Declaration of conformity

The product:
Model nº:
Serial nº:
Year of manufacture:

Described in the enclosed documentation is in conformity with:

 Directive 2006/42/EC of 29 December 2009 which replaces Directive

98/37/EC of 22 June 1998 on the approximation of the laws of the
Member States relating to machinery, which regroups Directives
89/392/EEC of 14 June 1989, 91/368/EEC of 20 June 1991, 93/44/EEC of
14 June 1993 and 93/68/EEC of 22 July 1993. Directive applicable to
standard EN ISO 12100-1 and EN ISO 12100-2, related to safety of
machinery; standard EN ISO 14121-1 and EN ISO 14121-2, related to
safety of machinery. Risk assessment; standard UNE-EN 60204-1, related
to safety of machinery. Electrical equipment of machines; standard UNE-
EN 61310-1, UNE-EN 61310-2 and UNE-EN 61310-3, related to safety of
machinery. Indication, marking and actuation.

 Directive 2006/95/CE of 12 December 2006 which replaces Directive

73/23/EEC of 19 February 1973 on electrical equipment.

 Directive 2004/108/EC of 20 July 2007 which replaces Directive

89/336/EEC of 3 May 1989 on Electromagnetic Compatibility.

 Directive 93/68/EEC of 22 July 1993 which modifies 73/23/EEC and

Directive 89/336/EEC.

 Hoses are factory tested at 100 bars and at 220ºC.

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
 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.
FAILURE TO FOLLOW SAFETY INSTRUCTIONS MAY RESULT IN
BURNS, INJURY OR PERMANENT PHYSICAL 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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 TABLE OF CONTENTS

CHAPTER 1 SAFETY INSTRUCTIONS ____________________________ 3

1.1. SYMBOLS AND TERMS:.................................................... 4
1.2. PURPOSE: .......................................................................... 6
1.3. FIRST AID: ........................................................................... 7
CHAPTER 2 DESCRIPTION _____________________________________ 9
2.1. INTRODUCTION: .............................................................. 10
2.2. MAIN PARTS: .................................................................... 10
2.3. TECHNICAL CHARACTERISTICS: ................................. 14
2.4. DIMENSIONS: ................................................................... 15
2.4.2. GENERAL DIMENSIONS WITH VACUUM FEEDING
(MODEL TYPE C):.................................................................... 16
CHAPTER 3 MACHINE INSTALLATION __________________________ 18
3.1. INTRODUCTION: .............................................................. 19
3.2. TRANSPORT:.................................................................... 19
3.3. INSTALLATION REQUIREMENTS: ................................. 19
3.4. MECHANICAL INSTALLATION:....................................... 20
3.5. PNEUMATIC INSTALLATION .......................................... 25
3.6. ELECTRICAL INSTALLATION ......................................... 25
3.6.1 Routing Low-Voltage Leads ............................................ 25
3.6.2 Connecting the Electrical Power ..................................... 26
3.6.3 Input/Output Connections................................................ 27
CHAPTER 4 MACHINE ADJUSTMENT ___________________________ 30
4.1. INTRODUCTION: .............................................................. 31
4.2. TEMPERATURE CONTROL: ........................................... 31
4.3. OTHER ADJUSTMENT ................................................... 43
CHAPTER 5 OPERATION ______________________________________ 69
5.1 START THE UNIT .............................................................. 70
5.2 TEMPERATURE ................................................................ 71
5.3 CLOCK ON/OFF ................................................................. 72
5.4 SETBACK ........................................................................... 73
5.5 POT FILL – EXTERNAL LOW LEVEL DETECTION ........ 74
5.6 HOPPER FEEDER – INTERNAL LOW LEVEL
DETECTION ............................................................................. 74
5.7 BEACON ALARM ............................................................... 74
5.8 EXTERNAL INPUT ............................................................. 74
5.9 FILLING THE TANK ........................................................... 75
5.10 STOPS: ............................................................................. 78
CHAPTER 6 MAINTENANCE ___________________________________ 80
6.1. INTRODUCTION: .............................................................. 81
6.2. MAINTENANCE RECOMMENDATIONS: ....................... 82
6.3. MAINTENANCE PROCESSES: ....................................... 82

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 CHAPTER 7 TROUBLESHOOTING THE EQUIPMENT _______________ 85
7.1. INTRODUCTION: .............................................................. 86
7.2. MECHANICAL FAULTS: ................................................... 86
7.3. ELÉCTRICAL FAULTS: .................................................... 89
7.4. ADHESIVE APPLICATION PROBLEMS: ........................ 95

CHAPTER 8 EQUIPMENT REPAIR GUIDE _______________________ 102

8.1. INTRODUCTION: ............................................................ 103
8.2. CHANGING THE FILTER: .............................................. 103
8.3. REPAIRING THE MANIFOLD: ....................................... 104
8.4. REPAIRING THE PNEUMATIC PUMP UNIT: ............... 105
8.5. CLEANING VALVES ....................................................... 114
8.6. REPAIRING ELECTRIC COMPONENTS: ..................... 115
8.7. REPAIRING VACUUM FEEDER .................................... 115
CHAPTER 9 LOG SHEETS ____________________________________ 117

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 CHAPTER 1
SAFETY
INSTRUCTIONS

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 1.1. SYMBOLS AND TERMS:

Miscellaneous European Community

prohibitions markings

Danger hot surface Note of special interest

Miscellaneous Use of goggles

precautions required

Precaution: Electric Use of safety gloves

current required

Precaution: Elements susceptible to

Flammable liquid electrostatic discharge

Precaution: risk of
fluid leakage under
high pressure

Precaution: risk of
entrapment between
mobile parts

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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 skin
injury.
Qualified personnel:
Qualified personnel are technical staff members who have acquired
sufficient knowledge in a specific field, through either training or
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:
Clothing will be compliant with EN510 and EN340 standards,
protecting against flying debris and high temperatures.
Clothing 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:
Goggles will be compliant with the EN 166 standard, protecting against
flying debris and high temperatures.
Goggles only protect the eyes. Face shields are preferable, as they
protect the entire face.
Protective gloves:
Gloves will be compliant with EN 407 and EN 420 standards,
protecting the hands against burns caused by external, heated
substances at temperatures above 100 °C.

Elements susceptible to electrostatic discharge:

When handling equipment, avoid contact with electronic components
and metal pins on the connectors.

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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 trained in correct operation (contacting
the manufacturer whenever necessary), the risks involved and
required safety measures, including adjustment and
maintenance, and expressly-forbidden operations.
 This unit is not designed 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 provided guards in
place (do not remove). These guards should be checked and
maintained according to the maintenance schedule.
 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 a basic knowledge of the machine, and of the
mechanical, pneumatic and electrical circuits involved.
 Maintenance operations and/or repairs should always be
performed with the machine switched off at the mains, and with
the main switch locked and tagged out.

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 1.3. FIRST AID:

In case of burns:
Immerse the 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 after 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 the site with
soap and water and discard all contaminated
cloths.
CONTACT WITH EYES: Wash the eyes in an
eye bath for at least 15 minutes.
INHALATION: In case of exposure to fumes,
take the patient to fresh air and let them rest.
INGESTION: Do not attempt to induce vomiting.
Seek medical attention at once.

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 CHAPTER 2
DESCRIPTION

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 2.1. INTRODUCTION:
This machine is designed to melt hot-melt adhesive, or similar
materials, in a heated reservoir. A pump then pressurizes the adhesive
and transfers it to a manifold, where it flows through heated hoses to
the application point.
2.2. MAIN PARTS:
The main machine parts are shown in the following figure:

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 Basic equipment description (optión A):

N. DESCRIPTION
1 Electrical cabinet
2 Frame
3 Pump
4 Manifold
5 Tank
6 Control panel
7 Discharge module

Optional equipment description:

Nº DESCRIPTION Intermediate (option B) Full (option C)

8 Level sensor
۷ ۷
9 Vacuum feeder
۷
2.2.1. Electrical cabinet:
The cabinet contains the temperature control interface and related
electrical components.

2.2.2. Frame:
The frame consists of a base plate on which the equipment is installed.

2.2.3. and 2.2.4. Pump-distribution system:

This system transfers adhesive from the tank to the manifold.
Manifold:
The manifold distributes the Hot-Melt, once filtered, to the hoses and
guns.
Made of aluminium, it is located on the lower part of the tank so the
tank heaters can heat it indirectly.
The manifold filter consists of a core and a fine, in-line filter screen to
filter crystal particles or dirt that could be present in the adhesive.
The manifold has six outlet holes to connect the Hot-Melt hoses: three
on the top row and three on the bottom row.
Pump:
The pump delivers the Hot-Melt, or other molten product, at a set
pressure, from the tank to the substrate (or material to be glued), after
passing through a manifold, filter, hoses and guns.
The pump system consists of an electrovalve, a pneumatic cylinder
and a double-acting hydraulic pump with a pressure compensator, to
avoid a drop in the flow produced when changing pump direction, and
enabling uniform Hot-Melt discharge.

