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Meler Micron 5, Instruction Manual

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Meler Micron 5 Instruction Manual Download Page 81

MA-5079-ENG

  MICRON GEAR ADHESIVE MELTER

6-1

TROUBLESHOOTING

6. TROUBLESHOOTING

This chapter shows basic help for solving simple problems without 

intervention from Meler technical personnel. 

It is very important to respect the security instructions in this manual at all 

times. Failure to do so may result in personal injury and/or damage to the 

machine or to the rest of the installation.

Warning:

 The melter/applicator equipment is equipped with current 

technology, but with certain foreseeable risks. Therefore, only allow 

appropriate personnel with enough training and experience to use, install or 

repair this equipment.

Each observed problem corresponds to a chapter section. There are four 

different columns in each one: 

•   Possible causes.

•  Verification to be performed.

•   Useful observations.

•   Actions.

The system is simple. Locate the chapter section that corresponds to the 

observed problem. Starting from the column on the left, follow vertically the 

causes. Once the cause is found check, the action is performed taking into 

account the comments and once the error checked carried out in each case 

corrective action.

If you do not reach the cause follow to the next problem.

If you are unable to solve the problem with the help provided in this chapter, 

contact your Area Technical Service Center or Meler headquarter directly.

Summary of Contents for Micron 5

Page 1: ...ADHESIVE MELTER MICRON GEAR SERIES INSTRUCTIONS MANUAL MA 5079 ENG 200718 GLUING SOLUTIONS ...

Page 2: ... of its owner is strictly prohibited The specifications and information contained in this manual may be modified without prior notice This manual is a translation of the original that was written by Focke Meler Gluing Solutions S A in spanish language If there is any discrepancy between the different versions of this manual the original written in the spanish language shall prevail Focke Meler Glu...

Page 3: ...mission declaration 1 3 Intended use 1 4 Limited use 1 4 2 INTRODUCTION 2 1 Description 2 1 Modes of operation 2 2 Hot melt melter identification 2 2 Main components 2 3 Main components Micron gear with two motor pumps 2 4 Control card components 2 5 Pumping control card components 2 6 Micron gear series range 2 7 Micron gear range option accessories 2 7 Automatic feeder option 2 7 Gas injection o...

Page 4: ... 3 Mounting the equipment 3 4 Electrical power connection 3 4 Pneumatic connection 3 5 Hose and applicator connection 3 6 Parameter Programming 3 6 Programming working temperatures 3 7 Selecting the overheating value 3 7 Keeping a component on display 3 8 External I O connections 3 8 Temperature ok 3 9 External standby 3 10 Low level optional 3 10 Output disabled 3 11 Starting up the motor ok ext ...

Page 5: ...een ON Standby OFF modes 4 13 Password to access parameter programming 4 14 Total equipment service hours counter 4 14 Counter that warns of the need to change the adhesive agent filter 4 15 Setting the clock 4 16 Programming the current day and hour 4 16 Programming equipment activation deactivation 4 17 Disabling the equipment activation deactivation program 4 18 Programming the equipment s stan...

Page 6: ...ms and reset function 4 29 Maximum rpm alarm 4 29 Minimum rpm alarm 4 29 Variator alarm 4 29 Configuring speed ramp 4 30 Programming speed ramp 4 31 Current Vin voltage display 4 32 By pass valve regulation 4 32 Manual valve control 4 32 Pneumatic valve control 4 32 Using the air drying system optional 4 33 Turning off the melter equipment 4 33 5 MAINTENANCE 5 1 Equipment cleaning 5 1 System depre...

Page 7: ...tank does not heat 5 10 and 20 adhesive melters 6 3 The tank does not heat 35 adhesive melter 6 3 The tank does not stop heating 5 10 and 20 adhesive melters 6 4 The tank does not stop heating 35 adhesive melter 6 4 Temperature fluctuations in the tank 6 4 Manifold 6 5 The manifold does not heat Micron 1 geared motor 6 5 The manifold does not heat Micron 2 geared motors 6 5 The manifold does not s...

Page 8: ...g 6 9 Temperature fluctuations in hose 6 9 Applicator 6 10 Applicator does not heat 6 10 Applicator does not stop heating 6 10 Temperature fluctuations in applicator 6 10 LAY OUT POWER BOARD 6 12 LAY OUT CONTROL BOARD 6 13 LAY OUT PUMP CONTROL BOARD 6 13 LAY OUT SENSOR BOARD 6 13 7 TECHNICAL CHARACTERISTICS 7 1 Generals 7 1 Dimensions 7 3 Micron gear range option accessories 7 5 Automatic feeder s...

Page 9: ...rying system optional 9 2 10 SPARE PARTS LIST 10 1 A TANK ASSEMBLY 10 4 B DISTRIBUTOR UNIT 10 5 C DISTRIBUTOR SIMPLE DOUBLE ASSEMBLY 10 6 D GEARED MOTOR PUMP ASSEMBLY 10 7 E CHASSIS ASSEMBLY 10 8 F ELECTRIC ASSEMBLY 10 9 G ELECTRONIC ASSEMBLY 10 10 H PNEUMATIC COMPONENTS 10 11 I GAS INJECTION ASSEMBLY OPTIONAL 10 11 J AIR DRYER ASSEMBLY OPTIONAL 10 12 EC DECLARATION OF CONFORMITY 11 1 ...

Page 10: ...FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS This page is intentionally left blank ...

