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MA-5081-E 030120

GLUING SOLUTIONS

ADHESIVE

MELTER

NON-STOP

INSTRUCTIONS

MANUAL

Содержание B4 NON-STOP

Страница 1: ...MA 5081 E 030120 GLUING SOLUTIONS ADHESIVE MELTER B4 NON STOP INSTRUCTIONS MANUAL ...

Страница 2: ...is strictly prohibited The specifications and information contained in this manual may be modified without prior notice This manual is a translation of the original that was written by Focke Meler Gluing Solutions S A in english language If there is any discrepancy between the different versions of this manual the original written in the english language shall prevail Focke Meler Gluing Solutions ...

Страница 3: ...onents 1 2 Thermal components 1 3 Materials 1 3 Noise emission declaration 1 3 Intended use 1 4 Limited use 1 4 2 INTRODUCTION 2 1 Description 2 2 Operating modes 2 2 Melter identification 2 3 Main components 2 4 Control panel 2 5 Pumping control card components 2 6 Optional equipment 2 6 3 INSTALLATION 3 1 Introduction 3 1 Installation requirements 3 1 Free space 3 1 Electrical consumption 3 2 Co...

Страница 4: ...re ok 3 7 External standby 3 7 Starting up the motor ok ext 3 8 Motor speed set point reference ref ext 3 9 Failures output in pump control card 3 9 4 MELTER OPERATION 4 1 General information 4 1 Loading the adhesive into the cylindrical hopper 4 2 Starting up the melter 4 3 Melter displays 4 4 Temperature display for each component 4 5 Alarm display 4 5 Display and adjustment of the cylinder work...

Страница 5: ...g control and internal speed control 4 16 Mode of operation with internal pumping control and external speed control 4 17 Mode of operation with external pumping control and internal speed control 4 18 Mode of operation with external pumping control and external speed control 4 19 User configuration menu 4 21 Displaying alarms and reset function 4 21 Maximum rpm alarm 4 21 Minimum rpm alarm 4 22 V...

Страница 6: ...e 5 6 Cleaning the motor fan 5 6 Checking the lubricant 5 6 Recommended lubricant 5 7 Safety Thermostat 5 7 Removing the equipment from its base 5 7 6 TECHNICAL CHARACTERISTICS 6 1 General 6 1 Dimensions 6 2 Melting unit 6 2 Base plate 6 2 Accessories 6 2 Level control system 6 2 7 ELECTRICAL DRAWINGS 7 1 8 PNEUMATIC DRAWINGS 8 1 Components list 8 1 Pneumatic cylinder control system 8 1 Pneumatic ...

Страница 7: ... E B4 NS ADHESIVE MELTER MANUAL TABLE OF CONTENTS B DISTRIBUTOR UNIT 9 4 C MOTOR PUMP UNIT 9 5 D ELECTRIC PANEL AND AUXILIARY COMPONENTS 9 6 E WARNING LIGHT UNIT OPTIONAL 9 7 EC DECLARATION OF CONFORMITY 10 1 ...

Страница 8: ...FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS This page is intentionally left blank ...

Страница 9: ...erform maintenance on it Also provide necessary safety material appropriate clothing footwear gloves and safety glasses In all cases observe local regulations regarding risk prevention and safety Symbols The symbols used on both the melter applicator equipment and in this manual always represent the type of risk we are exposed to Failure to abide by a warning signal may result in personal injury a...

Страница 10: ...voltage Periodically inspect the cables to check for crushing wear and tear as well as to prevent tripping and falls as a result of their placement Although the system meets EMC requirements it is inadvisable to use devices that transmit high levels of radiation i e mobile phones or soldering equipment in their vecinity Hydraulic components As this is a pressurized system precautions related to th...

Страница 11: ...er systems are designed for use with hot melt adhesives They should not be used with any other type of material and especially not with solvents which may cause personal injury or damage to internal system components Some units are specifically designed to use polyurethane reactive PUR hot melt adhesives Using PUR on a unit that is not prepared for that purpose may cause severe damage to the unit ...

Страница 12: ...bels accompanying the equipment using adequate means of protection during each mode of operation Limited use The equipment should never be used under the following conditions Use with reactive polyurethane or any other material that might cause safety or health risks when heated Use of equipment in environments where cleaning is necessary using water jets Use of equipment to heat or melt food prod...