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 Do not disassemble the manifold. This operation should only be
done if there is a Hot-Melt leak between the tank and the distributor.
2.2.5. Tank:
The Tank is where the Hot-Melt or other similar material is melted (the
other material can be in the form of pellets or blocks). The cast
aluminium tank is lined with Teflon to avoid carbon deposits and crystal
formation, and incorporates a resistance heating system.
A sensor with a micro-controller controls resistance heating, and can
be programmed up to 240ºC.

2.2.6. Control Panel

The control panel, containing the machine’s operating and adjustment
switches, is on the front of the main electrical cabinet.

2.2.7. Discharge module

The discharge module actuates like a flow valve.
When the system is operating normally, the
module stays closed, but if there is an electric
failure, the module will open immediately (the air
to maintain it closed has been stopped due to
the electric failure), so that pressure in the
hoses and guns will go to the tank.
The purpose of this module is to avoid
dangerous situations, due to residual adhesive
pressure, when electrical failures occur.

2.2.8. Level sensor:

The level sensor measures the adhesive level in the tank. With this, it
is possible to determinate acceptable high and low adhesive levels in
the tank. After adhesive reaches the top level, the sensor sends the
signal to stop filling. When it reaches the lowest level, it sends the low
signal and the vacuum feeder is automatically activated.

Adjustable level sensor

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 2.2.9. Vacuum Feeder:
The purpose of the vacuum feeder is to automatically fill the
tank with adhesive from an external container. This system is
controlled by sensors that automatically detect a need for
adhesive. It must be set as STATED in the settings section.
If the sensor detects a low level of adhesive, the electrovalve
opens and the vacuum feeder will supply adhesive until it
detects high adhesive level. If the adhesive does not load
before 200 seconds, an amber-colored light will blink and an
alarm will sound.
When the vacuum feeder lid is opened, it will deactivate. To
reactivate it, close the lid and lock it properly.

2.2.10. Other key elements

Pressure regulator:

This is the element used to raise or lower the pressure to the piston pump.
It is regulated dependent on the application. It includes an air filter to
prevent impurities entering the machine.

Bleed electrovalve:

This is the element that controls air passage to the pump. It is electrically
connected to the electrical control system. This allows the applicator to
adapt to the main machine speed.

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 2.3. TECHNICAL CHARACTERISTICS:

ELEMENT DATA
GENERAL

I 220V+N+T (50/60Hz), III 220V+T (50/60 Hz),

Power supply
III 380V+N+T (50-60Hz)

Hoses (max.) 6

Hydraulic pressure (maximum working) 2.8 – 80 bar (40 – 1138 psi)

Noise level 63 dB

Working temperature -10 – 50 ºC (32 – 122ºF) HR 20% to 80% non-condensed

CONTROL

Working temperature 15º - 230º C (59º - 446º F)

Temperature control precision +/- 0.5º C (+/- 1º F)

Type control PID Control

PUMP LOW FLOW HIGH FLOW

Pumping capacity (Kg./h) 35 100

Pump compression ratio 1:14 1:13

Pneumatic working pressure 0.5 to 6 bar

TANK EC4 EC8 EC14

Volume (litres) 4 8 14

Melting capacity (Kg./h) 4.2 7.9 13.5

Tank electrical consumption (W) 1700 2800 4000

VACUUM FEEDING

Compressed air input 2 - 6 bar (29 up to 87PSI) - 350 I/min (92 gallon/minute)

Hose length 3m (43,5PSI)

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 2.4. DIMENSIONS:

2.4.1. GENERAL DIMENSIONS (MODEL TYPES A/B):

F

A
D
F
C F
F
E
F

B
F
Dimensions (mm) EC4 EC8 EC14
A 307 307 367
B 583 658 658
C 532 532 592
D 631 631 691
E 340 340 398
F 0 51 51

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 2.4.2. GENERAL DIMENSIONS WITH VACUUM FEEDING
(MODEL TYPE C):

D
F

A
F
E
C
F F
B
F Dimensions (mm) EC4 EC8 EC14
A 307 307 367
B 583 658 658
C 532 532 592
D 662 662 724
E 296 296 358
F 0 51 51

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 CHAPTER 3
MACHINE INSTALLATION

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 3.1. INTRODUCTION:
This chapter explains how to install the machine correctly.
WARNING: The operations described in this chapter should be
performed by qualified personnel, following safety instructions.
3.2. TRANSPORT:
The unit is supplied packed in a cardboard box.
Remove the top and sides to unpack it.

Unpack carefully to prevent machine damage. Inspect the equipment

for damage caused during transport.

3.3. INSTALLATION REQUIREMENTS:

Install the following equipment, leaving enough space for access
during operations.

Avoid extreme temperatures (below -10°C and above +50 C).

Avoid installing the equipment where there are drafts. If this is not
possible, the guns will need protection; if the temperature falls rapidly
they may not work properly.

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 3.4. MECHANICAL INSTALLATION:
Mechanical installation includes the following:
 Positioning the equipment.
 Connecting the hoses.
 Connecting the Vacuum feeder (model type C only)
Positioning the equipment:
Remove the equipment from the box, and position it according to
installation requirements (chapter 3.3)
Connecting the hoses:
Proceed as follows:
Make sure the equipment is depressurised before connecting the
hose. Set the air pressure regulator to zero and activate valves to
bleed pressure. Heat the machine to melt any adhesive that may be
present.
Remove the appropriate hose outlet plug from the manifold (see
below):

Anti-vibration
mounts

AIR ENTRY

ALTERNATE AIR ENTRY

MINI FILTER

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 Connect the hoses from right to left. Failing to do so will create a dead
spot where carbon deposits accumulate, increasing nozzle blockage
problems.

For the hydraulic connection: If the unit is full of adhesive, heat the tank
before removing the manifold cap.

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 Hose Installation:
Never bend the hoses to a radius less than 150 mm.

YES

The hoses should not be in contact with very wide, cold surfaces.

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 Do not install hoses side-by-side; leave a minimum separation (25 mm)
between them so heat can dissipate.

YES

Do not cover the hoses. If it is necessary to do so, leave ventilation

holes for heat dissipation.

YES

Do not install hoses with tight clamps.

YES

Installing the Vacuum Feeder:

Proceed as follows to connect the vacuum feeder:
1. Remove the vacuum feeding kit from the packaging. This kit
includes all of the tubes needed to install the feeder, as well as other
components to be explained later.

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 2. Use a clamp to connect the lower tube to the part of the chimney
(located above the tank cover) reserved for the feed outlet, as shown in
the picture.

Secure with a
clamp

3. Connect the air line (provided in the vacuum feeder kit) to the flow
regulator, visible on the upper part of one of the sides, as shown in the
picture.

Flow regulator

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 3.5. PNEUMATIC INSTALLATION
Connect the air line to the regulator. Make sure the air-connection line
has the capacity necessary for proper pump operation.

Air inlet

Service
wires

3.6. ELECTRICAL INSTALLATION

3.6.1 Routing Low-Voltage Leads
Warning: Failure to observe could result in personal injury, death, or
damage to equipment.
When routing low-voltage leads, follow these guidelines:
 Do not route low-voltage leads in the same conduit as wires
carrying a high-current load.
 Do not route low-voltage leads adjacent to, or across wires
carrying a high-current load. If low-voltage leads must cross or
run parallel to wires carrying high current, keep the leads at
least 6" (152 mm) from high-current wires.
 Do not splice or solder leads.
 Trim leads to the required length. Leads should be only as long
as necessary for installation.
 All wiring should be in conduits or wireways.

