External Vacuum Feeder
Control Unit
Manual Number: MC099
Revision Date: 7/2014
© Valco Melton All Rights Reserved
This manual is furnished with the External Vacuum Feeder Control Unit and may be used or copied 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.
Part Number: MC099
Printed in the USA
Declaration of Conformity
(According to EN 45014)
Manufacturer:
Valco Melton
A division of Valco
Cincinnati, Incorporated
411 Circle Freeway Drive
Cincinnati, OH 45246
USA
Authorized Representatives in
Europe:
Valco Cincinnati, Ltd.
Unit 7-8
Hortonwood 32
Telford TF1 7YN
England
declares that the product:
Product Name:
External Vacuum Feeder
Control Unit
complies with the following Council Directives:
Safety of Machinery:
2006/42/EC
Low Voltage Equipment:
2006/95/EC
EMC:
2004/108/EC
and conforms to the following standards:
Safety:
EN60204-1:2006
EN13849-1
Risk:
EN14121-1:2007
EMC Emissions:
EN61000-6-4:2007
EN61000-4-2
EMC Immunity:
EN61000-6-2:2005
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
EN61000-4-8
EN61000-4-11
Place and Date:
Cincinnati, Ohio USA
CE Mark first fixed 2006
Signature:
David H. Swedes,
Director of Engineering &
Manufacturing
Melton S.L.U.
Pol. Industrial
Agustinos
calle G, n. 34
31160 Orcoyen
Navarra, Spain
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MC099 - External Vacuum Feeder Control Unit
Table of Contents
Table of Contents
Table of Contents ................................................................................................ 5
Section 1 - Introduction ....................................................................................... 7
System Description .................................................................................................................................................. 7
Section 2 - Safety and Use ................................................................................... 9
Read Thoroughly Before Handling Equipment ....................................................................................................... 9
Symbols ................................................................................................................................................................... 9
Owner Responsibilities ............................................................................................................................................ 10
Limitations of Use .................................................................................................................................................... 10
Installation/Startup/Use Safety Information............................................................................................................. 11
Shut Down Safety Information ................................................................................................................................ 12
Hot-Melt-Specific, General Safety Information ....................................................................................................... 12
What to Do if Contact with Hot Adhesive Occurs ................................................................................... 13
What to Do if Inhalation of Adhesive Fumes Occurs .............................................................................. 13
What to Do if Adhesive-Related Fire or Explosion Occurs ..................................................................... 14
Hose Safety Information .......................................................................................................................................... 15
Section 3 - Basic Features ................................................................................... 17
Feature/ Capabilities ................................................................................................................................................ 17
External Vacuum Feeder Control............................................................................................................................ 17
Front View ............................................................................................................................................... 17
Side View ................................................................................................................................................ 18
Electrical Enclosure................................................................................................................................. 19
Adjusting the time delay .......................................................................................................................... 19
Section 4 - Installation ......................................................................................... 21
D-E .......................................................................................................................................................... 21
NC 20, 30, and 40 ................................................................................................................................... 23
S-18, S-24, S-48, S-90 ............................................................................................................................ 24
Nordson 3100, 3400, 3500 ..................................................................................................................... 25
Nordson MESA M9 ................................................................................................................................. 26
Nordson Pro-Blue 4, 7 and 10 (Left Hinge) ............................................................................................ 29
Nordson Pro-Blue 7 and 10 (Front/Rear Hinge) ..................................................................................... 31
Nordson Pro-Blue 15............................................................................................................................... 33
Slautterback KB100 ................................................................................................................................ 34
Finishing Attachments ............................................................................................................................................. 35
Section 5 - Operation ........................................................................................... 37
Start-up..................................................................................................................................................................... 37
Calibrating the level sensor ..................................................................................................................................... 37
Adjusting the air flow control valve .......................................................................................................................... 38
Filling the tank .......................................................................................................................................................... 38
5
Table of Contents
MC099 - External Vacuum Feeder Control Unit
SECTION 6 - MAINTENANCE ............................................................................... 39
Cleaning the exterior of the control ......................................................................................................................... 39
Changing the air filter ............................................................................................................................................... 39
Changing the fuses .................................................................................................................................................. 40
Section 7 - Troubleshooting ................................................................................. 41
Mechanical Faults .................................................................................................................................................... 41
Section 8 - Specifications .................................................................................... 43
Section 9 - Part Number List ................................................................................ 45
How to Order Parts .................................................................................................................................................. 45
Vacuum Feeder Control Unit................................................................................................................................... 46
Section 10 - Warranty .......................................................................................... 51
Warranty Information ............................................................................................................................................... 51
Cold Glue Equipment and Electronic Controls ....................................................................................... 51
Hot Melt Units, Hoses, Valves, Guns, and Related Equipment ............................................................. 51
Section 11 - Service ............................................................................................ 53
Appendix A - Remote Mounted Light Stack .......................................................... 55
Description ............................................................................................................................................................... 55
Installation ................................................................................................................................................................ 55
6
MC099 - External Vacuum Feeder Control Unit
Section 1 - Introduction
Section 1 - Introduction
System Description
This manual has been prepared by Valco Cincinnati, Inc. to provide assistance in operating and servicing of your
external vacuum feeder control.
