UES perfectMelt User manual

Manual
perfectMelt
Hot melt system

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
Tel.: [phone] · Fax: [phone] · [e-mail] · www.ues-ag.net
2

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
Tel.: [phone] · Fax: [phone] · [e-mail] · www.ues-ag.net
3
Contents
Introduction....................................................................................................................................................................5
Safety Instructions.........................................................................................................................................................6
Safety symbols..............................................................................................................................................................8
Example of a hot glue system........................................................................................................................................9
Installation ...................................................................................................................................................................10
Assembly and mounting of the tank system ................................................................................................................10
Connection of the tank system ....................................................................................................................................11
Electrical connection....................................................................................................................................................11
If the perfectMelt/perfectMelt SE is connected to 230 volt the following compulsory .................................12
specifications must strictly be adhered to:...................................................................................................12
Terminal Block X1 control contact...............................................................................................................................13
Air connection..............................................................................................................................................................14
Hose connection..........................................................................................................................................................14
Application head connection........................................................................................................................................15
Service ........................................................................................................................................................................16
Commissioning............................................................................................................................................................18
Setting the pump pressure ..........................................................................................................................................19
Automatic pressure release.........................................................................................................................................19
Individual settings........................................................................................................................................................20
Menu overview ............................................................................................................................................21
Pump ...........................................................................................................................................................21
Options ........................................................................................................................................................22
Service.........................................................................................................................................................23
Format .........................................................................................................................................................25
Timer (time switch)......................................................................................................................................26
Standby (temperature reduction).................................................................................................................................28
Maintenance................................................................................................................................................................29
Position of the sensors of the heating units.................................................................................................30
Position of the sensors of the heating units.................................................................................................31
Bleeding the system....................................................................................................................................................32
Changing the filter .......................................................................................................................................................33
Basic cleaning .............................................................................................................................................................34
Mechanical malfunctions .............................................................................................................................................35
Problems with the glue application..............................................................................................................................35
Socket assignment on UES systems, depending on the model...................................................................................36
perfectMelt replacement parts....................................................................................................................................37
Recycling.....................................................................................................................................................................38
Mains connection.........................................................................................................................................................39
Connecting digital outputs ...........................................................................................................................................39
Connecting digital inputs .............................................................................................................................................39
Fuses...........................................................................................................................................................................40
Pump connection.........................................................................................................................................................40

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Thermostat and fuse....................................................................................................................................................40
Technical data.............................................................................................................................................................41
Electrical data..............................................................................................................................................................43
Main board item: 133521.............................................................................................................................................44
Pin assignment (main board).......................................................................................................................................46
Tank board item: 133511.............................................................................................................................................48
Pin assignment (tank board)........................................................................................................................................49
2 Channel board item: 133512 ....................................................................................................................................50
Integration of several channel boards .........................................................................................................52
Pin assignment (2 channel board)...............................................................................................................................53
Connection scheme.....................................................................................................................................55
Electric circuit plan.......................................................................................................................................56
EC Installation Declaration according to Machinery Directive 20061421EG Annex II 1.B .........................58

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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5
Introduction
UES hot glue systems meet your highest expectations in terms of quality, labour and production reliability
as well as maintenance and user friendliness.
By combining cutting-edge control technology with comfortable and complete features, you have the
greatest possible benefit. An extremely compact design and the modular extension option assure variable
use for versatile applications.
The UES tank system "perfectMelt"is equipped with carefully selected components of very high quality.
When adhering to these Operating Instructions, a long-term and unlimited use of the device is possible.
Along with a full range of standard applications of adhesive technology with tank systems, hose and gun
systems, we also offer individual solutions and system components for special applications in various
industrial sectors.
With the adhesive application systems of the "perfectMelt" series, the process is conducted in the context
of the hot melt adhesive application. In other words, depending on the application, the adhesive systems
are incorporated into production or packaging machines, and, as such, part of the equipment.
In the operation of adhesive application systems for hot melt, the adhesive is processed at high
temperatures and with high-pressure material. For this reason, safety precautions are to be taken during
installation, operation and maintenance.
In the description of the operation of the system, these safety precautions are marked by safety symbols
and, if applicable, further information.
The safety precautions described here refer exclusively to the handling of the adhesive system.
Before commissioning, the operating instructions are to be read in full in order to ensure safety and
proper operation. The device owner or operator is responsible for compliance with the safety regulations.
All operating instructions and manuals of the company UES are copyrighted. Copying, reproduction (or
part thereof), translation, etc. is not allowed without permission by UES AG. Additional copies of these
operating instructions can be acquired directly from the factory. Furthermore, the manufacturer is not
responsible for the accuracy of the contents of this manual.
These operating instructions are subject to changes.
UES AG