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 3.6.2 Connecting the Electrical Power
Warning: Electrical connections should be made only by
experienced service personnel! Failure to observe could result in
personal injury, death, or damage to equipment.
When connecting the supply of electrical power, follow these
guidelines:
 Connect the unit to a “clean” supply of electrical power. Use a
dedicated circuit if possible.
Caution: If a dedicated circuit is not available, do not connect the
unit to a circuit that supplies high-amperage equipment—use
another circuit such as a lighting circuit. Otherwise, equipment may
not function properly.
Warning: The external power source must be turned off before
connecting power to the unit! Failure to observe could result in
personal injury, death, or damage to equipment.
Only experienced service personnel should connect power to the
unit! Failure to observe could result in personal injury, death, or
damage to equipment.
The use of an earth-leakage or ground-fault power breaker is
recommended with this unit. This unit must be earthed or grounded.
Failure to observe could result in personal injury, death, or damage
to equipment.
The EC hot melt unit can be set up to use one of the following power
sources:
Power Connector Voltage Connector
Terminals Plug Label
Incoming Electrical Service
Part No. / Part No. /
A B C D PE
Color Color

380VAC 3-phase with 3/N/PE AC 029XX437 782XX262

L1 L2 L3 N PE
Neutral (4 wire service) 400/230V Blue Blue

200 to 240VAC 3-phase w/o 3/PE AC 029XX435 782XX260

L1 L2 X L3 PE
Neutral (3 wire service) 200-240V Black Black

200 to 240VAC 1-phase w/o 1/PE AC 029XX436 782XX261

L1 X X L2 PE
Neutral (2 wire service) 200-240V White White

The system should be connected via a suitable type of flexible conduit

from a supply isolator and ground-fault power breaker. The supply
should be clean and free from excess interference from other
machines.
Warning: You MUST follow these steps to connect power to the unit,
or personal injury and/or damage to the unit may result.
1. Open the electrical enclosure door.
2. Route the power cable through the cable clamp in the
chassis of the unit. The power cable must meet the
minimum requirements given in the chart above.

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 3. Referring to the chart above, locate the appropriate voltage
selector plug and power connector label corresponding to
the incoming electrical service.
4. Adhere the appropriate power connector label to the power
connector on the 12 zone board (see illustration).
Warning: The label must be correctly oriented on the power
connector.
5. Remove the power connector from the 12 zone board and
connect the power cable leads to the power connector
terminals as shown in the chart above.
6. Install the appropriate voltage selector plug into the
connector marked J15 on the 12 zone board (see
illustration).
7. Plug the power connector into the 12 zone board (see
illustration).
8. Verify that all connectors are fully seated and the power
connector terminal screws are secure.
9. Close the electrical enclosure door.

029XX435
240V 3Ø

POWER INPUT
240VAC, 1 PHASE
240VAC, 3 PHASE
400/380, 3 PHASE

40A MAX.

12 Zone Power Board

3.6.3 Input/Output Connections

The Input/Output connection interface is on the J-23 & J-24 terminals,
on the bottom of the CPU Board. The CPU Board is located directly
behind the Keypad.
There are four opto isolated inputs rated for +24VDC @ 15mA each,
that can be programmed by the user for a variety of options. See the
chart below.

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 There are also, four dry contact user selectable outputs rated for 250V
@ 5A each.

CPU Board Showing Input & Output Connectors

Inputs and Outputs can be programmed for the following functions:
Input and Output Functions
Inputs 1-4 (523) Outputs 1-4 (524)
Disabled Disabled
Hose and Gun #1 thru #6 On/Off Setback On
All Heaters On/Off Alarm
Pump On/Off Ready & Pump On
Auto Setback System Ready
Setback Power On
External Level
Internal Level
The diagrams show the functions of the CPU Board Connectors and
Wiring Connections.

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 CHAPTER 4
MACHINE ADJUSTMENT

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 4.1. INTRODUCTION:
The following adjustments should be made before the machine is
switched on or while it is working. They will ensure that the machine
works properly and safely.
4.2. TEMPERATURE CONTROL:
4.2.1. Introduction:
The temperature of the tank, hoses and guns in the Hot – Melt
application equipment is regulated by a digital electronic device
controlled by microprocessor. It’s equipped with calendar-clock to
connection control.
Regulation is proportional, with factory-set parameters for the separate
heating inertias of the tank, hoses and guns.
The temperature is measured by the RTD sensor on each of the
heating devices. These can be programmed individually and on each
output channel between 14º - 240º C (57,2ºF – 464ºF).
The range ability (measurement range) of the controller is between -
20ºC(-4ºF) and 240ºC(464ºF).

Bellow -20ºC(-4ºF), the equipment will display a probe short circuit

fault. Above 220ºC(454º), the display report an open probe fault.
4.2.2. Brief description of how the unit operates:
With menus to access the parameter programming as well as the main
machine operating permissions, alarms and diverse work functions that
will be described later on, the equipment regulates the temperature of
the resistors connected to the various dual hose-gun channels (2, 4 or
6 depending on the model) and those connected to a special channel
that heats the tank.
The control panel displays the equipment operating data as well as the
alarms generated in the probe signals. The LEDS also display the
status of the heat resistor regulator outputs, pressure pump, excess
temperature alarms, safety and maintenance required status.
Preheat function:
Given that the warmed adhesive tank has greater inertia than the
warmed peripherals (hoses and guns), the latter will get to the
programmed temperature faster. This quick warming process has an
enormous effect on the resistors and insulator. At the same time, this
process creates excessive pressure which flows through the hoses.
To correct this situation, the equipment features a pre-warming system
which on the one hand, will heat the peripherals sequentially while the
tank warms at normal speed. In other words, when the tank reaches a
temperature of 41ºC below the programmed temperature, the pre-
heating system will move on to the hoses; and when the tank reaches
a temperature of 14º below the programmed temperature, the systems
moves on to the guns.

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 4.2.3. Description of the control panel:
4.2.3.1 Keyboard:
The unit control panel has 11 control keys that provide access to the
programme menus and general operating processes.

6 3 7 21 20 23 22 13 1 2

4
9

10

16 17 14 15 18 19 12 11

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 Comp. Name Description
1 Heat On / Off LED Green when the unit is on and orange when in
Standby mode.
2 Heat On / Off Puts the unit in or out of Standby mode.
3 Tank Zone LED Green when the tank is warming and red when
there is an alarm.
4 Hose Zone LED Green when the hose zone is on and red when the
zone is on alarm.

5 Gun Zone LED Green when the gun zone is on and red when there
is an alarm.
6 System Ready LED Green when the system reaches the programmed
temperature.

7 Alarm LED Red when an alarm goes off.

8 More Button Increases the value of the selected parameter
9 OK Button Enter or exit a screen where the selected field can
be edited
10 Right Arrow Button Moves to the right through editable fields on the
selected menu

11 Less Button Decreases the value of the selected parameter

12 Left Arrow Button Moves to the left through editable fields on the
selected menu

13 Settings Screen Displays the menu screens

14 Configuration Button Displays the configuration screens
15 Configuration LED Green when the equipment enters the configuration
screen
16 Temperature Button Displays the temperature screens
17 Temperature LED Green when the equipment enters the temperature
screen
18 Release Control Button Disabled
19 Release Control LED Disabled
20 On/Off Cooling/Regression Puts the equipment in or out of Cooling/Regression
Button mode. (This mode reduces the temperature so that
the adhesive stays soft, but not melted when not in
operation so it doesn’t overheat)

21 On/Off Cooling/Regression Yellow when the unit is in Cooling/Regression

LED mode.

22 Clock On/Off Button Turns the timer function on or off

23 Clock On/Off LED Green when the timer function is activated.

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 4.2.3.2 On/Off Switch and Standby Mode:
The On/Off switch is at the bottom of the front casing (see photo).

Power On/Off
Switch

The Standby button controls the electricity to the Hot Melt unit. Press
the Standby button. The screen will turn on and the LED will be green
indicating that the unit is on. When the Standby button is pressed
again, the screen will go blank and the Standby LED will be orange
indicating that the unit is in Standby mode.

When the unit is in Standby mode,

the internal timer begins working.
The timer will turn the unit off and on
according to the programmed shifts.
However, if the switch is turned off,
the internal timer will not work nor
will the shifts.
Heat
button
On/Off

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 4.2.3.3 Vacuum Feeder:
Amber light: when it blinks, this means a low level has been detected in
the tank for a programmed time of 200 seconds. A buzzer will go off for
warning. It can be reset by pressing the Enter key, but the amber
light will continue to blink there is an adequate adhesive level in the tank.

4.2.3.4 Navigation
The navigation symbols at the top of the screen indicate that additional
menus are available. Use the following buttons to navigate:

4.2.3.5 Settings
The information displayed can be edited. Use the appropriate buttons
(depending on the symbols displayed) to navigate through the menus.

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 4.2.3.6 Entering Passwords
The password is required to prevent unauthorised access to the
programming unit. To enter a password:

Introduce the
password

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 4.2.3.7 Programming Temperatures

Press the temperature button (if the temperature LED is not green) to
display the first temperature screen.

