VALCO MELTON EC4 Manual Download Page 51

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MUS033202

18/10/2010

VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 ORCOYEN, NAVARRA

TEL: +34 948 321580 Fax: +34 948 326584 [email protected] www.valcomelton.com

CHAPTER

HAPTER

HAPTER 6

MAINTENANCE

Summary of Contents for EC4

Page 1: ...ic compatibility Directive 93 68 EEC of 22 July 1993 amending Directive 73 23 EEC and Directive 89 336 EEC within the scope of the specifications indicated in the chapter describing the equipment with...

Page 2: ......

Page 3: ...URE CONTROL CHECK 150 180 HYDRAULIC CHECK 100 bar PNEUMATIC CHECK APPLICATOR SERIAL NUMBER DISTRIBUTOR CONTACT ADDRESS TELEPHONE OEM ADDRESS TYPE BRAND MODEL USER CONTACT ADDRESS SYSTEM LOCATION TELEP...

Page 4: ......

Page 5: ...OW THE SAFETY INSTRUCTIONS PROVIDED IN THIS MANUAL WHEN USING AND HANDLING THE MACHINE IF YOU FAIL TO FOLLOW THE SAFETY INSTRUCTIONS THIS MAY GIVE RISE TO BURNS INJURIES AND EVEN IRREVERSIBLE DAMAGE Y...

Page 6: ...MECHANICAL INSTALLATION 20 3 5 PNEUMATIC INSTALLATION 25 3 6 ELECTRIC INSTALLATION 25 CHAPTER 4 CHAPTER 4 CHAPTER 4 CHAPTER 4 MACHINE ADJUSTMENT MACHINE ADJUSTMENT MACHINE ADJUSTMENT MACHINE ADJUSTMEN...

Page 7: ...IDE EQUIPMENT REPAIR GUIDE EQUIPMENT REPAIR GUIDE EQUIPMENT REPAIR GUIDE_______________________________ 66 8 1 INTRODUCTION 67 8 2 CHANGING THE FILTER 67 8 3 REPAIRING THE MANIFOLD 68 8 3 1 High Flow...

Page 8: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 3...

Page 9: ...ol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 4 CHAPTER 1 CHAPTER 1 CHAPTER 1 CHAPTER 1 SAFETY INSTRUCTIONS SAFETY INSTRUCTION...

Page 10: ...iscellaneous prohibitions Danger hot surface Miscellaneous precautions Precaution Electric current Precaution Flammable liquid Precaution risk of fluid leakage under high pressure Precaution risk of e...

Page 11: ...e clothing This clothing will be compliant with EN510 and EN340 standards protecting against fast moving particles and high temperatures It will be as tight as possible to prevent it from catching on...

Page 12: ...ardous explosive and or flammable atmospheres When working with this machine wear protective clothing gloves and face shields and remove rings bracelets and watches Since the machine is designed to fo...

Page 13: ...ot attempt to remove the adhesive from the skin even when it has cooled as this may cause more serious injury Seek qualified medical attention immediately In case of an accident with the solvent CONTA...

Page 14: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 9...

Page 15: ...MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 10 CHAPTER CHAPTER CHAPTER CHAPTER 2 2 2 2 DESCRIPTIO DESCRIPTIO D...

Page 16: ...ilar materials until it goes from solid to liquid state in a heated container A pump absorbs the glue at a certain pressure through heated hoses and transfers it to where it is applied 2 2 MAIN PARTS...

Page 17: ...directly The filter in the manifold consists of a core and fine in line filter screen to filter the crystal particles or dirt that could be present in the adhesive The manifold has 6 outlet holes to c...

Page 18: ...2 6 Vacuum feeding The vacuum feeding 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 fi...

Page 19: ...8 psi Noise level 63 dB Working temperature 10 50 C 32 122 F HR 20 to 80 non condensed CONTROL Working temperature 15 230 C 59 446 F Temperature control precision 0 5 C 1 F Type control PID Control PU...

Page 20: ...Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 15 2 3 GENERAL DIMENSIONS Dimensions mm EC4 EC8 EC14 A 307 307 367 B 583 658 658 C 532...

Page 21: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 16...

Page 22: ...3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 17 CHAPTER CHAPTER CHAPTER CHAPTER 3 3 3 3 INSTAL INSTAL INSTAL INSTALL L L LA A A ATIO TIO TIO TION N...

Page 23: ...tions described in this chapter should be performed by qualified personnel following safety instructions 3 2 TRANSPORT The unit is supplied packed with a paperboard box To unpack it will remove top co...

Page 24: ...2 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 19 Avoid extreme temperatures below 10 C and ab...

Page 25: ...ls rapidly they may not work properly 3 4 MECHANICAL INSTALLATION The mechanical installation includes the following Positioning the equipment Connecting the hoses Positioning the equipment Remove fro...

Page 26: ...6584 melton melton es www valcomelton com 21 Remove the cap from the distributor Start to connect the hoses from right to left If you do not do this you will create a dead centre where carbon deposits...

