.

4. Set the air Pressure to 80 psi (5.5 bars) minimum

• Rotate the Air Pressure regulator knob (Fig. 1, 9) clockwise to increase the Air Pressure.

• Rotate the Air Pressure regulator knob counterclockwise to decrease the Air Pressure.

5. The desired Air Pressure will be displayed on the screen.

6. Turn on the unit by pressing the power button (Fig. 5). The cartridge holder should move up to home position. If it does not move up, please check pressure connection.

Power Cord

Air Filter

Figure 8.0 Air and Power Connection

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6.3 Cartridge Kit Preparation

Injection Kit: The TS6500 Mixer has an automatic injection

device that will inject the hardener into the catalyst during the mixing operation. However the valve in the mix rod needs to be opened before placing the kit in the machine. Follow below instructions to open the valve.

1. Insert the ram rod into the mix rod

2. Push the ram rod to force the valve opened

3. Follow instructions in section 6.4 to mix the injection kit

Barrier Kit

1. Remove barrier tape from the kit

2. Pull the mix rod down to the fullest extend to remove the foil from the dasher.

3. Follow instructions in section 6.4 to mix the barrier kit

Barrier tape

Dasher Foil

Mix Rod

Figure 10.0 Barrier Kit

Valve Mix Rod

Figure 9.0 Injection Kit

6.4 Loading the Cartridge Kit

Note: a. The unit is setup to mix cartridge kit with 8”(203mm) mix

rod. To mix cartridge kit with 6”(152mm) mix rod, the spindle extension needs to be installed. Refer to section

6.5 for instructions.

b. The TS6500CIM-6 is setup to mix 6 oz. (177ml) cartridge

kit. To mix 2.5 oz. (74ml) or 8.0 oz.(237ml) kit, Refer to section 12. for instructions.

1. Open the safety cover (Fig. 2, 12).

2. Load the cartridge kit into the cartridge h older (Fig. 2, 2).

3. Pull the mix rod to the fullest extend then align the two through holes of the rod to the drive spindle (Fig. 2, 6).

4. Insert the plunger assembly (Fig.2,16) into the cartridge holder with the plunger sit properly inside the cartridge.

5. Align the dowel pins of the plunger assembly with the bayonet slots in the cartridge holder and turn counterclockwise until it locked in.

6. Connect the air hose into the plunger air inlet (Fig. 2, 4).

7. Close the safety cover.

Plunger Assembly

Plunger Air Inlet

Mix Rod

Drive Spindle

Cartridge Holder

Lock Dowel pins in the slots

Figure 11.0 Loading the Cartridge Kit

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6.5 Spindle Extension Installation

Refer to Fig. 12 and Fig. 13

1. Place the wrench on the motor shaft (beneath the spindle).

2. Place a screw driver between the two locking pins of the spindle.

3. Hold the wrench and turn the screw driver counter clockwise to unscrew the spindle assembly.

4. Remove the spindle assembly from the motor shaft

5. Install the spindle extension on the motor shaft by turning it clockwise

6. Install the spindle assembly on the spindle extension by turning it clockwise

Figure 12.0. Remove Spindle Assembly

Spindle Assembly

Wrench

Screw Driver

Spindle Extension

Spindle Assembly

Figure 13.0. Spindle Assembly with Extension

6.6 Mixed Cycle Program Setup:

Refer to Fig. 5 and Fig 6

1. Press the Mode button (Fig. 5) to select Auto mode.

2. Press and hold the Setup button (Fig. 5) for 3 seconds to enter setup screen.

3. Press the Setup button (Fig. 5) to move the cursor to the “CYCLE” indicator.

4. Press the (+) and (-) button (Fig. 5) to set number of mixed cycle required

5. If delay time is required, press the Setup button to move the cursor to the “DELAY” indicator then press the (+) and (-) button to adjust delay time

6. Press and hold the Setup button for 3 seconds to save data. The unit is now ready to run.

6.7 Start the unit

1. Ensure the unit is in the Automatic Mode and the desired profile has been selected.

2. Press and release the Start buttons (Green) (Fig 2, 7) simultaneously.

3. The unit will run the selected profile. The cycle count and elapsed time will be displayed on the LED screen.

6.8 Unloading The Cartridge Kit

1. The machine will automatically stop once the mixing cycles are completed.

2. Open the protective cover (Fig. 2, 12)

3. Remove the retaining collar plunger assembly (Fig.2, 16) by turning it clockwise.

4. Place the retaining collar plunger assembly on the side bracket

5. Turn the cartridge kit clockwise to remove it from the drive spindle

6. Pull the cartridge kit out of the cartridge holder

6.9 Manual Mode

While in the manual mode, the injection rod, main cylinder and drive spindle motor may be controlled independently. Note: while in manual mode any errors will not halt the operation of the motors. Refer to Fig. 14

