VALCO MELTON EC14, Instruction Manual

Page 1: ...chinery Indication marking and actuation Directive 2006 95 CE of 12 December 2006 which replaces Directive 73 23 EEC of 19 February 1973 on electrical equipment Directive 2004 108 EC of 20 July 2007 which replaces Directive 89 336 EEC of 3 May 1989 on Electromagnetic Compatibility Directive 93 68 EEC of 22 July 1993 which modifies 73 23 EEC and Directive 89 336 EEC Hoses are factory tested at 100 ...

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Page 5: ...RATION FOLLOW THE SAFETY INSTRUCTIONS PROVIDED IN THIS MANUAL WHEN USING AND HANDLING THE MACHINE FAILURE TO FOLLOW SAFETY INSTRUCTIONS MAY RESULT IN BURNS INJURY OR PERMANENT PHYSICAL DAMAGE YOU MAY ALSO DAMAGE THE EQUIPMENT OR OTHER MATERIALS WARNING If you alter the function performance or safety aspects of the machine replacing original parts with other similar but not identical components sub...

Page 6: ...TALLATION REQUIREMENTS 19 3 4 MECHANICAL INSTALLATION 20 3 5 PNEUMATIC INSTALLATION 25 3 6 ELECTRICAL INSTALLATION 25 3 6 1 Routing Low Voltage Leads 25 3 6 2 Connecting the Electrical Power 26 3 6 3 Input Output Connections 27 CHAPTER 4 MACHINE ADJUSTMENT ___________________________ 30 4 1 INTRODUCTION 31 4 2 TEMPERATURE CONTROL 31 4 3 OTHER ADJUSTMENT 43 CHAPTER 5 OPERATION______________________...

Page 7: ...UCTION 86 7 2 MECHANICAL FAULTS 86 7 3 ELÉCTRICAL FAULTS 89 7 4 ADHESIVE APPLICATION PROBLEMS 95 CHAPTER 8 EQUIPMENT REPAIR GUIDE _______________________ 102 8 1 INTRODUCTION 103 8 2 CHANGING THE FILTER 103 8 3 REPAIRING THE MANIFOLD 104 8 4 REPAIRING THE PNEUMATIC PUMP UNIT 105 8 5 CLEANING VALVES 114 8 6 REPAIRING ELECTRIC COMPONENTS 115 8 7 REPAIRING VACUUM FEEDER 115 CHAPTER 9 LOG SHEETS______...

Page 8: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 3 CHAPTER 1 SAFETY INSTRUCTIONS ...

Page 9: ... Miscellaneous prohibitions Danger hot surface Miscellaneous precautions Precaution Electric current Precaution Flammable liquid Precaution risk of fluid leakage under high pressure Precaution risk of entrapment between mobile parts Use of safety gloves required Use of goggles required Note of special interest European Community markings Elements susceptible to electrostatic discharge ...

Page 10: ...the machine Protective clothing Clothing will be compliant with EN510 and EN340 standards protecting against flying debris and high temperatures Clothing will be as tight as possible to prevent it from catching on mobile machine parts and the sleeves waist legs etc will be adjustable to the size of the wearer Goggles and face shields Goggles will be compliant with the EN 166 standard protecting ag...

Page 11: ...ammable atmospheres When working with this machine wear protective clothing gloves and face shields and remove rings bracelets and watches Since the machine is designed to form part of a series of machines arranged to work together the hot melt applicator cannot be operated until the entire series has been declared in compliance with applicable directives This machine should never work without the...

Page 12: ...to remove the adhesive from the skin even after it has cooled as this may cause more serious injury Seek qualified medical attention immediately In case of an accident with the solvent CONTACT WITH THE SKIN Wash the site with soap and water and discard all contaminated cloths CONTACT WITH EYES Wash the eyes in an eye bath for at least 15 minutes INHALATION In case of exposure to fumes take the pat...

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Page 14: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 9 CHAPTER 2 DESCRIPTION ...

Page 15: ...n es www valcomelton com 10 2 1 INTRODUCTION This machine is designed to melt hot melt adhesive or similar materials in a heated reservoir A pump then pressurizes the adhesive and transfers it to a manifold where it flows through heated hoses to the application point 2 2 MAIN PARTS The main machine parts are shown in the following figure ...