Page 11: ...erform maintenance on it Also provide necessary safety material appropriate clothing footwear gloves and safety glasses In all cases observe local regulations regarding risk prevention and safety Symbols The symbols used on both the melter applicator equipment and in this manual always represent the type of risk we are exposed to Failure to abide by a warning signal may result in personal injury a...

Page 12: ...voltage Periodically inspect the cables to check for crushing wear and tear as well as to prevent tripping and falls as a result of their placement Although the system meets EMC requirements it is inadvisable to use devices that transmit high levels of radiation i e mobile phones or soldering equipment in their vecinity Hydraulic components As this is a pressurized system precautions related to th...

Page 13: ...ler systems are designed for use with hot melt adhesives They should not be used with any other type of material and especially not with solvents which may cause personal injury or damage to internal system components Some units are specifically designed to use polyurethane reactive PUR hot melt adhesives Using PUR on a unit that is not prepared for that purpose may cause severe damage to the unit...

Page 14: ...bels accompanying the equipment using adequate means of protection during each mode of operation Limited use The equipment should never be used under the following conditions Use with reactive polyurethane or any other material that might cause safety or health risks when heated Use of equipment in environments where cleaning is necessary using water jets Use of equipment to heat or melt food prod...

Page 15: ...aphs and illustrations that appear in this manual refer to the 5 liter Micron melter This model has been used as a reference for writing this manual as its main characteristics with the exception of the tank capacity and the connection outputs are the same as those in the rest of the equipments of the serie Description These melters are designed for use with Meler hoses and applicators in hot melt...

Page 16: ...ping control and manual speed control Control of external pumping and speed_Switches in the position ok ext and ref ext In this working mode both pumping and speed are controlled from the main machine Speed is controlled by means of an external 0 10 V signal sent from the main machine Standby mode_The hot melt melter remains in a resting state with the materials kept at programmable temperature va...

Page 17: ...ntrol card 6 Air pressure gauge for pneumatic by pass valve 7 Pressure regulator of by pass valve opcionally pneumatic or mechanical regulator 8 Access door to filter and purge valve 9 Hose output distributor up to 4 hydraulic connections by motor pump assembly 10 Compressed air hook up max 6 bar 11 Hose applicator electrical connections 12 Characteristics plate 12 11 10 9 4 7 8 5 6 1 2 3 ...

Page 18: ...mponents is the same for all models with two motor pumps In this case the pictures refers to the 20 liter model For each motor pump assembly installed 1 Pumping control card 1 2 Pumping control card 2 3 Pressure regulator 1 4 Pressure regulator 2 5 Hoses output 1 6 Hoses output 2 7 Gear motor 1 8 Gear motor 2 1 7 3 2 8 4 5 6 ...

Page 19: ...nk indicator LED 2 Applicator indicator LED 3 Temperature set point 4 Real temperature 5 ON OFF switch 6 Standby function 7 Temperature OK LED 8 Time scheduling 9 Left right button channel selection 10 Up down button temperature modification 11 Hose indicator LED 7 1 11 5 6 8 2 9 3 4 10 ...

Page 20: ...arrow keys for selecting values 6 Left right arrow keys for selecting options 7 Speed ramp steps display screen 8 Speed ramp value selection LEDs voltage speed 9 Voltage pump speed errors display screen 10 Pumping control internal external selection 11 Pumping speed internal external selection 12 Voltage value display of the external signal of the speed control 1 2 3 4 9 8 5 6 7 12 11 10 ...

Page 21: ...n it will be necessary to purchase the following accessories Automatic feeder option The automatic adhesive loader must be requested separately and is the same for the 5 10 20 and 35l machines Micron gear series range Micron 5 2 M01 200 BE S8 V A0 PC LD2 B0 Micron series tank capacity 5 5kg 10 10kg 20 20 kg 35 35 kg no electric outputs 1 2 4 6 temperature sensor type M01 Pt100 N01 Ni120 type of pu...

Page 22: ...ontrol system To detect a low level of melted adhesive there is a choice between capacitive or float level detectors Either can be used with any of our equipment although if the detector is ordered after the equipment is delivered you may only use the float detector the capacitive detector requires a housing inside the tank that must be made by machine Warning light option The warning light must b...

Page 23: ...rical control Optionally a gas ventilation system Installation requirements Before installing Micron gear series melter equipment we must make sure that the space assigned to it permits installing connecting and using the entire system Similarly we must check to see that the electrical and pneumatic supplies meet the necessary requirements of the melter equipment being installed Free space Item De...

Page 24: ...e that is being connected to the melter is the correct one appearing on the equipment s characteristics plate Connect the machine and check to see if it is well grounded Warning Risk of electrocution Even when the equipment is turned off voltage remains in the intake terminals which may be dangerous during internal equipment manipulations Install a power switch for disconnecting the melter equipme...

Page 25: ... signals are shown As much as possible try to avoid unnecessarily long hoses that result in elevated electrical energy consumption levels and pressure drops Do not install the melter equipment beside powerful heat or cooling sources that may have distortional effects upon its operation Avoid melter vibrations Make sure that the melter maintenance areas filter purging valve tank interior etc are ea...

Page 26: ...ed to the electrical power supply in two possible ways depending on the power of different elements connected 1 phase 230 VAC with neutral 3 phases 230 VAC without neutral 3 phases 400 VAC with neutral A good ground connection is required in all cases Consumption figures according to melter and output configuration are included in the table For this calculation only the case of a single pump has b...

Page 27: ...rning each equipment can be found in the characteristics plate Pneumatic connection If a pneumatically controlled by pass pressure control valve is installed the equipment must have a compressed air supply Before connecting the pneumatic power to the melter make sure the pressure regulator is completely closed To do this turn the regulator handle located on the equipment base next to the pressure ...

