Manual ML-600 ENG

INSTRUCTIONS MANUAL

Vers. 2.30 - 120607

CENTRAL APPLICATION UNIT

600 SERIES

MA-5027-GB

P.I. Los Agustinos, calle G, nave D-43

E - 31160 ORCOYEN Navarra (Spain)

Tel.: + 34 948 351 110 / Fax: + 34 948 351 130

e-mail: [email protected]

www.meler.es

C.A.U. ML-600 Manual Contents

Meler Aplicadores de Hot-Melt S.A. - 3 -

CONTENTS

INTRODUCTION TO CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP .................5 1. TECHNICAL CHARACTERISTICS....................................................................................................................7

1.1. General characteristics ............................................................................................................................7 1.2. Electronic control.....................................................................................................................................7 1.3. Special P.U.R. system...............................................................................................................................8 1.4. Pumping system........................................................................................................................................8 1.5. Safety system ............................................................................................................................................8

2. USE OF THIS MANUAL......................................................................................................................................9 2.1. Regulations...............................................................................................................................................9 2.2. Warnings on risk prevention ..................................................................................................................10

3. DESCRIPTION OF FRONT PANEL..................................................................................................................11 USE AND START-UP OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP .........13

4. CONNECTION AND DISCONNECTION OF THE UNIT ................................................................................15 5. TEMPERATURE DISPLAY AND MODIFICATION .......................................................................................15 6. DAILY PROGRAMMING..................................................................................................................................16 7. DAILY AUTOMATIC CONNECTION AND DISCONNECTION ...................................................................17

7.1. Programming current time and day of the week ....................................................................................17 7.2. Automatic connection and disconnection programming ........................................................................17

8. DAILY STAND-BY PROGRAMMING.............................................................................................................18 8.1. Automatic stand-by program..................................................................................................................18

9. ALARM SIGNALS .............................................................................................................................................19 9.1. Alarms for over temperature ..................................................................................................................19 9.2. Sensor breakage .....................................................................................................................................19 9.3. Motor over temperature .........................................................................................................................20 9.4. Motor rotation failure ............................................................................................................................20 9.5. Low adhesive level..................................................................................................................................21

10. ON/OFF AND SPEED REGULATION OF THE PUMP ..................................................................................21 10.1. Manual mode........................................................................................................................................22 10.2. Automatic mode....................................................................................................................................22

11. RESTRICTED MENU.......................................................................................................................................24 11.1. Stand-by percentage value ...................................................................................................................24 11.2. Temperature units.................................................................................................................................24 11.3. Clear daily programming memory .......................................................................................................24 11.4. Low level alarm reset ...........................................................................................................................25

12. GAS DISPENSING SYSTEM...........................................................................................................................25 13. USE OF REACTIVE ADHESIVES ..................................................................................................................26

INSTALLATION OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP.................29 14. INTRODUCTION .............................................................................................................................................31 15. INITIAL CONDITIONS ...................................................................................................................................31

15.1. Material supplied .................................................................................................................................31 15.2. Tools required for the installation........................................................................................................31 15.3. Environmental conditions.....................................................................................................................32 15.4. Location conditions ..............................................................................................................................32 15.5. Dimensions and weights of the unit ......................................................................................................33

16. UNLOADING THE C.A.U. ML-600.................................................................................................................34 17. CONNECTION OF THE UNIT AND ITS ACCESSORIES .............................................................................35

17.1. Electrical power supply of the unit.......................................................................................................35 17.2. Identification of the connections...........................................................................................................36 17.3. Hose connection ...................................................................................................................................37 17.4. Gun connection.....................................................................................................................................37 17.5. Installation and connection of the solenoid valves...............................................................................38 17.6. Connection of the variable voltage signal ............................................................................................39 17.7. Other connections.................................................................................................................................39

C.A.U. ML-600 Manual Contents

- 4 - Meler Aplicadores de Hot-Melt S.A.

HANDLING GUIDE OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP ...........41 18. INTRODUCTION.............................................................................................................................................43 19. ADHESIVE CHARGE......................................................................................................................................43 20. PUMP SPEED AND FLOW REGULATION ...................................................................................................43 21. PRACTICAL RECOMMENDATIONS FOR USE...........................................................................................44

MAINTENANCE OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP.................45 22. INTRODUCTION.............................................................................................................................................47 23. GENERAL COMMENTS .................................................................................................................................47 24. GENERAL CLEANING ...................................................................................................................................47

24.1. Cleaning the tank .................................................................................................................................48 24.2. Cleaning hose.......................................................................................................................................49 24.3. Cleaning guns and nozzles ...................................................................................................................49

25. CHANGE FILTERS..........................................................................................................................................49 25.1. Change the mesh of the distributor filter..............................................................................................50 25.2. Change the mesh of the mini-filter .......................................................................................................50 25.3. Change cartridge of the air dryer filter................................................................................................51

SPARE PARTS OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP ....................53 26. SPARE PARTS .................................................................................................................................................55

26.1. General parts drawing .........................................................................................................................55 26.2. Control panel parts list ........................................................................................................................56 26.3. Tank unit...............................................................................................................................................57 26.4. Motor-pump unit ..................................................................................................................................58 26.5. Filter unit .............................................................................................................................................59 26.6. Limiting valve unit................................................................................................................................60 26.7. Cradle elements unit.............................................................................................................................61 26.8. Premelter unit.......................................................................................................................................62 26.9. Gas dispensing unit ..............................................................................................................................63 26.10. Dry air dispensing unit.......................................................................................................................64

ELECTRICAL DIAGRAMS OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP .........................................................................................................................................................................65

27. LIST OF DRAWINGS ......................................................................................................................................67 LIST OF COMPONENTS CENTRAL APPLICATION UNIT ML-600.................................................................68

FRONT VIEW ML-600

REAR VIEW ML-600 LEFT SIDE VIEW ML-600 RIGHT SIDE VIEW ML-600 ELECTRICAL PANEL. BOTTOM VIEW. ELECTRICAL PANEL. LEFT SIDE VIEW ELECTRICAL PANEL. RIGHT SIDE VIEW POWER CIRCUIT TANK AND PREMELTER HEATING CIRCUIT HOSE AND GUN HEATING CIRCUIT INTERCONNECTION CIRCUIT AND LEVEL DETECTOR MOTOR PUMP OPERATION CIRCUIT

C.A.U. ML-600 Manual Introduction


INTRODUCTION TO CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP



1. TECHNICAL CHARACTERISTICS

1.1. General characteristics

- Central Application Unit for high precision applications.

- Possibility of high viscosity adhesives

- Two capacities: ML-625 (25 kg) and ML-650 (50 kg) in a variety of models.

- Melting system controlled by regulated premelter recorder (standard in ML-650).

- Great melting capacity with minimum electrical power by compact construction.

- Pressure by-pass valve that permits the recirculation of the adhesive for high hydraulic

pressures.

- Low adhesive level detector with external warning output (standard in ML-650).

- Manual, external signal or programmable stand-by function that prevents premature

degradation of the adhesive.

- Automatic detection of the outputs installed.

- Control over start of main machine by means of potential-free signal when reaching the

work temperatures.

- Wide charging hole (195 x 280 mm) with easy access from any side.

- Guaranteed tank seal with floating lid.

- Front box that can slide out for easy access to internal elements.

- Large capacity distributor outlet filter that reduces interventions to a minimum.

- Tank with anti-adherent coating.

- Unit mounted on swivel wheels for easy movement.

- Complete safety system to protect the unit itself, the users and the industrial environment.

- Wide range of hoses and guns available.

1.2. Electronic control

- Special protection against electronic noises.

- It satisfies all the EC/EMC European standards.

- Digital reading of temperatures (C or F) of all heated areas, pump revolutions,

programmer clock and maintenance and alarm indications.

- Indication, by means of LED, of operation of the motor and of the heating system.

- It has up to six (6) individual temperature control areas.