Страница 13: ...ining the B4 NS adhesive melter from Meler This equipment is designed to melt 2 kilo blocks of adhesive Ø128 mm and height 165 mm It has a 0 45 litre reserve tank Moreover in this B4 version with gear pump speed regulation is possible The equipment is mainly designed to be used with thermo reactive PUR based adhesives in block format ...

Страница 14: ...al pumping and internal speed_Switches in the position ok ext and ref int This mode of operation is performed through external pumping control and manual speed control Control of external pumping and speed_Switches in the position ok ext and ref ext In this working mode both pumping and speed are controlled from the main machine Speed is controlled by means of an external 0 10 V signal sent from t...

Страница 15: ...from ascending possibly inflating the adhesive bag and causing it to expand when the cylinder moves up Melter identification You will need your melter model and reference when ordering spare parts or requesting support from our Technical Service Centre This data and other technical information can be found on the nameplate located on the side of the melter base ...

Страница 16: ...arning light optional 6 Cylinder 7 Cylindrical hopper adhesive load 8 Pressure relief valve for non moisture curing adhesives 9 Purge valve 10 Filter pump 11 Hose applicator hydraulic connection 12 Air supply input 13 Pump system connection switch optional 14 Hose applicator electrical connection 15 General power switch and power supply 5 6 7 3 4 1 2 15 14 12 13 11 8 9 10 ...

Страница 17: ...ator led 2 Hose indicator led 3 Applicator indicator led 4 Temperature set point 5 Actual temperature 6 ON OFF switch 7 Standby function 8 Temperatures ok led 9 Timer programming 10 Up Down arrows for element selection 11 Up Down arrows for value modification 1 2 3 4 5 11 8 9 6 7 10 ...

Страница 18: ...p value selection LEDs voltage speed 9 Voltage pump speed errors display screen 10 Pumping control internal external selection 11 Pumping speed internal external selection 12 Voltage value display of the external signal of the speed control 1 2 3 4 9 8 5 6 7 12 11 10 Optional equipment To increase the functionality of the B4 NS melters the following optional components can be incorporated Detectio...

Страница 19: ...ied by the user depending on the location and connections in each specific installation Melter anchoring screws Power cord for electrical power supply Pneumatic conduct and connection to compressed air network Stranded wire for external electric control functions Optionally a gas venting system Installation requirements Before installing a B4 NS melter you must ensure that the space allocated is s...

Страница 20: ...ns are indicated in the table in section Electrical power supply connection Compressed air The installation of melters from the B4 NS series requires a non lubricated compressed air dryer system with a maximum pressure of 6 bar to supply the pusher disk cylinder and the pneumatic bypass valve in case of the melter has one Other factors Other practical considerations should be taken into account wh...

Страница 21: ...r the base plate s M8 fastening screws The holes may be threaded or through holes depending on the bench on which they are being mounted Warning Make sure the bench on which the base plate is being mounted is level free from vibrations and able to support the weight of the equipment plus the full tank load Once the base plate has been secured to the bench the melter should be mounted on top Fit th...

Страница 22: ...wise until the desired pressure is reached Hose and applicator connection The B4 NS melter can use standard Meler components The entire range of Meler hoses and applicators may be connected to this equipment The B4 NS melter has two outputs for connecting the hose applicator for only one installed pump These are identified on the same plate with the numbers 1 and 2 These numbers correspond to the ...

Страница 23: ...re values are 160 C 320 F for the tank 150 ºC 302 ºF for the hoses and 160 ºC 320 ºF for applicators The general process for changing the set point temperature value for any component is described below 1 Use the arrows to select the component for which you wish to change the value The corresponding LED will blink rapidly 2 Use the up down arrows under the display to select the desired value for t...

Страница 24: ...the desired component The corresponding LED will blink rapidly 2 Hold the arrow button on the desired component for two seconds 3 The display will now remain on the selected component and will not be changed 4 Simply press the up down buttons again to restore the default display tank External I O connections The melter uses its input and output I O signals to communicate with the main machine simp...