Page 28: ...he maximum allowable power for each output Caution It is preferable to use couplings at 45º and 90 angle to minimize the space the hoses occupy Using straight couplings usually results in curves with very small radii that may damage the inside of the hose Save the screw on caps that are removed from the distributor in order to connect a hose They may be necessary in the future if a hose is removed...

Page 29: ...n arrow select the desired value for the set point temperature 3 After ten seconds the LED will stop blinking and the display will change by default to the set point temperature saving the changed data This simple process must be repeated for each one of the components installed on the melter Selecting the overheating value 1 Press the buttons with the clock symbol and the down arrow at the same t...

Page 30: ... to restore the default display tank External I O connections The melter s input and output signals I O allow it to communicate with the main machine simply and directly There are seven signals that may be used to communicate with the main machine Temperatures ok_an output from a non voltage contact that communicated to the main machine or to a warning light beacon that all the system temperatures...

Page 31: ...ight beacon the failure from the pump control card Warning Risk of electric shock Carelessness may cause injuries or death If any of these signals are to be connected open the electrical cabinet for greater convenience while carrying out this task To do this follow the steps outlined below 1 Remove the electrical cabinet casing following the instructions given in the maintenance section Removal an...

Page 32: ...han 50mA External standby 1 If this is the only signal being connected use 0 5 mm2 two wire cable Install an electrical wall bushing Pg13 5 next to the electrical supply input 2 Thread the power cord max Ø12 5mm through the electrical wall bushing Pg13 5 and fasten it to the inside anchor making sure that the cord reaches the control card connector at the position where it will be installed CN 4 3...

Page 33: ...gnal to 230V load current cannot be less than 50mA Output disabled 1 If this is the only signal being connected use a seven wire cable no smaller than 0 22 mm2 Install an electrical wall bushing Pg13 5 next to the electrical supply input 2 Open the door to the electrical cabinet as far as possible Thread the power cord max Ø12 5mm through the electrical wall bushing Pg13 5 and fasten it to the ins...

Page 34: ...le Install an electrical wall bushing Pg13 5 next to the electrical supply input 2 Thread the power cord max Ø12 5mm through the electrical wall bushing Pg13 5 and fasten it to the inside anchor making sure that the cord reaches the power card connector 3 Connect the two wires from the start up signal to the terminals XP1 and XP2 This is a double terminal which makes it necessary to connect each w...

Page 35: ...ntrol card 1 If this is the only signal being connected use 0 5 mm2 two wire cable Install an electrical wall bushing Pg13 5 next to the electrical supply input 2 Thread the power cord max Ø12 5mm through the electrical wall bushing Pg13 5 and fasten it to the inside anchor making sure that the cord reaches the power card connector 3 Connect the two wires from the start up signal to the terminals ...

Page 36: ...FOCKE MELER GLUING SOLUTIONS INSTALLATION 3 14 This page is intentionally left blank ...

Page 37: ...ough their set point values are the same Therefore when you program a set point value for the tank for example 170 C the distributor adopts this same value If two pumps are installed the distributors occupy channels 1 and 2 with set point values and control that are independent to the tank and to each other The second group is the hose group They are identified on the front panel depending on the ...

Page 38: ... fill the tank with adhesive Do not fill the tank above the loading opening level The lid must be able to close normally Warning Risk of burns Always refill using protective gloves and goggles 3 Close the lid when you have finished refilling the tank Model Capacity Micron5 5 15 L 5 15 kg Micron10 9 7 L 9 7 kg Micron20 19 7 L 19 7 kg Micron35 37 4 L 37 4 kg for density of 1g cm3 Starting up the mel...

Page 39: ...oint the LEDs turn off If the system is shut down for any possible mode when it is turning on the delay timer only starts again if the tank temperature is 20 below setting point 3 Make sure that the selectors in the pumping control card for each of the motors installed is in the correct position see Chapter 2 Introduction Operating modes Melter equipment displays Micron series melters have two dis...

Page 40: ...se1 applicator1 hose6 applicator6 For units that have two pumps installed the display sequence is the following null tank distributor1 Off distributor2 Off hose1 applicator1 hose4 applicator4 null tank distributor1 Off distributor2 Off hose1 applicator1 hose4 applicator4 To remove a component from permanent display simply press either of the left right arrows LED display On off Standby constantly ...

Page 41: ...tor4 broken sensor only applicator4 off off off Err 9 hose5 broken sensor only hose5 off off off Err 10 applicator5 broken sensor only applicator5 off off off Err 11 hose6 broken sensor only hose6 off off off Err 12 applicator6 broken sensor only applicator 6 off off off Err 13 distributor broken sensor only distributor off off off Err 100 tank overheating all components off off off Err 101 hose1 ...

Page 42: ...nly applicator3 off off off Err 11 hose4 broken sensor only hose4 off off off Err 12 applicator4 broken sensor only applicator4 off off off Err 13 null Err 100 tank overheating all components off off off Err 101 distributor1 overheating all components off off off Err 102 null Err 103 distributor2 overheating all components off off off Err 104 null Err 105 hose1 overheating all components off off o...

Page 43: ...The user will install the required device acoustic warning device lamp or PLC input Simply refill the tank and wait until the adhesive is sufficiently melted for the detector to provide a reading of the correct level Display and adjustment of the working speed The pump rotation speed in revolutions per minute is shown on the display for each pump control card on the equipment These revolutions may...

