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Manual Kobra.ingl

1. 2 73 8 3 REPAIRING THE PNEUMATIC PUMP 6 22 24 74 8 4 REPAIRING ELECTRIC ITEMS nnenennvnennnnenennvnenennenennvnnnenennenevennenensnnevensenensnnevensenener 82 CHAPTER 9 SOFTWARE SPECIFICATIONS eere sees eene 59 9 69 83 9 1 FUNCTIONS I O CARD PULSES 3 84 9 2 MODBUS COMMUNICATIONS rsennvnennnnvneunvnnnnnnnnennvnnnennnnenevennenensnnenensenensvnenensenennn 86 MUS0320201 27 03 2008 2 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati MUS0320201 27 03 2008 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com AD A Valco Cincinnati Compan CHAPTER 1 SAFETY INSTRUCTIONS MUS0320201 27 03 2008 4 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com A ELON A Valco Cincinnati 1 1 SYMBOLS AND TERM
2. CAA A Valco Cincinnati CHAPTER 2 DESCRIPTION MUS0320201 27 03 2008 10 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 6 KMD MELION A Valco Cincinnati 2 1 INTRODUCTION It is a machine that by means of thermal action transforms the Hot Melt or similar materials from solid state to liquid in a heated deposit and by means of a pump absorbs it at a specific pressure through heated hoses to the area to be used in 2 2 MAIN PARTS The unit s main parts are shown in the following figure Description of the basic unit option A 6 Control panel 7 Discharge module Description of optional units DESCRIPTION ides Complete option Chipping Loader V Level sensor V MUS0320201 27 03 2008 11 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com I WELTON A Valco Cincinnati Compan NOTE Lamp function changes for B and C options In B option lamp come on when the level sensor detects a low adhesive level In C option lamp come on when a failure in the applicator is detected 2 2 1 Rack It is the base on which the unit set it on 2
3. Ev ELECTRICAL VERIFICATIONS MENU PROGRAM VERIFICATIONS 150 180 TEMPERATURE CONTROL HYDRAULIC VERIFICATIONS 100 bar LU UU O UNIT NUMBER USER EE UNI E t ADDRESS ore i CITY nere TELEPHONE tess tc CONTACT MR MRS eerte LOCATION OF UNIT 55 2 64444 2 1 0 0 0 tnter EQUIPMENT START UP DATE UNIT NUMBER GA A Valco Cincinnati Compan IMPORTANT THIS INSTRUCTIONS MANUAL MUST BE KEPT IN AN ACCESIBLE PLACE AND ALL THE OPERATORS AND THE MAINTENANCE STAFF MUST BE AWARE IT BEFORE STARTING THE MACHINE UP THOROUGHLY READ THROUGH THE INSTRUCTIONS AND RESPECT THE INDICATIONS ON THE USE FOR THE UNIT S CORRECT USE AND MAINTENANCE IT IS NECESSARY CARRY OUT THE SAFETY INSTRUCTIONS PROVIDED IN THE PRESENT MANUAL NOT FOLLOWING THE SAFETY INSTRUCTIONS MAY CAUSE BURNS INJURIES AND EVEN WOUNDS OF IRREVERSIBLE CHARACTER AS ALSO CAUSING DAMAGE TO THE UNIT OR OTHER MATERIALS OWNED BY THE USER WARNING All change in the function performance safety of the unit replacement of original parts for other similar ones but not identical Substantial modifications carried out without MELTON s authorization and in accordan
4. Valco Cincinnati adjustments explained further on must be carried out before or during the machine s operating in order to guarantee a correct and safe machine operating 4 1 TEMPERATURE CONTROL MUS0320201 4 1 1 Introduction The units control panel is fitted with an electric digital circuit that is distributed in various printed circuit boards driven by a microcontroller system that includes hardware and software for the specific control of the compatible series gluing units It is fitted with calendar clock to control automatic connections and disconnections It includes a proportional type regulation of which the parameters were factory adapted to the thermal inertia of the tank the hoses and the guns separately The temperature is measured by means of RTD Resistance Thermometer Detector thermometers on each one of the heating devices as it is possible to program them individually and on each one of the output channels between the 30 C 240 C 86 F 464 F limits The controllers measuring rate is situated between 25 C 13 F and 240 C 464 F Under 25 C 13 F The unit will detect a failure by short circuited probe and over 240 C 464 A failure will be detected by open probe 4 1 2 A brief description of operating The unit allows a proportional regulation of the resistance temperature connected to 4 double hose gun channels or 6 double channels depe
5. A Valco Cincinnati WARNING The repairs indicated in this chapter must only be carried out by gualified staff that have understood the processes and are familiarized with the safety measures 7 1 INTRODUCTION This chapter includes the most common failures your unit may suffer The failures beginning when the adhesive flow drops it is cut or the alarm system shows one Try and solve the problem with the aid of this manual In the event the failure occurred may not be solved with information here expressed call our free assistance number 7 2 MECHANICAL FAILURES The pump does not carry out its run 1 See it the applicator is at the right temperature Check the air pressure Check that the modules are not obstructed Check the filters are not clogged up The pump carries out its run very quickly Check the tank has adhesive Check there are no leakages If it has check it is melted in the joints If it continues working very fast and continues with no pressure dismantle the pump and clean the valve seats in case of carbon deposit preventing its correct closing Check the hydraulic sub set joints Check that the command valve is working In the multiple guns the modules do not shoot at the same time Tighten screw on the back part ofthe module MUS0320201 27 03 2008 59 MELTON S L U POLIGONO INDUSTRIAL AG
6. 11 0 0118 12 0 0119 13 0x011A UE P14 0x011B Channel 5 in 6 outputs P15 0x011C In 4 outputs O is transmitted L E Channel 6 in 6 outputs P16 0x011D In 4 outputs 0 is transmitted P17 0x011E L E N terminal 45 and 65 P18 0x011F L E 4 and 6 outputs P19 0x0120 4 and 6 outputs P20 0x0121 L E 4 and 6 outputs P21 0x0122 L E 4 and 6 outputs P22 0x0123 L E 4 and 6 outputs P23 0x0124 L E 4 and 6 outputs P24 0x0125 L E 4 and 6 outputs P25 0x0126 L E 4 y 6 outputs En outputs 0 is transmitted L E 4 and 6 outputs P26 0x0127 En 4 outputs 0 is transmitted HC1 0x0128 L E MONDAY MC1 0x0129 L E MONDAY TC1 0x012A L E MONDAY HD1 0x012B L E MONDAY MD1 0x012C L E MONDAY MUS0320201 27 03 2008 89 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com AD i HOT MELT APPLICATIONS A Valco Cincinnati TD1 0x012D L E MONDAY HC2 0x012E L E MONDAY MC2 0x012F L E MONDAY TC2 0x0130 L E MONDAY HD2 0x0131 L E MONDAY MD2 0x0132 L E MONDAY TD2 0x0133 L E MONDAY 0x0134 L E TUESDAY MC1 0x0135 L E TUESDAY TC1 0x0136 L E TUESDAY HD1 0x0137 LE TUESDAY MD1 0x0138 L E TUESDAY TD1 0x0139 L E TUESDAY HC2 0x013A L E TUESDAY MC
7. WELTON A Valco Cincinnati To block the lid move the handle towards the left until the correct closing symbol is viewed This will enable the chipping loader To unblock the lid move the handle towards the right until the incorrect closing symbol is viewed This disables the chipping loader CLOSED OPEN MUS0320201 27 03 2008 49 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati MUS0320201 27 03 2008 50 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com GA A Valco Cincinnati CHAPTER 6 MAINTENANCE MUS0320201 27 03 2008 51 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OI A Valco Cincinnati Compan WARNING The maintenance operations indicated in this chapter must only be carried out by gualified staff that have understood the processes and is familiarized with the safety measures 6 1 INTRODUCTION This chapter includes the procedures for the unit s adeguate mainte
8. Declaration of conformity The product Model nr Serial Nr Year manufactured Described in the attached documents it is in conformity with The 98 37 CE Directive dated 22nd of June 1998 in regards to the approximation of the laws of the member States relating to machinery that covers in one only text the Directives 89 392 CEE dated the 14 of June 1989 91 368 CEE dated the 20 of June 1991 93 44 CEE dated the 14 of June 1993 and 93 68 CEE dated the 227 of July 1993 Directive 73 23 CEE dated the 19th of February 1973 relating to electric material Directive 89 336 dated 3rd of May 1989 Electromagnetic Compatibility Directive 93 68 CEE dated 22nd of July 1993 that modifies 73 23 CEE and the Directive 89 336 CEE covering the scope of the specifications indicated in the unit description chapter with a B1 risk level As it is part of a set of machines that to reach the same result are set and actioned to work jointly It must not be started up before the set it forms part of has not been declared in accordance with the Directives by the final assembly responsible Orcoyen date Signed by Gonzalo Marco General Manager UUEL A Valco Cincinnati Company Pol gono Industrial Agustinos calle G nave D 34 Tel 34 948 321 580 Fax 34 948 326 584 31160 ORCOYEN Navarra SPAIN CA MERT A Valco Cincinnati Compan CONTROL CARD CONTROL NUM irrisica inaa
9. www meltonhotmelt com IE KX MELIO _ Valco Cincinnati The pump s electrovalve does not work Check that the air pressure is received Over temperature alarm in Check the control card does Configuration alarm or the deposit of peripherals not have alarms connection alarm of the hoses and guns Inactivation of the service contactor Make sure of the external Check the electrovalve Within the connector check connector s perfect connectors correct the correct connection of the connection connection pines Check is there is a 24V output when the enabling pump led indicator is on Check the electrovalve coil The adhesive does not come out Remove the hose to check if the adhesive is coming out Check the solenoid valve as see if the adhesive comes out 7 Check if there is an air input d The detector module does not Clean the nozzles take adhesive nor does the air reach it MUS0320201 27 03 2008 65 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com WYO MELO A Valco Cincinnati Compan 7 4 PROBLEMS WHEN APPLYING THE ADHESIVE Cold Strands Low temperature Nozzles far from the surface to be glued SOLUTION Glue excess at the beginning or end of strand Nozzles far from the surface Lowpumppressue
10. 4 1 3 1 Keyboard 27 03 2008 25 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com KMD MELION A Valco Cincinnati Compan The unit s control panel has 11 control keys that will enable the access to the programming menus and the handling s general operating FO 05 oo BO Sn O Oy EH O RATATA Seog A KEY Heating On Off Turns the unit on and off When on it will be in the working mode or low maintenance depending on the state it was in when it was turned off With the unit off the display shows the week day and the time and the week day and time of the next connection if the CLOCK function is activated B KEY Clock On Off Enables the operation of the connections and disconnections programmed by the CLOCK function C KEY Scan On Off It activates the SCAN function with which the sequential temperatures of the active channels are viewed D KEY Low Maintenance on off It activates the LOW MAINTENANCE function in which the unit works with 5096 8096 of power D E AND F KEYS Keys to navigate among channels or programming parameters G KEYS Keys to modify programmable values K KEY ENTER Key to validate the change of programmed data This key is also used to reset the al
11. MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 7579 A Valco Cincinnati Temperature regulation The temperature regulation will be carried out by means of a control window This consists in activating the heating when the temperature drops to 2 C under the reference temperature and turning off the heating when it reaches the reference temperature This control guarantees a longer durability of the control components and minimizes the interferences emitted to the exterior fulfilling the Electromagnetic Compatibility EMC standards Pump Enabling signal control The pressure generating pump and the relay associated to enabling to the exterior with potential free contacts are activated when the temperature of all the heating devices deposit hoses and guns are at the temperature rate defined by the reference temperature deviations defined in the unit configuration normally 5 C and it deactivates when it is out of this deviation There is a parameter to delay the enabling signal P3 that provides an extra time of heating that is it delays the pump enabling signal starting to count when the last element enters in the work temperature rate The delay of the enabling signal will be restricted while the deposit keeps within the deviation temperature
12. when the unit is allowed to work normally 27 03 2008 38 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 7579 A Valco Cincinnati Start up Stop Whenever we have a 0 open circuit at the input that has the Start up Stop function the unit will remain Working When a 1 closed contact is reached the unit goes off Hose gun channel Whenever we have a 0 open circuit at the input that has the Hose gun function the channel is Enabled ON When 1 closed contact at the input that has the Hose gun function the channel is Disabled OFF P27 Parameter Selection of Communication Modes A parameter indicates if external communications will be used If P27 0 gt Itmeans that external communications will not be used by means of MODBUS nor I O State protocols If P27 1 gt Activation of the MODBUS I O State communications For the Modbus communications it is necessary to have an I O card available specified for communication mode If the communications of any protocol are enabled as well as the I O by states it is possible that order conflicts may occur due to the Priority of the wired communications State I O in respect with MODBUS 27 03 2008 39 MELTON S L U POLIGONO IND
13. www meltonhotmelt com KM MELION A Valco Cincinnati Compan Alarm readjustment process gt of 0 HO O BH o 21 Seog Press J gt Access to program Menu Press I gt Go to PO If you directly access P1 gt pass on to the next point Enter the password gt P0 123 ENTER Enter gt P1 1 ENTER K Press F until you access P10 Press B gt The filter changing alarm is now off Press E until you access P1 Enter gt P1 0 ENTER K Press J to leave the program Menu gt End of the readjustment process of the filter changing alarm Loader OPTIONAL When it flickers it means it has detected a low level of adhesive in the deposit during a programmed time of 200 seconds A Buzzer will sound You may reset by pressing the Enter E key but the amber light will continue flickering will an adequate level of adhesive in the deposit has been Reached v Green When this light goes on it means the temperature of all the devices is correct and there is no alarm present The unit is ready to work MUS0320201 27 03 2008 31 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonho
14. 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati MUS0320201 27 03 2008 15 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com AD A Valco Cincinnati Compan CHAPTER 3 INSTALLING THE MACHINE MUS0320201 27 03 2008 16 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati 3 1 INTRODUCTION In this chapter the unit s correct installation method is explained WARNING The operations described in this chapter must be carried out by gualified staff following the safety indications 3 2 TRANSPORTATION The unit is delivered wrapped up from the factory in a cardboard box approximate size k4 and k8 81x60x75 cm Approximate packet weight 70 kg To unwrap the top lid and the front will be removed Carry out the unwrapping process in a careful way to avoid damaging the unit Check the unit to detect any damage caused on the unit during transportation 3 3 INSTALATION REQUIREMENTS When installing the unit you must allow enough space to access it when at work Avoid extreme tempe
15. 4 4 LEVEL SENSOR ADJUSTMENT MUS0320201 To adjust the level sensor follow the next procedure Turn off and unplug the unit Remove the top cover Open the front door Plug in and start up the unit Locate the sensor s electronic box inside the electrical cabinet Disable the feeder by opening the deposit lid The feeders alarms may beep during the adjustment procedure to reinitiate or stop these alarms press the Enter button on the control panel Drain the deposit of adhesive until it is practically empty Remove the potentiometer s screw s plastic cap IF THE LIGHT IS FIXED RED NEGATIVE DETECTION gt Turn the screw clock wise just till the light changes to intermittent RED YELLOW Observing how after 3 seconds of intermittence the light goes GREEN gt After turn TWICE round anti clockwise IF THE LIGHT IS GREEN POSITIVE DETECTION gt Turn the potentiometer s screw anti clockwise just until the light changes RED gt Now turn the screw carefully clockwise until the light changes to intermittent RED YELLOW Observing how after 3 seconds of intermittence the light goes GREEN gt After turn TWICE round anti clockwise Assemble once again and verify its operating For correct calibration of the level probe it must be carried out with the tank completely empty or with minimum adhesive possible For further information on the level sensor please contact our free assistance number 27 03 2008
16. 50 1 10 N e Clean and unclog the nozzle Bring the nozzles closer Increase the pressure Strand break 2 Il S dhesive Increase the temperature Increase the temperature Replace the adhesive MUS0320201 27 03 2008 66 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com e E 7 Vall KX MELIO i A Valco Cincinnati Compan Adhesive with fine threads Applicator far from the 1 Slightly increase the Adhesive too viscous 0 LU T ON temperature Preheat the surface Air current to the applicator and or lower the surrounding 6 LU T 108 Fan pe Sam to temperature SOLUTION SOLUTIO 4 Slightly increase the Slightly increase the adhesive s temperature Heat the surrounding alr MUS0320201 27 03 2008 67 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com WYO MELO A Valco Cincinnati Compan Dripping of adhesive in the nozzle Open he end module inadeguate 21 Clean and or replace dirty Regulate the module EE parts and or worn out opening H Nozzles freguently clogged up n SOLUTION di Ch t f adhes
17. Indicates the unit is in the process of setting the time on the calendar clock 4 1 3 4 Functions ON OFF Function Heating turned on and off Through the control panel through a direct Connection via and by RS 485 communications If the communication via Modbus is installed and enabled it must remain connected so that the PLC to which it is connected may detect the temperature drop and control the unit On OFF the display shows the date and time CLOCK Function If it is enabled the unit carries out the programmed connections and disconnections SCAN Function This SCAN function allows sequentially viewing the actual temperatures of the enabled channels Every 4 seconds the temperature information of the channels is displayed in an ascending way This function only operates in the working mode LOW MAINTENANCE Function It sets the programmed temperatures at a programmed 96 50 to 80 The pump and the associated enabling signal towards the exterior will be deactivated and the corresponding LED will turn on and on the display a vertical line will appear They entry to this function is carried out in four different ways i e Pressing the key Ses programming the calendar clock e Activating the external signal of LOW MAINTENANCE OPTION e For the end of the programmed time with no gluing shots Applicator function OPTION e Through RS 485 Modbus communications OPTION 27 03 2008 28
18. L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com sc A Valco Cincinnati Compan 3 5 ELECTRIC INSTALLATION The electric installation will depend on the model to be used Read the guick installation guide chapter 6 Connection to the main machine External clearance This contact self closes when the unit is ready Alarm indicators This contact self closes when the unit s control connects to the ALARM probe Safety stop indicators This contact self closes when the unit s control connects to the STOP probe MUS0320201 27 03 2008 22 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati MUS0320201 27 03 2008 23 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com AD A Valco Cincinnati Compan CHAPTER 4 MACHINE ADJUSTMENTS MUS0320201 27 03 2008 24 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com
19. at working temperature Reduce the applicator s air pressure to 0 27 03 2008 55 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com I WELTON A Valco Cincinnati Compan 32 Eliminate the system s pressure by shooting the guns manually or opening the draining valve 42 Place acontainer under to collect the adhesive that may drip from the module 52 Use an open end wrench to unscrew the nozzle and replace it 62 Gradually increase the gun s air pressure MUS0320201 27 03 2008 56 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati MUS0320201 27 03 2008 57 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com AD A Valco Cincinnati Compan CHAPTER 7 HELPS TO REPAIR THE UNIT MUS0320201 27 03 2008 58 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OI
20. be carried out in the maintenance tasks or in case of a failure Before starting check the operator is duly protected and all the safety measures are followed Remove the air supply Eliminate the system pressure by shooting the guns manually or by opening the draining valve Disconnect the general switch Protect the general switch by means of a key to avoid reconnections 5 Check there is no power supply Work by following the applicable Safety and Health standards On the CD the breakdowns to which the procedures make reference may be found 8 2 REPAIRING THE DISTRIBUTOR The distributor is the element that distributes the Hot Melt once filtered to the hoses and guns Made in aluminum it is set on the bottom part of the tank in this way its resistances heat them indirectly The distributor has six output holes to connect the Hot Melt hoses three in the front part and another three in the bottom front part The distributor should not be dismantled this operation will be carried out only in the event that there is a leak of Hot melt between the tank and the distributor MUS0320201 27 03 2008 73 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com YD MELION A Valco Cincinnati Compan 8 3 REPAIRING THE PNEUMATIC PUMP SET The pump set includes a pne
