ADHESIVE SAVER DEVICEEFFIBEAD

INSTRUCTIONS MANUAL

MA-5104-E 010915

GLUING SOLUTIONS

Published by:

Meler Gluing Solutions, S.A

P.I. Los Agustinos, calle G, nave D-43E - 31160 ORCOYEN Navarra (España)Tel.: + 34 948 351 110 Fax: + 34 948 351 130e-mail: info@meler.eu

www.meler.eu

Edition September 2015

© Copyright by Meler

All rights reserved. Its reproduction, diffusion or use by electronic or other means of all or any part of this document without the express authorization of its owner is strictly prohibited.

The specifications and information contained in this manual may be modified without prior notice.

MA-5104-E MANUAL EFFI BEAD TABLE OF CONTENTS

TABLE OF CONTENTS

1. SAFETY GUIDELINES 1-1

2. INTRODUCTION 1-1

Description and use 1-1

Main components 1-2

Dimensions (mm) 1-2

3. INSTALLATION 1-3

4. USE 1-4

States of the device 1-4

Using and programming the device 1-4

Calculation and parameter tables 1-5

Error management 1-7

5. TECHNICAL FEATURES 1-8

MELER GLUING SOLUTIONS TABLE OF CONTENTS

This page is intentionally left blank.

MELER GLUING SOLUTIONSMA-5104-E EFFI BEAD MANUAL

1-1

1. SAFETY GUIDELINES

The information contained in these guidelines applies not only to normal use with the product, but also any action performed on it.

It is very important that the safety warnings contained in this manual are respected at all times. Failure to do so may cause injury and/or damage to the machine or the rest of the installation.

Before using the product, read this manual carefully and contact our Service Centre if you have any questions. We are at your disposal for any clarification you may need.

Keep the manuals in good condition and within reach of personnel using and performing maintenance on the machine.

Also provide the necessary safety material: appropriate clothing, footwear, gloves and safety glasses if necessary.

Respect at all times the local regulations on risk prevention and safety.

2. INTRODUCTION

Description and use

The EFFIBEAD product is a device responsible for 'chopping' an input pulse voltage of 24 VDC for a certain period in a series of output pulses of shorter duration and according to a selected pattern.

A continuous line of adhesive becomes intermittent lines (lines-holes), with the resultant saving in adhesive, provided the characteristics required for proper adhesion of the substrates are maintained.

The EFFIBEAD unit will be placed between the PLC (or activation signal gener-ating device) and the applicator electrovalve (See chapter 3, ‘Installation’).

Without the EFFIBEAD device, the signal sent to the applicator electrovalve would be:

while, with the EFFIBEAD installed, a chopped signal will be sent to the electro-valve as shown in the above image.

After applying the adhesive, the result would be:

MELER GLUING SOLUTIONS

1-2

MA-5104-E EFFI BEAD MANUAL

The top bead is continuous due to the continuous input signal while the bottom bead is chopped by the EFFIBEAD device, according to a pre-selected pattern

Main components

1- Voltage pulse input (terminal blocks).

2- Rotary switch % (percentage of adhesive saving).

3- Rotary switch P (pre-selected pattern to apply).

4- Multi-colour LED (red, orange, green).

5- Voltage pulse output (electrovalve connector).

6- Protective casing of device.

Dimensions (mm)

153.5 mm

30.5

mm

22 m

m

1

42 3

6

5

MELER GLUING SOLUTIONSMA-5104-E EFFI BEAD MANUAL

1-3

EFFIBEADApplicator

electrovalveSignal

generator

3. INSTALLATION

Install the EFFIBEAD unit between the PLC (or activation signal generating device), which sends a continuous voltage pulse, and the corresponding applicator electrovalve.

Note: You can only connect the EFFIBEAD unit to the PLC or activation signal generating device that generates 24 VDC without initial peak voltage. Only one electrovalve for each EFFIBEAD unit can be connected.

Do not place the device in places that might be affected by high temperatures, i.e., in contact with hoses or applicators.

Make sure that the EFFIBEAD and activation signal generating device are correctly connected to each other. If the polarization is incorrect the device will not work properly.

For each connection cable (strip):

- Strip off 11 mm of insulation (outer jacket) from the end of the cable. The connector has an indicating mark for this.

- Open the connector clip where no cable is inserted.

- Insert the stripped cable all the way in.

- Close the connector clip. - The system is ready for operation.

The polarity of the device must be considered:

Brown cable: 24 VDC connection

Blue cable: 0 V connection

The EFFIBEAD device has no external power supply because it is powered by the voltage impulses from the activation signal generating device. Charging will occur during the first duty cycles.

strip 11 mm from the cable

MELER GLUING SOLUTIONS

1-4

MA-5104-E EFFI BEAD MANUAL

4. USE

States of the device

The EFFIBEAD device can show different operating states.

Learning status: Process in which the device looks for patterns or input pulses with the same duration. During this process, the output pulse is equal to the input pulse (so the production line continues to operate perfectly). Every time the device is in this status, the LED will flash orange (See Using and programming the device).