Page 16: ...s can heat it indirectly The manifold filter consists of a core and a fine in line filter screen to filter crystal particles or dirt that could be present in the adhesive The manifold has six outlet holes to connect the Hot Melt hoses three on the top row and three on the bottom row Pump The pump delivers the Hot Melt or other molten product at a set pressure from the tank to the substrate or mate...

Page 17: ...ne s operating and adjustment switches is on the front of the main electrical cabinet 2 2 7 Discharge module The discharge module actuates like a flow valve When the system is operating normally the module stays closed but if there is an electric failure the module will open immediately the air to maintain it closed has been stopped due to the electric failure so that pressure in the hoses and gun...

Page 18: ...eder will supply adhesive until it detects high adhesive level If the adhesive does not load before 200 seconds an amber colored light will blink and an alarm will sound When the vacuum feeder lid is opened it will deactivate To reactivate it close the lid and lock it properly 2 2 10 Other key elements Pressure regulator This is the element used to raise or lower the pressure to the piston pump It...

Page 19: ...psi Noise level 63 dB Working temperature 10 50 ºC 32 122ºF HR 20 to 80 non condensed CONTROL Working temperature 15º 230º C 59º 446º F Temperature control precision 0 5º C 1º F Type control PID Control PUMP LOW FLOW HIGH FLOW Pumping capacity Kg h 35 100 Pump compression ratio 1 14 1 13 Pneumatic working pressure 0 5 to 6 bar TANK EC4 EC8 EC14 Volume litres 4 8 14 Melting capacity Kg h 4 2 7 9 13...

Page 20: ...RCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 15 2 4 DIMENSIONS 2 4 1 GENERAL DIMENSIONS MODEL TYPES A B Dimensions mm EC4 EC8 EC14 A 307 307 367 B 583 658 658 C 532 532 592 D 631 631 691 E 340 340 398 F 0 51 51 F A F E F D F C F B F ...

Page 21: ...COYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 16 2 4 2 GENERAL DIMENSIONS WITH VACUUM FEEDING MODEL TYPE C Dimensions mm EC4 EC8 EC14 A 307 307 367 B 583 658 658 C 532 532 592 D 662 662 724 E 296 296 358 F 0 51 51 F A F B F C F D F E F ...

Page 22: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 17 ...

Page 23: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 18 CHAPTER 3 MACHINE INSTALLATION ...

Page 24: ...ety instructions 3 2 TRANSPORT The unit is supplied packed in a cardboard box Remove the top and sides to unpack it Unpack carefully to prevent machine damage Inspect the equipment for damage caused during transport 3 3 INSTALLATION REQUIREMENTS Install the following equipment leaving enough space for access during operations Avoid extreme temperatures below 10 C and above 50 C Avoid installing th...

Page 25: ...odel type C only Positioning the equipment Remove the equipment from the box and position it according to installation requirements chapter 3 3 Connecting the hoses Proceed as follows Make sure the equipment is depressurised before connecting the hose Set the air pressure regulator to zero and activate valves to bleed pressure Heat the machine to melt any adhesive that may be present Remove the ap...

Page 26: ...x 34 948 326584 melton melton es www valcomelton com 21 Connect the hoses from right to left Failing to do so will create a dead spot where carbon deposits accumulate increasing nozzle blockage problems For the hydraulic connection If the unit is full of adhesive heat the tank before removing the manifold cap ...

Page 27: ...Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 22 Hose Installation Never bend the hoses to a radius less than 150 mm The hoses should not be in contact with very wide cold surfaces YES ...

Page 28: ...5 mm between them so heat can dissipate Do not cover the hoses If it is necessary to do so leave ventilation holes for heat dissipation Do not install hoses with tight clamps Installing the Vacuum Feeder Proceed as follows to connect the vacuum feeder 1 Remove the vacuum feeding kit from the packaging This kit includes all of the tubes needed to install the feeder as well as other components to be...

Page 29: ...lcomelton com 24 2 Use a clamp to connect the lower tube to the part of the chimney located above the tank cover reserved for the feed outlet as shown in the picture 3 Connect the air line provided in the vacuum feeder kit to the flow regulator visible on the upper part of one of the sides as shown in the picture Flow regulator Secure with a clamp ...