The purpose of the vacuum feeder system 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. If the sensor detects a low level,
the solenoid valve opens and the vacuum feeder supplies adhesive until it detects the high-adhesive level. If the
adhesive does not load before the preset time delay, a red light and alarm will signal the operator. When the vacuum
feeder lid is opened, the feeder will deactivate. It will reactivate after the lid is closed.
The external vacuum feeder system can be retrofitted to existing Valco Melton hot melt units, as well as to several
competitor units.
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Section 1 Introduction
MC099 - External Vacuum Feeder Control Unit
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8
MC099 - External Vacuum Feeder Control Unit
Section 2 - Safety and Use
Section 2 - Safety and Use
Read Thoroughly Before Handling Equipment
WARNING!
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.
Symbols
The following symbols may be used on the equipment and/or in this manual.
This symbol represents a 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.
This symbol represents a Hot Surface.
This symbol represents a Puncture Risk. It is usually used in regard to nozzle cleaning appliances
and other sharp instruments that can cause puncture wounds and risk exposure to bloodborne
pathogens and other debris.
This symbol means that Working Gloves are required.
This symbol means that Goggles are required.
This symbol indicates a Shock Hazard. There is a presence of non-insulated dangerous voltage
within the product’s enclosure. This voltage may cause electrical shock or fire.
This symbol indicates the need to Unplug/Disconnect All Power Sources and to let them de-energize
before attempting any type of work or maintenance. Remember that there can still be energy in
equipment, cords, and wires even when unplugged/disconnected.
This symbol indicates the need to Lock Out All Power Sources 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.
This symbol indicates a Note. Notes point out something of special interest or importance to the
reader. They give tips, hints, and information in addition to what is necessary for the step preceding
it.
9
Section 2 - Safety and Use
MC099 - External Vacuum Feeder Control Unit
Owner Responsibilities
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.
Limitations of Use
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.
10
MC099 - External Vacuum Feeder Control Unit
Section 2 - Safety and Use
Installation/Startup/Use 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):
WARNING!
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.
WARNING!
The equipment should be installed so that it can be turned off at a location away from the
equipment in case of injury, electrical problems, or malfunction. OTHERWISE, DEATH OR
PERSONAL INJURY COULD OCCUR.
WARNING!
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.
WARNING!
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.
WARNING!
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.
WARNING!
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.
11
Section 2 - Safety and Use
MC099 - External Vacuum Feeder Control Unit
Shut Down 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):
WARNING!
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.
WARNING!
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.
WARNING!
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.
WARNING!
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.
WARNING!
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.
WARNING!
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.
Hot-Melt-Specific, General Safety Information
Valco Melton hot melt units have the following universal safety precautions in addition to all other universal
precautions previously mentioned (this is not intended to be an exhaustive list; follow all instructions and safety
precautions for the specific type of equipment involved):
WARNING!
Never process any polyurethane reactive (PUR) hot 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 solvent-based materials. OTHERWISE, HAZARDOUS FUMES, EXPLOSION,
DEATH, OR PERSONAL INJURY COULD OCCUR.
WARNING!
Keep pump cover and electrical enclosures closed except during setup, service, and
checkout procedures. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.
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MC099 - External Vacuum Feeder Control Unit
Section 2 - Safety and Use
WARNING!
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.
WARNING!
Keep hot melt hoses away from walkways and the moving parts of hot melt systems.
OTHERWISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR.
WARNING!
Hot surfaces! Do not touch! Use extreme caution when refilling the unit by hand.
OTHERWISE, PERSONAL INJURY COULD OCCUR.
WARNING!
Wear protective gloves and goggles at all times around all machinery, especially hot melt.
OTHERWISE, SERIOUS PERSONAL INJURY COULD OCCUR.
WARNING!
Never use an open flame to heat hot melt components or adhesive. OTHERWISE, DEATH,
PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR.
What to Do if Contact with Hot Adhesive Occurs
If hot adhesive comes in contact with the skin, do the following:
WARNING!
Do not attempt to remove heated hot melt adhesive from the skin. OTHERWISE, SEVERE
PERSONAL INJURY AND DEATH COULD OCCUR.
