VALCO MELTON D4-L User manual

D4-L
User Manual
Polígono Industrial Agustinos, calle G, nave D-34
Tel: +34.948.321.580 Fax: +34.948.326.584
31160 ORCOYEN (Navarra) ESPAÑA
e-mail:[email protected]
http://www.valcomelton.com

Declaration of conformity
The product:
Model no.:
Serial no.:
Year of manufacture:
Described in the enclosed documentation is in conformity with:
➢Directive 2006/42/CE of 29 December 2009 replacing the 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
used law UNE-EN ISO12100:2012, relative to safety of the machines.
Evaluate of risk, law UNE-EN 60204-1, relative to safety of the
machines, laws UNE-EN 61310-1, UNE-EN 61310-2 and UNE-EN
61310-3, relative to safety in machines. Indication, marking and
actuation.
➢Directive 2014/35/UE of April, relating to electric equipment.
➢Directive 2014/30/UE of April, relating to electromagnetic compatibility.
➢Directive 93/68/EEC of July, 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
Polígono Industrial Agustinos, calle G, nave D-34
Tel.: +34.948.321.580 Fax: +34.948.326.584
31160 ORCOYEN (Navarra) SPAIN

CONTROL REGISTRATION
CONTROL #: .................................................................
DATE: .............................................................................
ELECTRIC CHECK: 
CONTROL BOARD CHECK: 
TEMPERATURE CONTROL CHECK 150/180C: 
HYDRAULIC CHECK (100 bar): 
PNEUMATIC CHECK: 
USER:.............................................................................................................................
CONTACT:......................................................................................................................
ADDRESS:......................................................................TELEPHONE :.......................
SYSTEM LOCATION:.....................................................................................................
DATE OF INSTALLATION: ......................................... GUARANTEE UNTIL:
................................
DISTRIBUTOR:.............................................................................................................
CONTACT:..................................................................................................................
ADRESS:............................................................................TELEPHON.......................
OEM:.............................................................................................................................
ADDRESS:...................................................................................................................
TYPE:..........................................BRAND:............................................MODEL:.............
................
GUARANTEE
CARD
APPLICATOR SERIAL NUMBER:
APPLICATOR SERIAL NUMBER:

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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.

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INDEX
CHAPTER 1 SAFETY INSTRUCTIONS_____________________________ 6
1.1. SYMBOLS AND TERMS: ................................................................7
1.2. PURPOSE:..........................................................................................9
1.3. FIRST AID:......................................................................................10
In case of burns........................................................................................10
CHAPTER 2 DESCRIPTION_____________________________________ 12
2.1. INTRODUCTION:...........................................................................13
2.2. MAIN PARTS:.................................................................................13
2.2.1. Baseframe:......................................................................................................... 14
2.2.2. Tank: ................................................................................................................. 14
2.2.3. Outer Cover:...................................................................................................... 14
2.2.4. Pumping and Distribution System:.................................................................... 14
2.2.5. Electrical System:.............................................................................................. 14
2.2.6. Control panel:.................................................................................................... 15
2.3. TECHNICAL SPECIFICATIONS:..................................................16
2.4. GENERAL DIMENSIONS:.............................................................17
CHAPTER 3 MACHINE INSTALLATION__________________________ 18
3.1. INTRODUCTION:...........................................................................19
3.2. TRANSPORT:..................................................................................19
3.3 INSTALLATION REQUIREMENTS: .............................................19
3.4. MECHANICAL INSTALLATION:.................................................20
3.4.1. HOSE POSITION: ............................................................................................ 21
3.5. ELECTRICAL WIRING:.................................................................23
CHAPTER 4 MACHINE ADJUSTMENTS__________________________ 24
4.1. INTRODUCTION:...........................................................................25
4.2. TEMPERATURE CONTROL: ........................................................25
4.2.1. Introduction:...................................................................................................... 25
4.2.2. Brief description of how the unit operates: ....................................................... 25
4.2.3. Description of the control panel:....................................................................... 26
4.2.4. Setting program menus:..................................................................................... 34
4.3. OUTPUT PRESSURE ADJUSTMENT: ......................................44
CHAPTER 5 OPERATION_______________________________________ 46
5.1. INTRODUCTION:...........................................................................47
5.2. COMMISSIONING:.........................................................................47
5.3. STOPS:.............................................................................................48
CHAPTER 6 MAINTENANCE ___________________________________ 50