1. Press and hold the Mode button for 3 seconds to select Manual mode

2. Press the Power (-) button to activate the injection rod (the injection rod will move up)

3. Press the Mode button (+) to activate the motor (the drive spindle will rotate)

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4. Press the Setup button (↵) to activate the main cylinder (the cartridge holder will move up and down)

7 SPEED CONTROL

7.1 For main air cylinder

The main air cylinder drives cartridge kit up and down. The stroke speed of the main air cylinder can be adjusted by rotating the flow control screw (Fig. 15) clockwise to increase the speed and counterclockwise to decrease the speed

7.2 For injection rod

The injection rod air cylinder drives the injection rod up and down. The injection speed can be adjusted by rotating the flow control screw (Fig. 15) clockwise to increase the speed and counterclockwise to decrease the speed

8 EMERGENCY STOP

In case of an emergency, the mixing operation can be stopped at any time by pressing the EMERGENCY STOP BUTTON, (Fig 2, 10). After problems have been fixed, the machine can be restart by pulling and turning the emergency button counter clockwise. The mix cycle will start from the beginning.

Main Air Cylinder Flow Control

Injection Rod Flow Control

Figure 15.0 Side View

MODE

Figure 14.0 Manual Mode Screen

ACTIVATE INJECTION

ACTIVATE

MOTOR

SAFE TO

RUN

ACTIVATE

MIX

PRESSURE

9 TROUBLESHOOTING

PROBLEM POSSIBLE CAUSE CORRECTION

Unit fail to start

•

No power input

• Emergency button is pressed

• Safety door is not fully closed

•

Check power cord

connections

• Turn Emergency button clockwise to release

• Closed safety door

LCD does not light

• No power input

•

Check power cord

connections

• Check Fuse

• Turn on power

Air Cylinder does not move

•

Insufficient air

pressure

• Air hoses not plugged in

• Regulator defective

•

Increase air supply

pressure to 80 psi

• Check air connection

• Replace regulator

The hardener is not completely injected

•

Air cylinder is

damaged

•

Replace air cylinder

The injection rod does not retract

•

Injection rod is dirty

• Injection rod is bent

•

Clean rod

• Replace rod

Material is not completely mixed

•

Not enough mixing

cycle

• Insufficient air pressure

•

Increase number of

cycles

• Increase air pressure to 80 psi

Cartridge holder is not in “Home” position

•

Insufficient air

pressure

• Air hoses not plugged in

•

Increase air supply

pressure to 80 psi

• Check air connection

Mixing rod does not reach spindle

•

Extension spindle is

not installed for 6” rod

• Mixing rod in not fully extend

•

Install extension

spindle for 6” rod

• Extend mixing rod

No pressure on plunger

•

Plunger air hose is

not connected

•

Connect plunger air

hose

Plunger disk does not fit inside cartridge

•

Wrong plunger disk

size

•

Use correct plunger

disk size

Cartridge holder remains in the down position during mixing cycle

•

Sensor and magnet

is not aligned

•

Turn off unit and adjust

sensor / magnet alignment

Motor is not running

•

No power to motor

• Motor burned out

•

Check motor

connection

• Replace motor

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10 PROGRAM SELECTION

Up to 10 programs can be store in the the TS6500 Mixer.

1. Press the Set button (Fig. 5) to highlight the program number selection.

2. Press the (+) or (-) buttons to select desired program.

3. Press the Set button to exit.

11 CYCLE COUNTER RESET

The cycle counter can record up to 99999 mix cycle. To reset the cycle counter follow below instructions:

1. Press and hold Setup button for 3 seconds to enter setup mode.

2. Once the setup mode is displayed, ress and hold Setup button again until the cycle counter reset to “00000”

12 CARTRIDGE HOLDER INSTALLATION

Refer to Figure 16 and 17 The TS6500CIM-6 is setup to mix the 6.0 oz.(177ml) kit. To mix the

2.5 (74ml) or 8.0 oz.(237ml) kit the cartridge holder needs to be re-

install at different mounting locations as shown in Fig. 10.