Page 44: ...s described below 1 Select the component whose value you wish to modify using the left right arrow The tank and the distributor have the same set point value The corresponding LED will blink rapidly 2 Select the desired set point temperature value with the up down arrow Below 40 C the set point value displays OFF canceling the heating of that element 3 After ten seconds the LED will stop blinking ...

Page 45: ...eously press the buttons with the clock symbol and the down arrow to enter the special menu The choice of temperature display units C or F will appear on the display 2 Select the desired value using the up down arrow Function Symbol on the dis play Default value Selects the temperature unit to display ºC ºF ºC Programs overheating 20 ºC Programs the temperature for the STANDBY mode 40 Delay time t...

Page 46: ...cent decrease in the real tem perature compared to the set point temperature that will occur when this function is activated 7 Use the right arrow to go to the next display where delay time value appears 8 Use the up down arrow to select the desired value between 0 and 60 min 9 Use the right arrow to advance to the next screen where the level detector activation deactivation is found 10 Use the up...

Page 47: ...andby OFF modes 13 Use the right arrow to go to the next display 16 Use the up down arrow to select the desired value see Password to access parameter programming 17 Use the right arrow to go to the next display This function is a counter that registers total hours of equipment opera tion that is with service temperature OK enabled This is an increment counter and its value cannot be modified The ...

Page 48: ...ired value see Counter that warns of the need to change the adhesive agent filter 20 Use the right arrow to return to the initial parameter For any parameter the left arrow may be used to exit the special menu and display the tank temperatures once again To record any parameter you must always move to the next parameter using the right arrow ...

Page 49: ...the ON mode again press the ON OFF push button on the control board The programmed S 1 time will begin a countdown the moment the melter reaches the service temperature S 1 S 2 Functionality dIS dIS The external Standby input CN4 is disabled The melter can be set to Standby mode with the push button OFF OFF The external Standby input CN4 runs normally Contact CLOSED Equipment in STANDBY Mode Conta...

Page 50: ...Enter the Password using the up and down keys Once the Password is displayed press the right key By pressing the left key the equipment will return to the same mode of ope ration that was active before the enter password message appeared If the Password is incorrect the equipment will not access the desired menu and it will return to the same mode of operation that was active before the PAS 000 me...

Page 51: ...arns that the adhesive filter of the equipment must be cleaned and or repla ced Press any key to delete the message and the counter will return again to 1000 hours The equipment will return to the same mode of operation that was activated before the message appeared Use the up and down keys of this function to modify this value so the filter cleaning warning adjusts to the specific needs required ...

Page 52: ...s the button with the clock symbol once again On the left display you will see the time with a dot indicating that this is the value that may be modified while the minutes appear on the second display 3 Use the up down arrow to select the desired value 4 Press the button with the clock symbol once again Now the dot will appear on the right display 5 Use the up down arrow to select the desired valu...

Page 53: ...he clock symbol once again Two times will appear one in each display The display on the left shows the start time while the display on the right shows the finish time 4 The blinking dot next to the start time indicates that this is the value that may be modified Use the up down arrow to select the desired value 5 Press the button with the clock symbol once again The dot changes to the finish time ...

Page 54: ...the right arrow button will exit this program and return to the tank temperature display Programming the equipment s standby function activation deactivation You may program an activation and a deactivation time for every day of the week from Monday 1 to Sunday 7 Time is expressed in 15 minute increments so we cycle from 10 0 10 hours and 0 minutes to 10 1 10 hours and 15 minutes to 10 2 10 hours ...

Page 55: ...t this program and return to the tank temperature display The green LED next to the maintenance button will remain blinking as long as there is an equipment standby function activation time programmed for the current day Disabling the equipment standby function programming It is possible to disable the equipment standby function programming without canceling the daily programming This way the prog...

Page 56: ...ture is programmed as 30 30 when you press the standby function button the tank set point temperature will drop to 112 C 70 of 160 C The three means for activating the standby function available with micron melters applicators have the following priority protocols 1 manual standby function button 2 standby function external signal 3 standby function activation deactivation programming Therefore if...

Page 57: ...rting up unexpectedly the control panel features by default a safety option that prevents pumping from commencing until enabled by pressing the ON OFF button on the control card This function may be disabled in the User configuration menu For the pumping control to allow the pump to operate the pumping ON OFF button must be pressed leaving it enabled the red LED on the pumping ON OFF button will t...

Page 58: ...lected in the password security configuration is 1 security enabled only the control card ON OFF and pumping ON OFF buttons will be operational While this security option is programmed in order to avoid the need to turn off and restart the machine to return to the User configuration menu on pressing any key except the control card ON OFF and pumping ON OFF buttons a password will be required When ...

Page 59: ...se LEDs are green in colour 4 Int and ext ref LEDs when the equipment is operating in internal reference mode the int LED will be illuminated and the ext LED turned off When the equipment is operating in external reference mode the ext LED will be illuminated and the int LED will be turned off These can never be both on or both off at the same time These LEDs are green in colour 5 Ext on LED when ...

Page 60: ...in which case starting the pump would be impossible In case of the pump be operating and this input is activated pumping will cease immediately If a speed has been previously set this value will be shown on the display and the pump will start to rotate at the speed indicated provided that all prior conditions are met Otherwise 3 Using the up down arrows select the rotation speed and or wait for pu...

Page 61: ...put is activated pumping will cease immediately The system will wait for the speed signal from the main machine When the signal has been received if a speed has been previously set it will appear on the display and the pump will begin to rotate at the indicated speed If not the rotation speed must be adjusted to the value required for the application There are three ways to do this 1 Change the vo...