- High precision P.I.D. system to control set temperatures.

- Manual and automatic connection and disconnection of the unit.

- Independent connection and disconnection time programming and stand-by activation for

each day of the week.

- Programmable stand-by temperature (value percentage)



1.3. Special P.U.R. system

- Special anti-adherent coating for P.U.R. reactive adhesives in tank and premelter.

- Lid with seal, designed to create the best conditions of use of P.U.R. adhesives

- Ecological protection of the P.U.R. adhesive against reticulation, by incorporating a high

capacity air dryer (*).

(*) This avoids the use of inert gas. This represents a reduction of production costs and decrease of expenses and logistic problems for the purchase of this gas, as well as protection of the atmosphere in compliance with

environmental regulations.

1.4. Pumping system

- With robust and high power direct current motor.

- Manual connection and disconnection of the motor, by switch, or automatically with external

potential-free signal.

- Flow volume control depending on motor revolutions.

- Adjustable from 1 to 100 rpm (recommended from 15 to 80 rpm). Real speed display.

- Manual regulation, with pushbuttons, or automatic, depending on the speed of the main

machine.

- Main machine speed reading input with variable voltage signal (0-10 V signal of frequency

inverter).

- Maintenance-free motor reducer.

- Special steel gear pump resistant to wear and corrosion.

1.5. Safety system

- Alarm system on screen and led on front panel and automatic application of protection

measures due to sensor breakage or over temperature of any heated elements.

- Alarm system on screen and external minimum adhesive level warning output (standard in

ML-650).

- Protection against excess hydraulic pressure.

- Minimum application temperature to protect pump from start-ups with solid or half-solid

adhesive.

- Protection of motor against electric over current , overheating and stopping failure.

- Electrical protection of elements with fuses and circuit breaker switch.



2. USE OF THIS MANUAL This manual aims at providing an easy to use help tool to be able to operate and program the Central Application Unit ML-600. The installation, handling and maintenance of the Central Application Unit ML-600 each have their own chapter in this manual. The manual is preceded by a list of contents where all the functions, assembly elements and handling and maintenance details required at any time, can easily be found. The manual also includes a list with the error and alarm messages that might appear with the use of the Central Application Unit ML-600, a list with the existing spare parts and electrical diagrams for correct maintenance of the unit.

It is advisable to read this manual carefully before starting up the Central Application Unit ML-600. All the safety and danger indications must be strictly observed.

2.1. Regulations The Central Application Unit ML-600 has been designed under European standards as proven by the EC marking on the characteristics plate

Directive 98/37/EC on Machines Directive 89/336/EC on Electromagnetic Compatibility Directive 73/23/EEC on Low Voltage with later modifications 91/263/CE, 92/31/CE and 93/68/CE,

!

Fig. 1. Identification plate of the unit with 'EC' marking.

99

9



2.2. Warnings on risk prevention The Central Application Unit ML-600 is supplied by mains current at 230/400 V / 50 Hz. To annul the risk of electrical discharges, do not remove the cover or access the interior, without disconnecting the appliance from the mains. Any interventions on the inside, carried out by unauthorised personnel, automatically leads to the loss of the right to guarantee. To avoid the risk of fire or electrical discharges, do not expose this product to the action of water or damp. To guarantee the electrical safety of the unit, the installation must satisfy the regulation in force and the system must be connected to earth. The electrical connection must coincide with the indications on the characteristics plate (rated supply voltage and maximum consumption foreseen). In order for this unit to work correctly, only use original accessories and spares. If you wish to use other makes of components, consult the manufacturer. This unit works at high temperatures and high pressures. Failure to comply with the instructions given in the manual may cause serious damage such as burns or high-power electrical discharges. The working temperature set for all the heated elements must necessarily be between the margins prescribed by the manufacturer of the adhesive used. Failure to comply with these instructions may have serious consequences. The standard Central Application Unit ML-600 is not prepared to use reactive adhesives. Their use causes irreparable damage to the unit. For applications with this type of adhesive you must only use model ML-600 P.U.R.



3. DESCRIPTION OF FRONT PANEL

1. LED indicator of the element selected whose

temperature is displayed on screen (rapid flashing). Indication of output of voltage to resistors (permanent or slow flashing).

2. Selection and modification pushbuttons of

data that appear on screen. 3. LCD screen lit to show information. 4. Selection pushbuttons of elements with

temperature control 5. [ENTER] pushbutton to accept modified

data. 6. Manual or automatic mode motor selection

switch of the pump. LED indicator for each work mode.

7. Selection pushbutton for weekly start-stop or stand-by programming clock of the unit or pump revolutions control. LED indicator for each selection.

8. Manual start/stop pushbutton of the unit. 9. Stand-by function activation / deactivation

pushbutton. LED indicator of its status. 10. Green LED indicator for permission to

operate motor. 11. Red LED indicator of over temperature of a

heated element, sensor breakage, motor over temperature or motor stopping failure.

1

2 3

4

5

6

8

9

710

11

Fig. 2 Front panel of the Central Application Unit ML-600.

C.A.U.. Manual ML-600 Use and start-up


USE AND START-UP OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP



4. CONNECTION AND DISCONNECTION OF THE UNIT

The Central Application Unit ML-600 has a general protection circuit breaker switch. For the unit to work, this switch must be placed in ON position (Fig. 3). In models ML-600 P.U.R. or ML-600 with gas dispensing system, this switch must not be disconnected if we wish to maintain the protection of the adhesive by means of the automatic injection of the gas used (dry air or inert gases).

When the circuit breaker switch is in OFF position it does not completely interrupt the current supply (see electrical diagrams). A protection circuit with low voltage relay remains supplied. This circumstance is reflected with a multi-language label next to the fuse block on the inside of the electric control box (Fig. 4).

Maximise precautions. Danger of electrical discharges when handling the elements inside the unit.

The Central Application Unit starts up when the ON/OFF key, on the front panel, is pressed (Fig. 5). The unit can be connected manually at any time, even though it is disconnected, by means of the daily automatic connection/disconnection programming. To disconnect the unit, press the ON/OFF key again.

5. TEMPERATURE DISPLAY AND MODIFICATION To display or modify the temperature of the different elements the selection pushbuttons [4] are activated (Fig. 6) until the LED of the element we wish to display or modify flashes quickly. Then we can decrease or increase the set temperature with the data modification pushbuttons [2]. To validate the data modified, press [ENTER]. If the data is not validated after a few seconds, the set temperature returns to the original value before modification.

!

Fig. 3

Fig. 4

Fig. 5

TENSIN PERMANENTE

PERMANENT VOLTAGE

TENSIONE PERMANENTE

TENSO PERMANENTE

DAUERSPANNUNG



We can access the display of the set temperatures at any time, just by pressing the selection pushbuttons [4] (Fig. 6).

If any heated element is not selected for 10 seconds, automatically the system returns to tank temperature display. It can be selected every heated element pushing selection button more than 2 seconds while its led is flashing quickly. This permanent display can be reset by pushing a selection button. It can be deactivate every heated element setting its set point temperature below 0C. Then the screen shows:

To activate the element set the temperature over 0C.

The work temperature set for all the heated elements must necessarily be within the margins prescribed by the manufacturer of the adhesive used. Failure to comply with these prescriptions may have serious consequences on the durability of the elements inside the unit.

6. DAILY PROGRAMMING To be able to program in clock mode, we must press the selection pushbutton of the programmer clock or pump revolutions [8] (Fig. 2) until the relative LED comes on. The screen will show two options: automatic connection/disconnection and programmable stand-by.

Select the desired option and push [ENTER] button.

Fig. 6

4

2

!

S: ----C R: ----C

ON/OFF %T



7. DAILY AUTOMATIC CONNECTION AND DISCONNECTION With this function the time and day of the current week can be displayed. The automatic connection and disconnection times for each day of the week can also be programmed. The system is universal and with no time limit, as the day that corresponds to the start of the week (1-Monday / 1-Sunday) can be chosen, not using a traditional calendar (day-month-year). After selected automatic connection/disconnection mode (ON/OFF), the screen will show the numbers of the days of the week and a small box.