Page 30: ...esult in personal injury death or damage to equipment When routing low voltage leads follow these guidelines Do not route low voltage leads in the same conduit as wires carrying a high current load Do not route low voltage leads adjacent to or across wires carrying a high current load If low voltage leads must cross or run parallel to wires carrying high current keep the leads at least 6 152 mm fr...

Page 31: ... equipment The use of an earth leakage or ground fault power breaker is recommended with this unit This unit must be earthed or grounded Failure to observe could result in personal injury death or damage to equipment The EC hot melt unit can be set up to use one of the following power sources Incoming Electrical Service Power Connector Terminals Voltage Plug Connector Label A B C D PE Part No Colo...

Page 32: ...connector terminals as shown in the chart above 6 Install the appropriate voltage selector plug into the connector marked J15 on the 12 zone board see illustration 7 Plug the power connector into the 12 zone board see illustration 8 Verify that all connectors are fully seated and the power connector terminal screws are secure 9 Close the electrical enclosure door 240V 3Ø 029XX435 POWER INPUT 240VA...

Page 33: ...5A each CPU Board Showing Input Output Connectors Inputs and Outputs can be programmed for the following functions Input and Output Functions Inputs 1 4 523 Outputs 1 4 524 Disabled Disabled Hose and Gun 1 thru 6 On Off Setback On All Heaters On Off Alarm Pump On Off Ready Pump On Auto Setback System Ready Setback Power On External Level Internal Level The diagrams show the functions of the CPU Bo...

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Page 35: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 30 CHAPTER 4 MACHINE ADJUSTMENT ...

Page 36: ...ess the parameter programming as well as the main machine operating permissions alarms and diverse work functions that will be described later on the equipment regulates the temperature of the resistors connected to the various dual hose gun channels 2 4 or 6 depending on the model and those connected to a special channel that heats the tank The control panel displays the equipment operating data ...

Page 37: ...8 321580 Fax 34 948 326584 melton melton es www valcomelton com 32 4 2 3 Description of the control panel 4 2 3 1 Keyboard The unit control panel has 11 control keys that provide access to the programme menus and general operating processes 6 3 7 1 2 5 4 21 23 20 22 13 8 9 10 16 17 14 15 18 19 12 11 ...

Page 38: ... Button Moves to the right through editable fields on the selected menu 11 Less Button Decreases the value of the selected parameter 12 Left Arrow Button Moves to the left through editable fields on the selected menu 13 Settings Screen Displays the menu screens 14 Configuration Button Displays the configuration screens 15 Configuration LED Green when the equipment enters the configuration screen 1...

Page 39: ...lt unit Press the Standby button The screen will turn on and the LED will be green indicating that the unit is on When the Standby button is pressed again the screen will go blank and the Standby LED will be orange indicating that the unit is in Standby mode When the unit is in Standby mode the internal timer begins working The timer will turn the unit off and on according to the programmed shifts...

Page 40: ...time of 200 seconds A buzzer will go off for warning It can be reset by pressing the Enter key but the amber light will continue to blink there is an adequate adhesive level in the tank 4 2 3 4 Navigation The navigation symbols at the top of the screen indicate that additional menus are available Use the following buttons to navigate 4 2 3 5 Settings The information displayed can be edited Use the...

Page 41: ...os C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 36 4 2 3 6 Entering Passwords The password is required to prevent unauthorised access to the programming unit To enter a password Introduce the password ...

Page 42: ...to display the first temperature screen 4 2 3 8 Temperature Screens The tank temperature screen displays the current and programmed temperature Output 1 and output 2 temperatures alternate on the screen to the right Press the temperature button repeatedly or use the navigation keys to select the desired temperature shown on the screen Current tank temperature Current hose temperature Current gun t...

Page 43: ...03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 38 4 2 3 9 Tank temperature 4 2 3 10 Hose Gun temperature END ...

Page 44: ...3 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 39 To programme hose gun 2 repeat the same process as described ...

Page 45: ...s green when each zone reaches the programmed temperature The system gives permission The permission activates the pump This prevents the pump from activating before the adhesive melts See the adhesive technical data sheet to find the melting point The pre programmed temperature must be set to at least 5ºF 3ºC If set too close to the point for example 1ºF the pump will stop momentarily until the t...

Page 46: ...ELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 41 4 2 3 12 Temperature unit The equipment has the option to choice between two temperature units ...