Mounting Location for 2.5 oz. (74ml) Kit

Mounting Location for 6.0 oz.(177ml) Kit

Mounting Location for 8.0 oz. (237ml) Kit

Figure 16.0 Mounting Location

The cartridge holder can be installed in a few simple steps

1. Pull the release knob and push the Fluid level sensor assembly to the left

2. Loosen the locking screw by turning it counter clockwise.

3. Rotate the cartridge holder outward and pull it up to remove from the machine

4. Install new cartridge holder in reverse order

5. Pull release knob to rotate fluid level sensor assembly back into position.

Release Knob

Fluid Level Sensor

Fluid Level Sensor Assembly

Cartridge Holder

Locking Screw

Figure 17.0 Cartridge Holder

Page 11

13 MAINTENANCE

The TS6500 Mixer is designed and built to be relatively maintenance free. To assure trouble free operation, the following recommendations should be followed:

1. Make certain the air supply is clean and dry.

2. Avoid connecting the unit to excessive moisture or solvent saturation.

3. Use only Amyl Alcohol to clean outside surface of the main housing.

4. Use only soft cloth to clean the LCD.

5. Clean the injection rod regularly with clea ning solvent

6. Clean the tray regularly with cleaning solv ent

14 LIMITED WARRANTY

OK International warrants this product to the original purchaser for a period of one (1) year 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.

15 APPENDIX

15.1 Spare Parts List

ITEM PART NUMBER DESCRIPTION QTY

7091-9010 CARTRIDGE HOLDER ASSEMBLY, 2.5oz/6oz/8oz 1 7091-9030 CARTRIDGE HOLDER ASSEMBLY, 20 oz 1

7091-9040 PLUNGER ASSEMBLY, 2.5oz/6oz/8oz 1

7091-9060 PLUNGER ASSEMBLY, 20 oz 1 3 7091-0420 HOLDER, PLUNGER ASSEMBLY 1 4 7091-0120 SPINDLE EXTENSION 1 5 7091-0530 WRENCH, THIN HEAD, 19mm 1

6 7091-9080

AIR FILER ASSEMBLY (Filter only = TSD800-6)

7 6002-0703 POWER CORD 1 8 7091-0430 TRAY 1 9 5100-0079 START PUSH BUTTON 1

10 TSD500-29 AIR REGULATOR 1 11 5100-0078 E-STOP SWITCH 1 12 7091-0510 LCD COVER 1 13 7091-9070 SPINDLE ASSEMBLY 1 14 7091-0430 SAFTY DOOR 1 15 5100-0077 INTERLOCK SWITCH 1

Figure 18.0 Main Assemly

Page 12

Figure 18.0 Inside Assembly Level One

ITEM PART NUMBER DESCRIPTION QTY

36 2900-0015 LCD 1 38 7091-9000 PCBA, TECHKIT MIXER 1

ITEM PART NUMBER DESCRIPTION QTY

39 535 PLUNGER AIR INLET 1 40 5500-0008 FLUID LEVEL SENSOR 1 41 3300-0408 TUBE HOLDER, ¼” TUBE DIA. 1 42 7091-9140 MAIN AIR CYLINDER 1 43 5100-0060 VOLTAGE SELECT SWITCH 1 44 2100-0372 POWER CONNECTOR 1

Figure 19.0 Inside Front Cover Assembly

Figure 19.0 Inside Assembly Level 2

ITEM PART NUMBER DESCRIPTION QTY

45 TSD650-21 SOLENOID VALVE 2 46 2600-0132 SOLENOID VALVE, 4-WAY 1 47 1700-0027 DC POWER SUPPLY 1 48 7091-9150 AIR CYLINER, INJECTION ROD 1 49 TSD210-6 FLOW CONTROL 1 50 7091-9130 SPINDLE SHAFT ASSY /BEARING SLEEVE 1 51 7091-9160 MOTOR ASSEMBLY 1 52 2700-0046 FILTER, EMI, 115/250 VAC, 3A, 50-60 Hz 2 53 7091-9120 MOTOR DRIVER 1

Page 13

15.2 TECHKIT PART NUMBER CHART

SIZE PART NUMBER ROD LENGTH KIT TYPE

2.5 oz. (74ml)

250-61T 6" (152mm) Taped Barrier 250-81T 8" (203mm) Taped Barrier

250-60 6" (152mm) Injection 250-80 8" (203mm) Injection

6.0 oz.

(177ml)

600-61T 6" (152mm) Taped Barrier 600-81T 8" (203mm) Taped Barrier

600-60 6" (152mm) Injection 600-80 8" (203mm) Injection

8.0 oz.

(237ml)

800-61T 6" (152mm) Taped Barrier 800-81T 8" (203mm) Taped Barrier

800-60 6" (152mm) Injection 800-80 8" (203mm) Injection

20 oz.

(591ml)

200-81T 8" (203mm) Taped Barrier

200-80 8" (203mm) Injection

1/10 gal (325ml)

110-81T 8" (203mm) Taped Barrier

110-80 8" (203mm) Injection

LOCAL DISPENSING SOLUTIONS WORLD WIDE

OK INTERNATIONAL

TECHCON SYSTEMS OEM DIVISION

12151 MONARCH STREET

GARDEN GROVE, CA 92841

PHONE: (714) 799-9910

www.techconsystems.com

7000-2860A