Page 62: ...iately The system will wait for the pumping control signal from the main machine If a speed has been previously set this value will be shown on the display and the pump will start to rotate at the speed indicated provided that all prior conditions are met Otherwise 3 Using the up down arrows select the rotation speed and or wait for pumping permission to be enabled red LED is turned off At this mo...

Page 63: ...ro this field is available on the control card User configuration menu That the failure input is not activated E5 in which case starting the pump would be impossible In case of the pump be operating and this input is activated pumping will cease immediately The system will wait for the main machine to send the pumping activation and rotation speed signals When this signal has been received if a sp...

Page 64: ...AXIMUM RPM ALARM TIME this will be a period programmed between 0 and 999 in seconds In the event that the output RPM exceed the value programmed for MAXIMUM RPM ALARM during the period established in this field MAXIMUM RPM error will be activated the pump will stop and an error message will be displayed By default this value is 30 seconds 3 MINIMUM RPM ALARM this will be a value set between 0 and ...

Page 65: ... speed that is below the MINIMUM RPM ALARM for the period established in the MINIMUM RPM ALARM TIME field When this alarm is triggered an E L error is shown on the control card To reset this error you must turn off and start up the control card with its ON OFF button Variator alarm This alarm is triggered when the control card input is activated by a variator error signal When this alarm is trigge...

Page 66: ...e speed ramp and therefore the voltage will always be 0 while the value for output RPM is editable The possible values for each point must be equal to or greater than the value corresponding to the previous point Point 5 is the final point for the speed ramp and therefore the voltage will always be 10 while the value for output RPM is editable It is not necessary to program the value for MAXIMUM R...

Page 67: ...to go to the next point The IN LED to the position OFF and the OUT LED to the position ON 3 XXX which means that the output speed value is being programmed for point 3 with the up down arrow keys the value may be modified within a range from 000 to MAXIMUM RPM press the right arrow key to go to the next point The IN LED to the position ON and the OUT LED to the position OFF 4 XXX which means that ...

Page 68: ...eeds the operating value normally with a closed circuit and the pump activated which makes the use of a discharge valve or a by pass valve necessary This valve may be a manual adjustment valve using a threaded screw or with pneumatic control using a pressure regulator and a pressure gauge In the latter case the adhesive circuit pressure has a 1 13 ratio to the pressure displayed on the pressure ga...

Page 69: ... preserved without premature reticulations inside the applicator unit To maintain the air drying system in perfect condition we recommend periodically observing the green indicator for filter saturation control If this indicator turns red it is necessary to replace the filter cartridges See the corresponding chapter for replacement parts Turning off the melter equipment If you need to disconnect t...

Page 70: ...FOCKE MELER GLUING SOLUTIONS 4 34 MELTER OPERATION This page is intentionally left blank ...

Page 71: ...liquids or solvents Operation Frequency Refer to External cleaning Daily Equipment cleaning System depressurization Before performing maintenance tasks and repairing the hydraulic system System depressurisation Remove electrical cabinet Before performing maintenance of distributor pump or gear motor Access inside the unit Filter cleaning or changing As needed once a year minimum With each adhesive...

Page 72: ...ng the 1 4 turn screw as indicated B slide it leftwards turn it and remove the screws C 5 To remove the electrical cabinet casing slacken the screws D that hold it to the base of the machine and the screws E that hold it to the structure of the electrical cabinet 6 To remove the tank casing remove screws F and G that hold this casing to the base of the equipment The lid and the casing are removed ...

Page 73: ...he corresponding program command Access to the interior of the equipment Access to distributor To access the distributor where both the bypass valve pressure regulator and the purge filter assembly are located it is necessary to open the casing as indicated To do this loosen the quarter turn screw that keeps the access door in the closed position A Access to pump gear motor To access the pump gear...

Page 74: ...decision The type and purity of the adhesives used The adhesive work temperatures Adhesive consumption in relation to the time it spends in the tank Changes in the type of adhesive used In any case we recommend checking and cleaning the filter at least every 1000 hours of operation melter equipment turned on Warning Always use protective gloves and goggles Risk of burns To change the filter it sho...

Page 75: ... Too much burnt material is generated in its interior Changing adhesive type 1 Use up as much of the adhesive as possible If it is necessary to unload the adhesive without having used it up as much as possible follow the instructions in the section Emptying the tank 2 Clean the remains of hot melt adhesive on the inside of the tank Warning Use appropriate protective equipment for high temperatures...

Page 76: ...etimes necessary to empty the tank directly without passing the adhesive through the pump system In the case of the Micron 5 the tank does not have a pouring chute so to empty out the adhesive you need to wait until it has cooled and separate it from the walls of the tank making it easier to remove For the other models empty the tank following these indications 1 Keep the tank at working temperatu...

Page 77: ... cycles it may be necessary to retighten the screws Before making any changes establish the location of the leak However before replacing any parts and in case of any doubt we recommend that you consult the Meler Technical Service Centre Warning Always wear protective gloves and goggles Risk of burns Gear motor maintenance Cleaning the motor fan Periodically inspect the condition of the motor fan ...

Page 78: ...not be guaranteed We recommend installing new cartridges once a year regardless of the indicator reading differential pressure Follow these steps to change the cartridge Close the air valve Release the drainage hose from the reservoir if connected Slowly turn the knurled screw clockwise This will purge the air from the filter Push the reservoir towards the head of the filter Slowly turn the reserv...