Temperatura
button

4.2.3.8 Temperature Screens

The tank temperature screen displays the current and programmed
temperature. Output 1 and output 2 temperatures alternate on the
screen to the right.
Current hose
Current tank
temperature
temperature
Current gun
temperature

Temperatura programada del depósito

Press the temperature button repeatedly (or use the navigation keys)
to select the desired temperature shown on the screen.

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 4.2.3.9 Tank temperature

END

4.2.3.10 Hose / Gun temperature

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 To programme hose/gun 2, repeat the same process as described.

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 4.2.3.11 Temperature Programming
It’s relative to the temperature established for each zone. The system
indicates that it is ready (and the System Ready LED turns green)
when each zone reaches the programmed temperature. The system
gives permission. The permission activates the pump. This prevents
the pump from activating before the adhesive melts.
See the adhesive technical data sheet to find the melting point.
The pre-programmed temperature must be set to at least -5ºF (-3ºC). If
set too close to the point (for example, -1ºF), the pump will stop
momentarily until the temperature is reached again.
The parameter range goes from 0ºF to 36ºF (0ºC to 20ºC) and the
manufacturer preset value is 5ºF (3ºC).

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 4.2.3.12 Temperature unit
The equipment has the option to choice between two temperature
units.

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 4.2.3.13 Beacon output
The control board has two alarm outputs for beacon of 24VDC. The alarm
options to have each one of them are:
- Low level
- Zone fault
- Ready
- Pump on
- Setback on

X7

X1

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 4.3. OTHER ADJUSTMENT

4.3.1 Ready Delay Time

When the Ready Delay Time is used, the System Ready LED will
illuminate a preset time after all of the zones reach their respective
temperature setpoints minus the System Ready Temperature Offset.
This feature allows the adhesive in the system to heat for an additional
period of time before the piston pump is enabled.
Once the zones have reached the System Ready Temperature, the
time remaining before the system is ready is displayed on the status
bar at the bottom of the screen.
The ready delay range is 1 minute to 120 minutes. The default factory
setting is ON at 15 minutes.
This parameter can be accessed in Password Level 2 or higher.

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 4.3.2 Over Temperature Alarm
The Over Temperature Alarm is relative to the temperature setpoint of
each zone.
The over temperature alarm tolerance is the number of degrees that
any zone can heat above its temperature setpoint before triggering an
over temperature alarm.
If any zone goes into Over Temperature Alarm, the heaters of the
affected zone are automatically shut off.
The over temperature alarm tolerance range is 9°F to 108°F (5°C to
60°C). The factory default setting is 45°F (25°C).
This parameter can be accessed in Password Level 2 or higher.

X4

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 4.3.3 Under Temperature Alarm
The Under Temperature Alarm is relative to the temperature setpoint of
each zone.
The under temperature alarm tolerance is the number of degrees that
any zone can cool below its temperature setpoint before triggering an
under temperature alarm.
If any zone goes into Under Temperature Alarm, the heaters of the
affected zone will remain on to compensate for the drop in
temperature.
The under temperature alarm tolerance range is 9°F to 108°F (5°C to
60°C). The factory default setting is 27°F (15°C).
This parameter can be accessed in Password Level 2 or higher.

X5

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 4.3.4 Maximum Temperature
The Maximum Temperature setting is the maximum value for the
setpoint of any zone.
The maximum temperature range is 32°F to 446°F (0°C to 230°C).
The factory default setting is 446°F (230°C).
This parameter can be accessed in Password Level 3 or higher .

X6

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 4.3.5. Setback Temperature
The setback feature is used to reduce the temperatures of all zones by
a given temperature differential to allow the hot melt to remain soft but
not molten during periods of inactivity.
The setback temperature differential is relative to the temperature
setpoint of each zone.
The setback temperature differential range is 45°F to 342°F (25°C to
190°C). The default factory setting is 90°F (50°C).
This parameter can be accessed in Password Level 2 or higher.

X2

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 4.3.6. Automatic Setback Timeout
If the Automatic Setback Timeout input is enabled and the unit does
not see an external input within the automatic setback timeout period,
the unit will automatically go into setback.
The Automatic Setback Timeout feature is used only in conjunction
with the Automatic Setback External Input. It is not used in manual or
scheduled setback modes.
The automatic setback timeout range is 1 minute to 120 minutes. The
default factory setting is 30 minutes.
This parameter can be accessed in Password Level 2 or higher.

X2

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 4.3.7. Sequential Start - Hose
The Sequential Start function allows the hoses to begin heating after
the tank reaches a specified temperature offset below the setpoint
temperature. This feature is used to reduce adhesive degradation
caused from heating adhesive in the hoses for long periods while
waiting for the tank to reach temperature.
The sequential start range is 0°F to 450°F (0°C to 250°C). The default
factory setting is OFF.
This parameter can be accessed in Password Level 2 or higher.

X2
X2

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 4.3.8. Sequential Start – Gun
The Sequential Start function allows the gun to begin heating after the
tank reaches a specified temperature offset below the setpoint
temperature. This feature is used to reduce adhesive degradation
caused from heating adhesive in the gun for long periods while waiting
for the tank to reach temperature.
The sequential start range is 0°F to 450°F (0°C to 250°C). The default
factory setting is OFF.
This parameter can be accessed in Password Level 2 or higher.

X2
X2

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 4.3.9. Input and output
Peripherals are user selectable inputs and outputs that can be
triggered by a remote signal. Inputs include pump enable, heater
enable, and setback. Outputs include alarms and system ready signal.
See below for other choices.
See “Connections” in Section 4 - Installation for a detailed description
of these features.
This parameter can be accessed in Password Level 3 or higher (see
Section 8 - Password Levels).

X3

X3

Sub Menu Choices:

Input 1-4 Output 1-4

Disabled Disabled

Setback System Ready

Auto Setback Ready & Pump On

Pump On/Off Alarm

Tank On/Off Standby

Tank Hose-Gun 1 Inside level sensor

Tank Hose-Gun 2 External level sensor

Tank Hose-Gun 3

Tank Hose-Gun 4

Tank Hose-Gun 5

Tank Hose-Gun 6

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 4.3.10. History
The Fault History Screen keeps a log of all faults that occur with any
zone.
The Change History Screen keeps a log of all parameter and setting
changes.
The Fault History and the Change History are cleared when the unit is
turned off.

X3

4.3.11. Diagnostics

The Diagnostics Screen shows the current software version as well as

the current temperature and status of each zone.

X3

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 4.3.12. Clock and 7-Day Timer

The Clock sub menu is used to set the current day and time and to
setup shifts with on, off, and setback times/temperatures that are
automatically run by the internal clock.

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 4.3.13. Shift Times / Cooling-Regression Times

From this screen, use the Up/Down

Buttons and the Right/Left Buttons to
go through and adjust the shifts and
setback times as desired. See the
next page for an in-depth review.

4. 3.14. Programming Shifts

Three shifts can be programmed into the unit. Start shift, end shift, and
setback times can be pre-programmed for each shift to reduce
downtime. Make certain all desired temperatures are set first (see
Programming Temperatures, this section).
First program the time the heaters will be on, off, and in setback for
each of the three shifts. Use the Right/Left Arrow Buttons to move
through the times and shifts and the OK Button to get a thumbwheel to
set the times and turn on the setback feature with a “switch” on the
thumbwheel. (The heaters can be set with or without using the setback
times.)

Set the start, stop, and setback times for all shifts. Leave the unused
shifts/times blank
(-- --).

Shift (A, B, or C)

Setback Start/Stop
Times (for the shift
Heaters Start/Stop
shown above)
Times
(for the shift shown
above)
This screen indicates that for shift A, the resistors will
begin at 7:00 AM until the programmed temperature
(previously established on the temperature screen) and
will turn off at 3:00 PM, with all the heaters reaching the
cooling/regression temperature before 11:30 AM and
12:00 PM.

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 Heaters Start/Stop Shift (A, B, or C)
Times
(for the shift shown
above)
Setback Start/Stop
Times (for the shift
shown above)

This screen indicates that for shift C,

nothing will be activated as there is no shift
C in operation.
.

After setting all shift times, program the shifts that will be enabled for
each day of the week. The Up/Down Arrow Buttons cycle through the
different combinations of shifts, and the Left/Right Arrow Buttons cycle
through the days of the week.

This screen indicates that three shifts (A, B,

C) will be operating on Monday.

This screen indicates only the A shift will

be operating on Monday.

After configuring all the shift times

(previous page) and programming the
shifts that are to operate on each day of
the week (current page), make sure the
timer function is on and is properly
configured.

