Valco Melton Linear Meter System User Manual

Below you will find brief information for Linear Meter System. The Fluid Kinetics linear metering system dispenses high viscosity materials at a programmable rate. Designed to dispense consistent ratios of multiple materials using a reciprocating design, it is controlled by stepper motors and monitors material pressures for optimal performance.

PDF

Document

Manual Number:

Revision Date:

MY039

9/2011

This manual is provided with the Linear Metering System and may be used only in accordance with the terms of purchase.

No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Valco

Cincinnati, Inc. The information in this manual is furnished for educational purposes only, is subject to change without notice, and should not be construed as a commitment by Valco Cincinnati, Inc.

This manual written and designed at Valco Cincinnati, Inc., 411 Circle Freeway Drive, Cincinnati, Ohio

45246. http://www.valcomelton.com

Part Number: MY039

Written and printed in the USA in the original language of English (US).

411 Circle Freeway Drive

Cincinnati, Ohio 45246, USA

TEL: (1) 513-874-6550

FAX: (1) 513-874-3612

Pol. Industrial Agustinos calle G, n. 34

31160 Orcoyen, Navarra, Spain

TEL: (34) 948-321-580

FAX: (34) 948-326-584

Unit 7-8

Hortonwood 32

Telford TF1 7YN England

TEL: (44) 1952-677911

FAX: (44) 1952-677945

Storkower Strasse 6

D-15749 Gallun, Germany

TEL: (49) 33764 8700

FAX: (49) 33764 87070

(According to EN 45014)

M an ufacturer:

Au tho rized Re pres enta tiv es in

E urop e:

V alco Melton

A div ision of V alco

Cincin nati, Inco rporated

4 11 Circle Free wa y Driv e

Cincin nati, OH 452 46

USA

V alco Cincinna ti, Ltd.

U nit 7 -8

H orton woo d 32

T elford T F1 7 YN

E ngla nd

M elton S.L .U

Pol. Industrial

Agustinos calle G, n. 34

31160 Orcoye

Navarra, Spain

declares that the product:

P rodu ct Name :

complies with the following Council Directives:

L inear Me tering Sys tem

In stru ction Man ual

S afety of M ac hine ry:

L ow Voltage E quip men t:

EMC :

and conforms to the following standards :

S afety:

Risk:

E MC Emis sion s:

2 006/42/E C

2 006/95/E C

2 004/108/EC

E N60 204-1:20 06

E N13 849-1

E N14 121-1:20 07

E N61 000-6-4:2 007

E N61 000-4-2

E MC Imm unity:

P lace and Date:

S igna ture:

E N61 000-6-2:2 005

E N61 000-4-3

E N61 000-4-4

E N61 000-4-5

E N61 000-4-6

E N61 000-4-8

E N61 000-4-11

Cincin nati, Ohio US A

CE M ark first fixed 2006

David H. S wed es,

Director of Eng ineering &

M anufactu ring

This Declaration of Conformity has been generated electronically and is legally binding without signature

Section 1 - Introduction ................................................. 1-1

LINEAR METER SYSTEM ........................................................................................ 1-1

LINEAR METER ......................................................................................................................... 1-1

ELECTRICAL ENCLOSURE ...................................................................................................... 1-1

Section 2 - Safety and Use ............................................. 2-1

Read Thoroughly Before Handling Equipment ..................................................... 2-1

Symbols .................................................................................................................... 2-1

Owner Responsibilities ........................................................................................... 2-3

Limitations of Use .................................................................................................... 2-4

Installation/Startup/Use Safety Information .......................................................... 2-4

Shut Down Safety Information ................................................................................ 2-5

Hot Melt Specific General Safety Information ....................................................... 2-6

What to Do if Contact with Hot Adhesive Occurs ................................................................... 2-7

What to Do if Inhalation of Adhesive Fumes Occurs .............................................................. 2-7

What to Do if Adhesive-Related Fire or Explosion Occurs .................................................... 2-8

Hose Safety Information .......................................................................................... 2-9

Section 3 - Operation ...................................................... 3-1

Electrical requirements ........................................................................................... 3-1

Air requirements ...................................................................................................... 3-1

POWER ON ............................................................................................................... 3-1

LINEAR METER MAIN MENU SCREEN .................................................................. 3-2

AUTOMATIC OPERATION ........................................................................................ 3-3

MANUAL OPERATION ............................................................................................. 3-3

DISPENSE CALIBRATION ....................................................................................... 3-4

FAULT MENU SETUP SCREEN ............................................................................... 3-4

DISPENSE RATE MONITOR .................................................................................... 3-5

DISPENSE QUANTITY MONITOR............................................................................ 3-5

MATERIAL ‘A’ MONITOR .......................................................................................... 3-6

MATERIAL ‘B’ MONITOR ......................................................................................... 3-6

REFILL TIMER MONITOR ........................................................................................ 3-7

Section 4 - Maintenance ................................................. 4-1

ROUTINE MAINTENANCE ....................................................................................... 4-1

ADJUSTING THE PRESSURE RELIEF VALVES ....................................................................... 4-1

Section 5 -Troubleshooting ............................................ 5-1

Valco Cincinnati, Inc.