1. 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.
2. Cover the affected area with a clean, wet compress and call the emergency medical response
system (such as 911) immediately.
3. 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:
1. Take the victim away from the immediate work area.
2. Provide victim with fresh air.
3. Call the emergency medical response system (such as 911) immediately.
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Section 2 - Safety and Use
MC099 - External Vacuum Feeder Control Unit
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.
WARNING!
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.
WARNING!
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.
WARNING!
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:
1. Sound a fire alarm.
2. Evacuate the immediate area.
3. Turn off all local electrical equipment at the source.
4. Leave the area immediately if conditions are unsafe.
If you feel you can fight the fire safely, do one of the following:
•
Smother the fire with a fire blanket.
•
Aim a CO2 fire extinguisher at the base of the flames.
•
Aim a dry-powder fire extinguisher at the base of the flames.
14
MC099 - External Vacuum Feeder Control Unit
Section 2 - Safety and Use
Hose Safety Information
DO NOT
DO
Do not use bindings, wire
ties, or unapproved
fasteners around the
hoses.
Do use approved
wrapping (P/N
KAP0434), making sure
the wrapping is slightly
snug but not tight.
Do not place hoses close
together.
Do allow at least 2
inches (5.1 cm) between
hoses for proper
ventilation.
Do not bend hoses
sharply. Do not allow kinks
or indentations in the
hoses.
Do use a minimum bend
radius of 10 inches for a
20-inch diameter coil
hose.
Do not use unapproved
hooks to hang hoses. Do
not wrap hoses over or
around objects.
Do use a hose hanging
kit (P/N 781xx827).
Do not use the “one
handed/one wrench”
technique to attach or
remove hoses. Do not
wrench on any surface
other than the large
hexagon swivel nuts.
Do use two hands and
two wrenches to tighten
or loosen connections
on hoses. Do wrench
only on large hexagon
swivel nuts.
Do not allow hoses to rub
against objects or to come
into contact with sharp
edges or points.
Do wrap the hoses in
approved padding (P/N
795xx549) if the hoses
must be installed where
they will come into
contact with objects.
Do not use worn,
damaged, or bent hoses.
Do inspect all hoses
regularly for damage
and/or wear and replace
damaged or worn hoses
immediately.
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Section 2 - Safety and Use
MC099 - External Vacuum Feeder Control Unit
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MC099 - External Vacuum Feeder Control Unit
Section 3 - Basic Features
Section 3 - Basic Features
Feature/ Capabilities
Features/capabilities of the external vacuum feeder include:
•
Can be operated with 120/240 VAC
•
Is provided with a 5 ft. power cord and a 10 ft. feed tube
•
A bi-color LED indicates power on, and a low level warning
•
An audible alarm (80 dB) indicates a low level warning
•
An adjustable time delay for low level alarm and LED.
•
A 24V solenoid valve with flow control to adjust adhesive pellet flow
•
Accurate and adjustable capacitive level sensor
•
Door switch to prevent accidental adhesive blow-out
•
Optional remotely-mounted light stack and alarm
External Vacuum Feeder Control
Front View
Item
Description
1
Electrical enclosure
2
Power switch
3
Bi-color LED
4
Alarm
5
Activator rod
17
Section 3 - Basic Features
MC099 - External Vacuum Feeder Control Unit
Side View
Item
6
7
8
9
10
Description
Name plate
Hole plug for optional light stack
Air filter
Solenoid valve
Feeder tube
18
MC099 - External Vacuum Feeder Control Unit
Section 3 - Basic Features
Electrical Enclosure
Item
11
12
13
14
Description
Level sensor amplifier box
Adjustable time delay
Remote light stack connector
24V power supply
Adjusting the time delay
The vacuum feeder PCB has a four-position rotary switch used to adjust the time delay on the board. This time delay
functions when the low-level signal is sent to the LED and alarm. If the tank is not filled within the set time period, the
LED and alarm will turn on, indicating a vacuum feeder fault. If the tank is filled within the set time period, the time
stops, and the LED and alarm remain off.
The default time delay is five minutes (position #3). The other time delay and positions are shown below.
Position
Time Delay (min)
1
1.5
2
3
3
5
4
7.5
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Section 3 - Basic Features
MC099 - External Vacuum Feeder Control Unit
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20
MC099 - External Vacuum Feeder Control Unit
Section 4 - Installation
Section 4 - Installation
Power Requirements
Voltage (VAC)
Phase (Ø)
Current (A)
120/220
1
1
A 3 ft. power cord is supplied with each system,
unless noted otherwise.