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  Moving Through the Shift Time/Day Screens

X2

X2 X4

X4

Continue using the Right/Left, Up/Down and OK

buttons to configure all of the shift times and which
shifts will operate on which day. Activate the timer
and the unit will be ready to function with the shift
times established.

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 Clock key

Press the Clock Button to enable all

shift settings (the 7-Day Timer).

4.3.15. Restoring Factory Default Settings

To restore the factory default settings, follow these steps:

Restoring the factory default settings will permanently

1. Switch off power to the unit.

2. Power the unit back up while pressing and holding the Setup
Button and the OK Button on the keypad. The buttons can be
released once the start-up screen appears.erase changes
made to any parameter or setting!

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 4.3.16. Language

Continued on next page.

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 4.3.17. SYSTEM/PUMP READY TEMPERATURE OFFSET
The System Ready Temperature is relative to the temperature setpoint
of each zone. The system is ready (and the System Ready LED
illuminates green) when all zones reach their respective temperature
setpoints minus the System Ready Temperature Offset.
The system ready signal enables the pump motor. This prevents the
pump motor from being activated before the adhesive in the pump has
softened.
Consult the adhesive data sheet to find the softening point
temperature.
The System Ready Temperature Offset must be set to at least -5°F (-
3°C). If it is set too close to the setpoint (for example, -1°F), the pump
motor will stop during momentary drops in temperature of any zone
until the zone is again within 1°F of the setpoint.
The System Ready Temperature Offset parameter range is 0°F to 36°F
(0°C to 20°C) and the default factory setting is 5°F (3°C).
This parameter can be accessed in Password Level 2 or higher.

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 4.3.18. FILTER CHANGE TIMER
The Filter Change Timer Screen is a count down timer that shows the
time remaining on the currently installed glue filter. When the counter
gets down to zero (0), an alarm can be sounded and the filter needs to
be changed or cleaned. Once the filter has been serviced, the timer
can be reset for a user set time of up to 2000 hours.

We have to program Beacon 2 (see page 50) to Alarm, in this way the
screen will show a message when we should change the filter.
After replacing the filter, we should reset the counter.

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 4.3.19. AUTOMATIC PUMP MODE
When the Automatic Pump Mode is on, the pump will automatically
start when the system reaches temperature and the System Ready
LED illuminates.
If the Ready Delay Time is enabled and set for a preset time (15
minutes), the pump will not start and the unit will not be ready until 15
minutes AFTER the control has gotten to temperature.
The factory default setting is OFF.
This parameter can be accessed in Password Level 2 or higher.

4.3.20. POT FILL MODE

In this mode of operation, melted glue is pumped into an external pot
when the external lever control falls below a set level. The external
level control is wired to the external level input on the CPU, J6.
In this mode, the pump turns on ONLY when it receives a signal from
the external level input, and the unit is ready. Normal pump operation
is ignored in this mode. The automatic pump mode should be ‘On.’
Pattern control and valves are typically not used in this operating
mode.
On-delay time is set by the operator to delay pump activation ‘x’
seconds after the external level input calls for glue.
After the delay time expires, the pump will turn on and run until the
external pot level triggers the level sensor that the pot is full, and the
pump then turns off.
This parameter can be accessed in Password Level 2 or higher

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 4.3.21. LEVEL SENSOR SETUP
ADJUSTING THE LEVEL SENSOR

To adjust the probe, follow the procedure:

Turn off and turn on the unit.

Find the electrical box of the probe into the unit.

Disable the feeder opening the tank lid. Feeder alarms may activate
during the adjustment procedure.

Drain the adhesive in the tank until this one be empty.

Remove the screw of the potentiometer.

IF THE LIGHT IS RED (NEGATIVE DETECTION):

 Turn the screw clockwise just until the light changes to RED-
YELLOW (flashing). Observe that after three seconds of
flashing, the light is green.
 After that, turn the screw 2 turns counterclockwise.

IF THE LIGHT IS GREEN (POSITIVE DETECTION):

 Turn the screw counterclockwise just until the light changes to

red.
 Now, turn carefully the screw clockwise just until the light
changes to RED-YELLOW (flashing). Observe that after three
seconds of flashing, the light is green.
 After that, turn the screw 2 turns counterclockwise.

Assembly the unit and test the working.

In order for the level probe to be calibrated properly, it must be done

with the tank completely empty, or with the least amount of adhesive
possible.

For more information on the level sensor, call our toll-free

assistance number.
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 4.3.21.1 Internal Level / External Level
There are two types of level control typically used with the Units, an
internal level sensor and an external level sensor. The internal level
sensor can be used inside the tank of the unit to trigger an auto-fill
device (see hopper feeder below), or an alarm state. The external
level sensor is used for pot fill mode (see Pot Fill Mode). The delay for
these sensors to activate can be set in this screen.

4.3.21.2 Hopper Feeder – Internal Low Level Detection

The Hopper Feeder option is used to refill the hot melt control’s tank
with fresh adhesive when the tank level drops below the set level
sensor. This eliminates the need for the operator to manually open the
tank lid and add adhesive to the tank.
The internal low level sensor is mounted in the hot melt control tank so
that when the adhesive drops below the sensor, a feeder valve is
energized to feed glue into the tank to be melted. This feature has a
safety door switch that will disable the feeder if the tank door is
opened. The door switch, internal level sensor and feeder valve need
to be connected to the CPU board, to operate properly.
The internal low level sensor plugs into J15 on the CPU board. This
feature does not need to be set up in the software. If the Hopper
Feeder and it’s components are connected as described above, the
valve will energize when the door switch is closed and the sensor calls
for glue.
Door Switch
The tank lid door switch will be wired to J14 on the CPU. The switch
must be in the closed position for the feeder valve to energize and add
adhesive to the tank. When the tank lid is opened, the feeder valve will
turn off.
Feeder Valve Operation
The feeder valve is a dedicated +24VDC @ 0.5A output that will
energize when the internal low level sensor calls for glue and the door
switch is closed. This is J17 on the CPU board; pin 1 is +24V, pin 2 is
ground.

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 4.3.22. ADJUSTING THE OUTPUT PRESSURE:
The adhesive output pressure is controlled by the pressure regulator
and electrovalve unit. It is located at the front of the unit.
Pressure gauge:
This is the element that indicates pressure, in bar and psi, at which the
pneumatic pump and the compensating valve are operating.

Pull the knob out to set and push it down to lock.

Set the pump pressure to 40 Psi (2.5 bar)
The pump will operate and pressurize the system.

Adjustment
Knob

This pressure is a starting point setting. You may need to change

the pressure setting, depending on application.
The ratio between pneumatic and hydraulic pressure is 1:14. This
means that, for each pneumatic bar indicated on the pressure gauge,
there will be 14 hydraulic bar at the pump.

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 4.3.23. MELTON-RECHNER LEVEL PROBE

This is a capacitive level probe that controls the vacuum feeder

system.

It detects the level of adhesive and orders activation. There is a three-

second disconnect delay when going from a low to a high level, in
order to ensure that the system performs minimum, effective loads.

Visual Indications:

Green Light  Full; Output not Red-Yellow blinking light Full;

activated Output activated, delay at
disconnect

Red Light  Empty; Output

activated
 Green Light: Positive Detection.

The probe interprets that the tank is full. It does not activate the
output that orders the feeder to load adhesive.

 Red Light: Negative Detection.

The probe interprets that the tank is not full and orders the
adhesive feeder to be loaded.

 Red/Yellow Intermittent Light: Positive Detection,

Disconnect Delay.

After switching from a negative detection to a positive detection,

the probe maintains the feeder load signal for three seconds. This
ensures a minimum effective load. This delay does not apply to the
initial transition; in other words, when the probe is turned on.

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 NOTE: As a last resort, if you need a longer delay because of a more
than 10 meters length of the vacuum and air pressure and low flow
conditions, could be increased by an external timer.

PRECAUTIONS:
 Do not modify the probe position; the correct height is obtained
by securing it as closely as possible to the end of the probe.
 The high-level detector must be situated at the level where the
adhesive covers the tip of the probe slightly. If the probe is re-
calibrated to the level with the probe fully covered, there may be
a risk of adhesive overflow and high air filter wear due to
adhesive splash during the filling process.
 It is necessary to secure the reference conductor connection to
the ground of the unit (probe red cable). Its disconnection could
cause that the system becomes unstable.

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 CHAPTER 5
OPERATION

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 Warning: It is recommended that the Machine Adjustment Section is
read, understood, and followed before attempting to read this
Section and operate the Universal Temperature Control unit.
OTHERWISE, DAMAGE TO EQUIPMENT AND PERSONAL INJURY
COULD OCCUR.