TOC-1

Table of Contents MY039 - Linear Metering System Instruction Manual

Section 6 - Operator Panel ............................................. 6-1

Operator Screens ..................................................................................................... 6-1

Main Menu ................................................................................................................................. 6-1

Dispense Menu .......................................................................................................................... 6-2

Dispense Help ........................................................................................................................... 6-2

Data Menu .................................................................................................................................. 6-3

Dispense Quantity Calibration ................................................................................................. 6-3

Fault Menu ................................................................................................................................. 6-4

Dispense Rate Limit Setup ....................................................................................................... 6-4

Dispense Rate Limit Help ......................................................................................................... 6-5

Dispense Quantity Limit Setup ................................................................................................ 6-5

Dispense Quantity Limit Help...................................................................................................6-6

Material ‘A’ Pressure Limit Setup ............................................................................................. 6-6

Material ‘B’ Pressure Limit Setup ............................................................................................. 6-7

Material Pressure Limit Help .................................................................................................... 6-7

Refill Time Monitor Setup ......................................................................................................... 6-8

Refill Time Monitor Setup Help ................................................................................................ 6-8

Section 7 - Electrical Schematics .................................. 7-1

Electrical Elementary Linear Meter SPC System 120VAC Service ...................... 7-1

Section 8 - Part Number List .......................................... 8-1

How to Order Parts .................................................................................................. 8-1

Two-Part Dispensing System - Overall Assembly (DLM3791) ............................. 8-2

Two-Part Linear Meter Assembly (DLM3793) ........................................................ 8-4

Dispensing Valve Assembly (704xx780) ................................................................ 8-6

Solenoid Valve Assembly (411xx740)..................................................................... 8-8

Electrical Enclosure Assembly (DPH5364) ............................................................ 8-9

Section 9 - Warranty........................................................ 9-1

Warranty Information ............................................................................................... 9-1

Cold Glue Equipment and Electronic Controls ....................................................................... 9-1

Hot Melt Units, Hoses, Valves, Guns, and Related Equipment .............................................. 9-1

Section 10 - Service ...................................................... 10-1

TOC-2 Valco Cincinnati, Inc.

LINEAR

METER

SYSTEM

LINEAR METER

ELECTRICAL

ENCLOSURE

The Fluid Kinetics linear metering system is designed to dispense high viscosity materials at a programmable rate. When using multiple component materials, the linear metering system’s unique design insures a consistent dispense ratio between the different materials. The linear meter system is composed of a linear meter, a dispense gun, an electrical control enclosure, and pneumatic solenoids.

The linear meter is a stepper motor driven, two rod, reciprocating design with stationary seals. During the dispense cycle, the air actuated dispense gun is opened and the stepper motor is energized. The stepper motor turns a ball screw mechanism that moves the two dispense rods into their respective metering chambers. The dispense rods displace the material in the metering chambers forcing them out the dispense gun. As the materials leave the dispense gun, they pass through a disposable static mixer blending them together. When the dispense is complete the dispense gun is closed.

During the refill cycle, the air actuated inlet valves are opened and the stepper motor’s direction is reversed. As the dispense rods are withdrawn the material supply system refills the metering chambers. When the dispense rods reach the home position, the stepper motor is turned off and the inlet valves are closed. The linear metering system is ready for the next dispense cycle.

The linear meter is equipped with two pressure transducers that continuously monitor the pressure of each material. Also mounted on the meter are pressure relief valves designed to open if the material pressure exceeds 1500 psi.

The electrical enclosure contains the controls necessary to operate the linear meter. Mounted on the door, are the Power On pushbutton and indicator light and the Power Off pushbutton. Also mounted on the door is the Allen Bradley

PanelView operator interface. The operator interface is displays the current status of the meter and the pressures of both materials. It is also used to access and adjust the meter parameters and clear any faults detected during the operation of the system

Located inside the electrical enclosure is the Master Control Relay that applies electrical power to the system. Also inside the enclosure is an Allen

Bradley Compact Logix programmable logic control, a stepper motor drive system, a +24 VDC power supply, a +5 VDC power supply, and an Ethernet switch.

The PLC interfaces to the PanelView and controls the operation of the linear meter. The CompactLogix system is capable of Ethernet communication to external devices through the Ethernet switch installed in the enclosure.

ValcoMelton.

1-1

Section 1 - Introduction

ELECTRICAL ENCLOSURE -

Continued

MY039 - Linear Metering System Instruction Manual

The stepper motor drive system is composed of a Superior Electric S2000-

OF oscillator follower and a Superior Electric S2000-D6 stepper motor drive.

The oscillator follower accepts a 0 to 10 volt DC analog signal from the PLC and converts this to a step signal to control the speed of the stepper motor.

The oscillator follower also accepts a direction signal from the PLC. Both these signals are supplied to the stepper motor drive for control of the stepper motor. An encoder mounted on the stepper motor sends pulses to the high speed counter card in the PLC. These pulses are used by the PLC to calculate the meter dispense rate and dispense quantity.

The pressure transducers are used to continuously monitor the pressure of each of the two materials. The Omega pressure transducer returns a 0-10V signal to the PLC’s Analog Input Module that corresponds to the actual material pressure.