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Safety Instructions
The following Safety Instructions must be observed!
Caution!
Before any repair and adjustment work, unplug from the mains!
Installation and maintenance work may only be performed by trained personnel.
Only those individuals shall be considered suitable who are qualified by specialised training and
experience in dealing with these or similar devices, who know the relevant safety and accident prevention
regulations, and who therefore can recognise and avoid hazards.
Work on the adhesive application system may generally only be conducted when the voltage has been
turned off and the compressed air has been blocked (depressurise the system).
The system must not be operated without the appropriate covers and safety panels. Be careful of non-
covered moving and rotating parts, such as motor and pump shafts, hub and swivelling mechanisms!
Caution!
Do not use the system for anything else than what it was manufactured for!
On many non-covered parts of the applicator device, the hot glue hoses and application guns consist of
high temperatures during operation. Hot and pressurised adhesive may cause severe skin burns.
Therefore, always wear protective clothing, gloves and safety goggles when working on the system, such
as when filling the melting tank or connecting and installing the hoses and valves. Some adhesives
produce toxic fumes that have to be extracted. The hot melt adhesive application equipment may not be
operated under the following circumstances:
• In the vicinity of volatile substances or explosive materials and gasses
• Without adequate protection
• At temperatures of less than 5 °C or more than 45 °C
Security measures with respect to the adhesive
When working with molten hot glue, always be extremely careful! These materials solidify very quickly,
even at high temperatures, so they can still be very hot even in their solid state and can result in burns
when in brought into contact with the skin. The safety precautions of the adhesive manufacturer are to be
observed. These can be found on the data sheet of the adhesive. Comply with the processing
temperatures recommended by the glue manufacturer!
When working with hot melt, wear gloves, safety glasses and long sleeves to prevent burns. In the case
of a burn, do not attempt to remove the glue from a person's skin; instead, hold the wounded site under
cold water until the glue has cooled and then contact a physician.

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Safeguards with respect to the production machine
For the safety regulations in dealing with the production or packaging machine, please refer to the
documentation supplied with these devices.
For installation and maintenance work, the Safety Instructions for the parent machine in which the
adhesive application system is installed must be observed.

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Safety symbols
The safety symbols below highlight activities in this manual where increased caution is necessary. The
proposed safety precautions should be observed in any case.
Attention, general safety instructions:
Regards to safety instructions when working with glues and other machines. Additional (special)
safety instructions can follow.
Caution hot surface:
Danger of burning. Appliance parts have a high operating temperature.
Caution high voltage:
This type of work is only to be carried out by qualified personnel.
Caution hand injury:
Risk of entrapment if incautiously operated.
Caution, possible danger of uncontrolled release/leakage of hot liquids!
Wear safety gloves! Use safety glasses!
Disconnect power supplier! Use face shield!
Disconnect power plug before opening! Wear protective clothing!

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Example of a hot glue system
(Connecting parts are not supplied with the perfectMelt)
Tankdeckel
Tank cap
Pumpe
Pump
Tank
Tank
Heißleim
Hot glue
Inline Filter
In-line filter
Tankfilter
Tank filter
Heizschlauch
Heat tube
Versorgungsblock
Supply block
Düse
Nozzle
Modul
Module
The fuel tank cap closes the tank. After filling, please use the fuel tank cap to close the tank of your
perfectMelt system.
The hot glue is melted in the tank. Your perfectMelt has two adjustable heating zones: the tank "t1" and
the manifold block "t2" (distribution block to connect the hot glue hoses).
The pump places the melted glue under pressure. UES-pumps have a translation ratio of 14:1. In other
words, at a set air pressure of 2 bar, there is a material pressure of 28 bar.
To prevent contamination in the hoses and application guns, the perfectMelt has a (tank) glue filter.
The hot glue hoses are connected to the glue dispenser. They are heated electrically and are connected
with the perfectMelt by a plug.
As an option, an in-line filter can be installed between the hose end and the gun.
The supply block is supplied with hot glue via the tube. It is also heated and is connected to the hose
electrically.
One or more modules are bolted onto the supply block. The modules open and close by air control (via a
solenoid valve).
For standard modules, screwable vents are necessary. Different nozzles are available for different
applications.