21. copied on all the active channels The channels are indicated as per the following codes t0 Deposit ti Hose OUTPUT 1 t2 Gun OUTPUT 1 The amount of outputs depends on t3 Hose OUTPUT 2 the unit model having two different types 4 double outputs up to t8 and 6 double outputs the one on this 15 Hose OUTPUT 3 chart t6 Gun OUTPUT 3 t7 Hose OUTPUT 4 t8 Gun OUTPUT 4 t9 Hose OUTPUT 5 10 Gun OUTPUT 5 11 Hose OUTPUT 6 12 Gun OUTPUT 6 To end the process press again 27 03 2008 34 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 49 A Valco Cincinnati Low maintenance programming To enter this programming mode it is necessary to press and to go ahead selecting the 4 icon its LED lights up On the two left digits the code of the output to be programmed will appear that may be selected by means of the keys that are located under these digits 3 groups may be selected 0 Deposit b1 Hoses b2 Guns On the middle digits the value of the working temperature that will be used as regulating value on low maintenance is viewed By means of the keys located under these digits the temperature value is modified between the values of 50 a
22. the set with the filter cartridge screw Insert the filter to the distributor and screw it in with a screw driver 102Close the draining valve with a screw driver 112Set the appropriate pressure to work 6 3 6 Cleaning the loader filter 12 22 12 22 39 12 22 MUS0320201 Reduce the applicator s air pressure to 0 Remove the loader s filter with an adjustable spanner Use a screw driver or any other long tool to remove the adhesive from the inside mesh of the filter and the lid If necessary the filters mesh may be cleaned with a solvent fit for your adhesive Contact the adhesive manufacturer for further information Assemble in reverse direction 6 3 7 Replacing a gun s module Before replacing the gun module put the face screen gloves and long sleeve clothes on to avoid possible burns caused by splashes of hot adhesive To replace the module the gun must be at working temperature Reduce the applicator s air pressure to Eliminate the system s pressure by shooting the guns manually or opening the draining valve Place a container under to collect the adhesive that may drip from the gun Remove the 2 module screws and replace it Gradually increase the gun s air pressure 6 3 8 Replacing the nozzle Before replacing the nozzle put the face screen gloves and long sleeve clothes on to avoid possible burns caused by splashes of hot adhesive To replace a nozzle the gun must be
23. 2 0x013B L E TUESDAY TC2 0x013C TUESDAY HD2 0x013D L E TUESDAY MD2 0x013E L E TUESDAY TD2 0x013F L E TUESDAY 0x0140 L E WEDNESDAY MC1 0x0141 L E WEDNESDAY TC1 0x0142 L E WEDNESDAY HD1 0x0143 L E WEDNESDAY MD1 0x0144 L E WEDNESDAY TD1 0x0145 L E WEDNESDAY HC2 0x0146 L E WEDNESDAY MC2 0x0147 L E WEDNESDAY TC2 0x0148 L E WEDNESDAY HD2 0x0149 L E WEDNESDAY MD2 0x014A L E WEDNESDAY TD2 0x014B L E WEDNESDAY HC1 0x014C L E THURSDAY MC1 0x014D L E THURSDAY TC1 0x014E L E THURSDAY HD1 0x014F L E THURSDAY MD1 0x0150 L E THURSDAY TD1 0x0151 L E THURSDAY MUS0320201 27 03 2008 90 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OI A Valco Cincinnati HC2 0x0152 L E THURSDAY MC2 0x0153 L E THURSDAY TC2 0x0154 L E THURSDAY HD2 0x0155 L E THURSDAY MD2 0x0156 L E THURSDAY TD2 0x0157 L E THURSDAY HC1 0x0158 L E FRIDAY MC1 0x0159 L E FRIDAY TC1 0x015A L E FRIDAY HD1 0x015B L E FRIDAY MD1 0x015C L E FRIDAY TD1 0x015D L E FRIDAY HC2 0x015E L E FRIDAY MC2 0x015F L E FRIDAY TC2 0x0160 L E FRIDAY HD2 0x0161 L E FRIDAY MD2 0x0162 L E FRIDAY TD2 0x0163 L E FRIDAY HC1 0x0164 L E SATURDAY MC1 0x0165 L E SATURDAY TC1 0x0166 L E S
24. 2 2 Deposit It is where the Hot Melt or other similar materials are melted that may be in chipping format or cubes The casting aluminum tank is covered by Teflon to avoid carbon deposits and crystallizations and it includes a resistance heating system The resistance heating is controlled by a sensor with a micro controller that may program up to 130 C 291 F 2 2 3 Distributor pumping system It is formed by the following elements Distributor The Distributor distributes the Hot Melt once filtered to the hoses and guns It is manufactured in aluminum it is set on the lower part of the tank so the resistances heat it indirectly The filter the distributor includes is formed by a core and a fine screen mesh to filter the crystallized or dirt particles that the adhesive may have The distributor has six outlet holes to connect the Hot Melt hoses three in the front and three on the lower front part Pneumatic pump The pump impels the Hot Melt or other thermo fusible product at a specific pressure from the tank to the surface or material to be glued passing through the distributor filter hoses and guns The pump set is formed by an electro valve a pneumatic cylinder and a double effect hydraulic pump that has a pressure compensator included to avoid the drop in flow caused by the pump s recirculation and enables a uniform output of the Hot Melt 2 2 4 Pressure regulator and Enabling Valve Pressu
25. 45 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati MUS0320201 27 03 2008 46 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com CAA A Valco Cincinnati CHAPTER 5 OPERATING MUS0320201 27 03 2008 47 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OA A Valco Cincinnati Compan WARNING The unit must only be used by qualified staff that have understood the processes and are familiarized with the safety measures 5 1 INTRODUCTION In this chapter instructions are explained on the unit s operating Before starting check that the operator is duly protected and that all the safety measures are being followed and that the unit has all the safety measures available in perfect state 2 5 2 STARTING UP Press the general switch Fs 15 Check that the unit adjustments are appropriate for the required operating readjusting them if not look up in the chapter 2 When the unit is at the programmed temp
26. ATURDAY HD1 0x0167 L E SATURDAY MD1 0x0168 L E SATURDAY TD1 0x0169 L E SATURDAY HC2 0x016A L E SATURDAY MC2 0x016B L E SATURDAY TC2 0x016C L E SATURDAY HD2 0x016D L E SATURDAY MD2 0x016E L E SATURDAY TD2 0x016F L E SATURDAY 0x0170 L E SUNDAY MC1 0x0171 L E SUNDAY TC1 0x0172 L E SUNDAY HD1 0x0173 L E SUNDAY MD1 0x0174 L E SUNDAY TD1 0x0175 L E SUNDAY HC2 0x0176 L E SUNDAY MUS0320201 27 03 2008 91 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com A Valco Cincinnati MC2 0x0177 L E SUNDAY TC2 0x0178 LE SUNDAY HD2 0x0179 L E SUNDAY MD2 0x017A L E SUNDAY TD2 0x017B L E SUNDAY DAY 0x017C HOUR 0x017D UE MINUTES 0x017E UE HEAT ON OFF 0x017F UE CLOCK 0x0180 UE LOW MANT 0x0181 UE Actual M1 0x0185 L Actual P1 0x0186 L Actual M2 0x0187 L Actual P2 0x0188 L Actual M3 0x0189 L Actual P3 0x018A L Actual M4 0x018B L Actual P4 0x018C L Actual 5 0x018E L 6 outputs Actual 5 0x018F L 6 outputs Actual 6 0x0190 L 6 outputs Actual 6 0x0191 L 6 outputs Note 1 1 meaning reading and E means writing Note 2 Where it states 6 outputs it is data only used in cards with 6 outputs For those of four we return a 0 value The I O contacts unit of 4 outputs may a
27. ER led will turn on and the external alarm output also the RED led will turn on in an 27 03 2008 29 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 7579 A Valco Cincinnati intermittent way during 2 5 minutes Should after this time has elapsed the state of the safety alarm remain unchanged the RED led will turn on in a fixed way all the outputs through the general contactor will be deactivated and the unit will block The displays will show the data intermittently The unit will include a safety system that has a bimetallic thermostat located in the deposit wall graded at 240 C The rise of the thermostat will deactivate the general contactor coil disconnecting the power supply to the resistance heating but keeping the supply of the control electronic circuits that will enable us to identify on the display the device that has caused the incident In the blocking state the unit freezes the temperature measuring data of the probes and the user may verify the state of every one of them In order to reassemble the unit it is necessary to turn it off and turn it on again after the failure has been solved Amber Due to temperature Whenever any device deviates from the working temperature of the programmed ALARM MARGIN the output alarm to the ext
28. NO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 A Valco Cincinnati On Led The time and date of the clock are being programmed 4 1 4 Parameterisation of the unit To enter the working parameter programming mode on the control CH all needed is to press the button and continue selecting through the button the reguired programming menu To end the process the gt key must be pressed In the event that the unit remains in the programming menu during more than one minute with no button being presses the unit will automatically leave this programming mode Programming the working temperatures To enter in this programming mode it is necessary to press 9 and after select the 1 icon its LED lights up On the two digits on the left the code channel to be programmed will appear that could be select by means of the MA keys that are located under these digits The middle digits indicate the programmed temperature value With the V A keys located under these digits the temperature value is modified between 30 and 240 C Under the minimum value the display indicates OFF that means that the channel is disabled Pressing the e key it is possible to record the viewed working temperature information Placed on t0 and pressing SCAN the deposit reference temperature is
29. ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com KMD MELION A Valco Cincinnati Compan 8 3 2 Low flow pump CYLINDER HYDRAULIC SET MUS0320201 27 03 2008 79 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com a ADI MELTON A Valco Cincinnati Compan 8 3 2 1 CYLINDER 1 Loosen the bottom part 4 screws 2 Loosen the 4 distantial ones 3 Loosen the ball and socket joint of the pin MUS0320201 27 03 2008 80 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com j a SODI MELION A Valco Cincinnati Compan 8 3 2 2 HYDRAULIC SET 1 Loosen the bottom part 4 2 Loosen screws 3 Loosen 4 Remove the pin 7 Remove the spring and impulsion 8 Remove the spring pin guide E i MUS0320201 27 03 2008 81 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 49 A Valco Cincinnati Compan 8 4 REPAIRING OF ELECTRIC ELEMENTS If in the operating any of these elements deteriorat
30. RIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OI A Valco Cincinnati Check the correct Check the service contactor Check if the safety temperature is activated thermostat is working programming Check the tank s fuses Check if there is a short circuit in the tank s resistance Check the terminals correct Check the tank connection in the deposit resistance s consumption Check the electronic card does not have alarms Check the temperature probe the tank Check the triac works correctly Check the tank resistance Once these verifications have been carried out restart the If the probe is short circuited the display shows CCC If the probe is open the display shows AAA unit turn off and turn on MUS0320201 27 03 2008 62 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OI A Valco Cincinnati A hose overheats Check the temperature probe ofthe hose Check ifthe hose s triac is short circuited Check the control card s good Check the hose s performance programmed temperature A gun does not heat Check the control card s Check that the channel is cor
31. S to the European Several Prohibitions Logotype corresponding Community marking Danger hot surface Note of special interest Several Precautions The use of safety glasses is needed The use of safety gloves is needed Precaution electric current Precaution inflammable liquid Precaution risk of leakage of high pressure liquids gt E E E RN Precaution risk of being trapped between machine mobile parts MUS0320201 27 03 2008 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 49 A Valco Cincinnati Compan Burns The burns may be caused by the uncovered parts of the applicator such as the guns or by splashes of the hot Hot Melt The Hot Melt being hot and under pressure in the nozzle may cause serious skin injuries Qualified Staff Is the person technician that has acquired enough knowledge in a specific field either by studies or by experience This person must be familiar with the safety and accident prevention regulations as well as having an overall knowledge on the machine s technical information Protection Clothes It must be the type that fulfils the EN510 and EN340 regulations being protected against particles at high speed and high temperatures It will be as tight as possible to avoid it catching on the mob
32. USTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 CD A Valco Cincinnati The gun does not deposit adhesive as it activates the valve Check the tank hose and gun temperature Check the gun s opening valve and closing is working Check if the nozzles are clogged up loosen and clean them Check if the module seat is stuck loosen and clean Check if there is a leakage through the draining hole of the module replace seals Check the filters Check if the hose is clogged up 27 03 2008 60 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OI A Valco Cincinnati The unit turn on but it is disabled Check the correct programming and unit parameterization 7 3 ELECTRIC FAILURES The unit does not turn on Check the unit s power supply connection Check the electronic card s supply fuses Check the security thermostat The tank overheats Check the temperature probe in the tank Check the tank triac is not short circuited Check the tank triac is not short circuited Check the tank s programmed temperature MUS0320201 27 03 2008 61 MELTON S L U POLIGONO INDUST
33. USTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com XS A Valco Cincinnati Compan Programming the connection disconnection with clock information To enter this programming mode it is necessary to press gt key and go ahead 2 selecting the con On the two left digits the code indicating the week day with values from 1 to 7 appears In the middle digits the code of the parameter to be viewed that may be selected by means of the E and F keys rogrammed is On the right digits the parameter s value is viewed By means of the and keys AA the values are modified within the ranges specified on the attached Table 2 Pressing the E key we may record the viewed information Table2 Codes of the clock connection disconnection parameters di 01 XX Hour of connection 1 on Monday d1 02 XX Minute of connection 1 on Monday d1 03 XX Type of connection 1 on Monday d1 04 XX Hour of disconnection 1 on Monday d1 05 XX Minute of disconnection 1 on Monday d1 06 XX Type of disconnection 1 on Monday d1 07 XX Hour of connection 2 on Monday d1 08 XX Minute of connection 2 on Monday d1 09 XX Type of connection 2 on Monday d1 10 XX Hour of disconnection 2 on Monday d1 11 XX Minute of disco
34. arm Level probe input Application MUS0320201 27 03 2008 84 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 ZS A Valco Cincinnati Compan This function works in the following way Once we have the pump permit and the P8 parameter is a different value from 0 what next happens is that the P8 value is the time the unit waits until it goes on to Low maintenance if it does not have a pulse at this entry If the time of the P8 value they are minutes goes by without a pulse by the entry that the Application Function has selected the machine will go to Low maintenance Once the machine is in Low Maintenance there are two options to set it at normal operating a Pressing the low maintenance button on the panel screen Giving a pulse for the entry that the Low maintenance function has If we give a pulse before all the P8 time has gone by for the entry that application function has that time will be reset and it starts counting once again Low Maintenance Meanwhile no pulse reaches the entry that the Low maintenance function has the unit will work normally When a pulse reaches the unit it will be set in low maintenance With another pulse we again set it to work normally On Off Meanwhile no pulse reaches the entry tha
35. arm s buzzer I KEY Programming Changes the parameter group on the programming menu J KEY Programming Key to access the programming menu soll MUS0320201 27 03 2008 26 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 49 A Valco Cincinnati Compan 4 1 3 2 Display The control panel has a10 digits display of 7 segments grouped in 3 blocks BLN E The two digits on the left show the device identification or area of which the information will appear in the digit blocks situated further to the right The middle block of 4 digits shows the temperature data SET working and the values of the parameters in programming The block of 4 digits located further to the right shows the ACTUAL temperature data working and is used also as complementary display during some programming phases Viewing channels By means of the navigating keys the selected channel the programmed temperature and the measured temperature are viewed CO Deposit C1 Hose OUTPUT 1 OUTPUT 4 C2 Gun OUTPUT 1 8 Gun OUTPUT 4 C3 Hose OUTPUT 2 C9 Hose OUTPUT 5 OUTPUT 2 10 Gun OUTPUT 5 C5 Hose OUTPUT 3 11 Hose OUTPUT 6 C6 Gun OUTPUT 3 12 Gun OUTPUT 6 4 1 3 3 LED Indicators e State ON OFF LED ON OFF Indicate
36. art up In the extreme event that there is a need for a longer delay due to loader tube being longer than 10m and air pressure conditions and low flow it could be increased by means of an external timer MUS0320201 27 03 2008 43 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com sc A Valco Cincinnati Electric Installation Follow the electric layouts Warnings e t is essential to ensure the connection of the reference conductor to chassis red wire of amplifier Its disconnection may cause the system to become unstable Do not modify the probe position the correct height is given by the fixation located the nearest possible to the probe s end e The high detection level must be situated at the adhesive level that slightly covers the unit tip If the probe calibration is readjusted in such a way that the probe is completely covered with the adhesive level there is a risk of adhesive overflow and high deterioration of the air filter due to adhesive splashes during the filling process MUS0320201 27 03 2008 44 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com KMD MELION A Valco Cincinnati
37. ce to what is specified in the Directive 89 392 will turn you into manufacturer and therefore you will be made responsible for having carrying out the modification A Valco Cincinnati Compan USER S MANUAL KOBRA 032SERIES COA A Valco Cincinnati Compan CHAPTER 1 SAFETY INSTRUCTIONS aiment d CHAPTER 2 DESCRIPTION geess 10 2 1 INTRODUCTION E 11 2 2 MAIN 4 4 4 4 4 69 5485549548 88 dd 11 2 3 SPECIFICATIONS 14 CHAPTER 3 INSTALLING THE MACHINE rnnrrnnvnnnvnnnvnnnvnnnvnnevnnevnnvvnnvvnnvnnnennnennnennnenn 16 3 1 INTRODUCTION E 17 3 2 TRANSPORTATION enennvnvnennvnvnnnnenennenennnnenennennnennenennvnnnennnnenevennenensnnevensenensnnenennenenan 17 3 3 INSTALLATION REQUIREMENTS Q nnenennnnvnennvnennnnenennvnnnennnnenevnnnenensenevensenensnnevensenenen 17 3 4 MECHANICAL INSTALLATION Qnnnennenennnnenennvnennnnnnennvnnnennnnenevennenensnnevennenennnnevennenennn 18 3 5 ELECTRICAL INSTALLATION nnenennvnennnnvnennvnenennenennvnnnennnsenevennenensnnevensenensnnevennenenen 22 CHAPTER 4 MACHINE ADJUSTMENTS masesosna nsannnannns nnnnnsanpennsssnenanssonnanennnnng nnsnnnt 24 4 1 TEMPERATURE CONTROL nnennvavvennvnvnnnnenennvnnnennnnennvnnnenens
38. chipping loader is opened it will deactivate In order to activate it the lid must be closed and correctly locked 27 03 2008 13 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com QS HOT MELT APPLICATIONS A Valco Cincinnati Compan 2 3 SPECIFICATIONS ELEMENT INFORMATION GENERAL ES 1P 220V N T 50 60Hz 3F P 220V T 50 60 Hz 380V N T 50 60Hz Hoses max 6 Hydraulic pressure max performance 2 8 100 bares 40 1450 psi Noise level 63 dB Work temperature 10 50 C 14 122 F HR 20 80 not condensed CONTROL Work programming range 305 2405 C 86 464 F Accuracy Control Temperature 0 55 C 1 F Proportional output at 230 V AC by semiconductor with Type of control yp zero crossing control PUMP Pump capacity 35 Kg h Pump compression rate 1 14 Pneumatic pressure 0 2 8 6 bares 3 87 psi Volume 4 litres 8 litres Fusion capacity 4 2 Kg h 79 Kg h 135 Kg h 1800W 2800W 4800W Deposit power consumption CHIPPING LOADER Compressed air input 2 6bar 29 up to 87PSI 350 I min 92 gallon minute araara Hose length 1 to 30 m up to 98 feet MUS0320201 27 03 2008 14 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948