7.1. Programming current time and day of the week To modify the current time and day of the week, place the cursor on the box, using the data selection pushbuttons [2] and press [ENTER]. The following screen will appear.

Use the modification pushbuttons [2] to change the values shown on the screen. To confirm the modified data and go on to the next data, press [ENTER].

7.2. Automatic connection and disconnection programming To program the automatic connection and disconnection for each day of the week we select the day to be programmed with the data selection pushbuttons [2] and we press [ENTER]. The connection time (ON) of the day selected will appear on the screen.

Use the modification pushbuttons [2] to change the values shown on the screen. To confirm the modified data and go on to the next data, press [ENTER]. With the validation of the connection minute, the menu jumps to the follow screen, showing the disconnection hour (OFF) of the selected day. Null values in both times deactivate the automatic mode.

1 2 3 4 5 6 7

1 00:00

day of the week current hour current minute

ON = 00:00 1

connection connection day of the week hour minute display



Use the modification pushbuttons [2] to change the values shown on the screen. To confirm the modified data and go on to the next data, press [ENTER]. With the validation of the disconnection minute, the menu returns to initial screen showing the numbers of the days of the week. Null values in both times deactivate the automatic mode.

8. DAILY STAND-BY PROGRAMMING This function allows to program daily stand-by activation/deactivation. The system is universal and with no time limit, as the day that corresponds to the start of the week (1-Monday / 1-Sunday) can be chosen, not using a traditional calendar (day-month-year). After selecting stand-by mode (%T), the screen shows the numbers of the day of the week.

8.1. Automatic stand-by program To program the automatic stand-by for each day of the week we select the day to be programmed with the data selection pushbuttons [2] and we press [ENTER]. The connection time (ON) of the day selected will appear on the screen.

Use the modification pushbuttons [2] to change the values shown on the screen. To confirm the modified data and go on to the next data, press [ENTER]. With the validation of the connection minute, the menu jumps to the follow screen, showing the disconnection hour (OFF) of the selected day. Null values in both times deactivate the automatic mode.

OFF = 00:00 1

disconnection disconnection day of the week hour minute display

1 2 3 4 5 6 7

ON = 00:00 1

connection connection day of the week hour minute display

OFF = 00:00 1

disconnection disconnection day of the week hour minute display



Use the modification pushbuttons [2] to change the values shown on the screen. To confirm the modified data and go on to the next data, press [ENTER]. With the validation of the disconnection minute, the menu returns to initial screen showing the numbers of the days of the week. Null values in both times deactivate the automatic mode.

9. ALARM SIGNALS

9.1. Alarms for over temperature A heated element is considered to have an over temperature when its real temperature exceeds the set temperature by 20 C. If any element should have an over temperature, the screen shows the symbol [ ^ ] followed by the number of the element, alternating the indication with the screen that was displayed before.

In the above example an over temperature alarm message in gun no. 1 is displayed. The alarm nomenclature for each element is as follows:

1 tank 2 premelter (optional) 3 hose channel 1

4 gun channel 1 5 hose channel 2 6 gun channel 2

When the over temperature alarm is activated, the screen shows the relative indication, red led turns on and green led turns off, the main machine output signal is deactivated and the pump motor stops. If the element corresponding to the over temperature has not disconnected within three minutes, the safety procedure is activated, disconnecting the circuit breaker switch. If the switch is connected again, but the defect persists, the over temperature alarm will connect again and after three minutes the safety procedure will be activated again.

9.2. Sensor breakage If the sensor of any heated element with temperature control should break, the symbol, [ -o/o- ] will appear on the screen followed by the number of the element, alternating the indication with the screen that was displayed previously.

The above example shows an alarm message due to sensor breakage in the tank. Remember the alarm nomenclature for each element:

[ ^ ] 4

[-o/o-] 1



1 tank 2 premelter (optional) 3 hose channel 1

4 gun channel 1 5 hose channel 2 6 gun channel 2

When the sensor breakage alarm is activated the screen shows the relative indication, red led turns on and green led turns off, the main machine output signal is deactivated and the pump motor stops. The remaining elements continue heating normally.

9.3. Motor over temperature Inside the motor there is a NC thermal switch to prevent overheating of the motor. It gives a very high durability. If the switch turns off, on the screen its shown:

When the alarm is activated the screen shows the relative indication, red led turns on and green led turns off, the main machine output signal is deactivated and the pump motor stops. The remaining elements continue heating normally. Pump driving motor is cooled by a external fan which allows working between temperature limits given by the manufacturer. Otherwise, in front of an overheating, a security system shut off motor power supply and red led on the front panel [11] turns on (Fig. 7).

9.4. Motor rotation failure If control card sends the signal to start motor and there is correct voltage applied to the motor but it doesnt receive signals from the inductive sensor (acting as a tachometer reading pulses from a special gear) the alarm shows on the screen:

When the alarm is activated the screen shows the relative indication, red led turns on and green led turns off and the main machine output signal is deactivated. The remaining elements continue heating normally.

Fig. 7 Alarm for over temperature of motor

10 11

[ ^ ] MOTOR

[ ] MOTOR

C.A.U. ML-600 Manual Use and start-up


9.5. Low adhesive level When the tank level has dropped more than 70% its capacity, the symbol, [ ------- ] will appear on the screen, alternating the indication with the screen that was displayed previously.

There is an external connection for this alarm. In the main machine output signal connection, on the rear of the unit, connection points 3 and 4 enable the user to adapt his own alarm system. The voltage applied to the connector may not exceed 24 V and the consumption may not be greater than 0.3 A. This connection, by means of a normally open contact, will remain closed until the [ENTER] pushbutton is activated, which annuls the activation signal. If, after a few minutes, the tank has not charged, the alarm will be activated again. Although the tank is charged, the contact remains closed until the [ENTER] pushbutton is operated.

In any alarm case, except for low adhesive level, the green LED [10] indicating permission for the motor to operate remains off.

10. ON/OFF AND SPEED REGULATION OF THE PUMP Depending on the work mode selected, the pump starts up manually, by means of a switch, or automatically, by means of an external potential-free signal (end of stroke, switch, relay or any other type of contact). For the external connection of this activation signal consult the relative chapter Electrical Diagrams. The adhesive flow volume can be adjusted by regulating the pump revolutions. This process can be carried out in two ways:

- manually, with the data modification pushbuttons [2] (Fig. 2) - automatically, with variable voltage signal provided directly by the main machine.

If the temperature of any heated element is not correct or the alarm signal is activated (except for low adhesive level) the LED corresponding to the pump revolutions control mode [7] will flash until the correct conditions exist for the motor to operate.

If, when the temperatures of all the heated elements are correct, some of them should drop 20 C below the set temperature, the motor will stop and the LED corresponding to the pump revolutions control mode [7] will flash until the conditions for the motor to operate are correct.

[- - - - - - - ]

!

!

!



10.1. Manual mode To use the manual working mode place the selector switch [6] (Fig. 2) in the position marked as MAN. Its LED indicator will light up. Apply the clock/pump revolutions pushbutton [7] until the LED corresponding to RPM comes on. The following screen will appear:

To modify the pump revolutions, or in other words, the adhesive flow volume, activate the data modification pushbuttons [2]. Press [ENTER] to confirm the data.

The motor rotates constantly at the set revolutions, providing that the selected work temperatures have been reached.