Страница 25: ...pport plate and power switch on the left side of the equipment Pass the signal cable Ø4 8 mm through the Pg9 bushing and attach it to the internal fitting ensuring that the cable reaches the control board connector at the point where it is to be installed CN4 3 Remove the connector from the panel and connect the two cable wires to their corresponding connector terminals 4 contact NO 6 contact NO 4...

Страница 26: ...DC If connected to 230 V the load current cannot be less than 50 mA Note take into account the image of CN4 external standby connector do not confused with CN4 temperature ok Starting up the motor ok ext 1 If this is the only signal being connected use 0 5 mm2 two wire cable Install an electrical wall bushing Pg9 next to the electrical supply input 2 Thread the power cord max Ø4 8mm through the el...

Страница 27: ...5 For the signal to work the led ref ext on the control panel must be on Warning When connecting the 0 10V signal to the equipment Make sure that the signal is not inverted or the signal applied is not excessive more than 10 volts Connect to inappropriate voltage or a wrong installation can result in an unpredictable behavior and even irreversible damage Failures output in pump control card 1 If t...

Страница 28: ...N 5 Check that the cable is correctly connected and that its passage through the electric cabinet presents no risk of jamming being cut or any other accidental damage Warning It must be connected to 24 AC or DC voltage with a maximum current of 1A ...

Страница 29: ...is the tank distributor pump unit They form one single unit and have the same temperature control and set point value Therefore when the set point value for the cylindrical hopper is set to 170 C for example this same value is set for the distributor and pump The second group is the hose unit These are identified on the front panel with the numbers 1 and 2 and the corresponding hose drawing Each h...

Страница 30: ...r and pusher disk 3 Open the adhesive block with the indicated marking leaving approximately 1 cm of the bag inside and insert the block into the cylindrical hopper Warning Risk of burns Always wear protective gloves and safety glasses when refilling 4 Reposition the unit in the support plate along with the cylinder and pusher disk using the retractable positioner Move the manual lever valve downw...

Страница 31: ... the temperature set point value a programmable delay timer is activated until a signal is given to start the pump activation of the solenoid valve or turning of the motor and connect to the main machine provided that the other components have also reached 3 C below their set point temperature While the system counts down the delay time the LEDs for pump activation and connection to the main machi...

Страница 32: ...standby function LED display Component heating Component status constantly lit constant low temperature blinking slowly as need according to PID parameters temperature near set point blinking rapidly programming or display change in set point values off not heating temperature reached LED display On off Standby constantly lit turned off unit function activated blinking slowly deactivation programm...

Страница 33: ...ivate the equipment s functions Activating the standby function does not trigger any alarm If the sensor is broken the system will keep all the components hot except for the one in which the fault has occurred In the event of overheating the system immediately stops heating the failed component If after three minutes the fault persists the system will stop heating all components and the power rela...

Страница 34: ...for hoses and 160ºC for applicators Display in C Overheating value 20 C Standby value 40 Delay time 10 mins Time programming ON The general procedure for adjusting the temperature of each of the components is described below 1 Use the up down arrows to select the component for which you wish to change the value The corresponding LED will blink quickly 2 Use the up down arrows under the display to ...

Страница 35: ...ection down arrow to move to the following screen where the standby function symbol appears 6 Use the up down arrows under the display to select the desired value between 25 and 55 The value displayed corresponds to the percentage decrease in actual temperature below the set point temperature that will occur when this function is activated 7 Use the component selection down arrow to move to the fo...

Страница 36: ...s the time with a dot indicating that this is the value that can be changed while the minutes are shown on the second display 3 Use the up down arrows under the display to select the desired value 4 Press the button with the clock symbol again Now the dot appears on the display on the right 5 Use the up down arrows under the display to select the desired value 6 Press the button with the clock sym...

Страница 37: ...o times will appear one in each display The display on the left shows the start time while the display on the right shows the end time 4 The flashing dot on the start time display indicates that this value can be changed Use the up down arrows under the display to select the desired value 5 Press the button with the clock symbol again The dot then appears on the end time display 6 Use the up down ...

Страница 38: ...te each time you press the button 4 Press any of the up down component selection buttons to exit this program and return to the tank temperature display Programming the activation deactivation of the equipment s standby function An activation and deactivation time can be set for each day of the week from Monday 1 to Sunday 7 Time is expressed in increments of 15 minutes starting with 10 0 10 hours...