Page 27: ...ol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 22 For the hydraulic connection if the equipment is full of adhesive heat the ta...

Page 28: ...tinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 23 Installation of hoses Never bend the hoses more than curves of 150 mm radius The hoses s...

Page 29: ...48 326584 melton melton es www valcomelton com 24 Do not install hoses together leave a minimum separation 25 mm between them so that the heat can dissipate Do not cover the hoses if it is necessary t...

Page 30: ...n com 25 3 5 PNEUMATIC INSTALLATION Connect the air line to the regulator Make sure the air connection line has the capacity necessary for proper pump operation There is a quick and easy plug that is...

Page 31: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 26...

Page 32: ...ol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 27 C C C CHAPTER HAPTER HAPTER HAPTER 4 4 4 4 MACHINE ADJUSTMENT MACHINE ADJUSTM...

Page 33: ...s the parameter programming as well as the main machine operating permissions alarms and diverse work functions that will be described later on the equipment regulates the temperature of the resistors...

Page 34: ...321580 Fax 34 948 326584 melton melton es www valcomelton com 29 4 2 3 Description of the control panel 4 2 3 1 keyboard The unit control panel has 11 control keys that provide access to the programme...

Page 35: ...the selected menu 11 Less Button Decreases the value of the selected parameter 12 Left Arrow Button Moves to the left through editable fields on the selected menu 13 Settings Screen Displays the menu...

Page 36: ...urn on and the LED will be green indicating that the unit is on When the Standby button is pressed again the screen will go blank and the Standby LED will be orange indicating that the unit is in Stan...

Page 37: ...elton es www valcomelton com 32 4 2 3 3 Navigation The navigation symbols at the top of the screen indicate that additional menus are available Use the following buttons to navigate 4 2 3 4 Settings T...

Page 38: ...inos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 33 4 2 3 5 Entering Passwords The password is required to prevent unauthorised access to the...

Page 39: ...n to display the first temperature screen 4 2 3 7 Temperature Screens The tank temperature screen displays the current and programmed temperature Output 1 and output 2 temperatures alternate on the sc...

Page 40: ...8 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 35 4 2 3 8 Tank Temperature 4 2 3 9 Hose Gun Tempe...

Page 41: ...10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 36 To programme hose gun 2 repeat the same process...

Page 42: ...green when each zone reaches the programmed temperature The system gives permission The permission activates the pump This prevents the pump from activating before the adhesive melts See the adhesive...

Page 43: ...r connected directly to the pneumatic pump Pressure gauge The element that indicates pressure in bar and psi at which the pneumatic cylinder of the pump and the compensating valve operate Lift up the...

Page 44: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 39...

Page 45: ...ALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 40 CHAPTER CHAPTER CHAPTER CHAPTER 5 5 5 5 OPERATION OPERATIO...

Page 46: ...adjusted Readjust if necessary see chapter 4 3 When the equipment is on the programmed temperature and no alarm led is lit the ON signal is received and the system is ready to run 4 Permission of mai...

Page 47: ...ank Before emptying the tank put on a face shield gloves and long sleeve shirt to prevent possible burns caused by hot adhesive splashing 1 Warm the equipment to the working temperature 2 Reduce the a...

Page 48: ...essurise the system Before purging the filter put on goggles gloves and long sleeve shirt to prevent possible burns caused by hot adhesive splashing 1 To purge the filter the applicator must be at the...

Page 49: ...g particles 6 Close the bleed valve with a screw driver 7 Return the pressure to the appropriate working pressure 5 3 STOPS There are two cases Pump stop If you wish to stop pumping you must turn the...

Page 50: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 45...

Page 51: ...MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 46 C C C CHAPTER HAPTER HAPTER HAPTER 6 6 6 6 MAINTENANCE MAINTENA...

Page 52: ...olved 6 1 INTRODUCTION This chapter contains the procedures involved in the maintenance of the follower plate These maintenance procedures guarantee safe operations and increase the life of the follow...

Page 53: ...of this operation depends on the type of adhesive used and the environmental conditions where the equipment is placed 6 3 MAINTENANCE PROCESSES 6 3 1 Cleaning the equipment Vacuum the dust or glue re...

Page 54: ...alcomelton com 49 6 3 3 Installing the Pump Casing To install and secure the pump casing you must follow these steps 1 Unscrew the 2 screws on the pump casing one fourth a turn 2 Release the fast on t...

Page 55: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 50...

Page 56: ...gustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 51 C C C CHAPTER HAPTER HAPTER HAPTER 7 7 7 7 EQUIPMENT REPAIR GUIDE EQUIPMENT REPAIR GU...

Page 57: ...the information provided here contact your Melton representative 7 2 MECHANICAL FAULTS Check to see if the filters are blocked Check to see if the modules are obstructed Check to see if the control s...