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Installation
Checking the components
After unpacking, please check all the components of your perfectMelt and (if applicable) the hot glue
hoses and application heads for any damage.
If you notice any damage, please contact UES AG immediately.
perfectMelt parts list
perfectMelt system
Manual
Filter wrench
Assembly and mounting of the tank system
Warning!
To prevent injury caused by falling, the tank system has to be firmly screwed
together with the production machine in any case.
The tank system is equipped with two mounting brackets. These angles have 9 mm holes to secure the
tank system with M8 bolts to the production machine. For this purpose, holes that are about 9 mm in
diameter have to be drilled in the seat for the tank system of the production machine.
The tank system should be positioned so that an operator is not ergonomically impaired. This particularly
applies to settings on the control panel, filling the tank and maintenance work, such as filter changes.
Warning!
Please make sure that, when drilling holes, no cables,
pipes or other equipment installations are damaged!

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Connection of the tank system
(necessary connections)
Electrical connection
Warning!
The work may only be performed by qualified personnel.
The power supply has to be interrupted.
Necessary: 400-V-(3L/N/PE/50 Hz) plug/connection.
The fuse for each phase cannot be more than 16A.
As an option, the tank system can be factory fitted with a connection cable. The power supply is
connected directly in the control box
Please only use the provided and designated terminals.
Only use the lines with the appropriate wire size as a feed.
For the performance data, please refer to the technical data.

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Attention!
If the perfectMelt/perfectMelt SE is connected to 230 volt the following compulsory
specifications must strictly be adhered to:
Connecting and initially operating the perfectMelt/perfectMelt SE must solely be conducted by
an electrically skilled person (comparable to German DIN VDE 0105-100 (2009-10)).
The connection terminals of the external conductors of the unit must be jumpered for that purpose.
This must be carried out with the help of a power-rated transversal section according to the appropriate
standards in the given country.
At the customer’s site the fusing of the phase must be power-rated and according to the
rules of the given country.
The supply line 230 V 1~/N/PE must be connected in a way that it is locked against rotation.
(Either with a 230 V CEE plug or the connection is made directly in the sub distribution.)
Please note that the maximum connected load available is 3000 watt only!
It is strictly prohibited to connect the unit with a shock-proof plug (comparable to the German Schuko
plug) because it does not provide a lock against rotation of the phases.
Improper connection can cause life-threatening situations.
We assume no liability, when these safety measures have not strictly been adhered to.
Power input
Product Tank size 4 kg or 8 kg
Number of possible
channels
perfectMelt 4/8-2
max. power input
2300 watt // 2000 watt
perfectMelt SE 4/8-2
max. power input
2100 watt // 2000 watt
perfectMelt 4/8-4
max. power input
2300 watt // 4000 watt
perfectMelt SE 4/8-4
max. power input
2100 watt // 4000 watt
perfectMelt 4/8-6
max. power input
2300 watt // 6000 watt
perfectMelt 4/8-8
max. power input
2300 watt // 8000 watt

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Terminal Block X1 control contact
Assignment 400V input supply voltage
L1,L2,L3/N/PE 400V50Hz
L1
external conductor 1
L2
external conductor 2
L3
external conductor 3
N
neutral conductor
PE
protective conductor
Assignment control contact
21/22
Ready (potential free) DO
31/32
Alarm (potential free) DO
23/35
Level sensor (potential free) DI
41/42
Level control (potential free) DO
K1 7/8
System switched on (potential free) DO
23/33
System start / stop (potential free) DI
23/34
Standby start / stop (potential free) DI
Terminal Block X1
Connection to
power supply and digital in-/output
(please see attachment electric circuit plan page 12)

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Air connection
Compressed air supply 6 bar (oil and anhydrous)
Connection via PK 8* 1.25 pneumatic hose.
Hose connection
Air connection
Hose connection
Hose connecting nipple (fittings)
The system is equipped with two glue nipples by the factory.
The corresponding electrical connections are labelled 1 & 2 accordingly.
To connect a hose, the end cap has to be placed under resistance with an SW 17 wrench.
The electrical connection is made by inserting the plug located on the hose into the socket located on the
system.

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Application head connection
The glue connection nipple on the application head has to be connected to the hose connection nipple on
the hose. You will also need an SW 19 wrench.
The electrical connection is established by inserting the plug located on the application head into the
socket located on the glue hose.
Warning!
Make sure that there is an absolutely tight connection between the system,
the hoses and the guns via the screwed glue nipple. Otherwise, any escaping
glue can lead to severe burns.
Pneumatic components are designed and constructed according to the
applicable standards and calculations such that, under the intended
conditions of use, rupture or failure due to fatigue or wear is not expected to occur.
Add glue
Caution!
When refilling the glue, any spouting hot glue can cause injuries.
In any case, observe the safety regulations for handling melted adhesives.
•Do not leave the adhesive supply open; only store it in sealed containers.
•The fuel tank lid should be able to be opened without foreign bodies (such as scraps of paper)
being able to fall into it.
•Before filling, check to see whether the tank and the adhesive supply are clean and free of debris.
•Do not overfill your system. Add adhesive carefully to a max. 20 mm below the tank opening.
•Close the tank lid after filling. This prevents unwanted foreign matter from entering the tank or hot
adhesive vapours from escaping.
•The tank lid should be closed without it coming into direct contact with the adhesive.
•Do not run your device when it is completely empty. If there is too little adhesive in the tank,
localised overheating can result in glue burns and deposits in your system, leading to a
malfunction.
•Refer to the data sheet of your adhesive supplier and set your device appropriately.