Installation
Please follow these instructions for all units, and then follow the unit-specific instructions.
For unit drawings and parts lists, refer to the “Parts Lists” section.
Proceed according to the unit:
Unit Series
Page Start
D-E Series
NC 20, 30 or 40
S-18, S-24, S-48 or S-90
Nordson 3100, 3400 or 3500
Nordson Mesa M9
Nordson Pro-Blue 4, 7 or 10 (Left Hinge)
Nordson Pro-Blue 7 or 10 (Front/Rear Hinge)
Nordson Pro-Blue 15
Slautterback KB100
21
23
24
25
26
29
31
33
34
Follow all steps on page 35 after installation.
D-E
1. Ensure the top of the Level Probe is approximately 1” above the cord grip for a D4-E, and
approximately 1/4” above for a D10-E.
Pull on the wire from the bottom of the auto feed box if more wire
length is needed.
2. Remove the current lid and hinge from the unit and discard.
3. Attach the new hinge to the unit using three (3) M6 button head cap screws taken from the old
hinge.
4. Attach the new lid with auto feed to the top of the unit.
5. Remove the knockouts from the rear corner of the case, and from the panel separating the
electrical cabinet from the reservoir.
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Section 4 - Installation
MC099 - External Vacuum Feeder Control Unit
D-E - Continued
Knockout
6. Attach cord grips into the holes left by the knockouts.
7. Run the leads through the cord grips to the power board.
8. Connect the wires into the three-pin, inverted connector as shown (yellow/green, brown and
blue, respectively).
9. Attach the connector to the open “fused AC connector” on the power board.
22
MC099 - External Vacuum Feeder Control Unit
Section 4 - Installation
NC 20, 30, and 40
CAUTION!
Make sure the top of the level probe is approximately 1/4” above the cord grip.
Pull the wire from the bottom of the auto feed box if more wire length
is needed.
1. Remove the current lid from the unit and discard.
2. Attach the new lid with auto feed to the top of the unit.
3. Insert brown wire in to any free “L2” opening.
4. Insert blue wire in to any free “L1” opening.
5. Insert green/yellow wire in to any free green/yellow opening.
23
Section 4 - Installation
MC099 - External Vacuum Feeder Control Unit
S-18, S-24, S-48, S-90
1.
Make sure the top of the level probe is approximately 1/4” above the cord grip.
Pull on the wire from the bottom of the auto feed box if more wire
length is needed.
2. Remove the current lid from the unit and discard.
3. Attach the new lid with auto feed to the top of the unit.
4. Connect the blue wire with terminal 3010.
5. Connect the brown wire with terminal 3011.
6. Connect the yellow/green wire to the yellow/green terminal to the right of terminals 3010 and
3011.
24
MC099 - External Vacuum Feeder Control Unit
Section 4 - Installation
Nordson 3100, 3400, 3500
1.
Make sure the top of the level probe is approximately 1/4” above the cord grip.
Pull on the wire from the bottom of the auto feed box if more wire
length is needed.
2. Remove the piston cover
3. Remove the lid and base plate from the top of the Nordson unit and place the eight (8) machine
screws aside.
4. Discard the old lid and base.
5. Attach the new base plate using the eight (8) machine screws from the previous step.
6. Place the new lid onto the new base plate
7. Push an E-clip onto one of the slotted sections near the end of the hinge rod.
8. Slide the side opposite of the side with the E-clip into of the hinge rod holes on the lid.
9. Push the hinge rod to the other side of the lid until the side with the E-clip is as far over as
possible.
10. Push the other E-clip into the other slot on the hinge rod.
11. Attach the blue wire to the terminal labeled “N”.
12. Attach the brown wire to the terminal labeled “L1”, “L2”, or “L3”.
13. Attach the yellow/green wire to an open yellow/green terminal.
25
Section 4 - Installation
MC099 - External Vacuum Feeder Control Unit
Nordson MESA M9
1. Ensure the top of the level probe is approximately 1/4” above the cord grip.
Pull on the wire from the bottom of the auto feed box if more wire
length is needed.
2. Remove the piston pump cover and place the two (2) socket head screws aside.
3. Remove the lid and tank mounting bracket from the top of the Nordson unit and place the seven
(7) socket head screws aside.
4. Discard the old lid and tank mounting bracket.
5. Attach the new tank mounting bracket with vacuum feeder using the seven (7) socket head
screws from the previous step. Be sure to apply downward pressure to full seat the tank
mounting bracket.
26
MC099 - External Vacuum Feeder Control Unit
Section 4 - Installation
Nordson MESA M9 - Continued
6. Reattach the piston pump cover.
This auto feed is supplied with a 9’ power cord.