Page 79: ...omfortably and with greater accessibility To do this the equipment should be removed from its base following these indications 1 Turn off the machine switch on the door of the electrical cabinet 2 Depressurise the system 1 3 Disconnect the hoses connected to the distributor outputs both electrically and hydraulically 4 Disconnect the input power supply and ground connection 5 Raise the machine to ...

Page 80: ...FOCKE MELER GLUING SOLUTIONS 5 10 MAINTENANCE This page is intentionally left blank ...

Page 81: ...aining and experience to use install or repair this equipment Each observed problem corresponds to a chapter section There are four different columns in each one Possible causes Verification to be performed Useful observations Actions The system is simple Locate the chapter section that corresponds to the observed problem Starting from the column on the left follow vertically the causes Once the c...

Page 82: ...ts Actions Equipment power supply malfunction Check voltage between phases and neutrals in the main terminal Check voltage in CN4 connector power board Voltages will vary depending on power supply Check wiring Check net power supply Change electric supply cable Melter thermostat malfunction Check continuity in thermostat 1 If continuity switch is OK Reset it Change thermostat Switch malfunction Ch...

Page 83: ...hange ribbon cable Tank fuse blown Check fuse continuity F01 Release the fuse to check it out with the system turned off Change fuse Power board damaged Check CN6 connector voltage pins 2 and 4 Correct if voltage is around 230V and DL2 is on Check wiring it might be wrong positioned Change board Power supply wire to the tank damaged Check CN6 connector voltage pins 2 and 4 and in the tank terminal...

Page 84: ...r Faulty thermal magnetic circuit breaker Check for continuity in the thermal magnetic circuit breaker 2 If there is no continuity in the actuated thermal magnetic circuit breaker the device is faulty Replace the thermal magnetic circuit breaker 2 solid state relays are faulty Check the voltage between output 2 of each relay and the neutral and 3 If there is 230 V the relay is OK if not it is faul...

Page 85: ...t heat Micron 1 geared motor The manifold does not heat Micron 2 geared motors Causes Checking Comments Actions Equipment power supply malfunction Check voltage between phases and neutrals Check voltage in CN4 connector Voltages will vary depending on power supply Check wiring Check net power supply Change electric supply cable 1 2 Manifold fuse blown Check fuse continuity 1 Release the fuse to ch...

Page 86: ...3 Pin 4 y 5 DL5 3 Pin 1 y 2 Pin 4 y 5 4 DL3 DL5 5 DL3 DL5 To differentiate between manifold 1 and 2 Causes Checking Comments Actions An element has not reached the required temperature Check the temperature on all heated devices Refer to the previous sections tank distributor hose and applicator Wait or repair the faulty device In units with 2 motors if no pumping operations are carried out due to...

Page 87: ...icron 1 geared motor Micron 2 geared motors Motor Motor 1 Motor 2 1 XV1 XV2 XV11 XV12 XV21 XV22 2 XP1 XP2 XP11 XP12 XP21 XP22 Causes Checking Comments Actions Faulty temperature OK contact With the temperature OK in all devices check for continuity in connector CN1 Pin 3 4 of the control board The contact is working properly if there is continuity With the temp OK the OK LED of the control board m...

Page 88: ...nce of adhesive Causes Checking Comments Actions The lack of adhesive warning is not activated in the board Check the parameter in the setup menu If you do not know how to open this menu contact Meler s Service Centre Change the parameter in the menu Burnt adhesive on the level sensor Check for continuity in pins 1 2 of connector CN1 of the power board If the level sensor detects adhesive there is...

Page 89: ...fuse damaged Verify fuse continuity 2 Check continuity with the unit turned off Change fuse Power board damaged Check voltage at the board output with the hose plugged CN board connector black wire neutral and blue wire hose M Fuse shows continuity DL LED light remains on 3 Change power board Hose Hose does not heat Causes Checking Comments Actions Power board damaged Check power board DL LED gree...

Page 90: ...ged Verify fuse continuity 2 Check continuity with the unit turned off Change fuse Power board damaged Check voltage at the board output with the hose plugged CN board connector black wire neutral and red wire applicator P Fuse shows continuity DL LED light remains on 3 Change power board Applicator Applicator does not heat Causes Checking Comments Actions Power board damaged Check power board DL ...

Page 91: ...CN11 P5 CN11 P6 2 F04 F05 F06 F07 F08 F09 3 CN9 P1 DL4 CN9 P2 DL6 CN10 P3 DL8 CN10 P4 DL10 CN11 P5 DL12 CN11 P6 DL14 4 DL4 DL6 DL7 DL10 DL12 DL14 5 CN2 CN3 CN4 CN5 CN6 CN7 Note Applicator 1 Applicator 2 Applicator 3 Applicator 4 1 CN10 P3 CN10 P4 CN11 P5 CN11 P6 2 F06 F07 F08 F09 3 CN10 P3 DL8 CN10 P4 DL10 CN11 P5 DL12 CN11 P6 DL14 4 DL7 DL10 DL12 DL14 5 CN4 CN5 CN6 CN7 Micron with 2 geared motors...

Page 92: ...L3 DL4 DL12 DL11 DL6 DL5 DL7 DL10 F7 DL8 DL14 DL13 F6 F4 F5 DL9 F1 F2 F7 F8 CN4 CN6 CN9 CN10 CN11 CN8 CN2 CN7 CN1 CN5 DL1 DL2 CN3 LAY OUT POWER BOARD CN9 CN10 and CN11 Applicator Common Hose Channel 2 4 or 6 Channel 1 3 or 5 4 3 2 1 Distributor Tank CN6 ...