Page 47: ... ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 42 4 2 3 13 Beacon output The control board has two alarm outputs for beacon of 24VDC The alarm options to have each one of them are Low level Zone fault Ready Pump on Setback on X1 X7 ...

Page 48: ... their respective temperature setpoints minus the System Ready Temperature Offset This feature allows the adhesive in the system to heat for an additional period of time before the piston pump is enabled Once the zones have reached the System Ready Temperature the time remaining before the system is ready is displayed on the status bar at the bottom of the screen The ready delay range is 1 minute ...

Page 49: ...oint of each zone The over temperature alarm tolerance is the number of degrees that any zone can heat above its temperature setpoint before triggering an over temperature alarm If any zone goes into Over Temperature Alarm the heaters of the affected zone are automatically shut off The over temperature alarm tolerance range is 9 F to 108 F 5 C to 60 C The factory default setting is 45 F 25 C This ...

Page 50: ...e The under temperature alarm tolerance is the number of degrees that any zone can cool below its temperature setpoint before triggering an under temperature alarm If any zone goes into Under Temperature Alarm the heaters of the affected zone will remain on to compensate for the drop in temperature The under temperature alarm tolerance range is 9 F to 108 F 5 C to 60 C The factory default setting ...

Page 51: ...26584 melton melton es www valcomelton com 46 4 3 4 Maximum Temperature The Maximum Temperature setting is the maximum value for the setpoint of any zone The maximum temperature range is 32 F to 446 F 0 C to 230 C The factory default setting is 446 F 230 C This parameter can be accessed in Password Level 3 or higher X6 ...

Page 52: ... reduce the temperatures of all zones by a given temperature differential to allow the hot melt to remain soft but not molten during periods of inactivity The setback temperature differential is relative to the temperature setpoint of each zone The setback temperature differential range is 45 F to 342 F 25 C to 190 C The default factory setting is 90 F 50 C This parameter can be accessed in Passwo...

Page 53: ...e unit does not see an external input within the automatic setback timeout period the unit will automatically go into setback The Automatic Setback Timeout feature is used only in conjunction with the Automatic Setback External Input It is not used in manual or scheduled setback modes The automatic setback timeout range is 1 minute to 120 minutes The default factory setting is 30 minutes This para...

Page 54: ...s the hoses to begin heating after the tank reaches a specified temperature offset below the setpoint temperature This feature is used to reduce adhesive degradation caused from heating adhesive in the hoses for long periods while waiting for the tank to reach temperature The sequential start range is 0 F to 450 F 0 C to 250 C The default factory setting is OFF This parameter can be accessed in Pa...

Page 55: ...ws the gun to begin heating after the tank reaches a specified temperature offset below the setpoint temperature This feature is used to reduce adhesive degradation caused from heating adhesive in the gun for long periods while waiting for the tank to reach temperature The sequential start range is 0 F to 450 F 0 C to 250 C The default factory setting is OFF This parameter can be accessed in Passw...

Page 56: ...tputs include alarms and system ready signal See below for other choices See Connections in Section 4 Installation for a detailed description of these features This parameter can be accessed in Password Level 3 or higher see Section 8 Password Levels Sub Menu Choices Input 1 4 Output 1 4 Disabled Disabled Setback System Ready Auto Setback Ready Pump On Pump On Off Alarm Tank On Off Standby Tank Ho...

Page 57: ...ory The Fault History Screen keeps a log of all faults that occur with any zone The Change History Screen keeps a log of all parameter and setting changes The Fault History and the Change History are cleared when the unit is turned off 4 3 11 Diagnostics The Diagnostics Screen shows the current software version as well as the current temperature and status of each zone X3 X3 ...

Page 58: ...NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 53 4 3 12 Clock and 7 Day Timer The Clock sub menu is used to set the current day and time and to setup shifts with on off and setback times temperatures that are automatically run by the internal clock ...

Page 59: ...d the OK Button to get a thumbwheel to set the times and turn on the setback feature with a switch on the thumbwheel The heaters can be set with or without using the setback times Set the start stop and setback times for all shifts Leave the unused shifts times blank Shift A B or C Setback Start Stop Times for the shift shown above Heaters Start Stop Times for the shift shown above This screen ind...