7. Route the cable to back of unit.
8. Route the cable along the side of unit using the clips provided.
9. Install cord grip and route the cable into the electrical cabinet.
10. Connect the wires to the two pin, inverted connector as shown (blue and brown respectively)
and plug in the connector to the open “AC OUT” connector on the power board.
27
Section 4 - Installation
MC099 - External Vacuum Feeder Control Unit
Nordson MESA M9 - Continued
11. Attach the green/yellow wire to an open quick disconnect ground terminal.
28
MC099 - External Vacuum Feeder Control Unit
Section 4 - Installation
Nordson Pro-Blue 4, 7 and 10 (Left Hinge)
1.
Make sure the top of the level probe is approximately 1/4” above the cord grip.
Pull on the wire from the bottom of the auto feed box if more wire
length is needed.
2. Remove the current lid from the Nordson ProBlue 7 or 10 by opening the lid and pulling back of
the right side of the hinge rod.
3. Discard the Nordson lid assembly.
4. Remove the two (2) screws from the locations indicated below.
Screws
5. Place the foot tap over the holes and reattach, using the two (2) screws that were removed in
the previous step.
6. Place the new lid with auto feed to the top of the unit.
29
Section 4 - Installation
MC099 - External Vacuum Feeder Control Unit
Nordson Pro-Blue 4, 7 and 10 (Left Hinge) - Continued
7. Push an E-clip into one of the slotted sections near the end of the hinge rod.
8. Slide the side opposite of the side with the E-clip into the hinge rod holes on the lid.
9. Push the hinge rod to the other side of the lid until the side with the E-clip is as far over as
possible.
10. Push the other E-clip into the other slot on the hinge rod.
11. Remove one of the knockouts from the back of the Nordson unit and open the back panel.
12. Feed the three power supply wires from the auto feed through the knockout and into the board
as shown below.
WARNING!
The Nordson Pro-Blue series has an option for 480 VAC operation. If operating the unit at
this voltage, an external power supply with an output of 110-120 VAC or 220-240 VAC is
required to power the auto-feed system.
30
MC099 - External Vacuum Feeder Control Unit
Section 4 - Installation
Nordson Pro-Blue 7 and 10 (Front/Rear Hinge)
All pictures included in this section show an auto feed front hinge.
The installation procedure is the same for the auto feed with the rear
hinge.
1. Ensure that the top of the level probe is about .25” above the cord grip.
Pull on the wire from the bottom of the auto feed box if more wire
length is needed.
2. Remove the current lid from the Nordson Pro-Blue unit by opening the lid and pulling back on
the right side of the hinge rod.
3. Remove the float switch from the tank bracket.
4. Remove the Nordson tank bracket by removing the eight (8) M5 socket head cap screws.
5. Discard the Nordson lid, tank bracket and mounting hardware.
6. Attach the new tank bracket using the eight (8) M5 button head cap screws provided.
7. Reattach the float switch that was removed in step #3.
8. Insert the new lid with auto feed into the hinge mounting holes on the tank bracket by angling
the lid assembly down and to the side.
9. Once the hinge rod is in the hole on the far side, close the lid.
10. Slide the entire lid forward until the hinge rod is in the mounting hole on the closest side.
11. Secure the lid in place using the M5 socket head cap Nyloc screw provided.
12. Insert the M4 socket head cap screw into the slot on the tank bracket and tighten completely.
31
Section 4 - Installation
MC099 - External Vacuum Feeder Control Unit
Nordson Pro-Blue 7 and 10 (Front/Rear Hinge) - Continued
13. Remove one of the knockouts from the back of the unit and open the back panel.
14. Feed the three power supply wires from the auto feed through the knockout and into the board
as shown below.
WARNING!
The Nordson Pro-Blue series has an option for 480 VAC operation. If operating the unit at
this voltage, an external power supply with an output of 110-120 VAC or 220-240 VAC is
required to power the auto-feed system.
32
MC099 - External Vacuum Feeder Control Unit
Section 4 - Installation
Nordson Pro-Blue 15
1. Make sure the top of the level probe is approximately 1/4” above the cord grip.
Pull on the wire from the bottom of the auto feed box if more wire
length is needed.
2. Remove the hinge from the previous Nordson lid by removing the two (2) M5 socket head cap
screws attached to the lid and the two (2) fasteners securing the lid to the unit. Save both the
hinge and the fasteners used to secure to the unit.
3. Discard the Nordson lid.
4. Place the hinge plate between the hinge and the outer lid, and attach the two (2) M5 socket
head cap screws.
5. Secure the lid to the unit using the two fasteners removed in step 2.
If necessary, push back or anchor the wires running in the location
where the activator rod engages with the base of the unit.