39. deposit hoses and guns may be selected with different work temperature percentages when the unit is on LOW MAINTENANCE Values between 50 and 80 may be selected ON led The percentage values of the work temperatures are being programmed for the different devices divided in 3 groups deposit hoses and guns The general parameters of work programming menu It enables to enter the units data that has been parameterized such as the temperature measuring units C 6 F delay time to enabling signal maximum temperature temperature deviation to cause alarms enabling options viewing working hours etc There is a parameter available that enables to automatically copy the temperature value selected for the deposit in all the output channels available channels that are not on OFF On Led The general working parameters are being programmed The connection disconnection by clock programming menu It enables to enter the machine s information on the hour and minute of automatic connection disconnection It is possible to program up to 2 connection disconnection groups for each day of the week and the way to go onto on off or low maintenance On Led The connection disconnection parameters are being programmed by clock Clock time setting programming menu It enables to enter the information of the actual day of the week hour and minute to set the time of the calendar clock 27 03 2008 33 MELTON S L U POLIGO
40. disable that parameter and it will not have any effect Application If we have a 0 with no potential open contact the input that has the application function appointed to during more time that what the P8 contemplates value in minutes and we have the pump s permission then the unit will enter in Low Maintenance If we set a 1 we close contact before the parameter P8 time has elapsed so then the timer is reset and we count again from the P8 value Once the unit is on Low Maintenance when we set a 1 we close contact on the input appointed to the application function the unit will then start up normally Meanwhile there is a 1 in the corresponding input the unit will work normally and the timer will not count with the P8 If P8 0 then we also disable the application function as we have disabled the timer Low Maintenance Meanwhile there is a 0 open circuit at the input that has the Low Maintenance Function the unit works normally When a 1 closed circuit reaches the unit it sets on Low Maintenance And we will have to keep that 1 closed circuit at the input in order to keep unit on Low Maintenance In the event that the Applicator and Low Maintenance functions are configured the system will give priority to the Low Maintenance function letting the applicator function work normally when the Low Maintenance indicates 0 that is
41. duce temperature Readjust temperature control adjustments or card replacement Gelatinous adhesive Empty and wash the 4 mensen eem Sume Check the adhesives Mixed incompatible adhesives Empty and wash the system completely compatibility MUS0320201 27 03 2008 70 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati MUS0320201 27 03 2008 71 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com A Valco Cincinnati CHAPTER 8 HELPS FOR THE REPAIRING OF THE UNIT MUS0320201 27 03 2008 72 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com QS A Valco Cincinnati Compan WARNING The repairing indicated in this chapter must only be carried out by qualified staff that have understood the processes and are familiarized with the safety measures 8 1 INTRODUCTION In this chapter the procedures to dismantle and replace some of the components is explained These procedures must
42. e and it is necessary to their replacement it will be carried out as laid out in Annex A and respecting the electric diagram attached in Annex B All the operation must be carried out with the consigned machine and disconnected from the general is network being sure that the system is duly drained and depressurized MUS0320201 27 03 2008 82 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com AD ELIO A Valco Cincinnati Compan CHAPTER 9 SOFTWARE SPECIFICATIONS MUS0320201 27 03 2008 83 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com LEON A Valco Cincinnati 9 1 I O Functions The I O card pulses The I O card diagram The I O card as well as supporting the communications through RS 485 it also has the ability to have a wired communication This wiring has four functions available Applicator lO diagram UO card photograph BER Low Maintenance On Off Mi Jumpers Chipping 220 48 24V from geed right to left alarm Connectors mass Connector Function Applicator Application function On Off On Off function Low Maintenance Low maintenance function Chipping loader Al
43. e hydraulic 14 kg cm in the pump MUS0320201 27 03 2008 42 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com iso Ok A Valco Cincinnati 4 3 OPERATING THE MELTON RECHNER LEVEL PROBE It is a capacitive level probe that controls the chipping loader system It detects the level of adhesive and orders activations It has a disconnection delay of 3 seconds that it carries out in the passing from the low level to the high level to ensure the system is performing effective minimum loads Visual Indications Green Light gt Full Outout not activated Red Yellow intermittent light gt Full Output activated delay to the disconnection Red Light gt Empty Output activated Green Light Positive Detection The probe interprets the deposit is full enough It does not activate the output that orders to load the adhesive feeder Red Light Negative Detection The probe interprets the deposit is not full enough and orders to load the adhesive feeder Intermittent Red Yellow Light Positive detection delay to the disconnection The probe after the change in Negative detection to Positive detection keeps the load sign to the feeder during seconds In this way a minimum effective load is ensured This delay is not applied in the initial transit that is in the probe st
44. enevennenensnnevensenensnneensenener 25 4 2 OUTPUT PRESSURE 5 4 4 48 1 11111 111111 nnne tnnt 42 43 OPERATING THE MELTON RECHNER LEVEL 43 4 4 ADJUSTMENT OF THE LEVEL SENSOR nnnnnnvnennvnennnnenennenennnnenennvnnnennnnenevnnnenennener 45 CHAPTER 5 OPERATING see E 47 5 1 INTRODUCTION E 48 5 2 START UP ec 48 STOPS 1299288855 aaa 48 5 4 DEPOSIT LID BLOCKING 5 2 1 2 48 CHAPTER 6 hi ggc ts ec aaa 27 6 1 INTRODUCTION 52 6 2 MAINTENANCE 6 tnnt 52 6 3 MAINTENANCE PROCESSES mnnenennvnvunnnnneunvnnnennnnennvnnnennnnenevennenensvnevennenensnnevennenenar 53 CHAPTER 7 HELPS TO REPAIR THE UNIT 58 7 1 INTRODUCTION E 59 7 2 MECHANICAL FAILURES 59 7 3 ELECTRICAL FAILURES i menennonennvnvnennenennnnenennenenennnnennvnnnenennenevennenensnnevensenensnnevennenennn 61 7 4 PROBLEMS IN THE APPLICATION OF ADHESIVE 66 CHAPTER 8 HELPS FOR THE REPAIRING OF THE UNIT 72 8 1 INTRODUCTION E 73 8 2 REPAIRING THE
45. erature and there is no alarm activated the service relay will light up 3 The main machine s permits are had in the case that both are connected 4 You may already start the application The unit will not work when it is linked to a main machine until it has the necessary permits These terminals are sent short circuited from factory Note Never operate the applicator if the deposit is empty If the amount of thermo fusible material is small the deposit may overheat causing carbonized thermo fusible material and the formation of residue inside the unit This may cause unnecessary dead time later on 5 3 STOPS There are two cases Stop pumping If you want to stop pumping you must turn the pressure regulator to O The temperature control will keep the unit s temperature If this stop is for a long period we recommend the Low Maintenance function to be activated See point D of chapter 4 4 Complete Stop For a complete unit disconnection press the general switch In the event you want to immobilize the unit for a period we recommend ou clean the unit and leave the plate in the lowest point possible 5 4 THE DEPOSIT LID BLOCKING SYSTEM The deposit lid has a blocking system available MUS0320201 27 03 2008 48 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com
46. erior will be activated and the AMBER led indicator will light up due to out of range temperature Failures in probe If there should be a failure due to short circuit in the measuring probe the unit will show the CCC indication instead of the temperature for the element deposit hose gun of the corresponding channel If a failure due to a probe in open circuit is detected the unit will show on the display the AAA indication instead of the element s temperature of the corresponding channel When this kind of alarm occurs and the corresponding channel is activated the AMBER led will light up and the exterior output alarm will activated and as well the RED led will light up intermittently during 2 5 minutes Should after this time has elapsed any of the described alarms remain unchanged the RED led will light up in a fixed way all the outputs will deactivate through the general contactor and the unit will block Changing the Filter This filter changing alarm will beep once the unit reaches 2000 working hours the P10 parameter is fixed by defect at 2000 hours We may recognise this alarm when the three leds under the START button are flashing at the same time Red Yellow Green We may adjust the alarm by selecting the P10 channel and pressing the CLOCK 27 03 2008 30 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http
47. es http www meltonhotmelt com KMD MELION A Valco Cincinnati Compan Start connecting the hoses from right to left if not a dead centre will be created in which carbon deposit will accumulate increasing the nozzles blocking problems For the hydraulic connection in the event the unit is full of adhesive heat the tank before loosening the distributor cap MUS0320201 27 03 2008 19 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com GA A Valco Cincinnati Disposition of the hoses Never bend the hoses with curves of under a 150 mm radius ii U N WIRT The must fastened to very wide cold surface areas MUS0320201 27 03 2008 20 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 4 MAk A Valco Cincinnati Compan Do not install hoses one next to the other leave a gap minimum 25 mm between them so they dissipate the heat adequately Do not cover the hoses if it is necessary to cover them then leave airing holes so the heat may be dissipated MUS0320201 27 03 2008 21 MELTON S
48. even after the starting up and turning off of a unit During heating while the unit is at right temperature and the waiting time has not ended the traffic light Green Led will remain flicking Preheat Function The preheat system PREHEAT makes all the peripheral devices hoses and guns heat up in a seguential way while the deposit does so at a normal speed When the deposit reaches 75 of its programmed temperature the power will be applied to the hoses When the hoses reach 75 of their programmed temperature the power is applied to the guns 4 1 3 5 Alarms The unit has various alarms that inform on the failures of the measuring sensors out of range temperatures or over the safety level Types of alarm Green fixed light The unit is ready to work Yellow fixed light The temperature is out of the programmed point Yellow intermittent light beep The loader is not filling the deposit Yellow fixed light and intermittent red Failure in the RTD viewed with AAA or CCC on the screen You have 2 5 minutes to solve the problem before the machine stops Red fixed light beep Machine safety halt Failure in the RTD or overheat All the leds are disabled and the screen flickers A beep will ring for each loader or stopping alarm The beep may be stopped by pressing the a key The loader alarms are reset once the adhesive level is right again Safety Whenever any device reaches the programmed safety temperature the AMB