Page 93: ...OUBLESHOOTING LAY OUT CONTROL BOARD LAY OUT SENSOR BOARD CN9 CN1 CN2 CN3 CN4 CN5 CN6 CN7 CN1 Distributor Tank CN2 CN3 CN4 CN5 CN6 CN7 Applicator Hose CN6 CN5 CN11 CN4 CN9 CN3 F1 LAY OUT PUMP CONTROL BOARD F6 E1 J7 S4 J8 S6 S5 S3 S2 S1 E2 E3 E4 E5 E6 ...

Page 94: ...FOCKE MELER GLUING SOLUTIONS 6 14 TROUBLESHOOTING This page is intentionally left blank ...

Page 95: ...6KW 3 x 4 0KW 1 x 7 2KW 3 x 3 9KW 1 x 9 6KW 3 x 5 1KW Temperature ok output Low level output optional External stand by activation Outputs disabled external control Motor start up input Motor speed control input Failures in pumping card output LN 230V 50 60Hz PE 3N 400V 50 60Hz PE 3 230V 50 60Hz PE 3 400V50Hz PEwithtransformerbase 0 a 40 C 730 x 360 x 630 mm 730 x 360 x 774 lid open 66 kg empty 9 ...

Page 96: ... 3 9KW 1 x 11 1KW 3 x 5 1KW Temperature ok output Low level output optional External stand by activation Outputs disabled external control Motor start up input Motor speed control input Failures in pumping card output LN 230V 50 60Hz PE 3N 400V 50 60Hz PE 3 230V 50 60Hz PE 3 400V50Hz PEwithtransformerbase 0 a 40 C 730 x 400 x 670 mm 730 x 400 x 1022 lid open 90 kg empty 37 4 liters 1 2 5 4 8 cc re...

Page 97: ... SEGURIDAD Formación requerida operario Nº de Pokayokes Piezas en proceso Calibración requerida 536 Micron 10 590 630 590 250 Micron 5 590 Micron 5 730 Micron 5 670 250 Micron 10 670 Micron 10 730 Micron 10 Micron 20 35 401 400 450 Micron 35 401 670 830 Micron 35 630 Micron 20 675 Micron 20 730 Micron 20 740 250 Micron 35 740 Micron 35 675 250 Micron 20 771 Micron 35 Note if using equipment with a...

Page 98: ...roceso Calibración requerida 569 5 328 5 13 15 96 377 5 75 9 721 5 422 5 96 529 5 13 15 75 Ø9 N Ing Fabricación Calidad Producción Nombre Nombre Nombre MANTENER ORDEN Y LIMPIEZA EN EL PUESTO Y EN LA LINEA EN GENERAL GUANTES ZAPATOS GAFAS OTROS EQUIPO DE SEGURIDAD Formación requerida operario Nº de Pokayokes Piezas en proceso Calibración requerida 370 5 654 5 13 15 Ø9 96 462 5 75 APROBACION Ing Fab...

Page 99: ...ed without premature reticulations inside the applicator unit Pneumatic by pass valve pressure control system The equipment s by pass valve provides an important safety feature as it limits the maximum pressure in the system especially during continuous pumping periods with closed applicators This valve may be a manual adjustment valve using a threaded screw or with pneumatic control using a press...

Page 100: ... MELER GLUING SOLUTIONS 7 6 TECHNICAL CHARACTERISTICS Optional equipment Wheel system For all the Micron gear machines there is the option to add 4 wheels to the base of the machine to make it easier to move ...

Page 101: ...ELECTRICAL DRAWINGS 8 1 MA 5079 ENG MICRON GEAR ADHESIVE MELTER 8 ELECTRICAL DRAWINGS To view the the electrical drawing of the purchased equipment see the CD of electrical drawings included ...

Page 102: ...FOCKE MELER GLUING SOLUTIONS 8 2 ELECTRICAL DRAWINGS This page is intentionally left blank ...

Page 103: ...umatic by pass valve control system optional 1 Pressure regulator 1 10 bar 2 Pressure gauge 0 10 bar 3 Pneumatic limit control valve ENTRADA AIRE AIR INPUT VÁLVULA LIMITADORA PRESSURE LIMIT VALVE RELACIÓN RATIO 1 15 3 1 2 MANÓMETRO MANOMETER P 0 10 bar REGULADOR DE PRESIÓN PRESSURE REGULATOR P 0 10 bar ...

Page 104: ... system optional 1 Filter 1st stage grade 7 2 Filter 2nd stage grade 5 3 Air dryer 4 3 2 solenoid valve with manual control 5 Pressure regulator 1 10 bar 6 Pneumatic relief valve 0 5 bar 7 Pressure regulator 0 1 0 7 bar 8 Pressure gauge 0 1 6 bar 9 Output nozzle ...

Page 105: ...e parts are grouped together naturally in the same way as they are located in the melters As a visual aid drawings of the parts are included and are numbered to help identify them in the list For further information about the content of the spare parts click on the number of the spare part The lists provide the reference and name of the spare part indicating when necessary whether the reference co...

Page 106: ...FOCKE MELER GLUING SOLUTIONS 10 2 SPARE PARTS LIST This page is intentionally left blank ...