Страница 39: ...ected program appears once again Use the up down button under the display to select other programs 9 Press any of the up down component selection buttons to exit this program and return to the tank temperature display The green LED next to the under maintenance button will always blink provided that an activation time has been set for the equipment standby function for the current day Disabling th...

Страница 40: ...erature for all the heated components drops to a certain value based on the programmed parameter see Programming the melter parameters For example if the tank set point temperature is 160 C and the standby function is set to 30 30 when the standby function button is pressed the tank set point temperature will drop to 112 C 70 of 160 C The three systems for activating the standby function in the B4...

Страница 41: ...o the rear round connector next to the hose connection optional applicator switch In this way the motor is activated while the external contact remains pressed down Pumping control Starting up the pump control card The pump control card hereingafter also control card features an ON OFF button that allows us to turn off the displays and LEDs leaving on only the 24 Vdc power supply LED The control c...

Страница 42: ...d again until the pumping ON OFF button is pressed and the red LED turns off Whenever an error occurs the control disables pumping red ON OFF button LED is illuminated and prevents the operation of the pump until the error is reset the pumping ON OFF button is pressed again and the red LED turns off When pumping safety is disabled In the event of loss of 24 Vdc power supply or the control is turne...

Страница 43: ...eappear on the screen and the process will recommence By default the password is set to 000 LED indicators Described below are the LED indicators on the pump control card to identify the status of the equipment 1 Control card ON OFF LED when the external 24 Vdc power supply is present this LED will always be illuminated with no power supply it will be turned off This LED is green in colour 2 Pumpi...

Страница 44: ...d control In this working mode the user has full control of the start stop function and speed pump set Follow the steps below to use this operating mode 1 Press the ON OFF button to light up the control card 2 Select ok in the position int and ref in the position int To activate the start up status all of the following conditions must be met That the input for pumping permission E4 at central cont...

Страница 45: ...ct ok in the position int and ref in the position ext The ref ext LED will illuminate when voltage is received To activate the start up status all of the following conditions must be met That the signal from the main machine reaches input E2 and its value is not 0 That the input for pumping permission E4 at central control is activated as pumping is not possible unless the equipment temperature is...

Страница 46: ...e speed is controlled from the equipment Follow the steps below to use this operating mode 1 Press the ON OFF button to light up the control card 2 Select ok in the position ext and ref in the position int The on ext LED will be illuminated when temperature is ok To activate the start up status all of the following conditions must be met That the input for pumping permission E4 at central control ...

Страница 47: ...mend working at speeds of not less than 10 rpm and not greater than 80 rpm The full scale can be adjusted by reducing this value in percentage terms To make adjustments consult the User configuration menu 1 MAXIMUM RPM Mode of operation with external pumping control and external speed control In this working mode both pumping and speed are controlled from the main machine Follow the steps below to...

Страница 48: ...he full scale see section 1 MAXIMUM RPM in the User configuration menu 3 Modify the speed ramp see section Configuring speed ramp Keeping the Vin key pressed will show the voltage sent by the main machine The pump will stop whenever The control card is disabled with its ON OFF button The pumping ON OFF button is pressed red LED is illuminated When the pumping permission input is deactivated E3 Whe...

Страница 49: ...lue programmed in the MAXIMUM RPM ALARM field If the value programmed is 0 the error function will be disabled By default this value is 0 disabled 4 MINIMUM RPM ALARM TIME this will be a period programmed between 0 and 999 in seconds In the event that the output RPM are less than the programmed value for MINIMUM RPM ALARM during the period established in this field MINIMUM RPM error will be activa...

Страница 50: ...d an E U error is shown on the control card The error message will be maintained while the variator error input E5 remains active As soon as this input is deactivated the alarm will be reset Note In the event that a RPM alarm and a variator ERROR alarm should coincide alternating messages will appear on the display Configuring speed ramp For equipment operating in external reference the display wi...

Страница 51: ...corresponding to the voltage speed ratio you must select external reference ref ext LED is illuminated and press the right arrow key Then the following message is displayed The IN LED to the position ON and the OUT LED to the position OFF 1 000 NOT EDITABLE press the right arrow to go to the next point The IN LED to the position OFF and the OUT LED to the position ON 1 XXX which means that the out...