If the pressure fault monitoring is enabled then the material pressures are monitored during the dispense and refill cycles. During the dispense cycle, if the pressure of either material exceeds the maximum set point pressure, the dispense is halted and a system fault is generated. This is to prevent damage to the meter seals by excessive pressure. During the refill cycle, if the pressure of either material falls below the minimum set point pressure, the refill is halted and a system fault is generated. This is to prevent air from being drawn into the meter system from a malfunctioning material supply system.

1-2 ValcoMelton

Read

Thoroughly

Before

Handling

Equipment

Symbols

Read and follow all safety precautions, warnings, cautions, and other recommendations in this manual.

OTHERWISE, DEATH, PERSONAL INJURY OR

EQUIPMENT DAMAGE COULD OCCUR.

Read this entire section before handling the equipment.

The following symbols may be used on the equipment and/or in this manual.

Caution or a Warning Cautions draw special attention to anything that could damage equipment or cause the loss of data. Warnings draw special attention to anything that could injure or kill the reader. Both Cautions and

Warnings are placed before the step they apply to.

regard to nozzle cleaning appliances and other sharp instruments that can cause puncture wounds and risk exposure to bloodborne pathogens and other debris.

Valco Cincinnati, Inc.

non-insulated dangerous voltage within the product’s enclosure.

This voltage may cause electrical shock or fire.

Continued next page

2-1

Section 2 - Safety Information

Symbols - Continued

MY039 - Linear Metering System Instruction Manual

This symbol indicates the need to Unplug/Disconnect All Power

Sources of work or maintenance. Remember that there can still be energy in equipment, cords, and wires even when unplugged/ disconnected.

and to let them de-energize before attempting any type of work or maintenance. If power is not locked out, the person working on the equipment may be injured or killed if someone unknowingly switches on the power to the equipment.

special interest or importance to the reader. They give tips, hints, and information in addition to what is necessary for the step preceding it.

2-2 Valco Cincinnati, Inc.

MY039 - Linear Metering System Instruction Manual Section 2 - Safety Information

Owner

Responsibilities

Valco Cincinnati, Inc.

The owner of the equipment is under obligation to manage all safety information. Some examples include:

• Examine all safety materials and documents as well as jurisdictional laws and make certain all laws, recommendations, and other safety/hazard laws, certification requirements, training, and instructions are followed and kept current.

• Maintain all safety materials including tags, labels, documents, and MSDS information. Make certain they are distinct and can be read/understood. Replace any that are dirty, worn, or unreadable.

• Make sure all personnel who will handle, install, maintain, operate, fix, and work around the equipment have ready access to the safety information, training, and equipment according to jurisdictional authorities.

The owner of the equipment is under obligation to make certain that all instructions, requirements, and jurisdictional laws are met. Some examples include:

• Make sure there are regular inspections of equipment and safety devices.

• Have regular safety drills and inspections supervised by the proper authorities.

• Provide all required safety items, first aid equipment, and training.

The owner of the equipment is under obligation to make certain that all personnel who will handle, install, maintain, operate, fix, and work around the equipment are qualified, trained, and up-to-date with all information regarding the equipment. Some examples include:

• Make sure all personnel have the proper safety training, equipment, education, and abilities necessary for the job function according to safety instructions and all jurisdictional laws and regulations.

• It is strongly advised that personnel receive first-responder medical care training in case of burns, medical emergencies, or other injuries. Training should be kept up to date.

• Make sure all personnel understand and can follow safety policies and procedures for the organization as well as for the specific equipment.

• Make sure that all personnel are consistently trained, evaluated, free of alcohol and medications that may impair judgment and reflexes, and are tested for banned substances according to jurisdictional authorities.

2-3

Section 2 - Safety Information MY039 - Linear Metering System Instruction Manual

Limitations of

Use

Installation/

Startup/Use

Safety

Information

2-4

Read this document and all information regarding the equipment before handling the equipment. The intended use of the equipment is stated in

Section 1 of this manual.

Do not use this equipment for anything other than its intended use. Do not modify, change, or alter the equipment in any way. If you are unsure of the intended use and the limitations of use for the equipment, contact your Valco

Melton Representative before handling the equipment.

Valco Melton hot melt units, cold glue units, controllers, inspection systems and all related accessories have the following universal safety precautions

(this is not intended to be an exhaustive list; follow all instructions and safety precautions for the specific type of equipment involved):

Only qualified personnel should install the equipment.

Valco Melton strongly recommends that a Valco Melton

Technician install all equipment. OTHERWISE, DEATH,

PERSONAL INJURY, OR DAMAGE TO EQUIPMENT

COULD OCCUR.

The equipment should be installed so that it can be turned injury, electrical problems, or malfunction. OTHERWISE,

DEATH OR PERSONAL INJURY COULD OCCUR.

Properly route all electrical wires. Never tamper with equipment. Only use approved and correct voltage, type of current, fuses, and other power supplies. Replace worn cords, hoses, etc. immediately. FAILURE TO OBSERVE

WARNING MAY RESULT IN DEATH, PERSONAL

INJURY, AND/OR EQUIPMENT DAMAGE.

Poor ventilation, smoking, and open flames can cause overheated hot melt to ignite. Adequate ventilation must be provided. Smoking should be prohibited in the immediate vicinity of the molten adhesive. Open flames must be kept away from the area around molten adhesive.