Page 107: ...GURIDAD Form ope Nº d TANK ASSEMBLY AIR DRYER ASSEMBLY GAS INJECTION ASSEMBLY ELECTRIC ASSEMBLY DISTRIBUTOR ASSEMBLY TANK DISTRIBUTOR UNION ASSEMBLY PNEUMATIC COMPONENTS GEARED MOTOR PUMP ASSEMBLY ELECTRONIC ASSEMBLY CHASSIS ASSEMBLY K I G H Calidad Producción Nombre Nombre MANTENER ORDEN Y LIMPIEZA EN EL PUESTO Y EN LA LINEA EN GENERAL GUANTES ZAPATOS GAFAS OTROS EQUIPO DE SEGURIDAD E C E B I A ...

Page 108: ... 4 150113400 Inlet tank micron 20 4 150121360 Inlet tank micron 35 5 150113410 Tank insulation mantle micron 5 5 150113420 Tank insulation mantle micron 10 5 150113430 Tank insulation mantle micron 20 5 150114920 Tank insulation mantle micron 35 6 150113440 Insulation mantle inlet tank micron 5 6 150113450 Insulation mantle inlet tank micron 10 6 150113460 Insulation mantle inlet tank micron 20 6 ...

Page 109: ...RIBUTOR UNIT Nº Ref Description 1 150113570 Tank distributor union o rings Micron 5 10 20 2 150026380 Coupling tank distributor o rings Micron 5 10 20 3 150090360 Tank distributor union o rings Micron 35 4 150023950 Coupling tank distributor o rings Micron 35 2 2 1 3 4 ...

Page 110: ... o ring 5 10100083 Pump o ring 6 150026260 Mechanical pressure regulator 6 1 150026280 Mechanical pressure regulator o rings 6 2 150026290 Mechanical pressure regulator spring 6 3 150026060 Closure needle of pneumatic pressure regulator 7 150117180 Coupling hydraulic outlets 8 10030007 Current connection strip 9 150117190 Heating element 315W Ø9 46 152mm 230V 10 150114530 Sensor Pt100 10 150117570...

Page 111: ...ump motor coumpling 4 150026430 Simple pump o rings 5 150111890 Double pump o rings 6 150025960 Simple gear pump 1 cc rev 6 150114020 Simple gear pump 2 5 cc rev 6 150025930 Simple gear pump 4 cc rev 6 150025970 Simple gear pump 8 cc rev 7 150111860 Double gear pump 0 93x2 cc rev 7 150111870 Double gear pump 1 86x2 cc rev 7 150111880 Double gear pump 3 71x2 cc rev 7 150030050 Double gear pump 4 8x...

Page 112: ...asing assembly with warning light 3 150113300 Micron 5 tank housing assembly 3 150113310 Micron 10 tank housing assembly 3 150113320 Micron 20 tank housing assembly 3 150114950 Micron 35 tank housing assembly 4 150113330 Micron 5 tank cover assembly 4 150113340 Micron 10 tank cover assembly 4 150113350 Micron 20 tank cover assembly 4 1 150114960 Micron 35 tank cover assembly For equipments with tw...

Page 113: ...r board ribbon cable assembly 5 150024740 Control to sensor board cable assembly 6 16010003 Female connector 8 pin base housing 7 150020720 Female connector 12 pin base housing 8 150119180 Cable gland Pg13 5 9 150119190 Cable gland Pg16 10 150114470 Main switch 11 150114460 Power board to DC power supply cable micron 5 10 20 11 150114980 Power board to DC power supply cable micron 35 5 10 7 8 9 4 ...

Page 114: ...d Micron 6 outlets 4 150024710 Sensor board Micron Pt100 Ni120 5 150110970 Fuse 0 315A 5x20 6 150117100 Pump control board 7 150117110 Inverter Siemens G110 0 55KW 8 150117120 Power supply 24V 2 2A 9 150117130 Programmable relay Siemens Logo only Micron 35 10 150114760 Capacitive detector and amplifier kit 11 R0002393 Capacitor 12 R0001938 Solid state relay 40A 4 3 2 5 1 6 9 7 8 10 12 11 ...

Page 115: ... 1 150110730 Pneumatic limit valve 2 150114480 Pressure gauge 3 10110031 Pressure regulator Note these elements are added to the equipment when by pass pneumatic regulation Nº Ref Description 1 150028420 Solenoid valve 3 2 1 8 24V DC 5 4W 2 10110031 Pressure regulator 3 150114040 Pressure gauge 10 130 bar 4 10110051 Silencer 2 3 1 2 1 3 4 ...

Page 116: ... Air dryer excelon pro 92 series 2 150110390 Filter F92C NND AT0 3 150110400 Filter F92G NNN AT1 4 10110031 Pressure regulator 5 150029540 Pressure regulator 0 1 0 7 bar 6 150029550 Pressure gauge 0 1 6 bar 7 150028380 Pneumatic limit vale 0 5 bar 1 4 8 150028420 Solenoid valve 3 2 1 8 24V DC 5 4W 6 7 1 2 8 4 3 5 ...

Page 117: ... human responses to contact with surfaces Part 1 Hot surfaces EN ISO 13849 1 2015 Safety of machinery Safety related parts of control systems Part 1 General principles for design EN ISO 14120 2015 Safety of machinery Guards General requirements for the design and construction of fixed and movable guards EN 60204 1 2006 Safety of machinery Electrical equipment of machines Part 1 General requirement...

Page 118: ...eak with your Focke Meler representative Focke Meler Gluing Solutions S A Pol Los Agustinos c G nave D 43 E 31160 Orkoien Navarra Spain Phone 34 948 351 110 Fax 34 948 351 130 info meler eu www meler eu A Focke Group Company ...

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