Page 60: ...ugh the days of the week Shift A B or C Setback Start Stop Times for the shift shown above Heaters Start Stop Times for the shift shown above This screen indicates that for shift C nothing will be activated as there is no shift C in operation This screen indicates that three shifts A B C will be operating on Monday This screen indicates only the A shift will be operating on Monday After configurin...

Page 61: ...6584 melton melton es www valcomelton com 56 Moving Through the Shift Time Day Screens X2 X2 X4 X4 Continue using the Right Left Up Down and OK buttons to configure all of the shift times and which shifts will operate on which day Activate the timer and the unit will be ready to function with the shift times established ...

Page 62: ...he factory default settings follow these steps Restoring the factory default settings will permanently 1 Switch off power to the unit 2 Power the unit back up while pressing and holding the Setup Button and the OK Button on the keypad The buttons can be released once the start up screen appears erase changes made to any parameter or setting Clock key Press the Clock Button to enable all shift sett...

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Page 64: ...ffset The system ready signal enables the pump motor This prevents the pump motor from being activated before the adhesive in the pump has softened Consult the adhesive data sheet to find the softening point temperature The System Ready Temperature Offset must be set to at least 5 F 3 C If it is set too close to the setpoint for example 1 F the pump motor will stop during momentary drops in temper...

Page 65: ...t shows the time remaining on the currently installed glue filter When the counter gets down to zero 0 an alarm can be sounded and the filter needs to be changed or cleaned Once the filter has been serviced the timer can be reset for a user set time of up to 2000 hours We have to program Beacon 2 see page 50 to Alarm in this way the screen will show a message when we should change the filter After...

Page 66: ...OT FILL MODE In this mode of operation melted glue is pumped into an external pot when the external lever control falls below a set level The external level control is wired to the external level input on the CPU J6 In this mode the pump turns on ONLY when it receives a signal from the external level input and the unit is ready Normal pump operation is ignored in this mode The automatic pump mode ...

Page 67: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 62 ...

Page 68: ... Turn the screw clockwise just until the light changes to RED YELLOW flashing Observe that after three seconds of flashing the light is green After that turn the screw 2 turns counterclockwise IF THE LIGHT IS GREEN POSITIVE DETECTION Turn the screw counterclockwise just until the light changes to red Now turn carefully the screw clockwise just until the light changes to RED YELLOW flashing Observe...

Page 69: ...level sensor is mounted in the hot melt control tank so that when the adhesive drops below the sensor a feeder valve is energized to feed glue into the tank to be melted This feature has a safety door switch that will disable the feeder if the tank door is opened The door switch internal level sensor and feeder valve need to be connected to the CPU board to operate properly The internal low level ...

Page 70: ...the element that indicates pressure in bar and psi at which the pneumatic pump and the compensating valve are operating Pull the knob out to set and push it down to lock Set the pump pressure to 40 Psi 2 5 bar The pump will operate and pressurize the system This pressure is a starting point setting You may need to change the pressure setting depending on application The ratio between pneumatic and...

Page 71: ...ve Detection The probe interprets that the tank is full It does not activate the output that orders the feeder to load adhesive Red Light Negative Detection The probe interprets that the tank is not full and orders the adhesive feeder to be loaded Red Yellow Intermittent Light Positive Detection Disconnect Delay After switching from a negative detection to a positive detection the probe maintains ...

Page 72: ... the probe position the correct height is obtained by securing it as closely as possible to the end of the probe The high level detector must be situated at the level where the adhesive covers the tip of the probe slightly If the probe is re calibrated to the level with the probe fully covered there may be a risk of adhesive overflow and high air filter wear due to adhesive splash during the filli...

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Page 74: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 69 CHAPTER 5 OPERATION ...

Page 75: ...ff Switch to the On position to power up the system Note The Standby LED will illuminate green when the power to the unit is on If the Standby LED illuminates orange the unit is in Standby Mode Press the Standby Button to turn the unit on Once the unit has completed its start up sequence it will turn on the heaters in the tank and all active hoses and guns The heater s corresponding Zone LED will ...

Page 76: ...ontains LEDs that indicate the status of each heated zone When the zone is in warm up mode the zone LED will illuminate green and stay on continuously Once the zone reaches its setpoint temperature the LED will blink on and off indicating that the heaters are switching on and off to maintain the setpoint temperature If the LED illuminates red it indicates a fault for that zone The status bar will ...

