VALCO MELTON EC4 User manual

Declaration of conformity
The product:
Model nº:
Serial nº:
Year of manufacture:
Described in the enclosed documentation is in conformity with:
Directive 98/37/EC of 22 June 1998 relating to the
approximation of the laws of the Member States relating to
machinery, combining in a single text Directives 89/392/EEC
of 14 June 1989, 91/368/EEC of 20 June 1991, 93/44/EEC of
June 14, 1993 and 93/68/EEC of 22 July 1993.
Directive 73/23/EEC of 19 February 1973 relating to electric
equipment.
Directive 89/336/EEC of 3 May 1989 relating to
electromagnetic 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 a B1 risk level. Since it is intended to form part of a
set of machines which, to obtain a result, are arranged and connected to
perform together, it cannot be operated until the set of machines has
been declared in conformity with the applicable Directives by the person
responsible for the final assembly.
Orcoyen, on :_____________
Signed:______________________
Gonzalo Marco, Managing Director.
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0
TEL: [phone] Fax: [phone] [e-mail]
www.valcomelton.com
ORCOYEN, NAVARRA (SPAIN)

CONTROL REGISTRATION
CONTROL NUM:
................................................................
DATE: ...............................................................................
ELECTRIC CHECK: ❏
CONTROL BOARD CHECK: ❏
TEMPERATURE CONTROL CHECK 150º/180º: ❏
HYDRAULIC CHECK (100 bar): ❏
PNEUMATIC CHECK: ❏
APPLICATOR SERIAL NUMBER:
DISTRIBUTOR:.................................................................................................................................
CONTACT :.......................................................................................................................................
ADDRESS:................................................
.............................................TELEPHONE.....................
OEM:..................................................................................................................................................
ADDRESS:.........................................................................................................................................
TYPE:.......................................BRAND:............................................MODEL:...................................
.
USER:.................................................................................CONTACT:.......................................................................
ADDRESS:...................................................................................................................................................................
SYSTEM LOCATION:..................................................................................................................................................
TELEPHONE:...........................................................................DATE OF INSTALLATION:........................................
GARANTEE UNTIL:.....................................................................................................................................................
GUARANTEE CARD
APPLICATOR SERIAL NUMBER:

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
0
IMPORTANT!
THIS INSTRUCTION MANUAL SHOULD BE KEPT IN AN
ACCESSIBLE PLACE KNOWN TO ALL OPERATORS AND
MAINTENANCE PERSONNEL.
READ THE INSTRUCTIONS CAREFULLY BEFORE OPERATING
THE MACHINE AND FOLLOW THEM WHILE THE MACHINE IS IN
OPERATION.
FOLLOW 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. YOU MAY ALSO DAMAGE THE EQUIPMENT OR OTHER
MATERIALS.
WARNING:
If you alter the function, performance or safety aspects of
the machine, replacing original parts with other similar but
not identical components (substantial alterations), without
the authorisation of MELTON and as specified in Directive
89/392/EEC, you will be classified as a manufacturer and
therefore become liable for the alterations made.

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
1
CONTENTS
CHAPTE 1 SAFETY INST UCTIONS
CHAPTE 1 SAFETY INST UCTIONSCHAPTE 1 SAFETY INST UCTIONS
CHAPTE 1 SAFETY INST UCTIONS ___________________________________ 4
1.1. SYMBOLS AND TERMS:.............................................................5
1.2. PURPOSE:....................................................................................7
1.3. FIRST AID:....................................................................................8
CHAPTE 2
CHAPTE 2CHAPTE 2
CHAPTE 2 DESC IPTION
DESC IPTIONDESC IPTION
DESC IPTION ___________________________________________ 10
2.1. INTRODUCTION:.......................................................................11
2.2. MAIN PARTS:.............................................................................11
2.2.1. Frame:..................................................................................12
2.2.2. Tank:.....................................................................................12
2.2.3. Pump-distribution system:....................................................12
2.2.4. Pressure regulator and electrovalve control........................12
2.2.5. Control Panel........................................................................13
2.2.6. Chipping loader:...................................................................13
2.3.TECHNICAL CHARACTERISTICS:............................................14
2.3.GENERAL DIMENSIONS ...........................................................15
CHAPTE 3
CHAPTE 3CHAPTE 3
CHAPTE 3 INSTALLATION OF THE MACHINE
INSTALLATION OF THE MACHINEINSTALLATION OF THE MACHINE
INSTALLATION OF THE MACHINE __________________________ 17
3.1. INTRODUCTION:.......................................................................18
3.2.TRANSPORT:..............................................................................18
3.3. INSTALLATION REQUIREMENTS: ..........................................18
3.4. MECHANICAL INSTALLATION:................................................20
3.5. PNEUMATIC INSTALLATION....................................................25
3.6. ELECTRIC INSTALLATION.......................................................25
CHAPTE 4
CHAPTE 4CHAPTE 4
CHAPTE 4 MACHINE ADJUSTMENT
MACHINE ADJUSTMENTMACHINE ADJUSTMENT
MACHINE ADJUSTMENT __________________________________ 27
4.1. INTRODUCTION:.......................................................................28
4.2. TEMPERATURE CONTROL: ....................................................28
4.2.1. Introduction:..........................................................................28
4.2.2. Brief description of how the unit operates:...........................28
4.2.3. Description of the control panel: ..........................................29
4.3. ADJUSTING THE OUTPUT PRESSURE:.................................38
CHAPTE 5
CHAPTE 5CHAPTE 5
CHAPTE 5 OPE ATION
OPE ATIONOPE ATION
OPE ATION _____________________________________________ 40
5.1. INTRODUCTION:.......................................................................41
5.2. SWITCH ON:...............................................................................41
5.3. STOPS:.......................................................................................44
CHAPTE 6
CHAPTE 6CHAPTE 6
CHAPTE 6 MAINTENANCE
MAINTENANCEMAINTENANCE
MAINTENANCE __________________________________________ 46
6.1. INTRODUCTION:.......................................................................47
6.2. MAINTENANCE RECOMMENDATIONS:.................................48
6.3. MAINTENANCE PROCESSES:.................................................48
6.3.1. Cleaning the equipment.......................................................48
6.3.2. Bleeding the air filter of the pressure regulator:...................48
6.3.3. Installing the Pump Casing..................................................49
CHAPTE 7
CHAPTE 7CHAPTE 7
CHAPTE 7 EQUIPMENT EPAI GUIDE
EQUIPMENT EPAI GUIDEEQUIPMENT EPAI GUIDE
EQUIPMENT EPAI GUIDE _______________________________ 51
7.1. INTRODUCTION:.......................................................................52
7.2. MECHANICAL FAULTS:............................................................52
7.3. ELECTRICAL FAULTS:..............................................................54
7.4. ADHESIVE APPLICATION PROBLEMS:..................................59