6. Close the lid and ensure that the auto feed activates by listening for the click of the switch in the
activator rod. If the auto feed does not engage, unscrew the rubber foot of the rod until you hear
activation. If necessary, replace the rubber foot with a longer M4 fastener.
7. Remove one of the knockouts from the back of the Nordson unit and open the back panel.
8. Feed the three power supply wires from the auto feed through the knockout and into the board
as shown below.
This auto feed is supplied with a 9’ power cord.
WARNING!
The Nordson Pro-Blue series has an option for 480 VAC operation. If operating the unit at
this voltage, an external power supply with an output of 110-120 VAC or 220-240 VAC is
required to power the auto-feed system.
33
Section 4 - Installation
MC099 - External Vacuum Feeder Control Unit
Nordson Pro-Blue 15 - Continued
Slautterback KB100
1.
Ensure that the top of the level probe is about .25” above the cord grip.
Pull on the wire from the bottom of the auto feed box if more wire
length is needed.
2. Remove the top portion of the case from the Slautterback KB100 by removing the ten (10) selftapping screws holding the top of the unit on.
3. Remove the current lid from the unit by removing the four (4) button head cap screws and four
(4) hex nuts.
4. Discard the Slautterback lid.
5. Attach the new auto feed to the case that was removed in step #1 using four (4) M5 hex head
cap screws four (4) M5 lock washers and four (4) M5 hex nuts.
6. Reattach the top portion of the case that was removed using the ten (10) self-tapping screws.
An external power source is necessary for this auto feed system.
34
MC099 - External Vacuum Feeder Control Unit
Section 4 - Installation
Finishing Attachments
1. If needed, use the supplied 10mm tubing and 10mm to 3/8" adapter for the air 35line input.
2. If supplied, remove the yellow cap on the end of the adhesive inlet.
3. Using a Phillips head screwdriver tighten the hose clamp so the hose is securely fastened to
inlet.
4. Attach the blue air line hose from the adhesive transporting tube to the top of the needle
regulator outlet port as shown below.
5. Attach the air line from any source to the inlet port on the regulator (needle valve can be turned,
to adjust for variations in input pressure).
See IS0274 for Operation and Calibration instructions.
35
Section 4 - Installation
MC099 - External Vacuum Feeder Control Unit
This Page Intentionally left Blank.
36
MC099 - External Vacuum Feeder Control Unit
Section 5 - Operation
Section 5 - Operation
Start-up
To turn on the vacuum feeder, press the main switch on the front panel. If the control is on, a green LED will light up.
Calibrating the level sensor
1. Close the flow control valve (turn the screw clockwise until it stops) or disconnect the incoming
air supply.
2. Fill the tank with adhesive so that the level covers half of the probe tip. The probe tip is the tan,
plastic cap.
3. With the lid closed, check the LED on the amplifier box.
a. If the light is red:
1) Turn the potentiometer until it turns green. Continue to “If the light is green”.
b. If the light is green:
1) Turn the potentiometer counterclockwise until the LED begins to flash. It should
eventually turn red. With the LED in the red state, turn the potentiometer clockwise
slowly until it turns green.
4. The level sensor is now calibrated.
37
Section 5 - Operation
MC099 - External Vacuum Feeder Control Unit
Adjusting the air flow control valve
1. Connect the incoming air supply.
2. Open the flow control valve slowly, counterclockwise until adhesive begins to flow into the tank.
WARNING! DO NOT open the valve too far as it will result in adhesive splash back on the lid and air
filter.
Filling the tank
When the level sensor detects a low adhesive level in the tank, the solenoid valve will open and the vacuum feeder
will transfer adhesive pellets from the container to the tank. Once the correct adhesive level is obtained the solenoid
valve will close.
If the correct adhesive level is not obtained after 5 minutes (programmable), the LED on the front panel will change to
red and the alarm will sound. The vacuum feeder can be reset by turning it off and back on or by satisfying the low
level sensor.
38
MC099 - External Vacuum Feeder Control Unit
Section 6 - Maintenance
Section 6 - Maintenance
Cleaning the exterior of the control
This section contains maintenance procedures for the external vacuum feeder control. A regular maintenance
program helps ensure longer life and efficient operation of your system. A few minutes spent on maintenance greatly
reduces downtime.
To clean the exterior of the vacuum feeder control, follow these steps:
CAUTION!
Never hose or steam-clean the control. If cleaning the surrounding area in this manner,
protect the control by covering it with plastic or other waterproof material. Failure to comply
could result in damage to the equipment.