10.2. Automatic mode The automatic mode has two different work options: without external regulation set signal (without TACHO) or with it (with TACHO). To use the automatic working mode place the selector switch [6] (Fig. 2) in the position marked as AUT. Its LED indicator will light up. Apply the clock/pump revolutions pushbutton [7] until the LED corresponding to RPM comes on. The following screen will appear:

The motor starts up by means of an external potential-free signal (end of stroke, switch, relay or any other type of contact). For the external connection of this activation signal consult the relative chapter Electrical diagrams. In the without TACHO modality, to modify the pump revolutions, or in other words, the adhesive flow volume, activate the data modification pushbuttons [2]. Press [ENTER] to confirm the data.

When the value of the motor revolutions is modified with the data modification pushbuttons [2], the rotation speed of the motor varies, but the data is not memorised until the [ENTER] key is pressed.

In TACHO mode, we must choose this possibility first. The adhesive flow volume in this case is proportional to a voltage input and this depends on the speed of the main machine. The voltage input is prepared for margins between 0 and 500 volts.

SET 0 RPM 0

set point speed value real value

!

SET 0 RPM 0

!



To inform the control card of the margins that are going to be used, there are some selection DIP switches. Consult the Technical Service on how to operate them. From the screen that indicates the revolutions, press [ENTER] to access the following screen.

Press [ENTER] again to access the work selection screen with TACHO.

Select TACHO yes/no with the data modification pushbuttons [2] (Fig. 2). With TACHO deactivated, the following screen appears:

Press [ENTER] again to return to the initial screen:

To adjust the flow volume to the needs of the application in variable speed machine, the Max and Min values are modified on the adjustment screen. From the previous screen, press [ENTER]:

The Max value limits the adhesive flow volume to the maximum speed of the main machine (maximum voltage of the variable signal), whilst the Min value does the same to the minimum speed (normally machine stopped, non-existing voltage). It is advisable to keep the Min value at zero rpm to prevent the motor from rotating, without intake of flow to the application, with the machine stopped. This value can be adjusted with the data modification pushbuttons [2]. Press [ENTER] to memorise the data and the cursor will go to the Max value. This value can be adjusted with the data modification pushbuttons [2]. Press [ENTER] to memorise the data and return to the initial screen.

It is possible to connect external pushbuttons to modify the Min and Max values. For the external connection of this signal, consult the relative chapter Electrical diagrams.

When an alarm occurs and motor is deactivated , reset of the alarm doesnt start the motor. Its necessary to deactivate start signal of the motor (switch on the front panel or external contact) and try again to restart motor working.

Min: 0 Max: 100

TACHO yes

TACHO no

SET 0 RPM 0

Min: 0 Max: 100

!

!



11. RESTRICTED MENU This menu allows certain users (pushing a sequence of buttons) to program some parameters. To access to this menu you must push the following buttons continuously (time limitation between pushing buttons):

[E] ENTER button

[E] ENTER button [] Data modification pushbutton [] Channel selection pushbutton

[E] ENTER button Fig. 8

All the Restricted Menu screens appears by pushing [ENTER] button. Values are modified by data modification pushbuttons [2] (Fig. 2).

11.1. Stand-by percentage value It can be selected the percentage value (from 50 to 100) of temperature set point. Set point shows this value when stand-by function is activated (set point temperature: 180 C percentage value: 60% - stand-by temperature: 108 C).

11.2. Temperature units It can be selected temperature working units (C: Celsius F: Fahrenheit).

11.3. Clear daily programming memory If its necessary you can clear data of the daily programming memory. Select yes/no and push [ENTER] button to clear.

%T 60

Grados C

Borra P.S. no



11.4. Low level alarm reset Low level alarm can be reset pushing [ENTER] button. After a while, if low level is present, the alarm turn on again. The time between two alarms can be selected.

To exit Restricted Menu push a channel selection pushbutton.

12. GAS DISPENSING SYSTEM Optionally the Central Application Unit ML-600 has an inert gas dispensing system (CO2, N2, etc). This option is recommended for use with easy-oxidation adhesives as polyamide, polyolefin base, etc. The dispensing system is comprised of a pressure regulator, a by-pass solenoid valve with the relative tube towards the inside of the tank of the unit and a timer that governs the solenoid valve. The system connections can be consulted in the relative chapter Electrical diagrams. 1. Time margin for the first activation timer circuit of the trip relay. 2. Absolute scale for precision adjustment of the first timer circuit 3. Margin of time for the second deactivation timer circuit or pause of the trip relay. 4. Absolute scale for precision adjustment of the second timer circuit. 5. LED indicators of the operation status Un Power supply voltage (green) R Relay activated (yellow) 6. Contact diagram (on the side) A1/A2 Power supply 15/16/18 Selected relay contact Time scales Margin Scale base 0.1-1s >>1s 1-10s >>10s 6-60s >>60s 1-10min >>10min 6-60min >>60min 1-10h >>10h 10-100h >>100h The continuous cycle timer for dispensing, permits programming a waiting time (between one injection and the next) and an injection time. The factory set values are 30 min for wait and 5s for the injection.

18 1616 A2

A1 15 Y1

Toff

Ton

Un

R

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

123

4 6 7 8910

123

4 6 7 8910

18 1616 A2

A1 15 Y1

18 1616 A2

A1 15 Y1

Toff

Ton

Un

R

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

123

4 6 7 89101

23

4 6 7 8910

123

4 6 7 89101

23

4 6 7 8910

1234 6

5

Fig. 9 Timer for gas dispensing system

Minutos nivel 4



Fig. 10 Timer connections drawing

13. USE OF REACTIVE ADHESIVES The Central Application Unit ML-600 is not specifically prepared for the use of polyurethane based reactive adhesives. Their use in these models causes irreparable damage to the unit. To apply this type of adhesives, only use models ML-600 P.U.R. Polyurethane-base reactive adhesives, known as P.U.R. (Reactive polyurethanes), require a totally dry atmosphere before being applied, as, in contact with the humidity of the atmosphere, they reticulate and quickly go hard.

The Central Application Unit ML-600 P.U.R. achieves a dry atmosphere thanks to the incorporation of an air drying system in these models, which provides a dehumidification degree of over 99.98%. This guarantees the preservation of the adhesive without premature reticulations within the application system of the unit. Like the gas dispensing system (see 12. Gas dispensing system), this system uses a continuous cycle dispensing timer, which permits programming a waiting time (between one injection and the next) and an

Fig. 1 Timer connection diagram

Fig. 11 Air dryer system

18 1616 A2

A1 15 Y1

Toff

Ton

Un

R

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

123

4 6 78910

123

4 6 78910

18 1616 A2

A1 15 Y1

Toff

Ton

Un

R

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

123

4 6 78910

123

4 6 78910

18 1616 A2

A1 15 Y1

18 1616 A2

A1 15 Y1

Toff

Ton

Un

R

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

0.1-110-100h

6-60min6-60s1-10 1-10h

1-10min

123

4 6 789101

23

4 6 78910

123

4 6 789101

23

4 6 78910

Transformer Primary 230V Secondary 24V

230V AC

Solenoid valve 24 V AC

Timer



injection time. The factory set values are 10 min for the wait and 10 s for the injection. A pneumatic pressure of 0.5 kg/cm2 is recommended. After charging new adhesive or each time the lid of the unit tank is opened, it is advisable to carry out a manual injection lasting for approximately 60s. To do so, activate the pushbutton included in the solenoid valve of the system. To keep the air drying system in perfect conditions, it is advisable to periodically watch the filter saturation control checking (Fig. 11). If this control checking changes colour to red, the filtering cartridges will have to be replaced. Consult the relative chapter for spare parts.