Page 58: ...eposit adhesive when the electrovalve works Check the temperature of the tank hoses and guns Check if the opening and closing valve of the gun works Check to see if the nozzles are obstructed remove a...

Page 59: ...the differential is the right one for the power requirement of the gluer The machine does not come on Check the connection of the power supply to the machine Check the power fuses of the electronic ca...

Page 60: ...he triac works correctly Check that there are no alarms on the electronic card Check the temperature sensor in the tank Check the tank resistance Once these checks have been made reboot the equipment...

Page 61: ...not heat up Check the correct programming of the electronic card Check the temperature sensor of the gun Check the correct connection of the gun connectors Check the electrical resistance of the gun...

Page 62: ...of the hose Check the correct connection of the hose connectors Check the electrical resistance of the hose Check the fuse of the hose Check the correct operation of the triac of the hose Check that t...

Page 63: ...safety thermostat Alarm for configuration or connection of hoses and guns Overtemperature alarm in the gluer or peripherals Service counter disabled Check FS15 FS4 fuses Check correct connection of t...

Page 64: ...eads Low temperature Nozzles far from the surface to be glued Bring nozzles closer Raise temperature Too much glue at the start and end of bead Nozzles far from surface to be glued Low pump pressure D...

Page 65: ...ads Applicator far from the surface to be glued Adhesive cold Adhesive old Adhesive too viscous Bring closer Fill tank with new adhesive Screen applicator to protect it Slightly increase the temperatu...

Page 66: ...open regulator Close by twisting several times Change to a smaller nozzle Drops of adhesive in the applicator nozzle Hole blocked and or seat worn or dirty Opening of obturators not correctly adjuste...

Page 67: ...Adhesive temperature too high Air pressure in the pump too high Viscosity of adhesives too low Reduce tank temperature Reduce air pressure of the pump Reduce temperature Use adhesive with higher visco...

Page 68: ...ure too high Temperature control fault Level of adhesive low Oxidation of the adhesive Reduce temperature of the tank Readjust temperature control or replace card Keep tank full Keep tank cover closed...

Page 69: ...k and operate applicators until the bubbles disappear Adhesive too viscous Slightly increase the temperature Use an adhesive of lower viscosity Humidity in the adhesive Check by applying adhesive on d...

Page 70: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 65...

Page 71: ...gustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 66 C C C CHAPTER HAPTER HAPTER HAPTER 8 8 8 8 EQUIPMENT REPAIR GUIDE EQUIPMENT REPAIR GU...

Page 72: ...LTER Before changing the filter put on a face shield gloves and long sleeve shirt to prevent possible burns caused by hot adhesive splashing Keeping a filter or mesh in stock to replace when necessary...

Page 73: ...ter in the manifold and screw it in with a screwdriver 10 Close the draining valve with a screwdriver 11 Put in the right working pressure 8 3 REPAIRING THE MANIFOLD The manifold is the element that d...

Page 74: ...PNEUMA REPAIRING THE PNEUMA REPAIRING THE PNEUMATIC PUMP UNIT TIC PUMP UNIT TIC PUMP UNIT TIC PUMP UNIT The pump unit consists of a valve an exchange a pneumatic cylinder and a double acting hydraulic...

Page 75: ...nually or opening the bleed valve 4 Disconnect the electricity 5 Disconnect the regulator unit electrically and mechanically 6 Loosen the 2 Soutcho screws 1 4 a turn and lift the pump casing Carefully...

Page 76: ...33202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 71 8 3 1 High Flow Pump CYLINDER HYDRAULIC...

Page 77: ...Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 72 8 3 1 1 CYLINDER 1 Loosen the screws 2 Separate the units 3 Loosen the 4 separat...

Page 78: ...ELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 73 8 3 1 2 HYDRAULIC UNIT 1 Loosen the screws 2 Separate the units...

Page 79: ...MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 74 4 Loosen 5 Remove the axle 6 Remove the spring and impulse tube...

Page 80: ...33202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 75 8 3 2 Low Flow Pump CYLINDER HYDRAULIC U...

Page 81: ...ol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 76 8 3 2 1 CYLINDER 1 Loosen the 4 screws on the bottom 2 Loosen the 4 separator...

Page 82: ...34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 77 8 3 2 2 HYDRAULIC UNIT 1 Loosen the 4 screws on the bottom 2 Loosen 3 Loosen 4 Remove the axle 5...

Page 83: ...ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 78 8 4 CLEANING VALVES 1 Loosen the 4 screws on the bottom 2 Loosen 3 Clean the valve 4 Use the M6 Allen wrench...

Page 84: ...s should be performed with the machine switched off at the mains and disconnected from the main air circuit making sure that the system has been duly bled and depressurised WARNING When a fuse is brok...

Page 85: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 80...

Page 86: ...O MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 81 C C C CHAPTER HAPTER HAPTER HAPTER 9 9 9 9 LOG LOG LOG LOG SH...

Page 87: ...MUS033202 18 10 2010 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 82 DATE INCIDENCE...

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