Meler STARBI User manual

PATTERN
CONTROLLER
STARBI
INSTRUCTIONS
MANUAL
MA-5151-ENG 190919
GLUING SOLUTIONS

Published by:
Focke Meler Gluing Solutions, S. A.
P.I. Los Agustinos, calle G, nave D-43
E - 31160 Orkoien Navarra (España)
Tel.: + 34 948 351 110
Fax: + 34 948 351 130
e-mail: [e-mail]
www.meler.eu
A Focke Group Company
Edition September 2019
© Copyright by Focke 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.
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 Gluing Solutions, S. A. shall not be liable
in any way for any damages and/or losses that may be directly or indirectly
derived from discrepancies between the original version of the manual and this
translation.

MA-5151-ENG PATTERN CONTROLLER STARBITABLE OF CONTENTS
TABLE OF CONTENTS
1. SAFETY GUIDELINES 1-1
General 1-1
Symbols 1-1
Electrical components 1-2
Thermal components 1-2
Intended use 1-3
Limited use 1-3
2. INTRODUCTION 2-1
Description 2-1
Intended use 2-1
Basic terminology 2-2
Mods of operation 2-3
Controller identification 2-3
Main components 2-4
Rear connections StarBi 4-6 Outputs 2-5
Lower connections StarBi 2 Outputs 2-6
Additional components to the installation 2-7
Applicators 2-7
Incremental encoder 2-7
Pressure regulator 2-8
Controller bracket 2-8

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
3. INSTALLATION 3-1
Introduction 3-1
Installation requirements 3-1
Electrical consumption 3-1
Unpacking 3-2
Attaching the device 3-2
Electrical installation 3-2
Connection of the peripheral components (StarBi 4-6 Outputs) 3-4
1. Output for applicators 3-4
2. Input for Photocells 3-4
3. Input for encoder 3-5
4. Input for 0-10 V signal 3-5
5. Output for 0-10 V signal 3-5
6. Input for general inhibition and temperature OK 3-6
7. Error and status warning output 3-6
Description of I/O signal status 3-6
Additional configuration 3-7
Enable / disable temperature ok 3-7
Voltage activation time (PWM) 3-7
Connection of the peripheral components (StarBi 2 Outputs) 3-8
Location of the peripheral components 3-9
Photocell 3-9
Encoder 3-9
Pressure regulator 3-10

MA-5151-ENG PATTERN CONTROLLER STARBITABLE OF CONTENTS
4. USE 4-1
Start-up and automatic process 4-1
Manual change from RUNNING mode to STOPPED mode 4-1
Automatic change from RUNNING mode to STOPPED mode 4-1
Change from RUNNING mode to STOPPED mode by inhibit signal 4-2
Temperature OK 4-2
Status 4-2
Error 4-2
Operating anomalies 4-3
List of errors and anomalies 4-3
Screen navigation. User menu 4-3
General characteristics 4-3
Navigation icons 4-3
Save changes 4-4
Interpretation of the screens 4-4
Description of screens 4-5
Password management 4-25
ModBus communications 4-28
Modbus connections 4-29
Comunicaciones Profibus 4-30
Profibus connections 4-31
Application for PC 4-33

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
5. MANTENANCE 5-1
General 5-1
Outside cleaning 5-1
Connection leads 5-1
Calibrate the screen 5-2
6. TECHNICAL CHARACTERISTICS 6-1
General 6-1
Environmental conditions 6-2
StarBi 2 channels dimensions 6-3
StarBi 4/6 channels dimensions 6-4
7. ACCESSORIES AND SPARE PARTS LIST 7-1
Spare parts 7-2
Accessories 7-3
EC DECLARATION OF CONFORMITY 8-1

MA-5151-ENG PATTERN CONTROLLER STARBISAFETY GUIDELINES
1-1
1. SAFETY GUIDELINES
General
The information contained in this section applies not only to everyday
equipment operation, but also to any procedure carried out on it, whether for
preventive maintenance or in the case of repairs and the replacement of worn
out parts.
It is very important to observe the safety warnings in this manual at all times.
Failure to do so may result in personal injury and/or damage to the equipment
or the rest of the installation.
Before beginning work on the equipment, read this manual carefully, and in
case of any doubt, contact our Technical Service Center. We are available for
any clarification that you might need.
Keep manuals in perfect condition and within reach of personnel that use the
equipment and perform 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 and/or damage to the equipment
or the rest of the installation.
Warning: Risk of electrical shock. Carelessness may produce injury or death.
Warning: Important information for the correct use of the system. May include
one or several of the previous hazards, and therefore must be kept in mind to
avoid damage and injury.