Page 77: ...setpoints minus the System Ready Temperature Offset The system ready signal enables the pump motor This prevents the pump motor from being activated before the adhesive in the pump has softened Consult the adhesive data sheet to find the softening point temperature of the adhesive 5 3 CLOCK ON OFF The Clock must be On Clock LED illuminated green for all of the programmed scheduled shifts to run un...

Page 78: ... the arrow navigation keys to access the temperature and time set screens and entering values on these screens see the Machine Adjustment section 5 4 1 Automatic Setback Automatic setback can be programmed through one of the remote inputs from the input screen When an input is set for Auto Setback AND the Auto Setback Timeout is enabled the control will AUTOMATICALLY go into set back if the input ...

Page 79: ... tank lid and add adhesive to the tank For setup details refer to Section 4 5 7 BEACON ALARM The Beacon Alarm output connector is provided as a dedicated 24VDC 0 5A output for a visual or audio alarm This can be set up to alert the operator of one of 4 fault conditions see Section 5 Setup for description The installer can connect the lead of the alarm to Beacon 1 pin 3 and the lead to GND pin 1 of...

Page 80: ...elow the edge of the tank 2 Close the tank cover immediately after filling the tank Models type C With Vacuum Feeding 1 Make sure that the tank is clean and free of foreign particles 2 In this case the equipment is fed automatically by the installed vacuum feeder The sensors detect when the tank needs adhesive as well as when it is no longer needed This way the person handling the equipment does n...

Page 81: ...ver is closed it will begin loading again automatically Note Never operate the applicator if the tank is empty If the quantity of hot melt material is very small the adhesive may degrade leading to the carbonisation of the HOT MELT material and the formation of deposits inside the unit This may lead to unnecessary downtimes later on Emptying the Tank Before emptying the tank put on a face shield g...

Page 82: ...g the filter and seals on the dismantled parts is recommended once the tank is empty Bleed Process The bleed process is done to sweep away small crystallisations that may be produced in the filter and to depressurize the system Before purging the filter put on goggles gloves and a long sleeve shirt to prevent possible burns caused by hot adhesive splashing 1 To purge the filter the applicator must...

Page 83: ...minating particles 6 Close the bleed valve with a screw driver 7 Return the pressure to the appropriate working pressure 5 10 STOPS There are two cases Pump stop If you wish to stop pumping you must turn the pressure regulator to 0 The temperature control will maintain the equipment temperature If the stop is to be for an extended period activating the Setback function is recommended See Section 4...

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Page 86: ...al recommendations for proper maintenance Keep the tank as full of adhesive as possible This will reduce the formation of charred adhesive on the tank s inner walls Keep the tank cover closed Any contamination in the tank will increase the possibility of low performance Humidity dirt and charred adhesive are the main causes of nozzle obstruction Use cheesecloth to remove material leaking from the ...

Page 87: ...uency depends on the type of adhesive used and the environmental conditions where the equipment is placed 6 3 MAINTENANCE PROCESSES 6 3 1 Cleaning the equipment Vacuum the dust or glue remnants or remove them with a soft cloth especially from the manifold and bleed valves Clean the control panel periodically with a soft cloth Do not use solvents which could damage the control panel Use a soft clot...

Page 88: ...ove the pump casing follow these steps 1 Unscrew the two screws on the pump casing one quarter turn 2 Release the fast on terminal on the inside 3 To reinstall the cover do the steps in reverse order 6 3 4 Changing Adhesive To replace one adhesive with another empty the system See 5 2 Emptying the Tank Emptying the system is important when changing the adhesive Not doing so may cause equipment dam...

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Page 90: ...US0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 85 CHAPTER 7 TROUBLESHOOTING THE EQUIPMENT ...

Page 91: ...solved with the information provided here contact your Melton representative 7 2 MECHANICAL FAULTS Check to see if the filters are blocked Check to see if the modules are obstructed Check to see if the control solenoid is working The pump does not stroke Verify that the applicator is at the right temperature Check the air pressure Check the hydraulic sub unit seals The pump strokes too quickly Che...

Page 92: ...gun does not deposit adhesive when the electrovalve operates Check the temperature of the tank hoses and guns Check if the gun electrovalve works Check to see if the nozzles are obstructed remove and clean Check the filters Check if the module seat is blocked remove and clean Check if there is a leak from the module bleed hole change seals Check if the hose is blocked ...