Fig. 12

C.A.U. Manual ML-600 Installation


INSTALLATION OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP



14. INTRODUCTION Before installing and starting up your Central Application Unit ML-600 it is advisable to fill in the guarantee card that is enclosed with the unit (Fig. 13). This card entitles you to the guarantee and ensures a periodical follow-up of your unit. If you do not have this card, request it from our Commercial Dept. The Central Application Unit ML-600 must be installed by specialised personnel to guarantee a correct start-up and correct operation of the application. The following indications will be given in this chapter:

- material, conditions and space necessary for the installation

- connection of the unit to the electrical and pneumatic mains

- connection of peripherals

15. INITIAL CONDITIONS

15.1. Material supplied The following standard accessories are supplied with the Central Application Unit ML-600:

2x Wheels without brake 2x Wheels with brake 1x Bent connector for main machine output and level detector 1x Bent connector for motor activation, automatic pump flow regulation and external

pushbuttons 1x Technical instructions manual

On order, other optional material can be supplied to complete the installation of the unit: 1x Filter extractor ref. 10140066 1x Silent block supports ref. 10140068 1x Rubber support legs ML-600 ref. 10140067

15.2. Tools required for the installation The minimum tools required to carry out the installation tasks of the unit and its peripherals are the following: 1x Allen wrench no. 6 1x Set fixed wrenches nos. 9 to 22 1x Medium flat-tip screwdriver 1x Medium star-tip screwdriver 1x Thermal protection gloves 1x Protection goggles

Fig. 13 Guarantee Card of the C.A.U. ML-600



15.3. Environmental conditions The ambient work temperature must be between -5 C and +50 C. In damp atmospheres, or if working with aggressive chemical agents (e.g. bleach) the ANTIHUMIDITY equipment efficiently protects the system against premature deterioration. In dusty environments, dirty must be prevented from entering the tank, whilst it is being filled with adhesive, in so far as possible. The lid must always be kept closed.

15.4. Location conditions The decision on where to place the Central Application Unit ML-600 depends on several practical, technical and economic type factors. If in doubt, contact the Technical Service. It is advisable to install the unit in a place where it is easy to reach its control elements and filters, and also its adhesive charging hole. Objects or parts of any kind must be prevented from being able to fall into the tank or into the virgin adhesive containers. On the contrary the actual adhesive could be contaminated or damage could be caused to the internal mechanisms of the unit. When the unit is operating it gives off heat, which is greater the higher the work temperature is, so the operator must stay at a prudent distance from the machine and from other elements of the main machine that might be affected. Fig. 14 shows the external dimensions of the two basic models (ML-625 and ML-650) with their approximate weights. Firm placement must be guaranteed. The structure of the supports designed to secure the unit (if this does not rest on the floor) must be able to sustain its weight without any problems. Add the maximum adhesive charge that it has to store to the weight of the unit. The Central Application Unit ML-600 is designed to support vibrations. In any case, it is advisable to reduce them as much as possible, as in the long run they end up having damaging effects on the mechanical, electrical and electronic components. Try to place the unit as close as possible to the application in order to reduce the length of the connection hoses. However, observe the installation indications for the hoses and more specifically its maximum curvature radius (150 mm) and twisting during assembly.



15.5. Dimensions and weights of the unit

MOKM

1

2

ON/OFF

ML - 600

790

100 590 100

132

334

366

Weight: 110 kg (1) 130 kg (2)

(1) Model ML-625 (2) Model ML-650

Fig. 14 Dimensions of the C.A.U. ML-600



16. UNLOADING THE C.A.U. ML-600

Fig. 15 Unloading the C.A.U. ML-600



17. CONNECTION OF THE UNIT AND ITS ACCESSORIES

17.1. Electrical power supply of the unit Central Application Units ML-600 offers three connection possibilities to the electricity mains: - 3 x 400V AC / 50 Hz + neutral + earth - 3 x 230V AC / 50 Hz + earth - 230V AC / 50 Hz + earth (*) (*) The latter is advised against due to the direct charge of the whole power onto one single phase.

Unscrew the plate from the housing of the circuit breaker switch, situated on the right-hand side of the unit. Make the connection according to the system chosen: - 230V single-phase (cable section 6 mm2):

1. connect the earth cable 2. connect the neutral cable to N 3. connect the phase cable to T 4. bridge phase T with inputs S and R

- 230V three-phase (cable section 6 mm2):

1. connect the earth cable 2. connect a phase cable to N 3. connect a phase cable to T 4. bridge phase S to input T 5. connect a phase cable to R

- 400V three-phase + neutral (cable section 1.5 mm2):

1. connect the earth cable 2. connect the neutral cable to N 3. connect a phase cable to T 4. connect a phase cable to S 5. connect a phase cable to R

Fig. 16 Connection strip of the unit to the electricity mains

RS

TN R S T N R S T N R S T N

F1 F2 F3 N

RS

TN R S T N R S T N R S T N

F1 F2 F3 N

Section cable: 6

Section cable: 6

Section cable: 1.5

230 V SINGLE-PHASE

230 V THREE PHASE

400 V + NEUTRAL

F1 F2 F3F N



The different elements of the unit are distributed between the three input lines as follows: LINE 1 Phase T Tank LINE 2 Phase S Control card supply Motor fan supply Air dryer or gas dispensing system supply Motor driver control Gun resistors nos 1 and 2. LINE 3 Phase R Minimum relay circuit supply Premelter resistor Hose resistors nos. 1 and 2

The maximum power to be connected for each output channel (nos. 1 and 2) is 1300W in the hose and gun assembly.

17.2. Identification of the connections All the electrical and hydraulic connections required for the unit to operate are on the rear of the equipment. Figure 17 shows these connections and their functions.

1. Electrical connections for hose-gun. 2. Electrical connection for main machine output, low adhesive level signal and external stand-by. 3. Connection for motor on/off input, variable voltage signal for flow volume regulation and external

pushbuttons. 4. Hydraulic connections for hoses. 5. Filter housing plug.

1

4

2 3

5

Fig. 17 Conexiones de la U.C.A. ML-600

!

Fig. 17 Connections of the C.A.U. ML-600



17.3. Hose connection After locating the Central Application Unit ML-600 the guns that are going to be used must be placed on the machine. The length of the hoses will have to be chosen depending on the distance planned between these and the unit. There is a technical installation instructions sheet for the hoses (supplied with each one of them), which must be read with care. Avoid twisting the hoses and bends with a radius of less than 150 mm. Mechanically couple each hose to one of the hydraulic outputs of the unit (Fig. 17), screwing the nut of the hose to one of the male connectors of the outputs. If necessary, take the plug off the pump and fit the right male connector for the connection. The connector has an O-ring on one of the ends. This side is the one that must be connected to the filter block, leaving the metal cone for connection with the hose nut. In 45 or 90 connectors, once the hoses have been positioned, the nut of the connector will be tightened against the block to secure it in place. Screw the first turns by hand to start the thread. Later use the fixed wrench to tighten it firmly, but not too much.

WORK WITH PROTECTION GLOVES AND GOGGLES.

It is advisable to heat the elements to a temperature of over the softening point of the adhesive used to make the connection of the threads easier without damaging them. This precaution is unnecessary with new material, without adhesive.

It is advisable to make the electrical connections and disconnections of the hose and gun with the unit switched off. On the contrary, errors may momentarily be displayed on the screen, and sparks may occur in the connection pins.

17.4. Gun connection

Each gun is supplied with a thermal isolating plate (3) to isolate it from its support (2). This isolating plate prevents heat from dispersing in the gun (1) and guarantees its correct operation as well as thermal stability (Fig. 18). Mechanically couple the hose to the gun, screwing the nut of the former to the male input connector of the latter. The connector has an O-ring on one of the ends. This side is the one that must be connected to the body of the gun, leaving the metal cone for connection with the hose nut. In 45 or 90 connectors, once the hoses have been placed, the connector nut will be tightened against the gun to secure it in place. Screw the first turns by hand to start the thread. Later use the fixed wrench to fasten it firmly, but not too much.

In the connection of the hose with the gun it is advisable to avoid adhesive cooling areas, for example in the composition of the connectors used (splices). If they are necessary for the installation, protect the connections with thermal sleeves.

!

!

Fig. 18 Thermal gun isolator

1

3

2




It is advisable to heat the elements to a temperature over the softening point of the adhesive used to make the connection of the threads easy without damaging them. This precaution is unnecessary with the new material, without adhesive.