5.1 START THE UNIT

To start the unit, do the following:
1. Toggle the Power On/Off Switch to the “On” position to power up the
system.

Standby Key

Power On/Off Switch

Note: The Standby LED will illuminate green when the power to the
unit is on. If the Standby LED illuminates orange, the unit is in
Standby Mode. Press the Standby Button to turn the unit on.
Once the unit has completed its start-up sequence, it will turn on the
heaters in the tank and all active hoses and guns. The heater’s
corresponding Zone LED will illuminate green when the heater is on.
Warning/Alarm LED Setback On/Off Key & LED
System Ready LED Setback On/Off Key & LED Standby Key & LED

Tank Heater LED

Navigation Keys

Hose Zone LEDs Valve Menu Key

Setup Key & LED
Gun Zone LEDs
Heater (temperature) Menu Key & LED

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 5.2 TEMPERATURE
The tank temperature screen will show the actual tank temperature and
the tank temperature setpoint. For operator convenience, the right side
of the display screen alternately displays the Hose & Gun temperatures
(see the Machine Adjustment section for setting zone temperatures).
Press the Heater Key (or use the Navigation Buttons) to cycle through
the temperature screens until you reach the desired screen.

5.2.1 Setpoint and Actual Temperature

Warning/Alarm LED
System Ready LED Actual Temperature

Setpoint Temperature
Tank Heater LED

Hose Zone LEDs Gun Zone LEDs Heater (temperature) Menu Key & LED

5.2.2 Temperature Status LEDs

The Control Panel contains LEDs that indicate the status of each
heated zone. When the zone is in warm-up mode, the zone LED will
illuminate green and stay on continuously. Once the zone reaches its
setpoint temperature, the LED will blink on and off indicating that the
heaters are switching on and off to maintain the setpoint temperature.
If the LED illuminates red, it indicates a fault for that zone. The status
bar will provide a more detailed explanation of the fault. Also, if the
fault triggers a temperature alarm, the Temperature Alarm LED will
illuminate red (see the Machine Adjustment section, “Over
Temperature Alarm” and “Under Temperature Alarm,” for details).

System Ready LED Warning/Alarm LED

Tank Heater LED

Hose Zone LEDs Gun Zone LEDs

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 If the temperature set points are not correct or need to be adjusted,
select the appropriate zone and adjust the temperature setting (see the
Machine Adjustment section for setting temperatures). The system is
ready (and the System Ready LED illuminates green) when all zones
reach their respective temperature setpoints minus the System Ready
Temperature Offset.
The system ready signal enables the pump motor. This prevents the
pump motor from being activated before the adhesive in the pump has
softened.
Consult the adhesive data sheet to find the softening point temperature
of the adhesive.

5.3 CLOCK ON/OFF

The Clock must be On (Clock LED illuminated green) for all of the
programmed scheduled shifts to run, unless the unit will be operated
manually (no pre-programming).
To turn the clock on or off, press the Clock On/Off Button. When the
clock is on, the Clock LED illuminates green. See the Machine
Adjustment section for detailed information on setting the clock.

Clock On/Off Key & LED

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 5.4 SETBACK
The Setback Temperatures are pre-programmed (see “Setback
Temperatures”, Machine Adjustment section). When setback times are
set (See “Clock - Shift Times/Setback Times,” Machine Adjustment
section) and the clock is on, the unit automatically enters setback
during each shift as programmed. If, however, an unscheduled break
occurs, the Setback Button can be pressed (Setback LED illuminated
yellow) to put the unit into setback manually. To exit setback mode,
press the Setback Button again (LED not illuminated). The setback
time and temperature can be set manually by using the arrow
navigation keys to access the temperature and time set screens and
entering values on these screens (see the Machine Adjustment
section).
Setback On/Off Key & LED

5.4.1 Automatic Setback

Automatic setback can be programmed through one of the remote
inputs from the input screen. When an input is set for Auto. Setback,
AND the Auto Setback Timeout is enabled, the control will
AUTOMATICALLY go into set back if the input has not been triggered
for the timeout set by the user.
For instance, if a valve fire signal is connected to Input #2, Input #2 is
programmed for Auto. Setback and the Auto. Setback Timeout is
enabled and set for 30 minutes, the control will automatically go into
set back if the valve has not been fired for 30 minutes. Each valve fire
within that 30 minute time period will reset the Timeout timer to start
back at 30 minutes. The setback symbol will start to flash 2 minutes
prior to the control going into setback.

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 5.5 POT FILL – EXTERNAL LOW LEVEL DETECTION
Pot Fill is used when the hot melt control is being used to heat the hot
melt adhesive and remotely fill a pot. Using the Pot Fill mode, the hot
melt control can precisely monitor the pot level and fill the pot on
demand from the low level sensor mounted in the pot.
For setup details, refer to Section 4.

5.6 HOPPER FEEDER – INTERNAL LOW LEVEL DETECTION

The Hopper Feeder option is used to refill the hot melt control’s tank
with fresh adhesive when the tank level drops below the set level
sensor. This eliminates the need for the operator to manually open the
tank lid and add adhesive to the tank.
For setup details, refer to Section 4.

5.7 BEACON ALARM

The Beacon / Alarm output connector is provided as a dedicated
+24VDC @ 0.5A output for a visual or audio alarm. This can be set up
to alert the operator of one of 4 fault conditions (see Section 5 – Setup
for description).
The installer can connect the “+” lead of the alarm to Beacon 1 (pin 3)
and the “-” lead to GND (pin 1) of J30 on the CPU board. When the
Beacon / Alarm screen is set up for an alarm condition, the +24VDC
output will enable the alarm device to signal that the condition on the
control has been met (eg. Low Level).

5.8 EXTERNAL INPUT

The External Input can accept 230VAC, 24VAC or +24VDC to reset the
Setback Timeout when the control is in Auto. Setback. This is used in
special applications and the programmable inputs should be used for
this feature (see Automatic Setback, above). The pin out for this
connector on the CPU board is critical (see Section 4 for this connector
location).

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 5.9 FILLING THE TANK

Before filling the tank, put on goggles, gloves and long sleeves to
avoid possible burns from splashes of hot adhesive.
 Models type A / B (Without Vacuum Feeding):
1. Ensure that the tank is clean and free of foreign particles.
1. Fill the heated tank with the hot-melt material, to a maximum of
10mm below the edge of the tank.

Filling tank

2. Close the tank cover immediately after filling the tank.

 Models type C (With Vacuum Feeding):

1. Make sure that the tank is clean and free of foreign
particles.
2. In this case, the equipment is fed automatically by the
installed vacuum feeder. The sensors detect when the tank
needs adhesive, as well as when it is no longer needed.
This way, the person handling the equipment does not have
to worry about anything except making sure the vacuum
feeder is always supplied with adhesive, in the container
used to hold it. Said container must be placed near the
equipment so the tubes comprising the vacuum feeder are
not pulled, which might cause damage.

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 Air tube
Vibrator

Suction
tubes set

Input for the

pellets

Warning: When you wish to check the tank adhesive level, you can
do so while the equipment is loading, without any problem, as the
micro (sensor) installed on the cover allows the equipment to detect
when the cover is opened and stops the vacuum feeding. Once the
cover is closed, it will begin loading again automatically.

Note: Never operate the applicator if the tank is empty. If the quantity
of hot-melt material is very small, the adhesive may degrade, leading
to the carbonisation of the HOT-MELT material, and the formation of
deposits inside the unit. This may lead to unnecessary downtimes
later on.

Emptying the Tank:

Before emptying the tank, put on a face shield, gloves and long-sleeve
shirt to prevent possible burns caused by hot adhesive splashing.
1. Warm the equipment to the working temperature.
2. Reduce the air pressure to zero.

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 3. Eliminate system pressure by releasing the manual guns or
opening the bleed valve.
4. Place an appropriate container under the manifold to collect
the adhesive.
5. Unscrew the purging valve with a screw driver.
6. Increase the pressure gradually until adhesive flows through
the purging valve and the manifold, and the tank empties.
7. Changing the filter and seals on the dismantled parts is
recommended once the tank is empty.

MANIFOLD

DRAIN PLUG
CONTAINER

Bleed Process:
The bleed process is done to sweep away small crystallisations that
may be produced in the filter, and to depressurize the system.
Before purging the filter, put on goggles, gloves and a long-sleeve shirt to
prevent possible burns caused by hot adhesive splashing.
1. To purge the filter, the applicator must be at the operating
temperature.
Tip:
Bleed the 2. Reduce the air pressure of the applicator to “0”.
equipment once
3. Place a container below the equipment to collect the
a week, or every
adhesive from the manifold.
40 hours of
operation.
4. Open the bleed valve with a screw driver..