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6.1. INTRODUCTION:...........................................................................51
6.2. MAINTENANCE RECOMMENDATIONS:...................................52
6.3. MAINTENANCE PROCESSES:.....................................................53
6.3.1. PUMP REPLACEMENT.................................................................................. 53
6.3.2. MOTOR REPLACEMENT: ............................................................................. 55
6.3.3. REPLACING THE ADHESIVE FILTER: ....................................................... 56
6.3.4. REPLACING THE PROBE AND RESISTORS .............................................. 57
CHAPTER 7 TROUBLESHOOTING ______________________________ 58
7.1. INTRODUCTION:...........................................................................59
7.2. MECHANICAL FAULTS:...............................................................59
7.3. ELECTRICAL FAULTS:.................................................................59
7.4. ADHESIVE APPLICATION PROBLEMS: ....................................65
ANNEX A TORQUE INSTRUCTIONS _____________________________ 72
Torque and UNF Connectors:..................................................................73
Torque and NPT/BSP Connectors:..........................................................73
Tightening Screws on Steel or Helicoil:..................................................73
Tightening Screws on Other Materials: ...................................................74
Tightening Screws on Electrical Elements: .............................................74
ANNEX B SOFTWARE SPECIFICATIONS ________________________ 76
9.1. I/O FUNCTIONS. I/O CARD PULSES:..........................................77
9.2. MODBUS COMMUNICATIONS: ..................................................79
9.2.1. COMMUNICATION STRUCTURE:............................................................... 79
9.2.2. COMMUNICATION MODES: MODBUS (RS-485, 8N +1)........................... 81
ANNEX C LOG SHEETS ________________________________________ 88

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CHAPTER 1
SAFETY INSTRUCTIONS

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1.1. SYMBOLS AND TERMS:
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

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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 have acquired sufficient know-how in a specific
field, either through training or from experience.
These 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.

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1.2. PURPOSE:
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.
➢Maintenance operations and/or repairs should always be performed with the
machine de-pressurised and disconnected from the pressure circuit.

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1.3. FIRST 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.
In case of entrapment:
Press directly the wound with a clean cloth to control
hemorrhage..
Protect and immobilize the injured area.
Seek qualified medical attention immediately.

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CHAPTER 2
DESCRIPTION

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2.1. INTRODUCTION:
This machine transforms the hot-melt or polyurethane (or similar materials)
contained in a heated tank from a solid to a liquid state by means of a thermal action. A
pump absorbs the adhesive and raised it to a certain pressure to send it to the place of
use through hoses.
2.2. MAIN PARTS:
The main parts of the D4-L machine are shown in the following figure:
Motor
Power
card
Control
panel
Baseframe
Pump
Tank
Outer
cover

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2.2.1. Baseframe:
The base that supports the entire machine and where the manifold, the pump and
the motor are stored.
2.2.2. Tank:
This is where the hot-melt or other materials are melted; these materials may be in
bulk form or in chunks.
The tank is made of cast aluminium and is coated with Teflon to prevent soot and
crystallisations. It includes a resistance heating system with probe temperature control
(PT-100 or nickel, depending on the temperature control model) from the main control.
2.2.3. Outer Cover:
Prevents accidental access to the inside of the machine as well as possible
operational interferences.
2.2.4. Pumping and Distribution System:
It features the following components:
Manifold:
This manifold distributes the Hot Melt to the hoses and guns. Made of aluminium, it
is assembled inside the bench. It heats up through internal resistors. The manifold
features outlets to connect the hoses and a filter to remove impurities and a regulator.
The regulator controls the unit’s output pressure.
The manifold should not be dismantled; this operation should
only be done if there is an adhesive leak between the tank and
the manifold.
Pump:
The pump is what moves the Hot Melt or other thermal fusible product at a certain
pressure from the pump manifold through the manifold to the hoses and guns.
The pump is located inside the bench and is driven by an alternating current
gearbox. The pump speed is shown on the display located on the front of the control
panel.
Gearbox:
The purpose of the gearbox is to control the pump. It is an alternating current
motor that is controlled by a vector-controlled frequency variator which transmits the
power through a connection to the pump. The motor speed can be manually or
automatically adjusted depending on the ratio required in the main machine. It can not
exceed 100 rpm.
2.2.5. Electrical System:
It is in the electrical box with the exception of the heat resistors and the motors. All
of the control electronics and the power needed to operate the machine are located
here.

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2.2.6. Control panel:
It is situated at the front of the machine with the machine operating and adjustment
switches.