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
2
CHAPTE 8
CHAPTE 8CHAPTE 8
CHAPTE 8 EQUIPMENT EPAI GUIDE
EQUIPMENT EPAI GUIDEEQUIPMENT EPAI GUIDE
EQUIPMENT EPAI GUIDE _______________________________ 66
8.1. INTRODUCTION:.......................................................................67
8.2. CHANGING THE FILTER:..........................................................67
8.3. REPAIRING THE MANIFOLD:...................................................68
8.3.1 High Flow Pump:...................................................................71
8.3.2 Low Flow Pump:....................................................................75
8.4. CLEANING VALVES..................................................................78
8.5. REPAIRING ELECTRIC COMPONENTS:................................79
CHAPTE 9 LOG SHEETS
CHAPTE 9 LOG SHEETSCHAPTE 9 LOG SHEETS
CHAPTE 9 LOG SHEETS ____________________________________________ 81

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
3

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
4
CHAPTE 1
CHAPTE 1 CHAPTE 1
CHAPTE 1
SAFETY INST UCTIONS
SAFETY INST UCTIONSSAFETY INST UCTIONS
SAFETY INST UCTIONS

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
5
1.1. SYMBOLS AND TE MS:
Miscellaneous
prohibitions
Danger hot surface
Miscellaneous
precautions
Precaution: Electric
current
Precaution:
Flammable liquid
Precaution: risk of
fluid leakage under
high pressure
Precaution: risk of
entrapment between
mobile parts
Use of safety gloves
required
Use of goggles
required
Note of special interest
European Community
markings
Susceptible elements to
electrostatic discharge

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
6
Burns:
Burns can be caused by the uncovered parts of the applicator, such as
the guns or by splashes of hot melt.
The hot adhesive under pressure in the nozzles can cause serious
injuries to the skin.
Qualified personnel:
This is personnel (technical staff) who has acquired sufficient know-
how in a specific field, either through training or from experience.
This personnel must be familiar with safety and accident prevention
standards, and have general knowledge of the technical aspects of the
machine.
Protective 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 mobile
machine parts, and the sleeves, waist, legs, etc. will be adjustable to
the size of the wearer.
Goggles and face shields:
They will be compliant with the EN 166 standard, protecting against
fast-moving particles and high temperatures.
Goggles only protect the eyes. Face shields are therefore preferable,
since they protect the entire face.
Protective gloves:
They will be compliant with EN 407 and EN 420 standards, protecting
the hands against the burns caused by external thermal masses at
temperatures of above 100 °C.
Susceptible elements to electrostatic discharge:
When handling the equipment, avoid contact with the electronic
components and metal pins on the connectors.

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
7
1.2. PU POSE:
This unit has been manufactured according to current safety
standards.
This unit has been designed for the purpose described in chapter 2 of
this manual, Description.
To use the machine correctly, follow the instructions provided in the
Operating Manual, particularly:
The machine should only be installed and used by qualified
personnel, previously familiarised with the operating instructions
(contacting the manufacturer whenever necessary) and the
risks involved, the safety measures required, including
adjustment and maintenance, and expressly forbidden
operations.
This unit has not been manufactured to operate in hazardous,
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 form part of a series of
machines, arranged to work together, the hot melt applicator
cannot be operated until the entire series has been declared in
compliance with applicable directives.
This machine should never work without the guards provided
(which should not be removed). These guards should be
checked and maintained with the specified frequency.
Make sure that the equipment is properly grounded.
Never operate the machine if you are aware that there is a leak
in the glue circuit.
Maintenance operations and/or repairs should be performed by
personnel with basic knowledge of the machine and the
mechanical, pneumatic and electric circuits involved.
Maintenance operations and/or repairs should always be
performed with the machine switched off at the mains, and with
the main switch blocked.