17.5. Installation and connection of the solenoid valves The control solenoid valves for the guns are directly placed on their metal tubes.

The length and material of the tube are calculated so that the heat transmission to the solenoid valve is minimum. This length must not be shortened and the material must not be modified without consulting previously with the Technical Service.

When pneumatically connecting a solenoid valve to the gun, whether it is single or double-acting must be taken into consideration. If it is single-acting (pneumatic opening, spring close), connect the supply tube ( out 6 mm) in input (1). Output (2) is connected with the relative connector to the metal tube of the gun or directly if it is the rapid connection model. Output (3) is the outlet where the silencer is situated (Fig. 19). No more fastenings of the solenoid valve are necessary.

If the gun is double-acting (pneumatic open and close) the solenoid valve model is different, as two air tubes are required to control the gun. The supply tube ( out 6 mm) is connected in the input (IN). Output (B) is connected with the relative connector to the metal close tube of the gun or directly if it is the rapid connection model. The other output (A) is connected with the relative connector to the metal open tube of the gun or directly if it is the rapid connection model. The output (EX) is the outlet where the silencer is situated (Fig. 20). No more fastenings of the solenoid valve are necessary. The correspondence of the tubes with the outputs of the solenoid valve is that shown in figure 21.

Good filtering and the elimination of the humidity from the supply air guarantee an optimum performance of all the components. Use air without lubrication.

!

!

Fig. 19 Solenoid valve for single-acting gun

1

2

3

AB

EX IN

Fig. 20 Solenoid valve for double-acting gun

!

!



The electrical connections of the coil are common to both gun models, either single-acting or double-acting.

If the power supply is on alternating current AC (230V or 24 V) it does not matter where the phase and neutral are connected, whilst the earth must be connected to its relative terminal. If the power supply is on direct current DC (24 V) the positive pole (+) will be connected in terminal no. 1 and the negative pole (-) in terminal no. 2, whilst the earth must be connected to its relative terminal.

17.6. Connection of the variable voltage signal The variable voltage signal may be generated from the actual main machine, as a 0-10 V signal. The 0-10 V signal is connected directly in connector no. 3 (see Fig. 17) on the rear of the unit. The positive voltage signal and the negative signal are connected in pins 6 and 7 of the connector, respectively (see electrical diagram chapter). To activate and program this signal, consult chapter 10.2. Automatic mode.

17.7. Other connections To avoid any type of interference in the electronic control elements and microprocessors of the Central Application Unit ML-600, these installation instructions must strictly be observed. The 230V/400V power supply cables must be separated from the signal cables (main machine output signal, automatic motor on/off, solenoid valves and other accessory elements such as photocells, encoder or control signals for proportional valves) at a distance of no less than 200 mm. All the input or output signal connections of the unit will preferable carried out with screened cable.

2 B A

Fig. 21 Identification of air tubes in single and double-acting guns

1

2

Fig. 22 Electrical connections of solenoid valve



The potential-free contact for the main machine output signal has low power thus permitting direct connection to an external relay. This relay may activate other power circuits. It is not possible to directly activate these power circuits (motors, solenoid valves, etc.).

External stand-by signal (potential-free contact) set this function from the main machine. Closing contact between two signal pins activates stand-by mode. Opening the contact, deactivates stand-by mode. Manually activation has priority over external contact and this one over daily programming.

MML-600 ~

M

ML-600 ~

5

4 Fig. 23 Connection of the main machine output signal

C.A.U. ML-600 Manual Handling Guide


HANDLING GUIDE OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP



18. INTRODUCTION This small handling guide sums up the essential concepts for the basic application operations. To program temperatures consult chapter 5. Display and modification of temperatures. The guide describes the adhesive charge, the regulation of the pump revolutions, the adhesive flow control and some practical recommendations for using the unit.

19. ADHESIVE CHARGE The adhesive is charged through the top of the tank, coated with anti-adherent material and with wide opening. It has a lid with floating seal system, which guarantees a perfect seal in the whole contact surface. The lid must always be kept closed and it must only be opened to control the level and recharge the adhesive, in order to prevent strange particles from getting inside.

20. PUMP SPEED AND FLOW REGULATION The pump revolutions provide the correct adhesive flow for each application. To automatically or manually regulate the adhesive flow consult chapter 10. On/off and speed regulation of pump. The Central Application Unit ML-600 permits regulating the pump revolutions between values of 1-100 rpm, however, for efficiency reasons, values of between 15 and 80 rpm are recommended. The maximum flow that the unit pump can supply is 40 kg/h, under standard conditions. There are several factors that affect the flow provided:

- The adhesive, its viscosity, which depends on the technical demands of the application. The work temperature must necessarily be within the margins established by the manufacturer.

- The length and diameter of the transport hose. - The section of the output opening of the application nozzle.

The flow increases when the temperature of the adhesive increases (less viscosity), with an increase of the hose diameter and of the nozzle outlet opening, and it decreases with the viscosity of the adhesive and the length of the hose. It is also related to the pressure drops of the installation (elbows, narrowing, material roughness, etc.) As a safety measure, the Central Application Unit ML-600 is equipped with a pressure limiting valve, which permits the recirculation of the adhesive in the pump if the maximum pressure is exceeded.

DO NOT ADJUST THE LIMITING VALVE UNDER ANY CIRCUMSTANCES.

!



21. PRACTICAL RECOMMENDATIONS FOR USE These recommendations are extremely important to guarantee optimum efficiency of the unit: - Do not exceed the temperature recommended by the adhesive manufacturer - When you are not going to work with the C.U. for several hours it is advisable to activate the Stand-by function or just disconnect the unit with the ON/OFF pushbutton. - Perform periodical maintenance of the unit, replacing filters if necessary. - When charging the adhesive, prevent remains of it from sticking to the upper fairing around the charge opening. With the heat, these remains melt and soil the lid, and when they cool down, they stick, preventing the lid from opening. - Prevent strange particles from entering containers with adhesive. When emptying the containers into the tank, the particles get into the inside and may eventually obstruct the filters. - Avoid cleaning the inside of the tank with sharp tools. Using them it damages the anti-adherent coating. - Do not mix adhesives on the inside of the tank. At times product incompatibility causes obstructions in the pumping system. - Respect the safety standards. Use protection equipment when handling the unit.


!

C.A.U. ML-600 Manual Maintenance


MAINTENANCE OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP



22. INTRODUCTION The correct use and maintenance of the Central Application Unit ML-600 is aimed at optimising the durability of your installation. We advise reading all the chapters of this manual carefully. This chapter sums up the most important points necessary for a long-lasting preservation of the unit.

Any handling of the Central Application Unit ML-600 must be carried out by authorised personnel.

23. GENERAL COMMENTS Select the temperatures recommended by the adhesive manufacturer for the heating elements. Under no circumstances must the specified limits be surpassed. Lower the temperatures of the unit during transitory production stoppages:

< 4 hours activate stand-by function > 4 hours disconnect the unit

Avoid oscillations in the power supply voltage. The powers indicated in the heated elements are considered for 230V AC / 50 Hz. Voltage reductions represent lower powers and with them greater heating times. In some cases the maximum permitted temperatures may not be reached. The compressed air supply must be free from particles and humidity. Use filters and decanters. It is not necessary to lubricate pneumatic elements. It is advisable to carry out a general cleaning and change the filter meshes every three (3) months. Each year it is advisable for authorised personnel to carry out a complete overhaul of the whole Central Application Unit ML-600.

24. GENERAL CLEANING

MAXIMISE PRECAUTION WITH THE TEMPERATURE AND PRESSURE OF THE ADHESIVE

SERIOUS RISK OF BURNS

The unit tank and the inside of the hose have an anti-adherent coating to make the cleaning work easier and prevent carbonised adhesive remains on the walls. Before starting the cleaning process, obtain the following material:

!