OTHERWISE, DEATH, PERSONAL INJURY, OR

DAMAGE TO EQUIPMENT COULD OCCUR.

Never use any Valco Melton equipment in an explosive environment. Explosive environments include, but are not limited to, solvent-based cleaners or adhesives, explosive materials, radioactive materials, etc. OTHERWISE,

DEATH OR PERSONAL INJURY COULD OCCUR.

Equipment will start automatically when remotely controlled by triggering devices. Be sure to disable all triggering devices, carefully release hydraulic pressure, and disconnect air pressure before servicing or working near guns, valves, and other triggered devices.

OTHERWISE, DEATH OR PERSONAL INJURY COULD

OCCUR.

Valco Cincinnati, Inc.

MY039 - Linear Metering System Instruction Manual

Shut Down

Safety

Information

Section 2 - Safety Information

Valco Melton hot melt units, cold glue units, controllers, inspection systems and all related accessories have the following universal safety precautions

(this is not intended to be an exhaustive list; follow all instructions and safety precautions for the specific type of equipment involved):

Purge the fluid pressure and the air pressure from the system before disconnecting/disabling any part of the system. OTHERWISE, DEATH OR PERSONAL INJURY

COULD OCCUR.

Disconnect and lock out all power before maintenance or other need to open the equipment. Only qualified personnel should open and service the control.

OTHERWISE, DEATH OR PERSONAL INJURY

COULD OCCUR.

Equipment may still be energized even if unplugged!

When making adjustments or performing checkout procedures, stay clear of any moving mechanical parts and do not touch exposed electrical equipment or electrical connectors. OTHERWISE, DEATH OR

PERSONAL INJURY COULD OCCUR.

Disconnect/disable all mechanical and/or electrical devices that send activation signals to the gun(s), valve(s), melter pump(s), etc. This includes pattern controls, timers, input/output signals, etc. Only qualified personnel should open and service the control.

OTHERWISE, DEATH OR PERSONAL INJURY

COULD OCCUR.

Disable all triggering devices, relieve all residual pressure (hydraulic and air) and allow adhesive to cool before attempting to disconnect guns, hoses, valves, etc. Only qualified personnel should open and service the control. OTHERWISE, DEATH OR PERSONAL

INJURY COULD OCCUR.

Never point an adhesive dispensing gun, valve, hose, air hose, or anything else at yourself or another person.

OTHERWISE, DEATH OR PERSONAL INJURY

COULD OCCUR.

Valco Cincinnati, Inc.

2-5

Section 2 - Safety Information MY039 - Linear Metering System Instruction Manual

Hot Melt

Specific

General Safety

Information

intended to be an exhaustive list; follow all instructions and safety precautions for the specific type of equipment involved):

Never melt or solvent-based material in a Valco Melton unit unless you are certain that the unit is compatible and is marked “PUR”! Read all instructions and MSDS sheets carefully, following manufacturer’s instructions, especially regarding heat levels. If you have any question as to the compatibility of a Valco Melton unit for

PUR hot melt, call your Valco Melton Representative before attempting to use the unit for PUR or solventbased materials. OTHERWISE, HAZARDOUS FUMES,

EXPLOSION, DEATH, OR PERSONAL INJURY

COULD OCCUR.

Keep pump cover and electrical enclosures closed except during setup, service, and checkout procedures.

OTHERWISE, DEATH OR PERSONAL INJURY

COULD OCCUR.

People with respiratory problems (e.g., asthma, bronchitis, etc.) should not work in the vicinity of molten adhesive. RESPIRATORY PROBLEMS MAY BE

AGGRAVATED BY THE FUMES. Do not wear a face mask when working around molten adhesive. THE

MASK MAY TRAP THE FUMES AND DEATH OR

PERSONAL INJURY COULD OCCUR.

Keep hot melt hoses away from walkways and the moving parts of hot melt systems. OTHERWISE,

PERSONAL INJURY OR EQUIPMENT DAMAGE

COULD OCCUR.

Hot surfaces! Do not touch! Use extreme caution when refilling the unit by hand. OTHERWISE, PERSONAL

INJURY COULD OCCUR.

Wear protective gloves and goggles at all times around all machinery, especially hot melt. OTHERWISE,

SERIOUS PERSONAL INJURY COULD OCCUR.

2-6

Never use an open flame to heat hot melt components or adhesive. OTHERWISE, DEATH, PERSONAL

INJURY, OR DAMAGE TO EQUIPMENT COULD

OCCUR.

Valco Cincinnati, Inc.

MY039 - Linear Metering System Instruction Manual Section 2 - Safety Information

What to Do if Contact with Hot Adhesive

Occurs

Do not attempt to remove heated hot melt adhesive from the skin. OTHERWISE, SEVERE PERSONAL INJURY

AND DEATH COULD OCCUR.

Immediately immerse the contacted area in clean, cold water.

It is strongly recommended that a source of clean, cold water be provided near the hot melt work area.

Cover the affected area with a clean, wet compress and call the emergency medical response system (such as 911) immediately.

Watch for and treat the subject for signs of shock while waiting for professional help to arrive.

What to Do if

Inhalation of

Adhesive Fumes

Occurs

If adhesive fumes are inhaled, immediately follow these steps:

Take the victim away from the immediate work area.