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Service
(general)
Our perfectMelt is equipped with a touch-sensitive 4.3" colour touch display. You will be guided through
the menu intuitively. If you wish to enter data, touch the screen at the desired location and enter your
values via the input field. Confirm this by pressing ENTER. The display then automatically jumps back to
the so-called Overview after a few seconds. All the important information is displayed here during
operation.
In addition, the perfectMelt has a rotary adjustment knob. Turn the knob until the desired number is
entered. By pressing the knob, this field is activated. Now activate the input field. Now set the desired
value by turning the knob again. Confirm this value by pressing the knob again. Through these two
methods, you can make your entries quickly, easily and intuitively.

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Through the menu, you will be informed about the current settings via our traffic light system. In the
heating phase, the corresponding fields are entered in yellow. The percentage of colouring of these fields
provides information on the heating progress. Once all the temperatures have been reached, these fields
are displayed in green. As soon as the ready signal is activated, the entire display switches to green.
You can therefore already see from a distance that your system is ready. If there is still a problem, the
corresponding area is displayed in red. Here, as well, the entire display will change after a few seconds
and turn red. This allows you to see from a distance that something is wrong.
Warning!
Never use sharp objects to adjust the touch panel. This could lead to irreparable damage.
Likewise, the display can be damaged if too much pressure is used when entering data.
Always keep the screen clean so that you can enter data without any problem.

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Commissioning
Quick start
In order to be able to work with your perfectMelt, you only need a few steps to put it into operation. All the
parameters are pre-set so that you only have to adjust the values to your requirements. You have made
all the electrical and pneumatic connections and connected your peripherals.
Now, turn on the perfectMelt with the main switch. The system is now in the off-line mode. Touch the
screen in the middle of the switch symbol until the system jumps to the on-line mode.
You can also turn the system on via the rotary adjustment knob. Press it until the system switches to the
on-line mode. After a few seconds, the display jumps to the Overview display. Set the appropriate
temperature tank by tapping on the Tank Temperature field.
This opens the input window. Here, enter your value and confirm your entry with Enter. Then, set the
temperatures for each channel that you need. You either enter this area by using the "down arrow key" or
the Overview by touching the Channel temperatures field. Here, activate the hose and the application
head and set the corresponding temperatures. At the end, confirm your entries with ENTER. The system
starts to heat up the individual temperature ranges. Once the temperatures have been reached, the
READY signal will be activated. Now please set the appropriate working pressure on the pressure
regulator.
Your system is ready!

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Setting the pump pressure
The pump working pressure is set at the pressure regulator. The pressure regulator can be secured
against unintended changes by pressing the control knob into a grid position. If you want to adjust the
knob again, first pull it out of the catch position. The set pump pressure can be read on the pressure
gauge. The maximum pump pressure in the perfectMelt is reduced to max. 5.3 bar by the safety valve. If
you need a higher working pressure, please contact our technicians.
Automatic pressure release
Upon removal of the air supply to the hot glue system, a safety valve opens and pressure in the hydraulic
circuit is released.
When using this function, please note:
•You need an input pressure to the system of at least 4 bar with a quick exhaust function upon
shutdown
•The removal of the input pressure has to be conducted by the customer, such as by opening a
security door and then by switching the main air supply.
•For maintenance tasks in hydraulics, inadvertent switching on of the air after removal of the input
pressure has to be prevented; please follow the instructions in the machine manual for this
purpose. It is also urgently necessary to activate the manual pressure relief devices (chapter->
Bleeding the system). Of course, the safety instructions regarding adhesives are to be observed
(PSA, among others).
Attention!
The pressure relief function has to be checked regularly,
depending on your operating conditions!

UES AG · Breuershofstr. 48 · 47807 Krefeld · Germany
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Individual settings
Menu structure = Settings
The settings consist of 4 fields, which are constructed as follows.
In these areas, you can customise your settings and adapt them to your needs.
Caution!
In the Setting area, you can define your settings simply by using
the rotary adjustment knob. At the end of the settings, you need to save
these settings/changes by clicking on the icon.
If you leave the area without saving, your entries will be lost.
The previously pre-set parameters apply.