Page 93: ...tank Check that the tank is not empty Check tank pneumatic connections and air pressure Comprobar la presencia de obstrucciones en el recorrido de la granza Check Vacuum Feeding electrovalve operation The charger exceeds the desired adhesive level Check loader valve pneumatic connections and air pressure Check loader valve operation manually Check that the charger module pellet vibrator Works corr...

Page 94: ...Check that the breaker is the right one for the unit power requirement The machine does not come on Check the connection of the power supply to the machine Check the power fuses of the electronic card The unit turns on but is not enabled Check that the unit is programmed with the correct parameters Check the over temperature thermostat The Tank overheats Check the Tank RTD Check if the zone triac ...

Page 95: ...connected correctly Check if the triac functions correctly Check that the control board does not read faults Check the Tank temperature sensor Check the tank heaters Once these checks are made restart the unit cycle power Check the over temperature thermostat function Verify that the temperature is programmed correctly Check if the tank heaters are short circuited Verify correct tank Heather curre...

Page 96: ...Check the gun fuse Check for correct gun triac operation Check that the channel is enabled and that it is at the right temperature Ensure that the connector is inserted correctly Check that the pins inside the hose unit and gun connectors are in good condition and not turned back If the sensor is short circuited or opened the display shows RTD Disconnected A hose overheats Check the hose temperatu...

Page 97: ...mperature sensor Check the correct connection of the hose connectors Check the hose electrical resistance Check the hose fuse Check for correct hose triac operation Check that the channel is enabled and is at the right temperature Ensure that the connector is inserted correctly Check that the pins inside the hose and unit connectors are in good condition and not pushed back If the sensor is short ...

Page 98: ...ect safety thermostat operation Alarm for configuration or hose and gun connections Overtemperature alarm in the gluer or peripherals Check fuses Check for correct electrovalve connections Check that the pins inside the connector are in goodcondition Ensure that the connector is connected correctly Check if there is a 24V output when the LED lights up Check the electrovalve coil Check to see if th...

Page 99: ...level Check that the probe ground wire is attached to the unit Check that the charger timer settings are correct Consult your ValcoMelton representative The charger does not fill the tank at the desired level Check that the probe ground is linked to the unit Check that the charger timer settings are correct Consult your ValcoMelton representative Check that the alarm timer settings are correct Con...

Page 100: ...beads Low temperature Nozzles far from the surface to be glued Raise temperature Bring nozzles closer Too much glue at the start and end of bead Nozzles far from surface to be glued Low pump pressure Dirty nozzle blocked Bring nozzles closer Increase pressure Clean and unblock nozzle Bead break Adhesive too viscous Adhesive cold Adhesive old Increase temperature Increase temperature Change the adh...

Page 101: ...gel Hair Applicator far from the surface to be glued Adhesive cold Adhesive old Adhesive too viscous Bring closer Fill tank with new adhesive Screen applicator to protect it Increase the temperature slightly Warm the ambient air Preheat the substrate Increase the temperature slightly Draft on the applicator and or low ambient temperature Increase the adhesive temperature slightly ...

Page 102: ...et too large Reduce pump pressure Close by twisting several times Change to a smaller nozzle Drops of adhesive forming on the applicator nozzle Hole blocked and or seat worn or dirty Incorrect adjustment Incorrect air pressure to shut off valves Clean and or replace dirty and or worn parts Adjust the stroke opening Adjust air pressure Frequent nozzle obstructions Change adhesive type Increase in s...

Page 103: ...dhesive from the substrate Adhesive temperature too high Pump pressure too high Adhesive viscosity too low Reduce the temperature Reduce pump pressure Reduce temperature Use higher viscosity adhesive Use smaller nozzle Reduce pump pressure Open the regulator Adhesive is smoking Applicator is too far from the substrate Adhesive too hot Use more stable adhesive Reduce temperature ...

Page 104: ...nk temperature too high Temperature control fault Adhesive level low Adhesive oxidation Reduce tank temperature Readjust temperature control or replace card Keep tank full Keep tank cover closed Gelatinous adhesive Overheating Incompatible adhesives mixed together Reduce the temperature Empty the system and wash it thoroughly Check adhesive compatibility Empty the system and wash it thoroughly ...