- a container for the adhesive, if possible metal - thermal protection gloves - safety goggles - a set of traditional tools (fixed wrenches, hexagonal wrenches, pliers, screwdrivers, etc.)

24.1. Cleaning the tank Follow the procedure in strict order: - heat the unit to its working temperature. - disconnect the hose from the connector corresponding to the equipment. - empty the tank, through the outlet, connecting the motor and increasing the pump revolutions. Collect the adhesive in the container for this purpose. - once empty, disconnect the motor and wait until the residual pressure is eliminated through the outlet connector. - take the filter out of the distributor block and clean the mesh and body of the filter. If necessary fit a new mesh (see section 25.1. Change distributor filter mesh).

- mount the filter in the distributor block again. - with a soft and absorbent cloth, thoroughly clean the remains of adhesive from the tank, especially carbonised remains.


- Clean the metal filter inside the tank, which is located in the intake opening to the pump. Eliminate remains of carbonised adhesive. - Connect the hose again and refill the adhesive unit.

!

Fig. 24 Filter extraction



24.2. Cleaning hose Follow the procedure in strict order: - clean the tank (see previous point). - select the temperatures at a lower value than the working temperature (10-15 C less). By doing this, greater viscosity is achieved and therefore the cleaning capacity is increased. - disconnect the hose from the connector corresponding to the gun and place it straight. - empty the tank, through the hose, connecting the motor and increasing the pump revolutions. Collect the adhesive in the container for this purpose. - if the adhesive comes out with dirt once the tank is empty, repeat the operation with new adhesive. - disconnect the motor and wait until the residual pressure is eliminated through the hose. - connect the hose into the gun again.

24.3. Cleaning guns and nozzles Follow the procedure in strict order: -clean the tank and the hose (see previous points). - release the nozzle from the injector module and clean them when hot with pressurised air or with the cleaning kit (ref. 23000000). To heat the nozzle you have to use a hot air gun. Do not use soldering guns. - blow the nozzle from the outside opening towards the connection thread. On the contrary, the outlet opening may become even more blocked. - empty the tank, through the gun (without nozzle), connecting the motor and increasing the pump revolutions. Collect the adhesive in the container for this purpose. - if the adhesive comes out with dirt after emptying the tank, repeat the operation with new adhesive. - disconnect the motor and place the nozzle in the injector module again.

25. CHANGE FILTERS The filters are changed depending on the dirt that is generated in the system, depending on the working temperature and the adhesive used. Changing the filter meshes every three months of continued work is recommended.

To change the filters or replace the meshes, disconnect the motor and make sure that the residual pressure is zero, manually activating the guns.

!



25.1. Change distributor filter mesh Follow the procedure in strict order:

- maintain the unit at its working temperature.

- keep the pump motor disconnected. - depressurise the system. - place the filter plug in opening position, rotating the bayonet lock 90 to the left. - take the filter out of its housing.

Fig. 25

Maximise precautions. When it is removed some hot adhesive will come out. If the filter should seize up use an extraction tool (ref. 10140066).

- remove the filter, releasing the lid with wrench no. 20. - take the mesh out pulling the inner pin with some pliers. Replace or clean it.

- fit the filter lid and insert it into the distributor again, securing it by rotating the bayonet 90 to the right. Characteristics and references of the filter mesh: ref. 10140026 Filter mesh (MW01) ML-600 ref. 10140065 Extra-thick filter mesh (MW08) ML-600

25.2. Change mini-filter mesh If the installation is equipped with filtering system for the gun (situated between the gun and the hose connection) the mesh of this type of filters must be changed as follows:

90

!

Fig. 26 Extraction of the filter mesh



STANDARD MINI-FILTER:


- keep the pump motor disconnected. - depressurise the system.

- completely disconnect the mini-filter from the hose and gun.

- unscrew the connector-plug of the mini-filter. - extract the filtering cartridge and replace it with another new one.

- screw the connector-plug on again and fit the mini-filter between the hose and gun again.

IN LINE MINI-FILTER:

The in line mini-filter permits changing cartridge without having to disconnect the mini-filter (see instructions in the leaflet enclosed with the mini-filter):


- keep the pump motor disconnected. - depressurise the system.

- unscrew the filtering cartridge and replace it with another new one.

25.3. Change cartridge of the air dryer filter The filtering elements, prior to the air drying device in the Central Application Unit ML-600 PUR, include a filter saturation indicator, which indicates the best time to change the filtering cartridge: - green: low contamination of the cartridge. - red: contaminated cartridge. Replace immediately, the performance of the equipment is not guaranteed It is advisable to install new cartridges once a year, regardless of the indicator reading (differential pressure).

Fig. 27 Change standard mini-filter mesh

Fig. 28 Change mesh of in line mini-filter

Fig. 29 Filter saturation indicators



To change the cartridge, follow these steps: - close the air passage. - release the drainage hose from the vessel, if connected. - slowly turn the knurled screw in clockwise direction. This will purge the air stored inside the filter. - push the vessel towards the filter head. - slowly turn the vessel in clockwise direction as far as possible (1/8 turn) and remove it, pulling it downward. - extract the cartridge and replace it with a new one (do not touch the filter mesh with your hands). - mount the vessel following the instructions in reverse order. - give pressure to the filter, slowly opening the by-pass valve.

It is necessary to maintain the supply to the unit to keep the air drying system in operation. The system must operate even with cold adhesive, to keep the internal atmosphere without humidity.

!

C.A.U. ML-600 Manual Spare parts


SPARE PARTS OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP

C.A.U. ML-600 Manual Electric drawings




26. SPARE PARTS

26.1. General parts drawing

2

3

4

56

7

8

10 9



26.2. Control panel parts list

No REFERENCE NAME 2.1 150021070 Front card ML-600 2.1 150021080 Front card ML-600-P 2.1 150021090 Front card ML-600-LD 2.1 150021100 Front card ML-600-PLD 2.2 150020810 Radiator ML-600 2.3 10000427 Transformer ML-600 2.4 10000428 Solid state relay ML-600 2.5 150020820 Motor inverter ML-600 (533) 2.6 10000430 Electronic filter ML-600 2.7 10000450 Level detector ML-600 2.8 10000456 Level detector connection cable 2.9 10000451 Level detector amplifier 2.10 10010010 Fuse 10 A 2.10 10010300 Fuse 6 A 2.10 10010009 Fuse 3 A ML-600

2.1

2.2

2.3

2.4

2.5

2.6

2.7

2.9 2.8

2.10



26.3. Tank unit

No REFERENCE NAME 3 10140006 Complete tank unit ML-625 3 10140073 Complete tank unit ML-650 3 10140074 Complete tank unit ML-625 PUR 3 10140075 Complete tank unit ML-650 PUR 3.1 10140007 Tank opening silicone joint ML-600 3.2 10110035 Casing insulating mat ML-625 3.2 10110071 Casing insulating mat ML-650 3.3 10140058 Teflon-coated tank ML-625 3.3 10140072 Teflon-coated tank ML -650 3.3 10140076 Teflon-coated tank with special coating ML-625 PUR 3.3 10140077 Teflon-coated tank with special coating ML-650 PUR 3.4 10030013 Safety thermostat 240C kit 3.4 150022220 Safety thermostat 180C kit (ML-625/650 PUR) 3.5 10030006 Tank connection unit 3.6 10000446 Sensor Pt-100 ML-600 3.7 150020860 Upper tank distance insulator 3.8 150020870 Tank fastening kit ML-600 10120103 Flat tank grating ML-600 10120104 Flat tank grating ML-600 PUR