Operating status: This is when the device is applying the selected pattern. When the device is in this status, the LED will flash green.

Operating error status: If there is any error in the EFFIBEAD device, the output signal will be equal to the input signal. The LED will be red for the duration of the error (See error management).

Using and programming the device

After connecting the EFFIBEAD unit, you must select the required savings percentage and pattern to apply, always following the correct adhesion criteria for the substrates, so it won't always be possible to use all the values offered by the unit.

Refer to the tables in this manual to select the two parameters, where you can choose the most suitable percentage and pattern for your application needs.

The selection is made with the different combinations of rotary switch positions.

Rotary switch %: adhesive savings percentage.

Rotary switch P: chopping pattern.

Use a small flat-head screwdriver to change the various positions of the rotary switches.

The EFFIBEAD device does not work in every position. The following table shows in what positions the EFFIBEAD does not work. If you select a position that does not work, the output pulse will be equal to the input pulse (so the production line will continue to operate perfectly), while the multi-colour LED will be lit red indicating an error.

Rotary switch % Adhesive saving

0, 1, 2, 7, 8, 9 0% (device not operational)

3 30%

4 40%

5 50%

6 60%

MELER GLUING SOLUTIONSMA-5104-E EFFI BEAD MANUAL

1-5

Calculation and parameter tables

The original pattern (A) is divided into up to 4 sections:

1- Start line (B).

2- End line (E).

3- Intermediate lines (C).

4- Holes (saving) (D).

The length of the sections (B-E) is programmed as a percentage of the length of the initial pattern (A). The system ensures that the End line (E) is always aligned with the end of the original pattern.

Original pattern

Chopped pattern

Rotaryswitch %

Rotary switch P

Start and end lines

Centrallines Output signal

3

0 5% 5%

1 10% 5%

2 10% 10%

3 15% 5%

4 15% 10%

5 15% 15%

6 20% 5%

7 20% 10%

8 20% 15%

9 20% 20%

4

0 5% 5%

1 10% 5%

2 10% 10%

3 15% 5%

4 15% 10%

5 15% 15%

6 20% 5%

7 20% 10%

8 20% 15%

9 20% 20%

MELER GLUING SOLUTIONS

1-6

MA-5104-E EFFI BEAD MANUAL

Rotaryswitch %

Rotary switch P

Start and end lines

Centrallines Output signal

5

0 5% 5%

1 10% 5%

2 10% 10%

3 15% 5%

4 15% 10%

5 15% 15%

6 20% 5%

7 20% 10%

8 20% 15%

9 20% 20%

6

0 5% 5%

1 10% 5%

2 10% 10%

3 15% 5%

4 15% 10%

5 15% 15%

6 20% 5%

7 20% 10%

8 20% 15%

9 20% 20%

Example of 10 types of patterns with 30% adhesive saving:

ORG

3-0

3-1

3-2

3-3

3-4

3-5

3-6

3-7

3-8

3-9

MELER GLUING SOLUTIONSMA-5104-E EFFI BEAD MANUAL

1-7

After selecting the pattern, start the application.Initially, the output signal will be equal to the input signal, and the applica-tion will be a continuous bead. This will occur during the first duty cycles (3 substrates with bead applied) to later automatically start applying the selected pattern.The pattern being used can be modified at any time, changing the rotary switch combinations. The EFFIBEAD unit will not enter learning mode and instantaneously apply the new pattern selected.

However, if the input signal is modified (directly, varying its duration by more than 10% or simply modifying the speed of the machine), the EFFIBEAD unit will enter learning mode for the following 3 substrates to calculate the new pattern. During those 3 learning substrates, the EFFIBEAD unit will continue to apply the above pattern.

Error management

Errors in the EFFIBEAD unit (red indicator LED) may occur for the following causes:

- If a disabled combination has been selected in the rotary switches.

- If the frequency of the input pulses is greater than the maximum working input frequency of the unit (10 ms ON and 10 ms OFF).

- If the selected pattern (according to the length of the input pulse) causes output pulse times of less than 3 ms ON time or 3 ms OFF time.

Every time there is an error of this type, the output signal will be equal to the input signal and the multi-colour LED will be lit red.

MELER GLUING SOLUTIONS

1-8

MA-5104-E EFFI BEAD MANUAL

Maximum input frequency 166 Hz (9960 cycles per minute)

Minimum input pulse ON-OFF time 10 ms

Maximum input pulse ON time 50 s

Input voltage 24 VDC (input without initial peak)

Output voltage 24 VDC (an output)

Minimum output pulse ON-OFF time 3 ms

Output resolution 1 ms

Power 16 W

Savings selection 30%-40%-50%-60%

No. output patterns 10 for each savings selection

IP degree of protection IP54

Regulations CE and Rohs

Working temperature

-5ºC (23ºF) to 60ºC (140ºF)

NOTE: The maximum temperature depends on the frequency of the input and output pulses

5. TECHNICAL FEATURES