1. Turn off the main power.
2. Using a damp cloth, clean the electrical enclosure with a mild soap and water solution.
Changing the air filter
To change the air filter, follow these steps:
1. Turn off the main power.
2. Unscrew the air filter from the top of the vacuum feeder.
WARNING!
Use a wrench to unscrew filters that cannot be easily removed by hand. Squeezing the filter
too hard can damage it.
3. Use a screwdriver or long tool to remove the adhesive from the filter’s inner mesh and cap. If
necessary, replace the filter.
39
Section 6 - Maintenance
MC099 - External Vacuum Feeder Control Unit
Changing the fuses
In the event that a fuse must be replaced, simply remove the cover using a flat head screwdriver and replace the
appropriate fuse. The first set of fuses protects the 24V power supply on the AC supply side. The second fuse
protects the components of the assembly that are powered by 24VDC.
Item
1
2
Part #
085XX220
085XX239
Qty
2
1
40
Description
Fuse, 2A, 5 X 20 mm
Fuse, 1A, 5 X 20 mm
MC099 - External Vacuum Feeder Control Unit
Section 7 - Troubleshooting
Section 7 - Troubleshooting
Mechanical Faults
•
The 24V LED confirms that the power supply is functioning properly and 24VDC is being supplied to
the rest of the board.
•
The 5V LED confirms that the 5VDC required for certain components is being supplied to the board.
•
The error LED is used to signal a problem on the board, for example the time delay switch is set in
between two positions.
•
The solenoid valve LED turns on when the valve is activated, this occurs when a low level is detected.
•
The alarm/light LED turns on when a low level is detected and the time delay has expired.
•
The low level signal LED is used to signal when a low level is detected.
41
Section 7 - Troubleshooting
MC099 - External Vacuum Feeder Control Unit
This Page Intentionally left Blank.
42
MC099 - External Vacuum Feeder Control Unit
Section 8 - Specifications
Section 8 - Specifications
Item
Control Dimensions
Input Voltage
Full-Load Amps
Indicators
Safety
Miscellaneous
External Vacuum Feeder Control
Height: 11.45 (290.8 mm)
Width: 5.28 (134.1 mm)
Depth: 11.54 (293.1 mm)
120/240 VAC, 50/60 Hz
See name plate
Bi-color LED indicates power on and a low level warning state
Audible alarm (80 dB) indicates a low level warning state
Optional remote mounted light stack and alarm (KJC1356t)
Door switch to prevent accidental adhesive blow out
24V solenoid valve with flow control to adjust adhesive pellet flow
Accurate and adjustable capacitive level sensor
43
Section 8 - Specifications
MC099 - External Vacuum Feeder Control Unit
44
MC099 - External Vacuum Feeder Control Unit
Section 9 - Part Number List
Section 9 - Part Number List
How to Order Parts
To order parts, please contact your closest Valco office by mail, phone, or Email:
USA
Valco Cincinnati, Inc.
411 Circle Freeway Drive
Cincinnati, OH 45246
TEL: (513) 874-6550
FAX: (513) 874-3612
Email: sales@valcomelton.com
Web: http://www.valcomelton.com
England
Valco Cincinnati Limited
Hortonwood 32
Telford, TFI 7YN, England
TEL: (+44) 1952-677911
FAX: (+44) 1952-677945
Email: sales@valco.co.uk
Web: http://www.valco.co.uk
Germany
Valco Cincinnati GmbH
Storkower Strasse 6
D-15749 Gallun, Germany
TEL: (+49) 337 648 700
FAX: (+49) 337 648 7070
Email: info@valcogmbh.de
Spain
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
45
Section 9 - Part Number List
MC099 - External Vacuum Feeder Control Unit
Vacuum Feeder Control Unit
46
MC099 - External Vacuum Feeder Control Unit
Section 9 - Part Number List
47
Section 9 - Part Number List
MC099 - External Vacuum Feeder Control Unit
48
MC099 - External Vacuum Feeder Control Unit
Section 9 - Part Number List
Item
Part #
Qty
Description
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
17
18
19
20
21
KJC1023
066XX160
KJC1321
KJC1044
784XX352