Provide victim with fresh air.

Call the emergency medical response system (such as 911) immediately.

Valco Cincinnati, Inc.

2-7

Section 2 - Safety Information MY039 - Linear Metering System Instruction Manual

What to Do if

Adhesive-Related

Fire or Explosion

Occurs

During the heating and melting process, the surface of the adhesive will be exposed to air. The mixture of polymer fumes and air can catch fire if the hot melt is overheated.

OR DAMAGE TO EQUIPMENT COULD OCCUR.

Exposed arcing may ignite the fume/air mixture. Shield all electrical equipment from melt fumes to avoid exposed arcing. OTHERWISE, PERSONAL INJURY OR

EQUIPMENT DAMAGE COULD OCCUR.

Do not use a water extinguisher to extinguish the fire!

OTHERWISE, PERSONAL INJURY OR EQUIPMENT

DAMAGE COULD OCCUR.

If the hot melt adhesive ignites, promptly perform the following steps:

Sound a fire alarm.

Evacuate the immediate area.

Turn off all local electrical equipment at the source.

Leave the area immediately if conditions are unsafe.

IfIf you feel you can fight the fire safely one

- Smother the fire with a fire blanket.

- Aim a CO

fire extinguisher at the base of the flames.

- Aim a dry-powder fire extinguisher at the base of the flames.

2-8 Valco Cincinnati, Inc.

MY039 - Linear Metering System Instruction Manual

Hose Safety

Information

Section 2 - Safety Information

Do not fasteners around the hoses.

making sure the wrapping is slightly snug but not tight.

Do between hoses for proper ventilation.

Do not kinks or indentations in the hoses.

Do inches for a 20-inch diameter coil hose.

Do not

Do not technique to attach or remove hoses. Do not large hexagon swivel nuts.

Do tighten or loosen connections on hoses.

Do nuts.

Valco Cincinnati, Inc.

2-9

Section 2 - Safety Information

Hose Safety Information -

Continued

MY039 - Linear Metering System Instruction Manual

Do not objects or to come into contact with sharp edges or points.

(P/N 795xx549) if the hoses must be installed where they will come into contact with objects.

Do not hoses.

Do damage and/or wear and replace damaged or worn hoses immediately.

2-10 Valco Cincinnati, Inc.

Electrical requirements

Air requirements

POWER ON

120 volts AC, single phase, 15 amps

60 psi filtered and lubricated

Connect the system to a source of electrical power.

Connect the system to a source of air.

Check that the supply pumps are connected to shop air and at the correct pump pressure (approximately 40 psi).

To ensure the correct mix ratio, the air regulators of the material supply pumps should be adjusted so that the material pressure of both materials is within 10 psi of each other at the linear meter.

Press the Power On pushbutton on the front of the electrical enclosure. The Power On light turns on indicating electrical power is applied to the system. After a few seconds, the linear meter enters a refill cycle. The Main Menu is displayed on the

PanelView at power up.

ValcoMelton.

3-1

Section 3 - Operation MY039 - Linear Metering System Instruction Manual

LINEAR

METER MAIN

SCREEN

The Main Menu screen displays the current meter status, the dispense rate and quantity of the last dispense, and the current material pressures.

3-2

In addition, the Main menu provides the following functions:

DISPENSE MENU speed, refill speed, and the manual dispense pushbutton.

Calibration is accessed in this screen.

Configuration mode is accessed in this screen.

FAULT RESET Button: operation of the meter is halted until either the Fault Reset pushbutton is pressed or electrical power is turned off and then back on.

All operator screens are shown in

Section 6 - Operator Panel.

ValcoMelton

MY039 - Linear Metering System Instruction Manual

AUTOMATIC

OPERATION

MANUAL

OPERATION

Section 3 - Operation

In the automatic mode of operation, the linear meter is controlled by an external device. The meter dispenses when it receives a dispense signal from the line controller. It continues to dispense for as long as the dispense signal is present or until it reaches the end of its stroke. The meter does not refill until it receives the refill signal from the line controller.

The quantity of material dispensed on each part is controlled by the meter dispense speed and the duration of the dispense signal. The dispense speed may be changed in the Dispense Menu.

The meter is rated for a maximum dispense pressure of

1500 psi. After increasing the dispense speed, check the material pressure during a dispense cycle to insure it does not exceed this pressure.

The refill speed may also be adjusted in the Dispense Menu screen.

If the refill speed is adjusted too high, the meter can develop material voids causing dispense problems.

There should be a minimum material pressure of 20-30 psi in the meter during the refill process.

If the refill speed is set too low, the meter may generate a Refill Time out system fault. An adjustable timer in the

PLC monitors the time it takes the meter to refill. If the refill takes longer than the set time, a system fault is generated.

A manual dispense may also be initiated from the Dispense Setup screen by pressing the green Manual Dispense button. The meter continues to dispense as long as this key is pressed or until the meter runs out of stroke.

When the Manual Dispense key is released, the meter automatically enters the refill mode.