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 5. Increase the air pressure until the adhesive flows through
the bleed hole and leaves the filter free of any
contaminating particles.

6. Close the bleed valve with a screw driver.

7. Return the pressure to the appropriate working pressure.

5.10 STOPS:
There are two cases:
Pump stop:
If you wish to stop pumping, you must turn the pressure regulator to 0.
The temperature control will maintain the equipment temperature.
If the stop is to be for an extended period, activating the Setback
function is recommended. (See Section 4, 4.18 and Section 5, 5.5)
Total stop:
To power down the equipment, switch the unit off.

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 CHAPTER 6
MAINTENANCE

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 WARNING: The maintenance operations described in this chapter
should be performed only by qualified personnel who understand the
processes and are familiar with the safety measures involved.

6.1. INTRODUCTION:
This chapter contains the procedures involved in the maintenance of
the EC equipment. These maintenance procedures guarantee safe
operation and increase machine life. Before starting a maintenance
operation, read chapter 1. “Safety” carefully.

General recommendations for proper maintenance:

 Keep the tank as full of adhesive as possible. This will reduce the
formation of charred adhesive on the tank’s inner walls.
 Keep the tank cover closed. (Any contamination in the tank will
increase the possibility of low performance. Humidity, dirt and charred
adhesive are the main causes of nozzle obstruction).
 Use cheesecloth to remove material leaking from the seals and other
connectors when the machine is hot, but not in operation.
 Empty and clean the system completely when there are frequent
obstructions, due to dirt and char.

Make sure that you are properly protected and follow all pertinent
safety measures:

1. Switch off the air at the mains.

2. Switch off the main switch.
3. Lock and tag out the main switch.
4. Make sure power is off.
5. Follow all applicable safety standards.

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 6.2. MAINTENANCE RECOMMENDATIONS:
The following table shows the frequency with which maintenance
operations should be performed:

Frequency Maintenance
Clean the outer surface of the equipment. Use a liquid
cleaner, following the instructions for the adhesive being
used.

Inspect all the electric, pneumatic and hydraulic

Weekly
connections. Replace or repair when necessary
(40 hours)

Bleed the drain valve.

Change the air regulator filter.

6 Months
(2000 hours)
Clean the tank filter.

Operation frequency depends on the type of adhesive used and the

environmental conditions where the equipment is placed.

6.3. MAINTENANCE PROCESSES:

6.3.1. Cleaning the equipment
Vacuum the dust or glue remnants, or remove them with a soft cloth,
especially from the manifold and bleed valves.
Clean the control panel periodically with a soft cloth. Do not use
solvents, which could damage the control panel.
Use a soft cloth to remove dust and glue remnants from the cylinder,
valve and exhaust mufflers.

If you use a cleaning agent, make sure that it is compatible with the
adhesive being employed.
When in doubt, contact the adhesive manufacturer.
6.3.2. Bleeding the pressure regulator air filter:
Bleed the air-regulation unit by pushing the lower button on the filter.
Change the regulator filter as necessary, depending on the
contaminants that accumulate in the pneumatic system.

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 6.3.3. Removing the Pump Casing

To remove the pump casing, follow these steps:

1. Unscrew the two screws on the pump casing one-quarter turn.

2. Release the fast-on terminal on the inside.

3. To reinstall the cover, do the steps in reverse order.

6.3.4 Changing Adhesive

To replace one adhesive with another, empty the system (See 5.2
"Emptying the Tank").

Emptying the system is important when changing the adhesive. Not doing
so may cause equipment damage.

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 CHAPTER 7
TROUBLESHOOTING THE EQUIPMENT

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 WARNING: The maintenance operations described in this chapter
should be performed only by qualified personnel who understand the
processes and are familiar with the safety measures involved.
7.1. INTRODUCTION:
This chapter refers to the most common equipment faults.
Problems may occur when glue flow is reduced or stopped, or when
the alert system signals a fault. Many problems can be solved with the
help of this manual.
If the problem cannot be solved with the information provided here,
contact your Melton representative.

7.2. MECHANICAL FAULTS:

The pump does not stroke The pump strokes too quickly

Verify that the applicator is at Check that there is adhesive

the right temperature in the tank

Check the air pressure Check for leaks at the If not, check that the
connectors adhesive is melted

Check to see if the modules If the pump continues to work too quickly,
are obstructed and continues without pressure,
disassemble the pump and clean the valve
seats for any carbon deposits that might
Check to see if the filters are prevent them from closing properly
blocked

Check the hydraulic sub-unit

Check to see if the control
seals
solenoid is working

The modules in the multiple

guns do not fire at the same
time

Adjust the screw on the back

of the module

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 The gun does not deposit
adhesive when the electrovalve
operates

Check the temperature of

the tank, hoses and guns

Check if the gun

electrovalve works

Check to see if the nozzles

are obstructed (remove and
clean)

Check if the module seat is

blocked (remove and clean)

Check if there is a leak from

the module bleed hole
(change seals)

Check the filters

Check if the hose is blocked

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 The pellets do not reach the The charger exceeds the
adhesive tank desired adhesive level

Check that the tank is not Check loader valve operation

empty manually

Check tank pneumatic

connections and air Check loader valve
pressure pneumatic connections and
air pressure

Check Vacuum Feeding

electrovalve operation

Comprobar
Check thatlathe
presencia
chargerde
obstrucciones en el recorrido
module pellet vibrator Works
decorrectly
la granza

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 7.3. ELÉCTRICAL FAULTS:

Circuit Breaker that supplies

energy to the unit trips

Check electrical leakage in

unit resistance and
peripherals

Check that the breaker is

the right one for the unit
power requirement

The unit turns on, but is not

The machine does not come on enabled

Check the connection of the Check that the unit is

power supply to the machine programmed with the correct
parameters

Check the power fuses of the

electronic card Check the over temperature
thermostat

The Tank overheats

Check the Tank RTD

Check if the zone triac is

short circuited

Check for the correct Check the programmed tank

Control Board functioning temperature

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 The Tank does not heat

Verify that the Check the over

Check if the service
temperature is temperature thermostat
contactor is activated
programmed correctly function

Check the tank zone fuses Check if the tank heaters are
short-circuited

Verify that the tank terminals Verify correct tank

are connected correctly Heather current
consumption

Check that the control board

does not read faults

If the RTD sensor is short-

Check the Tank temperature
circuited or open, the display
sensor
reads, “RTD Disconnected”

Check if the triac functions

correctly

Check the tank heaters

Once these checks are

made, restart the unit (cycle
power)

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 A hose overheats

Check the hose

temperature sensor

Check to see if the hose

triac is short-circuited

Check that the electronic Check the programmed

card is working correctly hose temperature

A gun does not heat up

Check for correct electronic Check that the channel is

card programming enabled, and that it is at the
right temperature

If the sensor is short-

circuited or opened, the Check the gun temperature
display shows RTD sensor
Disconnected

Check that the pins inside

Ensure that the connector is Check for correct gun the hose, unit and gun
inserted correctly connector connections connectors are in good
condition and not turned
back

Check the gun fuse

Check for correct gun triac

operation

Check the gun electrical

resistance

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 A hose does not heat up

Check that the channel is

Check for correct electronic
enabled and is at the right
card programming
temperature

If the sensor is short-

circuited or opens, the Check the hose
display shows RID temperature sensor
Disconnected

Check the correct connection Check that the pins inside the
Ensure that the connector is hose and unit connectors are
of the hose connectors
inserted correctly in good condition and not
pushed back

Check the hose fuse

Check for correct hose triac

operation

Check the hose electrical

resistance

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 The pump electrovalve does
not work

Check to see if the air

pressure reaches it

Check that the electronic

Overtemperature alarm in card does not have alarms Alarm for configuration or
the gluer or peripherals hose and gun connections

Check for correct safety Check to see if the air

thermostat operation pressure reaches it

Check fuses

Ensure that the connector is Check that the pins inside

connected correctly Check for correct the connector are in
electrovalve connections goodcondition

Check if there is a 24V output

when the LED lights up

Check the electrovalve coil

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 The unit does not switch on The charger exceeds the
desired adhesive level

Check the equipment power

connection
Check that the probe ground
wire is attached to the unit
Check the fuse cabinet

Check that the charger timer

settings are correct. Consult
your ValcoMelton
representative.

The charger does not fill the

tank at the desired level

Check the air hoses and the

correct pressure in the charger

Check that the probe ground

is linked to the unit

Check that the charger timer

settings are correct. Consult
your ValcoMelton
representative.