3

3.1

3.2

3.3 3.4

3.5

3.6

3.7

3.8



26.4. Motor-pump unit

No REFERENCE NAME 4.1 150020880 Self-ventilated motor ML-600 4.2 10140010 Motor brush kit ML-600 4.3 150020890 Complete motor shaft with cotter pins ML-600 4.4 10140013 Motor coupling 4.5 10140015 Pump 40 L ML-600 4.6 10140017 Complete pump shaft packing kit ML-600 4.7 10140018 Pump seat joint kit 4.8 10140019 Distributor block ML-600 4.9 10140021 Distributor block O-ring ML-600 4.10 10000439 Pump coupling-filter block resistor 100W 230V 4.11 10100082 Pump plug 20030000 Short straight connector 20200000 O-ring (pump-connector plug) 4.12 10140022 Complete filter cover ML-600 4.13 150021060 Motor speed inductive detector

4.1 4.2

4.3 4.4

4.5 4.6

4.7

4.8

4.9

4.10

4.11

4.10 4.12

4.13



26.5. Filter unit

No REFERENCE NAME 5 10140024 Complete filter ML-600 5 10140064 Extra-thick complete filter ML-600 5.1 10140025 Filter joint kit ML-600 5.2 10140026 Filter mesh (MW01) ML-600 5.2 10140065 Extra thick filter mesh (MW08) ML-600 10140066 Filter extractor ML-600

5.1

5.2

5



26.6. Limiting valve unit

NO REFERENCE NAME 6 150020910 Limiting valve ML-600 (red spring) 6.1 10140027 Limiting screw ML-600 6.2 10140028 Limiting nut ML-600 6.3 150020900 Limiting spring ML-600 (red) 6.4 10140030 Limiting piston ML-600 6.5 10140033 Limiting valve joint kit 6.6 10140034 Limiting valve body seat joint kit ML-600 6.7 10100058 Plug 1/8 gas 6.8 10000439 Pump coupling-filter block resistor 100W 230V 6.9 10140035 Limiting valve-pump coupling body ML-600 6.10 150020920 Limiting valve flange unit ML-600

6.1

6.2

6.3

6.4

6.5

6.6

6.7

6.86.9

6.10 6



26.7. Cradle elements unit

NO REFERENCE NAME 7.1 16010011 8-pole wall female connector ML-600 7.2 16010001 8-pole wall female connector (TP) 7.3 16010003 8-pole wall female connector (Pt-100) 7.4 10140040 Stuffing box PG-13 ML-600 7.5 10000436 Minimum relay ML-600 7.6 10000440 Circuit breaker 16 A 16010012 Main machine interconnection elbowed connector 16010013 Motor interconnection elbowed connector 10140067 Rubber support legs ML-600 10140068 Silent-block support ML-600 7.7 10140041 Wheel ML-600 7.8 10140042 Wheel with brake ML-600 7.9 150020850 Motor inductance

7.1 7.2

7.3

7.4

7.8

7.7

7.6

7.5

7.9



26.8. Premelter unit

NO REFERENCE NAME 8 10000437 Complete pre-melting unit ML-625 8 10000447 Complete pre-melting unit ML-650 8 10000448 Complete pre-melting unit ML-625 PUR 8 10000449 Complete pre-melting unit ML-650 PUR 8 10000452 Complete pre-melting unit ML-625 with level detector 8 10000453 Complete pre-melting unit ML-650 with level detector 8 10000454 Complete pre-melting unit ML-625 PUR with level detector 8 10000455 Complete pre-melting unit ML-650 PUR with level detector 8.1 10140043 Intake grating ML-600 8.2 10140044 Body premelter only ML-600 8.2 10140078 Body premelter only ML-600 PUR 8.2 10140088 Body premelter only ML-600 PUR with level detector 8.2 10140089 Body premelter only ML-600 with level detector 8.3 10000446 Sensor Pt-100 ML-600 8.4 10020003 Resistor 630 W 230V premelter ML-625 8.4 10020004 Resistor 1000W 230V premelter ML-650 8.5 10140045 Plug joint 3/8 gas ML-600 8.6 10120068 Premelter bushing fastening kit 8.7 10120069 Premelter bushing

8

8.1

8.2

8.3

8.4

8.5

8.6

8.7



26.9. Gas dispensing unit

NO REFERENCE NAME 9 08000000 Gas dispensing unit 9.1 10110072 By-pass solenoid valve ML-600 9.2 10110030 Meler pressure gauge 9.3 10110031 Pressure regulator 9.4 10110050 Fast male straight connector 1/8 6 9.5 10110064 Connector 90 1/8 6 9.6 10110065 Male-male connector 1/8 9.7 10110066 PTFE 4-6 tube with reinforcements 9.8 10110067 Gas connector unit for lid 6 9.9 10110068 Tube fastening clip unit 6 9.10 10000444 Gas dispensing unit transformer 9.11 10000445 Gasification timer

9.1

9.2

9.39.5

9.6

9.7

9.9

9.8

9.11

9.10

9.4



26.10. Dry air dispensing unit

NO REFERENCE NAME 9.1 10110072 By-pass solenoid valve ML-600 9.2 10110030 Meler pressure gauge 9.3 10110031 Pressure regulator 9.5 10110064 Connector 90 1/8 6 9.6 10110065 Male-male connector 1/8 9.7 10110066 PTFE 4-6 tube with reinforcements 9.8 10110067 Gas connector unit for lid 6 9.9 10110068 Tube fastening clip unit 6 9.10 10000444 Gas dispensing unit transformer 9.11 10000445 Gasification timer 10.1 10140079 Air dryer cartridge ML-600 PUR 10.2 10140080 1st stage filter cartridge ML-600 PUR 10.3 10140081 2nd stage filter cartridge ML-600 PUR

9.1

9.2

9.39.5

9.6

9.7

9.9

9.8

9.10

9.11

10.1

10.2

10.3


Meler Aplicadores de Hot-Melt S.A. - 65-

ELECTRICAL DIAGRAMS OF CENTRAL APPLICATION UNIT ML-600 SERIES WITH GEAR PUMP


Meler Aplicadores de Hot-Melt S.A. - 67-

27. LIST OF DRAWINGS

List of components Central Application Unit ML-600

Front view ML-600 Rear view ML-600 Left side view ML-600 Right side view ML-600 Electrical panel. Bottom view. Electrical panel. Left side view Electrical panel. Right side view Power circuit Tank and premelter heating circuit Hose and gun heating circuit Interconnection circuit and level detector Motor pump operation circuit



LIST OF COMPONENTS CENTRAL APPLICATION UNIT ML-600

REFER. DESCRIPTION LOC. A00 CONTROL CARD ML-600 /10/11/12/13 A01 MOTOR SPEED REGULATOR /13.2 B00 SENSOR PT100 TANK /10.2 B01 SENSOR PT100 PREMELTER /10.6 B06 CAPACITIVE LEVEL DETECTOR /12.7 EMI ELECTROMAGNETIC EMISSION FILTER /9.3 F01 MINIMUM VOLTAGE RELAY 3A FUSE /9.3 F02 LOW CONSUMPTION ELEMENTS 6A FUSE /9.2 F03 GUN 2 6A FUSE /11.8 F04 HOSE 2 6A FUSE /11.6 F05 GUN 1 6A FUSE /11.4 F06 HOSE 1 6A FUSE /11.2 F07 PREMELTER 10A FUSE /10.7 K00 MINIMUM VOLTAGE RELAY /9.1 K02 INTERVAL TIMER /9.6 L02 MOTOR INDUCTANCE /13.3 M00 PUMP GEAR REDUCER /13.3 M01 FAN /9.4 Q00 3 POLE 16A CIRCUIT BREAKER /9.1 R00 3000W TANK RESISTOR /10.4 R01 100W PUMP RESISTOR /10.4 R02 100W FILTER RESISTOR /10.5 R03 630W (625)/1000W (650) PREMELTER RESISTOR /10.7 R04 630W (625)/1000W (650) PREMELTER RESISTOR /10.7 T00 CARD SUPPLY TRANSFORMER. /9.5 T01 DRY AIR TRANSFORMER /9.5 TE00 FAN

Date post:	08-Apr-2016
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Manual ML-600 ENG

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