784XX349
151XX703
784XX968
KJC1045
915XX305
075XX303
075XX215
784XX308
798XX488
781XX228
KJC1017
075XX301
KJC1354
540XX052
540XX048
075XX305
1
2
4
4
8
8
1
4
2
1
3
1
6
6
1
1
3
1
74 IN
74 IN
17
ENCLOSURE, MODIFICATION
*CORD GRIP,4-8MM,BLACK
BHCS M5 X 40 SS
SPACER M5 X 25
LOCK WASHER M5
NUT, HEX M5 ZI
PCB ASSY
PHMS M3 X 8 SS
STS #6-32 X 5/16 ZI
RECHNER SENSOR: N8 W/TIME DEL
*FERRULE, INS, 20 AWG, WHITE
WIRE TERMINAL RING, #8
LOCK WASHER M4 ZINC
NUT,HEX M4 ZINC
*HOLE PLUG, DOUBLE D, .625
*LED, GREEN/RED, 11/16 OD
*FERRULE, INS, 24 AWG, LT-BLU
ALARM, 24V, 30MM OD
*WIRE PVC 18 AWG BLU 300V 80C
*WIRE PVC 18 AWG BRN 300V 80C
*FERRULE, INS, 18 AWG, RED
49
Section 9 - Part Number List
MC099 - External Vacuum Feeder Control Unit
Item
Part #
Qty
Description
22
23
24
25
26
27
28
29
30
31
32
33
34
35
36
37
38
39
40
41
42
43
44
45
46
47
48
49
50
51
52
53
90
91
98
KJC1355
075XX386
KJC1012
KJC1013
KJC1046
784XX910
KJC1047
KJC1048
KJC1049
KJC1014
430XX075
KJC1051
KJC1050
KJC1007
D050170100
DG05101600
784XX008
784XX159
910XX465
411XX863
799XX642
799XX662
KJC1024
066XX075
784XX125
755XX087
540XX051
034XX006
075XX204
KJC1286
KJC1064
091XX517
797XX839
K051701002
KJC1358
1
6
1
1
1
1
1
1
7 IN
1
1
2
2
1
1
1
2
4
1
1
1
1
1
1
2
22 IN
24 IN
6
1
1
1
2
1
1
1
*SWITCH, DPST, 8A
*WIRE TERMINAL, FASTON
ACTIVATOR ROD MOUNTING TUBE
ACTIVATOR ROD
SPACER, M4 X 14 MM
SHCS M4 X 20 SS
SQUARE PLUG, 1/2
THREADED BUMPER, #4-40 X 5/16
TAPE, FOAM, 1/8 X 1/2
SWITCH MOUNTING BRACKET
SWITCH; LIMIT, SA LEVER
SLW M2.5 SS
SHCS M2.5 X 14 SS
VALVE MOUNTING BRACKET
FEEDER TUBE
THREADED FEEDER TUBE
SHCS M6 X 10 BO
BHCS M5 X 8 SS
VACUUM FEEDING FILTER
3-WAY SOLENOID,1/4" PRT
SOCKET HEAD PIPE PLUG, 1/4
FITTING, PUSH, 1/4 NPT X 10MM
CONTROL, FLOW
CABLE CLAMP, 1/4
SHCS M4 X 25 ZI
*SLEEVING, FIBERGLASS, #4, BLK
*WIRE PVC 18 AWG GRN/YEL
*CABLE, POWER 18/3 BULK SJ
*WIRE TERMINAL, RING #10
LABEL, VALCO MELTON LOGO
NAMEPLATE
RIVET, BLIND, 1/8 DIA X 1/4 L
FITTING, PUSH, 1/4 NPT X 3/8 IN
ASSEMBLY, FEEDER TUBE
ILLUSTRATION DWG, WIRING DIA.
50
MC099 - External Vacuum Feeder Control Unit
Section 10 - Warranty
Section 10 - Warranty
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, Orings, 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 disclose any defect of workmanship
or material, any 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. Cast-in 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.
51
Section 10 - Warranty
MC099 - External Vacuum Feeder Control Unit
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MC099 - External Vacuum Feeder Control Unit
Section 11 - Service
Section 11 - Service
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, Inc. 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.
53
Section 11 - Service
MC099 - External Vacuum Feeder Control Unit
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54
MC099 - External Vacuum Feeder Control Unit
Appendix A - Remote Mounted Light Stack
Appendix A - Remote Mounted Light Stack
Description
This optional kit is used to establish a remote a light and alarm. The remote light functions the same way as the light
and alarm located on the front of the vacuum feeder control.
This can also be used to send the warning signal to the customer PLC.
Pin #
1
2
3
4
5
Description
- (Alarm)
N.C.
+ (Common)
- (LED)
N.C.
Installation
1. Remove the black plastic plug from the side of the vacuum feeder control.
2. Attach the panel mounted M12 connector to the side of the enclosure.
3. Attach the 5 pin connector to the open connector on the circuit board.
55
Appendix A - Remote Mounted Light Stack
MC099 - External Vacuum Feeder Control Unit
Installation - Continued
4. Mount the light and alarm using the hardware provided.
5. Connect the light stack to the enclosure using the 6m long cable provided (other lengths are
available but must be purchased separately).
56