Страница 52: ... to go to the following message The IN LED to the position OFF and the OUT LED to the position ON 5 XXX which means that the speed value is being programmed for point 5 with the up down arrow keys the value may be modified within a range from 000 to MAXIMUM RPM press the right arrow key to exit the menu Press the right arrow key to return to the menu and the initial message is displayed The IN LED...

Страница 53: ...0 bar 2 Gradually loosen anti clockwise until the desired pressure is reached Each millimetre the spindle sticks out corresponds approximately to a reduction of 9 kg cm2 8 82 bar By default the equipment is calibrated with a hydraulic pressure of approximately 40 bar Pneumatic valve control To adjust the pressure with this valve model follow these steps 1 Unlock the pressure regulator control by p...

Страница 54: ...FOCKE MELER GLUING SOLUTIONS 4 26 MELTER OPERATION This page is intentionally left blank ...

Страница 55: ...ean the exterior using a cloth moistened with water Do not use flammable liquids or solvents External cleaning Use cleaning products compatible with painted surfaces Apply the cleaning product with a soft cloth Do not use sharp tools or scrapers with sharp edges Operation Frecuency Refer to External cleaning Daily Equipment cleaning Despresurización del sistema Before performing maintenance tasks ...

Страница 56: ...e 4 To replace the cover follow steps 1 to 3 in reverse order Opening the control box to access the components inside 1 Perform steps 1 to 3 to remove the control box cover 2 Remove the two screws fastening the control panel to the frame of the melter 3 Tilt the control panel to the left 4 Follow steps 1 to 3 in reverse order to close the control panel System depressurisation The B4 NS melter is a...

Страница 57: ...unloading of the hot melt adhesive and prevent it from remaining inside which would result in burning Also when adhesives are mixed reactions may occur between them causing degeneration and problems unloading to the pump It is therefore recommended that the tank is cleaned each time A different hot melt adhesive is used Too much carbon deposit is generated inside Changing adhesive type 1 Use up as...

Страница 58: ... the purge valve to collect the adhesive Note in case of pneumatic bypass valve purge manually using the applicator used 3 Open the purge valve anti clockwise using a screwdriver 4 Set the pump to maximum speed 5 After emptying the tank close the purge valve remove the container and clean the valve output for future operations Warning Use the appropriate protective equipment for high temperatures ...

Страница 59: ...inside so that the inside of the distributor stays perfectly clean The filter can be cleaned or replaced with a new one No rule exists for determining when the filter should be changed Several factors influence this decision The type and purity of the adhesives used The working temperatures of the adhesive Adhesive consumption in relation to the time in the tank Changes to the type of adhesive use...

Страница 60: ... changes make sure the position of the leak Warning Change the gasket when the pump is hot Remove the shaft coupling from the pump Remove the screws fastening the gasket Replace the gasket system in the shaft or the gaskets in the seating pump and reassemble However before making any changes and in case of doubt should check with the Technical Assistance Service of Meler Warning Always wear protec...

Страница 61: ...icated to reset it Removing the equipment from its base For more thorough maintenance of the equipment the melter needs to be removed from its location so that it can be handled with greater ease and accessibility To do this remove it from its base as follows 1 Disconnect the equipment from the mains using the power switch on the side 2 For safety reasons disconnect the supply of compressed air to...

Страница 62: ...FOCKE MELER GLUING SOLUTIONS 5 8 MAINTENANCE This page is intentionally left blank ...

Страница 63: ...ormal conditions EVA PUR block 2 Kg Ø128 mm height 165 mm up to 45 000 cps between 1 2 and 15 6 Kg hr with 2 cc rev pump 5 Kg h 6 bar max adjustable 0 45 litres Depends on the adhesive viscosity and the length of time the block is in the lower tank three phase 179 W two pole forced ventilation 2 cc rev 0 100 rpm recommended 10 80 rpm continuously 80 bar max 1160 psi mechanical or pneumatic bypass ...

Страница 64: ...RACTERISTICS Dimensions Melting unit Base plate Accessories Level control system The adhesive level is controlled using an inductive sensor which triggers an alarm signal via a warning light 700 600 840 620 320 400 For ML 240 ST series replacement ...

Страница 65: ...ELECTRICAL DRAWINGS 7 1 MA 5081 E B4 NS ADHESIVE MELTER MANUAL 7 ELECTRICAL DRAWINGS ...