ValcoMelton 3-3

Section 3 - Operation

DISPENSE

CALIBRATION

MY039 - Linear Metering System Instruction Manual

FAULT MENU

SETUP

SCREEN

This screen is accessed from the Data Menu. It is used to calibrate the dispense quantity of the linear meter for the material in use. It is necessary because different materials at different pressures will vary in the amount dispensed per step of the Motor. To calibrate the meter, place a container under the gun nozzle and press the DISPENSE START key. The meter will dispense for 10 revolutions. When the meter stops dispensing, measure the quantity, then enter the quantity dispensed in cubic inches.

3-4

Pressing the Fault Menu key from the Main Menu displays the Fault Menu

Screen. This screen displays the current status (off or on) of the different fault monitoring options and allows access to the individual fault monitoring screens.

ValcoMelton

MY039 - Linear Metering System Instruction Manual

DISPENSE

RATE

MONITOR

Section 3 - Operation

DISPENSE

QUANTITY

MONITOR

This fault monitoring option allows a fault to be generated if the dispense rate falls below the minimum setpoint value or exceeds the maximum setpoint value.

ValcoMelton

This fault monitoring option allows a fault to be generated if the dispense quantity falls below the minimum set point value or exceeds the maximum set point value.

3-5

Section 3 - Operation

MATERIAL ‘A’

MONITOR

MY039 - Linear Metering System Instruction Manual

MATERIAL ‘B’

MONITOR

This fault monitoring option allows a fault to be generated if the material ‘A’ pressure exceeds the maximum set point during a dispense cycle or falls below the minimum set point during a refill cycle.

3-6

This fault monitoring option allows a fault to be generated if the material ‘B’ pressure exceeds the maximum set point during a dispense cycle or falls below the minimum set point during a refill cycle.

ValcoMelton

MY039 - Linear Metering System Instruction Manual

REFILL TIMER

MONITOR

Section 3 - Operation

This fault monitoring option allows a fault to be generated if the meter refill time exceed the set point value.

ValcoMelton 3-7

ROUTINE

MAINTENANCE

The only routine maintenance required on the linear meter is to periodically refill the fluid isolation chambers on the meter body. The fluid lubricates the meter rods and seals helping to prevent material from sticking to either and prolonging seal life.

ADJUSTING THE

PRESSURE RELIEF

VALVES

Each metering chamber is equipped with a spring style pressure relief valve to help prevent damage to the meter seals if the meter is over pressured. To set the valves to the proper relief pressure, follow the procedure listed below:

Disconnect the air supply to the dispense gun or install a “cured” static mixer to block the flow of material out of the dispense gun.

Loosen the locknut on the pressure relief valves for both materials and slowly back the adjusting screws out until it they are almost all the way out.

In the Dispense Menu, press the Manual Dispense key. While watching the pressure gauge for Material ‘A’ slowly turn the adjusting screw until the Material ‘A’ pressure gauge reads approximately 1500 psi. Tighten the locknut.

Repeat the above process for Material ‘B’.

Reconnect air to the dispense gun or replace the ‘cured’ static mixer. Check operation under normal conditions.

ValcoMelton.

4-1

PROBLEM

NO ELECTRICAL POWER

METER NOT MOVING

METER NOT DISPENSING MATERIAL

METER NOT REFILLING

METER NOT DISPENSING PROPER AMOUNT

POSSIBLE SOLUTION

Check electrical power connections

Check main power fuse

Check MC relay

Check for system fault. Fault Reset on Main Menu screen

Check dispense/refill speed not set to 0 percent

Check stepper drive fuses

Check oscillator follower fuses

Check analog output of PLC

Check for High Pressure fault. Fault Reset on Main

Menu screen

Check for cured material in nozzle

Check material supply system is not empty or air pressure present

Check meter dispense speed not set to 0 percent

Check dispense gun solenoid turning on and air pressure present

Check for Low Pressure fault. Fault Reset on Main

Menu screen

Check for Refill Time-out error. Fault Reset on Main

Menu screen

Check meter refill speed not set to 0 percent

Check meter home prox operation

Check nozzle not cured or obstructed

Check for empty supply system

ValcoMelton.

5-1

Operator

Screens

Main Menu

ValcoMelton.

6-1

Section 6 - Operator Panel

Dispense Menu

MY039 - Linear Metering System Instruction Manual

6-2

Dispense Help

ValcoMelton

MY039 - Linear Metering System Instruction Manual

Data Menu

Section 6 - Operator Panel

Dispense Quantity

Calibration

ValcoMelton 6-3

Section 6 - Operator Panel

Fault Menu

MY039 - Linear Metering System Instruction Manual

Dispense Rate Limit

Setup

6-4 ValcoMelton

MY039 - Linear Metering System Instruction Manual

Dispense Rate Limit

Help

Section 6 - Operator Panel

Dispense Quantity

Limit Setup

ValcoMelton 6-5

Section 6 - Operator Panel

Dispense Quantity

Limit Help

MY039 - Linear Metering System Instruction Manual

Material ‘A’ Pressure

Limit Setup

6-6 ValcoMelton

MY039 - Linear Metering System Instruction Manual

Material ‘B’ Pressure

Limit Setup

Section 6 - Operator Panel

Material Pressure

Limit Help

ValcoMelton 6-7

Section 6 - Operator Panel

Refill Time Monitor

Setup

MY039 - Linear Metering System Instruction Manual

Refill Time Monitor

Setup Help

6-8 ValcoMelton

Electrical Elementary Linear Meter SPC System 120VAC Service

ValcoMelton.