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
8
1.3. FI ST AID:
In case of burns :
Immerse affected part in cold clean water as
quickly as possible until the adhesive has
cooled.
Do not 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 :
CONTACT WITH THE SKIN: Wash with soap
and water and discard all contaminated cloths.
CONTACT WITH EYES: Wash in an eye bath for
at least 15 minutes.
INHALATION: In case of overexposure take
patient to fresh air and let them rest.
INGESTION: Do not attempt to induce vomiting.
Seek medical attention at once.

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
9

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
10
CHAPTE
CHAPTECHAPTE
CHAPTE 2
2 2
2
DESC IPTIO
DESC IPTIODESC IPTIO
DESC IPTION
NN
N

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
11
2.1. INT ODUCTION:
This machine heats hot-melt adhesive (or similar 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 PA TS:
The main parts of a machine are shown on the following figure:
N. DESCRIPTION
1 Electric closet
2 Frame
3 Pump
4 Manifold
5 Tank
6 Control panel
Nº DESCRIPTION Intermediate (option B)
Full (option C)
7 Level sensor
٧
٧
8 Vacuum feeding
٧

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
12
2.2.1. Frame:
The frame consists of a base plate on which equipment is installed.
2.2.2. Tank:
Where the Hot-Melt or other similar material is melted in a tank (the
other material can be in the form of pellets or blocks). The cast
aluminium tank is lined with Teflon to avoid carbon deposits and crystal
formation, and incorporates a heating system through resistances.
The heating of the resistances is controlled by sensor with a micro-
controller, and can be programmed up to 240ºC.
2.2.3. Pump-distribution system:
It transfers the adhesive from the drum to the distributor.
Manifold:
The manifold distributes the Hot – Melt, once filtered, to the hoses and
guns.
Made of aluminium, it is assembled on the lower part of the tank so
that the tank resistances can heat it indirectly.
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 connect the Hot-Melt hoses: three at
the front and three at the back.
Pump:
The pump drives the Hot-Melt or other heat-meltable product at a
certain pressure from the tank to the substrate (or material to be
glued), passing through a distributor, filter, hoses and guns.
The pump unit consists of an electrovalve, a pneumatic cylinder and a
double-acting hydraulic pump with a pressure compensator to avoid a
drop in the flow produced in changing the direction of the pump, and
enabling uniform discharge of the Hot-Melt.
Manifold mustn’t be dismantled, only this operation will be able in
case of leaking adhesive between tank and manifold.
2.2.4. Pressure regulator and electrovalve control
Pressure regulator:
The element used to raise or lower the pressure indicated on the
pressure gauge. It is regulated depending on the application that has to
be made. It includes an air filter to avoid the entry of impurities into the
machine.

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
13
Bleed electrovalve:
The element that controls the passage of air to the pump. It is
electrically connected to the electrical control system.
2.2.5. Control Panel
The control panel containing the machine’s operating and adjustment
switches is on the front of the main electric closet.
2.2.6. 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 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 chipping loader is opened it will deactivate.
In order to activate it, the lid must be closed and correctly locked.

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
14
2.3.TECHNICAL CHA ACTE ISTICS:
ELEMENT DATA
GENERAL
Power supply
I 220V+N+T (50/60Hz), III 220V+T (50/60 Hz),
III 380V+N+T (50-60Hz)
Hoses (max.) 6
Hydraulic pressure (maximum working) 2.8 – 80 bar (40 – 1138 psi)
Noise level 63 dB
Working temperature -10 – 50 ºC (32 – 122ºF) HR 20% to 80% non-condensed
CONTROL
Working temperature
15º - 230º C (59º - 446º F)
Temperature control precision +/- 0.5º C (+/- 1º F)
Type control PID Control
PUMP LOW FLOW HIGH FLOW
Pumping capacity (Kg./h) 35 100
Pump compression ratio 1:14 1:13
Pneumatic working pressure 0.5 to 6 bar
TANK EC4 EC8 EC14
Volume (litres) 4 8 14
Melting capacity (Kg./h) 4.2 7.9 13.5
Tank electrical consumption (W) 1700 2800 4000
VACUUM FEEDING
Compressed air input 2 - 6 bar (29 up to 87PSI) - 350 I/min (92 gallon/minute)
Hose length 3m (43,5PSI)

MUS033202 18/10/2010
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] [e-mail] www.valcomelton.com
15
2.3. GENE AL DIMENSIONS :
Dimensions (mm) EC4 EC8 EC14
A 307 307 367
B 583 658 658
C 532 532 592
D 631 631 691
E 340 340 398
F 0 51 51