49. fter having followed these steps protect yourself adequately and remove the pump placing it in an appropriate place Dismantle the pump following the next instructions MUS0320201 27 03 2008 75 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com APPLICATIONS MIELTON A Valco Cincinnati 8 3 1 High flow pump CYLINDER HYDRAULIC SET MUS0320201 27 03 2008 76 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com A Valco Cincinnati Compan 8 3 1 1 CYLINDER 1 Loosen 2 Separate the sets 4 Loosen the indicated screws and remove the Cover 5 Remove the tube 6 Loosen the indicated screw MUS0320201 27 03 2008 77 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 7 4 A Valco Cincinnati 8 3 1 2 HYDRAULIC SET 1 Loosen 2 Separate the sets 3 Loosen 4 Remove the pin 7 Remove the spring and impulse 8 Remove the spring guide pin MUS0320201 27 03 2008 78 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160
50. he filter to the distributor and screw it in with a screw driver 122Close the draining valve with a screw driver 132Set the appropriate pressure to work 6 3 5 Replacing the filter Before replacing the filter put the face screen gloves and long sleeve clothes on to avoid possible burns caused by splashes of hot adhesive It is recommendable to keep a filter or its mesh in stock to replace it when necessary It is a quick to carry out the replacement and it improves the unit working 12 To remove the filter the unit must be at working temperature 22 Reduce the applicator s air pressure to 32 Place acontainer under to collect the adhesive that is in the distributor 42 Open the draining valve with a screw driver to eliminate the residual pressure lo Open the filter knob screw with an open end wrench and remove the filter set 62 Loosen the filter cartridge screw with an Allen wrench and the mesh of the filter cartridge and the interior body will be freed MUS0320201 27 03 2008 54 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 7 8 95 QS A Valco Cincinnati Compan Once the filter has been dismantled it is recommended to change the seals and mesh Assemble the seals on the knob screw the mesh and insert the filter inside body Screw in
51. he micro controller The microcontroller uC always communicates by means of the Modbus functions The uC programming supports two functions 0x03 Reading of Stored Records 0x10 Writing of Multiple Records e 0x03 Reading of Stored Records This function carried out the continuous reading of a set of records The function specifies the addresses of the first record and from then on continues reading depending on the amount of values the function has indicated Function characteristics Request Function Code 1Byte 0x03 Initial address 2 Bytes0x0000 a OxFFFF Amount of Records 2 Bytes1 a 125 0x7D Reply Function Code 1Byte 0x03 Account of Bytes 1 Bytes2 x N Amount of Records Record values N x 2 Bytes Error Error Code 1 Byte 0x83 Exception Code 1 Byte 01 or 02 or 03 or04 27 03 2008 86 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 49 A Valco Cincinnati Compan Example Request Reply Function 03 Function 03 Initial address Hi 00 Account of Bytes 06 Initial address Lo eB Value of Record Hi 108 02 Nr of Records Hi 00 Value of Record Lo 108 2B Nr of Records Lo 03 Value of Record Hi 109 00 Value of Record Lo 109 00 Value of Record Hi 110 00 Value of Record Lo 110 64 e 0x10 Writing of Multiple Records This functio
52. hine depressurized and disconnected from the air supply 27 03 2008 7 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com COA A Valco Cincinnati Compan 1 3 FIRST AID In case of a burn Immediately dip the injured part into cold and clean water until the adhesive has cooled down Under no circumstances should you try to remove the adhesive from the skin even though it is cold as more serious injuries could be caused IMMEDIATELY go to a Medical Centre In case of an accident with solvent CONTACT WITH THE SKIN Wash thoroughly with water and soap CONTACT WITH THE EYES Wash thoroughly with running water for 15 minutes INHALING In case of over exposure take the affected person to fresh air and let him rest INGESTION Do not induce vomiting IMMEDIATELY seek medical care MUS0320201 27 03 2008 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati MUS0320201 27 03 2008 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com
53. i Reduce the temperature Too much adhesive flow Flow control valve too open Hole clogged up and or seat worn out or dirty SOLUTION To many r p m in the pump Nozzle hole too big Reduce the r p m in the Replace the nozzle to a Close with several turns pump or open the regulator smaller size MUS0320201 27 03 2008 68 S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OI A Valco Cincinnati Compan Adhesive bounce backs or splashes from the surface Reduce the plate s temperature Adhesive temperature too high Reduce the pump s r p m Reduce the pump s r p m Va LG adhesive Fuming adhesive Applicator far from the Reduce temperature surface to be glued SOLUTIon ee Cold adhesive SOLIITION al Use more stable adhesive Keep the deposit lid closed MUS0320201 27 03 2008 69 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OI A Valco Cincinnati Compan Charred adhesive in the en el fuser Fuser temperature too high Temperature control failure 1 Re
54. igurable Functions 0 9 P20 I O State Configurable Functions 0 9 P21 I O State Configurable Functions 0 9 P22 I O State Configurable Functions 0 9 P23 I O State Configurable Functions 0 9 P24 I O State Configurable Functions 0 9 P25 I O State Configurable Functions 0 9 P26 I O State Configurable Functions 0 9 RS 485 Communications Section Parameter to select the external communication P27 0 mode 0 Disabled UO CARD REQUIRED NO ACCESS VIA COMS MUS0320201 27 03 2008 37 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 GA A Valco Cincinnati P4 parameter Maximum Temperature In the event a change of this value is performed setting it at under the programmed temperature of any of the channels it will egual them to the P4 value P18 to P26 parameters UO Configurable Functions It is possible to configure the I O card contact functions for the different functions Function Number Disabled Application Start Stop Low Maintenance Hose gun channel 1 Hose gun Channel 2 Hose gun Channel 3 Hose gun Channel 4 Hose gun Channel 5 Hose gun Channel 6 jo SI o O PO O Disabled With this function we
55. ile elements of the machine allowing the worker to adjust it to his size the sleeves waist legs etc Safety glasses and face screens They must be the type that fulfills the EN 166 regulation protecting against particles at high speed and high temperatures The glasses only protect eyes therefore face screens are better for the protection of the whole face Safety gloves They will be the type that fulfills the EN 407 and EN 420 regulations protecting hands against the burns caused by external thermal masses at temperatures higher than 100 C 27 03 2008 6 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 7579 A Valco Cincinnati 1 2 PREDICTED USE This unit has been manufactured in accordance with the safety regulations in force The predicted use of this unit and what it has been designed for has been described in chapter 2 of this manual Description For the correct and safe use of this machine you must follow what has been indicated in this Instruction Manual and specifically gt MUS0320201 The machine must only be installed and used by gualified staff and that have previously been duly informed on the correct use of it enquiring the manufacturer on its use if needed as well as the dangers it represents of the safety measures to be ta
56. ires on the state of the variables desired Hi Lo Hi Lo 10 00 01 00 02 Using the before mentioned functions the PLC starts the communications provoking the micro to transmit the state of the variables The PLC is in charge of updating its values that is to say that it will be in charge of in a cyclical way read the unit s values in case it has suffers a modification through its control panel MODBUS Protocol addresses DATA AND MOBUS ADDRESSES FOR SERIES K MODBUS HEX DATA NEEDED ADDRESS REMARKS Prog dep 0x0100 1 0 0101 Prog P1 0x0102 Prog 2 0 0103 2 0 0104 Prog M3 0x0105 L E Prog P3 0x0106 L E Prog M4 0x0107 L E Prog P4 0x0108 L E Prog M5 0x0109 L E 6 outputs Prog P5 0x010A L E 6 outputs 27 03 2008 88 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com OI A Valco Cincinnati Prog 6 0x010B L E 6 outputs Prog P6 0x010C L E 6 outputs 81 0x010D 2 0x010E UE B3 0x010F UE P1 0x0110 2 0 0111 0 0112 4 0 0113 5 0 0114 P6 0x0115 UE P7 0x0116 P8 0x0117
57. ken at work including adjustments and maintenance and the expressly prohibited actions This unit has not been built to operate in dangerous environments such as explosive and or inflammable environments When working with the unit safety clothes gloves and face screens must be used likewise rings bracelets and watches must be removed As the machine has been designed to form part of a set of machines that to achieve the same result are prepared and operated jointly the machine to apply hot melt must not be started up until it has been declared in accordance with the provisions in the Directives of the set it is part of The operating must always be carried out with the safety systems provided on the machine they must not be removed nor annulled and they must undergo revision and maintenance with the indicated regularity Ensure the unit is connected to earth Never operate the unit if you know there is a leakage in the adhesive circuit The maintenance and or repair operations must be carried out by staff that has the basic mechanical pneumatic and electrical knowledge on the machine s operating that qualifies them to carry out their function correctly The maintenance and or repair operations will always be carried out with the machine locked out which means disconnected and with the switch mechanically blocked from the electric power supply The maintenance and or repair operations will also be carried out with the mac
58. le Hose RS P12 Gun Channel 2 0 Allows disabling the Channel 2 P12 1 0 1 Enable Disable Hose OM P13 Gun Channel 3 0 Allows disabling the Channel P1321 0 1 Enable Disable Hose P14 Gun Channel 4 0 Allows to disable the Channel 4 P14 1 0 1 P15 Enable Disable Allows disabling the Channel 5 P15 1 0 1 ONLY Gun Channel 5 0 CARD ACCESSIBLE 6 OUTPUTS 050320201 27 03 2008 36 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com mme Description 1 A Valco Cincinnati Compan P16 Enable Disable Hose Gun Allows disabling the Channel 6 P16 1 0 1 Channel 6 0 ONLY ACCESSIBLE ON 6 OUTPUTS CARD Identifies the node Nr for communications 45 17 Card Node Number 0 and 68 Configurable parameter Con 1 0 Disabled I O Configurable parameter Con 2 0 Disabled Configurable parameter Con 3 0 Disabled Configurable parameter Con 1D 0 Disabled I O Configurable parameter Con 2D 0 Disabled Configurable parameter Con 3D 0 Disabled I O Configurable parameter Con 4D 0 Disabled Configurable parameter Con 5D 0 Disabled Configurable parameter Con 6D 0 Disabled P18 I O State Configurable Functions 0 9 19 I O State Conf