Page 105: ... tank and operate applicators until the bubbles disappear Adhesive too viscous Increase the temperature slightly Use a lower viscosity adhesive Moisture in the adhesive Check by applying adhesive on dry substrate Dry the substrate Operate applicator until the bubbles disappear Moisture in the substrate Check for Moisture in the adhesive Use adhesive that is free of Moisture Consult the adhesive ma...

Page 106: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 101 ...

Page 107: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 102 CHAPTER 8 EQUIPMENT REPAIR GUIDE ...

Page 108: ...Before changing the filter put on a face shield gloves and a long sleeve shirt to prevent possible burns caused by hot adhesive splashing Keeping a filter on hand to replace when necessary is recommended This replacement is quick and improves equipment performance 1 To change the filter the applicator should be at working temperature 2 Reduce the applicator air pressure to 0 3 Place a receptacle b...

Page 109: ... element that distributes Hot Melt after it has been filtered to the hoses and guns It is assembled at the bottom of the tank so that the tank heaters heat it indirectly The manifold has six outlet ports to connect the Hot Melt hoses three at the bottom and another three at the front Do not disassemble the manifold This operation should only be done if there is a Hot Melt leak between the tank and...

Page 110: ...hat occurs when changing pump direction and to enable maximum uniformity in Hot Melt flow Before disassembling the hydraulic unit put on goggles gloves and long sleeves to avoid possible burns from splashes of hot adhesive 1 Warm the tank until the adhesive is melted 2 Reduce the air pressure to zero 3 Eliminate system pressure by releasing the guns manually or by opening the bleed valve 4 Disconn...

Page 111: ...instructions carefully Positioning and alignment of some elements are critical to perfect pump operation In the event the pump not working correctly carry out the following checks Is the air pipe connected Does the electrovalve work Is the equipment at the right temperature Is the regulator working at the right pressure Are the filters clean Are the modules blocked Is the shaft aligned correctly ...

Page 112: ...330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 107 8 4 1 High Flow Pump CYLINDER HYDRAULIC UNIT ...

Page 113: ...Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 108 8 4 1 1 CYLINDER 1 Loosen the screws 2 Separate the units 3 Loosen the four standoffs 4 Loosen the shaft knob and socket joint ...

Page 114: ...MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 109 8 4 1 2 HYDRAULIC UNIT 1 Loosen the screws 2 Separate the units 3 Turn and separate the nut ...

Page 115: ...O MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 110 4 Loosen 5 Remove the shaft 6 Remove the spring and inlet tube 7 Remove the spring guide ...

Page 116: ...330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 111 8 4 2 Low Flow Pump CYLINDER HYDRAULIC UNIT ...

Page 117: ... Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 112 8 4 2 1 CYLINDER 1 Loosen the four screws on the bottom 2 Loosen the four standoffs 3 Loosen the shaft knob and socket joint ...

Page 118: ... 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 113 8 4 2 2 HYDRAULIC UNIT 1 Loosen the four screws on the bottom 2 Loosen 3 Loosen 4 Remove the shaft 5 Remove the spring and inlet tube 6 Remove the spring guide ...

Page 119: ...ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 114 8 5 CLEANING VALVES 1 Loosen the four screws on the bottom 2 Loosen 3 Clean the valve 4 Use the M6 Allen wrench to remove the compression valve 7 Remove the ball and spring and clean ...

Page 120: ...rly bled and depressurised WARNING When a fuse is blown it is essential to replace it with fuses supplied with the equipment If fuses are not available use ULTRAFAST fuses with the same characteristics ELECTRONIC CARD WARNING During equipment manipulation avoid contact with electronic elements and connector metallic parts elements susceptible to electrostatic discharge 8 7 REPAIRING VACUUM FEEDER ...

Page 121: ...80 Fax 34 948 326584 melton melton es www valcomelton com 116 Attach the quick connect fitting Place the air filter onto the exhaust to the air inlet module Press the end of the cable and Vibrator module mounted insert the air hose Open the main air inlet Turn on the equipment The equipment is ready again ...

Page 122: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 117 CHAPTER 9 LOG SHEETS ...

Page 123: ...MUS0330202 03 10 2014 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 118 DATE INCIDENCE ...