Check that the alarm timer

settings are correct. Consult
your ValcoMelton
representative.

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 7.4. ADHESIVE APPLICATION PROBLEMS:

Cold beads

Low temperature Nozzles far from the

surface to be glued

Raise temperature Bring nozzles closer

Too much glue at the start

and end of bead

Nozzles far from surface Low pump pressure Dirty nozzle (blocked)
to be glued

Clean and unblock

Bring nozzles closer Increase pressure nozzle

Bead break

Adhesive too viscous Adhesive cold Adhesive old

Increase temperature Increase temperature Change the adhesive

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 Adhesive with “Angel Hair”

Bring closer Applicator far from the

surface to be glued

Increase the
Adhesive cold temperature
slightly

Fill tank with new

adhesive Adhesive old

Increase the
Adhesive too viscous temperature
slightly

Preheat the Draft on the applicator

Screen applicator
substrate and/or low ambient
to protect it
temperature

Increase the adhesive

Warm the ambient
temperature slightly
air

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 Drops of adhesive forming
on the applicator nozzle

Incorrect adjustment Incorrect air pressure to

Hole blocked and/or seat
shut-off valves
worn or dirty

Clean and/or replace Adjust the stroke

opening Adjust air pressure
dirty and/or worn parts

Frequent nozzle obstructions

Increase in solids Clean filters

Rinse the system

Change adhesive type Reduce temperature

Too much adhesive flow

Excessive pump pressure Valve stroke opening too Nozzle outlet too large
large

Reduce pump pressure Close by twisting several Change to a smaller nozzle

times

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 Splashes of adhesive from
the substrate

Reduce the
Adhesive temperature too temperature
high

Reduce pump Pump pressure too high

pressure

Reduce pump Adhesive viscosity too low

pressure Use smaller nozzle

Reduce temperature Use higher-viscosity Open the regulator

adhesive

Adhesive is smoking

Applicator is too far from

the substrate

Adhesive too hot Reduce temperature

Use more stable adhesive

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 Tank adhesive
carbonisation

Reduce tank
Tank temperature too temperature
high

Readjust temperature
Temperature control fault
control or replace card

Keep tank full

Adhesive level low

Keep tank cover Adhesive oxidation

closed

Gelatinous adhesive

Empty the system

and wash it Overheating Reduce the
thoroughly temperature

Check adhesive
Empty the system Incompatible adhesives compatibility
and wash it mixed together
thoroughly

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 Bubbles in the adhesive

Fill the tank and

operate applicators
Tank empty until the bubbles
disappear

Increase the Use a lower-

Adhesive too viscous viscosity
temperature
slightly adhesive

Dry the substrate.

Check by applying
Operate applicator
adhesive on dry Moisture in the substrate until the bubbles
substrate
disappear

Use adhesive Check for

that is free of Moisture in the adhesive Moisture in the
Moisture adhesive

Consult the
adhesive
manufacturer

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 CHAPTER 8
EQUIPMENT REPAIR GUIDE

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 WARNING: The maintenance operations described in this chapter
should be performed only by qualified personnel who understand the
processes and are familiar with the safety measures involved.

8.1. INTRODUCTION:
This chapter explains the procedures for dismantling and replacing
some components. These procedures must be done during
maintenance tasks, or when there is a failure.
Before beginning, make sure the operator is properly protected and all
safety measures are being followed.

1. Switch off the air at the mains.

2. Switch off the main switch.
3. Lock and tag out the main switch.
4. Make sure the electricity is off.
5. Follow applicable safety and health standards.

Attached are the exploded views that illustrate the procedures.

8.2. CHANGING THE FILTER:

Before changing the filter, put on a face shield, gloves and a long-sleeve
shirt to prevent possible burns caused by hot adhesive splashing.
Keeping a filter on hand, to replace when necessary, is recommended.
This replacement is quick and improves equipment performance.
1. To change the filter, the applicator should be at working
temperature.

2. Reduce the applicator air pressure to "0".

3. Place a receptacle below to collect the adhesive from the

manifold.

4. Open the drain valve with a screwdriver to eliminate residual

pressure.

5. Open the filter plug screw with a screwdriver, and take out the
filter unit.

6. Place the filter into the manifold and screw it in with a

screwdriver.

7. Close the drain valve with a screwdriver.

8. Set to the desired working pressure.

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 8.3. REPAIRING THE MANIFOLD:
The manifold is the element that distributes Hot-Melt, after it has been
filtered, to the hoses and guns.
It is assembled at the bottom of the tank so that the tank heaters heat it
indirectly.
The manifold has six outlet ports to connect the Hot-Melt hoses; three
at the bottom and another three at the front.
Do not disassemble the manifold. This operation should only be
done if there is a Hot-Melt leak between the tank and the manifold.

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 8.4. REPAIRING THE PNEUMATIC PUMP UNIT:
The pump unit consists of a valve, a shifter valve, a pneumatic cylinder
and a double-acting hydraulic pump, equipped with a pressure
compensator to avoid a drop in flow rate that occurs when changing
pump direction, and to enable maximum uniformity in Hot-Melt flow.

Cylinder unit

Hydraulic unit

Before disassembling the hydraulic unit, put on goggles, gloves and

long sleeves to avoid possible burns from splashes of hot adhesive.

1. Warm the tank until the adhesive is melted.

2. Reduce the air pressure to zero.

3. Eliminate system pressure by releasing the guns manually

or by opening the bleed valve.

4. Disconnect the electricity.

5. Disconnect the regulator unit electrically and mechanically.

6. Loosen the two pump cover screws 1/4 turn and lift the
pump casing.

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 Follow the assembly procedure instructions carefully.
Positioning and alignment of some elements are critical to perfect
pump operation.
In the event the pump not working correctly, carry out the following
checks.

Is the air pipe connected?

Does the electrovalve work?
Is the equipment at the right temperature?
Is the regulator working at the right pressure?
Are the filters clean?
Are the modules blocked?
Is the shaft aligned correctly?

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 8.4.1 High Flow Pump:

CYLINDER

HYDRAULIC
UNIT

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 8.4.1.1 CYLINDER:

1. Loosen the screws. 2. Separate the units.

3. Loosen the four standoffs. 4. Loosen the shaft knob and

socket joint.

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 8.4.1.2 HYDRAULIC UNIT:

1. Loosen the screws. 2. Separate the units.

3. Turn and separate the nut.

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 4. Loosen. 5. Remove the shaft.

6. Remove the spring and inlet 7. Remove the spring guide.

tube.

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 8.4.2 Low Flow Pump:

CYLINDER

HYDRAULIC
UNIT

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 8.4.2.1 CYLINDER:

1. Loosen the four screws on the 2. Loosen the four standoffs.

bottom.

3. Loosen the shaft knob and socket

joint.

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 8.4.2.2 HYDRAULIC UNIT:
1. Loosen the four screws on the 2. Loosen.
bottom.

3. Loosen. 4. Remove the shaft.

5. Remove the spring and inlet 6. Remove the spring guide.

tube.

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 8.5. CLEANING VALVES

1. Loosen the four screws on the 2. Loosen.

bottom.

3. Clean the valve. 4. Use the M6 Allen wrench to

remove the compression valve.

7. Remove the ball and spring and

clean.

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 8.6. REPAIRING ELECTRIC COMPONENTS:
If one of the electric components needs to be repaired, proceed
according to the part listings in Addendum A and the electric diagrams
in Addendum B.
All these operations should be performed with the machine switched
off at the mains and disconnected from the main air circuit, making
sure that the system has been properly bled and depressurised.
WARNING: When a fuse is blown, it is essential to replace it with fuses
supplied with the equipment.
If fuses are not available, use ULTRAFAST fuses with the same
characteristics.
ELECTRONIC CARD WARNING
During equipment manipulation, avoid contact with electronic elements
and connector metallic parts; elements susceptible to electrostatic
discharge.

8.7. REPAIRING VACUUM FEEDER

For any electrical part requiring replacement, contact your Melton
dealer. For mechanical, stress the following:

Changing the vibrator module

Locate the vibrator module, Remove the air hose fitting.

mounted on the loader arm Press the plunger

Remove the two screws and Install the new module with
remove the module the screws

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 Attach the quick connect fitting Place the air filter onto the exhaust
to the air inlet module

Press the end of the cable and Vibrator module mounted

insert the air hose

Open the main air inlet.

Turn on the equipment.

The equipment is ready again!

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 CHAPTER 9
LOG SHEETS

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 DATE INCIDENCE

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