7-1

Section 7 - Electrical Schematics MY039 - Linear Metering System Instruction Manual

Electrical Elementary Linear Meter SPC System 120VAC Service - Continued

7-2 ValcoMelton

MY039 - Linear Metering System Instruction Manual

Electrical Elementary Linear Meter SPC System 120VAC Service - Continued

Section 7 - Electrical Schematics

ValcoMelton 7-3

Section 7 - Electrical Schematics MY039 - Linear Metering System Instruction Manual

Electrical Elementary Linear Meter SPC System 120VAC Service - Continued

7-4 ValcoMelton

How to Order

Parts

USA:

To order parts, please contact your closest Valco Melton office by mail, phone, or Email:

411 Circle Freeway Drive

Cincinnati, OH 45246

TEL: (513) 874-6550

FAX: (513) 874-3612

Email: [email protected]

Web: http://www.valcomelton.com

England:

Hortonwood 32

Telford, TFI 7YN, England

TEL: (+44) 1952-677911

FAX: (+44) 1952-677945

Email: [email protected]

Web: http://www.valco.co.uk

Germany:

Spain:

Storkower Strasse 6

D-15749 Gallun, Germany

TEL: (+49) 337 648 700

FAX: (+49) 337 648 7070

Email: [email protected]

Melton S.L.U.

Pol. Industrial Agustinos calle G, n. 34

31160 Orcoyen, Navarra, Spain

TEL: (34) 948-321-580

FAX: (34) 948-326-584

ValcoMelton.

8-1

Section 8 - Part Number List MY039 - Linear Metering System Instruction Manual

Two-Part Dispensing System - Overall Assembly (DLM3791)

8-2 ValcoMelton

MY039 - Linear Metering System Instruction Manual

Two-Part Dispensing System -

Overall Assembly (DLM3791) -

Continued

Section 8 - Part Number List

ITEM DESCRIPTION

098XX016

029XX079

795XX400

795XX401

797XX038

797XX039

PART #

JUNCTION BOX,DC SIGNALS

CABLE ASSY,SOLENOID INTERFACE

SOC PIPE PLUG

HEX HEAD PIPE PLUG

QTY

ValcoMelton 8-3

Section 8 - Part Number List MY039 - Linear Metering System Instruction Manual

Two-Part Linear Meter Assembly (DLM3793)

8-4 ValcoMelton

MY039 - Linear Metering System Instruction Manual Section 8 - Part Number List

Two-Part Linear Meter Assembly

(DLM3793) - Continued

ValcoMelton

ITEM

12 GUARD, PRO X. SW ITCH TAR GET

19 CAB LE

22 BEARING

23 BUS HING , DISPENSE RO D G UIDE

31 O-R ING

32 O-R ING

33 O-R ING

36 BUS HING

37 JIC-ELBOW

D ESCRIPTION

SOCKET HEAD PIPE PLU G

48 SEAL KIT ; BALL VALVE

49 KEENSERT

50 SCR EW

51 SCR EW

52 SCR EW

53 SCR EW

54 SCR EW

55 SCR EW

57 GAUGE

PAR T # QTY

110XX325 1

791XX191 1

111XX095 1

704XX481 2

111XX136 1

793XX821 1

793XX315 1

111XX099 1

111XX165 1

794XX910 1

111XX306 2

111XX305 1

111XX304 1

581XX493 1

111XX218 1

111XX307 1

068XX210 2

450XX031 2

790XX045 1

790XX120 2

789XX097 2

746XX047 2

794XX575 1

794XX576 1

793XX067 1

793XX385 1

793XX169 1

793XX824 2

745XX358 4

745XX104 2

745XX043 2

704XX500 2

703XX692 2

797XX045 2

795XX350 2

795XX323 2

786XX114 2

799XX583 2

795XX309 6

797XX005 2

797XX378 6

411XX601 2

797XX084 2

797XX041 2

745XX934 0

795XX881 8

798XX034 2

798XX061 11

798XX090 2

798XX112 10

798XX116 8

798XX161 3

784XX140 2

786XX058 2

8-5

Section 8 - Part Number List

Dispensing

Valve

Assembly

(704xx780)

MY039 - Linear Metering System Instruction Manual

8-6 ValcoMelton

MY039 - Linear Metering System Instruction Manual

Dispensing Valve Assembly

(704xx780) - Continued

Section 8 - Part Number List

ITEM

10 JIC

11 ADAPTER

DESCRIPTION

VALVE; SNUFF BACK

MIXER; STATIC - 16 ELEMENTS

704XX476 2

111XX209 10

JACKET; STATIC MIXER 111XX210 1

STATICK ELEMENTS 111XX211 10

JACKET; STATIC MIXER

PART #

704XX775

QTY

799XX388 2

SEAL KIT, FLUID SECTION

REBUILD KIT; VALVE

111XX212 1

793XX682 1

799XX257 1

795XX352 2

797XX029 1

797XX378 2

746XX004

704XX477

ValcoMelton 8-7

Section 8 - Part Number List

Solenoid

Valve

Assembly

(411xx740)