59. lso be configurable as well as the 6 outputs outputs P17 m The number of Node will be in the same parameter both for 4 as also 5 MUS0320201 27 03 2008 92 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com SODI MELION A Valco Cincinnati MUS0320201 27 03 2008 93 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com
60. n carried out the writing of a continuous block of up to 120 records in our case 32 The transmission sends the values in two bytes per record The normal reply sends the function code the initial address and the amount of written records The function characteristics Transmission Function code 1Byte 0x10 Initial address 2 Bytes0x0000 a OxFFFF Amount of Records 2 Bytes0x0001 a 0x0078 Account of Bytes 1 Bytes2 x N Amount of Records Record values N x 2 Bytes Reply Function code 1Byte 0x10 Initial address 2 Bytes0x0000 a OxFFFF Amount of Records 2 Bytes1 a 123 0x7B Error Error code 1 Byte 0x90 Exception code 1 Byte 01 or 02 or 03 or 04 MUS0320201 27 03 2008 87 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 A Valco Cincinnati Compan Example Transmission Function Initial address Initial address Amount of Records Amount of Records Account of Bytes Value of Record Value of Record Value of Record Value of Record Hi Lo Hi Lo Hi Lo Hi Lo 10 00 01 00 02 04 00 01 02 Reply Function Initial address Initial address Amount of Records Amount of Records 9 2 2 Communication modes MODBUS RS 485 8n 1 In this communication mode the micro works as a slave that is the micro waits till the PLC enqu
61. nance Their follow up will guarantee the operating safety and will lengthen the unit s life Before staring the maintenance process please thoroughly read chapter 1 Safety Before starting check that the operator is duly protected and all the safety measures are followed Remove the air supply Eliminate the system s pressure by manually shooting the guns or opening the discharge valve Disconnect the general switch Block the general switch Check there is no power supply Work by following the applicable Safety measures 6 2 MAINTENANCE RECOMMENDATIONS The following table shows how often the maintenance operations must be carried out Make an inspection on all the electric pneumatic and hydraulic connections Change or repair whenever necessary Check and whenever necessary drain the humidity of the filter container Clean the exterior of the unit Drain the distributor by means of the discharge valve months Evera Dismantle check and clean the deposit filter months Replace the deposit filter Whenever Loader Check and clean the filter necessary Modules Replace the gun modules Nozzles Replace the nozzles MUS0320201 27 03 2008 52 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com GA A Valco Cincinna
62. nd 80 Pressing the pul key it is possible to record the viewed temperature information To end the process press again Working general parameter programming To enter the programming mode it is necessary to press and to go ahead selecting the icon On the two left digits the code of the Em to be programmed appears that V may be selected by means of the digits keys that are located under these On the middle digits and in an ek on the right digits the parameter value is viewed By means of the keys located under these digits the values within the range specified in attached Table 1 are modified Press the key it is possible to record the viewed working parameter information To end the process press e again 27 03 2008 35 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com HOT MELT APPLICATIONS A Valco Cincinnati Table 1 General parameter codes Between brackets the standard values by default Enter the password Enables to enter the code to allow modifying the access 000 level 000 255 P1 Access level 0 Configures the units access level 0 1 2 P2 Measuring unit 0 Selection of the measuring grade unit 0 C 1 F P3 Waiting time for Pum
63. nding on the model and those of a special channel dedicated to heat the deposit with its access menus to parameter programming as well as permission to operate the main machine alarms and a variety of work functions SCAN LOW MAINTENANCE that will described further on The control panel will be viewed on a 10 digit high brightness 7 segment display the information on the working unit as well as the alarms detected by the probes Likewise by means of LEDS the state of the regulating outputs of the heating resistances the pressure pump the alarms related to temperature safety and the state of low maintenance are viewed Preheating Given that the heating of the adhesive deposit has more inertia that that of the surrounding devices hoses and guns these last mentioned will sooner reach the programmed temperature This fast heating process has an enormous repercussion on the resistances and on the insulation At the same time this process creates an excessive pressure that flows through the hoses To solve this situation the unit has a preheating system which on the one hand will heat the surrounding devices a sequential mode as the deposit will heat up at a normal speed That is when the deposit reaches 75 of the programmed temperature the preheating system will go onto the hoses and when these have reached 75 of the programmed temperature the system will go onto the guns 4 1 3 Description of the control panel
64. ning valve with a screw driver to eliminate the residual pressure 52 Gradually increase the air pressure 27 03 2008 53 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com QS A Valco Cincinnati Compan 6 3 4 Cleaning the filter Before cleaning the filter put on the glasses gloves and long sleeve clothes to prevent possible burns caused by splashes of hot adhesive 19 To remove the filter the unit must be at working temperature 22 Reduce the applicator s air pressure to 32 Place acontainer under to collect the adhesive that is in the distributor 42 Open the draining valve with a screw driver to eliminate the residual pressure 52 Open the filter knob screw with an open end wrench and remove the filter set 62 Loosen the filter cartridge screw with an Allen wrench and the mesh of the filter cartridge and the inner body will be freed 72 Once the filter has been dismantled it is recommended to change the seals and mesh 82 Clean the filter mesh with solvent fit for your adhesive Contact the adhesive manufacturer for further information 92 Make an inspection on the state of the screen Change it if necessary 102Assemble the seals on the knob screw the mesh and insert the filter inside body Screw in the set with the filter cartridge screw 112 Insert t
65. nnection 2 on Monday d1 12 XX Type of disconnection 2 on Monday This same table is repeated for each week day that is 12 parameters for each day The TYPE parameter has the following functions Connected TYPE 0 Selection of inactive connection TYPE 1 The unit goes from actual state to normal WORK TYPE 2 The unit goes from OFF to LOW MAINTENANCE Disconnected TYPE 0 Selection of inactive disconnection TYPE 1 The unit goes from actual state to OFF TYPE 2 4 from actual state to LOW MUS0320201 27 03 2008 40 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 XS A Valco Cincinnati Compan To make the entry of the data easier pressing the key in the first parameter of the day positions the 12 pieces of information of the Monday programming are copied to the corresponding day depending on the pressed key To end the process press the Ki key again Set the clock on time To enter this programming mode it is necessary to press EI and to go ahead selecting the icon On the two left digits the code of the data to be programmed appears that may be selected by means of the A keys that are located under these digits On the middle digits the value of the information on the set time on the clock is viewed By means of the A keys located under
66. p delay Time in minutes to activate the pump and the permission 15 permission after preheat 0 60 mins Maximum temperature P4 permitted 240 464 Unit maximum temperature 80 240 C 176 464 F SI Any probe measuring higher or lower temperature than P5 Deviation for deposit that at work deviation will activate the temperature alarm 5 C 9 F alarm light and corresponding external notification output 1 30 C 2 54 F Any probe measuring higher or lower temperature than P6 Deviation for hose alarm that at work deviation will activate the temperature 5 C 9 F alarm light and corresponding external notification output 1 30 2 54 Any probe measuring higher or lower temperature than P7 Deviation for gun alarm that at work deviation will activate the temperature 5 C 9 F alarm light and corresponding external notification output 1 30 2 54 F EE EE If the selected time has exceeded between 1 and 255 H minutes with revisions EV pulses of shots the unit will P8 maintenance from the Th ill disable thi last signal 0 go to ow maintenance e 0 value will disable this function UO CARD REQUIRED P9 Hour counter It views the number of hours the unit has been working Hours till filter change me P10 2000 Time till filter change 0 2000 Enable Disable Hose SE P11 Gun Channel 1 0 Allows disabling the Channel 1 P11 1 0 1 Enable Disab
67. rature conditions lower than 10 C and over 50 C When installing the unit try not to set the unit in draughts should there be any its guns should be protected as if the temperature guickly dissipates it may prevent it working correctly MUS0320201 27 03 2008 17 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 4 A Valco Cincinnati 3 4 MECHANICAL INSTALLATION The mechanical installation includes the following steps Position the unit gt Connect the hoses Position the unit Remove the unit from the box and set it following the installation requirements chapter 3 3 Hose installation The next procedure must be followed to install the hoses Before installing the hose ensure the unit is with no pressure Heat the unit to melt any trace of adhesive Remove the distributor cap LEY t El SILENBLOCK AIR INPUT ALTERNATIVE AIR INPUT Pl al us gt T MINI FILTER MUS0320201 27103 2008 18 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton
68. re regulator It is the element used to increase or lower the pressure indicated by the gauge and it is regulated depending on the application to be carried out It includes an air filter to prevent the entrance of impurity to the unit Enabling Valve It is the element that controls the air input to the pump It is electrically connected to the electric control It enables the applicator to adapt to the main machine s speed MUS0320201 27 03 2008 12 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com MUS0320201 4 A Valco Cincinnati Compan 2 2 5 Control Panel The control panel which is located on the front monitors the whole system applicator hoses and guns by means of an electronic digital unit controlled by a microprocessor 2 2 6 Chipping loader The chipping loader is used to load the adhesive this systems is controlled through sensors that automatically detect the end of the adhesive in the adjustment section it must be fixed as STATED In the event the sensor should detect a low level of adhesive the valve will open and the chipping loader will convey the adhesive until a higher level of adhesive is detected In the event the adhesive is not loading after 200 seconds an amber light will flicker and an alarm beep will ring The moment the lid of the
69. rect programming enabled and at appropriate temperature If th is short circui 2 Check the 5 temperature If the probe is open the probe display shows AAA Make sure of the external Check the correct connection Within the connector check connector s perfect of the gun connectors that the pines are in perfect connection state Check the gun fuse Check the gun triac s correct working Check the gun s resistance MUS0320201 27 03 2008 63 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com IM MELIS A Valco Cincinnati Compan hose does not heat Check the control card s Check that the canal is correct programming enabled and at appropriate temperature If the sensor is short circuited Check the hose s the display shows CCC temperature probe If the sensor is open the display shows AAA Make sure the final connector Check the correct connection Check that the internal pines is correctly inserted on the hose connectors of the connector are in perfect state Check the hose fuse Check the hose triac s correct working Check the hose resistance electric MUS0320201 27 03 2008 64 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http
70. s the unit s state CLOCK LED Indicates the Clock function SCAN LED Indicates the state of the SCAN function BM LED Indicates that the unit is on LOW MAINTENANCE CO D e State of heating and pumps LEDS 1 3 5 7 9 11 depending on model They indicate the activation of the power outputs Hoses LEDS 2 4 6 8 10 12 depending on model They indicate the activation of the power outputs towards the resistance heating of the dispensing guns LED 0 Itindicates the activation of the deposit s resistance heating LED Bi It indicates if the pump Enabling has been set on MUS0320201 27 03 2008 27 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com D D MUS0320201 49 A Valco Cincinnati Compan 9 Other states STOP LED Stop signal due to serious failure Heating disabled AL LED Indicates alarm OK LED Unit in operational state Intermittent during heating up waiting time P TEMP LED Indicates unit is in Temperature programming P BM LED Indicates that the unit is in Low Maintenance programming P PAR LED Indicates the unit is in Working Parameter Programming P REL1 LED Indicates the unit is in the programming process of the connection and disconnection parameters by means of the calendar clock P REL2LED
71. t On Off function has the unit will work normally When a pulse reaches the unit will turn off With another pulse we set it to work normally Loader Alarm Through this entry the unit is able to manage the loader alarm This function will always be wired and working for the correct operating of the loading system When we shut the circuit between the I O card GNR and the entry for moment a pulse will be emitted If the contact is shut no signals may be sent to other contacts Con1 1 2 Con X GND Con2 3 4 Con3 5 6 It is not possible to send more than one pulse at a time 27 03 2008 85 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com 7579 A Valco Cincinnati 9 2 MODBUS COMMUNICATIONS MUS0320201 9 2 1 Communication Structure Selecting of communication modes Parameter P27 Through a parameter it is possible to identify if external communications will be used If P27 0 gt It implies that external communications will not be used through the MODBUS protocols but yes by States If P27 1 gt Activating the MODBUS communications I O by States In both communication cases when units of 4 outputs are used in the positions not used as it is exclusive of the 6 outputs we will send a O Functions supported by t
72. these digits the value of this information is modified Pressing the key this information may be recorded Identification codes r1 Week Day 1 Monday to 7 Sunday r2 Actual time 0 to 23 r3 Actual minute 0 to 59 To end the process press the key again 27 03 2008 41 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com KMD MELION A Valco Cincinnati Compan 4 2 OUTPUT PRESSURE ADJUSTMENTS The output pressure of the adhesive is controlled from a valve regulating set This element that includes the pneumatic and electro pneumatic commands of the pump is placed on the back part of the applicator directly connected to the pneumatic pump Manometer This is the element that indicates the pressure in bars and psi in which the pneumatic cylinder of the pump and the compensation valve is working with Pull out the knob to graduate and push it to block it Graduate the pump pressure at 40 Psi 2 5 bar Manometer Knob NOTE This pressure is a point of origin There may be a need to change it to adjust it to your application The pump will start up and will pressurize the system The ratio between pneumatic pressure and hydraulic pressure is of 1 to 14 Which means that for each pneumatic Kg cm the manometer indicates we will hav
73. ti 6 3 MAINTENANCE PROCESSES MUS0320201 6 3 1 Draining the humidity of the air filter At the bottom of the manometer container there is a yellow plug with button with a hand in the centre It is also used to depressurize the unit Press this button to drain the water from the humidity container filter If possible close the main air input The remaining pressure will cause the water to spray out of the container Place a face screen gloves and long sleeve clothes 6 3 2 Cleaning the external part of the unit Vacuum or remove the dust and the adhesive residue with a soft cloth specially the distributor and the drain valve Regularly clean the control panel with a soft cloth Do not put the panel in contact with solvent that may corrode the commands Remove the dust and the adhesive residue with a soft cloth should there be any in the cylinder valve and gear set If a cleaning agent is used make sure it is compatible with the adhesive being used Contact the adhesive manufacturer if you have any doubt 6 3 3 Draining the deposit Before draining the deposit put on the glasses gloves and long sleeve clothes to prevent possible burns caused by splashes of hot adhesive 12 To drain the deposit the applicator must be at working temperature 22 Reduce the applicator s air pressure to 32 Place 8 container under to collect the adhesive that is in the distributor 42 Open the drai
74. tmelt com MUS0320201 7579 A Valco Cincinnati 4 1 3 6 Connections with the main machine Permission to the exterior This potential free contact closes when the unit is ready to work that is to say when the pump has been enabled Alarm indication This potential free contact closes when the control connects to the ALARM led the amber LED Safety stop indication This potential free contact closes at the same time as the control activates the STOP indicator led Access levels There are two access levels To allow to enter the programming mode gt PO 232 P1 1 b To allow to modify the whole the configuration gt PO 123 P1 2 To have these two levels implies that the P1 must have three kinds of access that are the following a P1 2 there are no passwords we may access in the programming mode and modify the P parameters P1 1 we may access the programming mode but not modify the P parameter data except PO and P1 0 1 Admissible range P1 0 when trying to access the programming mode PO appears to enter Password Pressing ENTER with incorrect password you leave the programming Menu With correct password and ENTER you access the programming Menu which you must confirm to fix the level of access If you do not confirm the access this privilege is lost as the programming Menu is left Any of the passwords 232 123 must be possible to enter In the e
75. umatic cylinder and a double effect hydraulic pump to which a pressure compensator has been incorporated to prevent the flow drop caused in the reverse direction of the pump and enables a maximum uniformity in the exit of the Hot Melt Cylinder unit Hvdraulic unit Before dismantling the pump put the face screen gloves and long sleeve clothes on to avoid possible burns caused by splashes of hot adhesive Heat the tank until the adhesive is melted Reduce the air pressure to zero Eliminate the system pressure by shooting the guns manually or opening the draining valve Disconnect the electric connection MUS0320201 27 03 2008 74 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com ADI Valco Cincinnati Compan To access the pump follow this procedure 2 Locate the four fastening screws of the casing and Locate me unit and deactivate the loader by unscrew them the loader s air connection should be opening the lid latch green removed 3 Remove the casing 4 Loosen the input pipes and output of the pump air 5 Setthe tank at working temperature to melt the 6 Eliminate the remaining pressure by shooting the 2 he depon ANET guns manually or opening the draining valve 7 Loosen the three pump screws A
76. vent you enter 123 it should enable you to access the programming Menu to enter the P1 to 2 It should not be necessary to enter the passwords in order 232 gt 123 Navigating in the introduction of the Access Password PO will enable the way from 0 to 255 in an ascending and descending direction The PO parameter is of free access but at view 000 will always be seen independently from the access level the unit is in The P1 parameter will have the modification possibilities limited depending on the unit s access level or the entered password 27 03 2008 32 MELTON S L U POLIGONO INDUSTRIAL AGUSTINOS CALLE G 34 31160 ORCOYEN NAVARRA TEL 00 34 948 321580 Fax 00 34 948 326584 e mail melton melton es http www meltonhotmelt com et Lie MUS0320201 Gen MELION A Valco Cincinnati 4 1 3 7 Programming menus ao o 65 0 BO Oy Os BH HAN ANINE os o o Programming Menus Temperature programming menu It enables the pre selection of the working temperature of each hose and each gun as well as that of the deposit in a range between 30 and 240 C 85 464 F Under 30 C 85 F the device remains permanently OFF ON Led The work temperature of the different devices is being programmed Low maintenance programming menu It enables to preselect a of the work temperature of the deposit the hoses and the guns The

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