Страница 66: ...FOCKE MELER GLUING SOLUTIONS 7 2 ELECTRICAL DRAWINGS This page is intentionally left blank ...

Страница 67: ... B4 NS ADHESIVE MELTER MANUAL 8 PNEUMATIC DRAWINGS Components list Pneumatic cylinder control system 1 Inlet filter filtering disk 2 Pressure regulator 3 Pressure gauge 4 Pneumatic valve 5 2 5 Pneumatic cylinder 6 Exhaust port filter ...

Страница 68: ...FOCKE MELER GLUING SOLUTIONS 8 2 PNEUMATIC DRAWINGS Pneumatic by pass valve control system optional 1 Pressure regulator 1 10 bar 2 Pressure gauge 0 10 bar 3 Pneumatic limit control valve AIR INPUT ...

Страница 69: ...wn in this chapter to give you a quick and sure guideline to choose them The spare parts are listed by groups in a natural order as they are located on the units As a visual help the manual includes drawings of the components with a drawing number to easy find them through the list The list includes the reference and description of the spare part ...

Страница 70: ...FOCKE MELER GLUING SOLUTIONS 9 2 SPARE PART LIST This page is intentionally left blank ...

Страница 71: ... 2 150113750 O ring for empty tank cover 3 150113760 Cylinder tank o ring 4 150113770 Manual valve 5 150113780 300W tank heating element 6 150113820 750W tank heatin element 7 10030007 Current connection strip 8 150028100 Retractable positioner 9 150114620 Safety thermostat 200 C 10 150022640 Sonde Pt 100 11 150022650 Sonde Ni 120 12 150113730 Fan 24VDC ...

Страница 72: ...r seating o ring 3 10100082 Pump plug with o ring 3 1 10100083 Pump plug o ring 4 10120095 Plug with balancing valve o ring 4 1 10120096 Balancing valve plug o ring 5 150029000 Filter plug with o ring 5 1 10100053 Filter plug o ring 6 10100090 Pump filter unit 6 1 10100051 Pump filter 100 mesh 7 150026330 Complete purge valve 7 1 150026340 Purge valve o ring 8 150026270 Pneumatic pressure regulato...

Страница 73: ...L C MOTOR PUMP UNIT Nº Ref Description 1 150026110 2cc rev gear pump 1 1 150090410 Pump seating o rings 1 2 R0007984 Gasket system in the shaft 2 150026090 Motor coupling 3 150026080 Geared motor ratio 43 39 1 4 150026100 Geared motor support 2 4 1 1 1 1 2 3 ...

Страница 74: ...ssure regulator 4 150113840 Pressure gauge 5 150021010 Circuit breaker 16A 2 pole 6 16010003 8 pin female connector base housing 7 150020720 12 pin female connector base housing 8 10140040 Cable gland Pg 13 5 9 150021590 Cable gland Pg 9 10 10120021 Air inlet quick coupling 11 150117110 Inverter Siemens G110 0 55KW 12 150117120 Power supply 24V 2 2A 12 1 10010401 Fuse 1A 5x20 power supply 4 3 1 2 ...

Страница 75: ...MA 5081 E B4 NS ADHESIVE MELTER MANUAL E WARNING LIGHT UNIT OPTIONAL Nº Ref Description 1 150110170 Inductive detector 2 150113710 Colourless warning light 2 1 R0006220 Lamp 24V 3 150090430 24V AC 2 contact relay 2 1 2 1 3 ...

Страница 76: ...FOCKE MELER GLUING SOLUTIONS 9 8 SPARE PART LIST This page is intentionally left blank ...

Страница 77: ...esponses to contact with surfaces Part 1 Hot surfaces EN ISO 13849 1 2015 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 14120 2015 Safety of machinery Guards General requirements for the design and construction of fixed and movable guards EN 60204 1 2006 A1 2009 AC 2010 Safety of machinery Electrical equipment of machines Part 1 General req...

Страница 78: ...ormation speak with your Focke Meler representative Focke Meler Gluing Solutions S A Pol Arazuri Orkoien c B nº3 A E 31170 Arazuri Navarra Spain Phone 34 948 351 110 info meler eu www meler eu A Focke Group Company ...

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