MY039 - Linear Metering System Instruction Manual

8-8

ITEM DESCRIPTION

2 SOLENOID

PART # QTY

411XX414 3

411XX637 1

4 ELBOW

5 HEX HEAD PIPE PLUG

797XX981 6

797XX039 3

6 MUFFLER

7 SOCKET HEAD PIPE PLUG

411XX661 2

797XX044 1

8 REDUCER 795XX844 2

066XX024 1

10 LOCKNUT

11 TUBING

066XX083 1

755XX131 216

12 TUBING 755XX126 216

ValcoMelton

MY039 - Linear Metering System Instruction Manual

Electrical

Enclosure

Assembly

(DPH5364)

Section 8 - Part Number List

CINCINNATI, OHIO

ValcoMelton 8-9

Section 8 - Part Number List

Electrical Enclosure Assembly

(DPH5364) - Continued

8-10

MY039 - Linear Metering System Instruction Manual

ITEM DESCRIPTION

6 PUSHBUTTON

7 PUSHBUTTOM,E-STOP,ILLUM

9 LEGEND PLATE SET

10 ELECTRICAL ELEMENTARY, LM

11 CONTACTOR

15 HIGH SPEED COUNTER MODULE

16 ANALOG MODULE

19 RIGHT END CAP

23 DRIVE; MOTOR CONTROLLER

28 FUSE

31 JUMPER

33 ANCHOR

35 DIN MOUNTING RAIL

36 DUCT

40 RECEPTACLE

49 LOCKNUT

PART # QTY

DPH5365 1

025XX287 1

781XX011 1

105XX067 1

480XX026 1

480XX198 1

DPH5366 1

781XX694 1

DPH5363 1

061XX433 1

148XX055 1

118XX155 1

118XX157 1

118XX177 1

118XX134 1

118XX156 1

DPH9395 1

118XX139 1

118XX138 1

029XX361 1

110XX189 1

110XX188 1

056XX111 1

086XX012 4

085XX055 1

085XX046 3

075XX093 1

075XX091 100

091XX079 25

075XX092 1

091XX076 2

667XX074 36

091XX277 48

067XX015 144

067XX016 144

023XX036 1

023XX037 1

061XX055 1

794XX949 1

091XX075 1

091XX369 1

030XX781 1

030XX782 1

066XX022 4

066XX023 4

066XX024 4

066XX083 12

066XX006 12

DPH9582 1

TAJ9105 1

ValcoMelton

Warranty

Information

Valco Cincinnati, Inc. warrants its equipment worldwide against defects in material and workmanship as outlined in this section.

Liability of the company is limited to repair of the product, or replacement of any part shown to be defective, and does not extend to defects caused by accidents, misuse, abuse, neglect, tampering or deterioration by corrosion.

This warranty does not cover those items determined by Valco Cincinnati,

Inc. to be normal wear items such as seals, O-rings, diaphragms, springs, etc.

Reconditioned equipment, unless specified otherwise at the time of purchase, will be warranted as described above for a period of ninety (90) days from the date of shipment by Valco Cincinnati.

Components purchased by Valco Cincinnati, Inc. from others for inclusion in its products are warranted only to the extent of the original manufacturer’s warranty. In no event shall Valco Cincinnati, Inc. be liable for indirect or consequential damages arising out of the use of Valco Cincinnati products.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to Valco Cincinnati, Inc. for examination and verification. If claimed defect is verified, repairs or replacements will be made

F.O.B. Cincinnati, Ohio, U.S.A. or ex-works Telford, U.K. If the inspection of the equipment does not necessary repairs will be made at a reasonable charge and return transportation will be charged.

This is the only authorized Valco Cincinnati, Inc. warranty and is in lieu of all other expressed or implied warranties, representations or any other obligations on the part of Valco Cincinnati, Inc.

Cold Glue Equipment and Electronic

Controls

The warranty for cold glue equipment and electronic controls for a period of one (1) year from the date of shipment by Valco Cincinnati, Inc.

Hot Melt Units,

Hoses, Valves, Guns, and Related

Equipment

All hot melt components except cast-in heating elements are warranted for a period of six (6) months from the date of shipment by Valco Cincinnati. Castin heaters carry an additional, pro-rated warranty not to exceed three (3) years from the date of shipment by ValcoMelton, a Valco Cincinnati, Inc.

company.

ValcoMelton 9-1

If a problem with your system persists, contact a ValcoMelton Technical

Support Representative. If your need is urgent, we encourage you to contact our corporate office in Cincinnati, Ohio, U.S.A. at (513) 874-6550. If the problem cannot be resolved, Valco Cincinnati will promptly arrange to have a technical representative visit your facility. Any charges for a service call will be quoted at that time. Any part that fails during the warranty period shall be returned prepaid to Valco Cincinnati, Inc. by the customer for disposition.

Upon request, ValcoMelton personnel are available to repair or replace such parts at the customer’s facility. Charges for this service include travel time and expenses.

If an equipment problem is the result of customer abuse, improper installation or operation, all travel time, labor, parts, and expenses will be charged to the customer.

If the responsibility for a problem cannot be absolutely determined, the customer will be charged for travel time and expenses only. No charge will be made for parts and labor.

Valco Cincinnati, Inc.

10-1