FOCKE MELER GLUING SOLUTIONS
1-2
SAFETY GUIDELINES
Electrical components
The system works with single-phase of a certain power. Never handle the
equipment with the power connected, as this may result in powerful electrical
shocks.
The installation must be correctly grounded.
The installation’s power cable conductors must match the required electric
current and 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.
Thermal components
The controller maybe works in hotmelt sistems with temperatures that can
exceed 200°C (392°F). The equipment must be operated using adequate
protection (clothing, footwear, gloves and protective glasses) that completely
cover exposed parts of the body.
Keep in mind that, due to the high temperatures reached, the heat does not
dissipate immediately, even when the power (in this case, electric) source is
disconnected. Therefore, use caution, even with the adhesive itself. It may
remain very hot, even in a solid state.
In case of burns:
1. If the burn is the result of contact with melted adhesive, do not try to
remove the adhesive material from the skin. Do not try to remove it
once it has solidified either.
2. Cool the affected area down immediately with lots of cold and clean
water.
3. Seek medical attention as soon as possible either from the company’s
medical service or the nearest hospital. Provide the medical staff with
the Safety Information Sheet of the adhesive.

MA-5151-ENG PATTERN CONTROLLER STARBISAFETY GUIDELINES
1-3
Intended use
The equipment are designed to be used in the following conditions:
• Use of equipment with Focke Meler accessories.
• Installation of equipment according to the security regulations
currently in force and the instructions provided in this manual
(anchoring, electrical connection, hydraulic connection, etc).
• Use of equipment in non-explosive, non-chemically aggressive
environments.
• Use of equipment following the safety instructions indicated in this
manual, as well as on the labels 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 of equipment in environments where cleaning is necessary using
water jets.
• In potentially explosive atmospheres, aggressive chemical
environments or outdoors.
• Use or operation without adequate safety protection.
• If the person in question does not have the necessary training to use
the unit or to apply all of the necessary safety measures.
Note: Do not modify the equipment or use components that were not supplied
by Focke Meler. For any modification of a component of the equipment or part
of the installation, you must firstly consult the After-Sales Service

FOCKE MELER GLUING SOLUTIONS
1-4
SAFETY GUIDELINES
This page is intentionally left blank.

MA-5151-ENG PATTERN CONTROLLER STARBIINTRODUCTION
2-1
2. INTRODUCTION
Description
Focke Meler’s StarBi pattern controller is a control system for the dispensing
and positioning of hot-melt or vinyl glue (cold glue) adhesives in gluing
applications.
This device has a place in any market related to industrial gluing with hot-
melt or cold glue, such as labelling machines, box folding machines, wood
lamination, bookbinding…
The adhesive is applied by patterns with each pattern configurable with
various beads. These patterns are executed by controlling the opening
and closing of the application components in two different ways: by TIMES
(programming in units of milliseconds) or by DISTANCES (programming in
units of millimetres).
• A product by TIMES works without knowing the speed of the production
line. Delays and execution times are programmed and the pattern
controller makes the patterns based on those times.
The time elapsed from the detection of the substrate by the photocell
until the moment of the start of the application of the adhesive, as well
as the time that defines the size of the bead, is established for each
bead. If there is any variation in speed, the program will no longer be
valid and the execution times will have to be modified.
• A product by DISTANCES works by knowing the speed of the
production line. The positions and sizes of the beads to be executed are
programmed and the pattern controller makes the patterns based on
those distances.
The distance of the position of the start of the bead with respect to the edge
of the substrate, detected by the photocell, and the size (length) of the bead is
established for each bead.
In the latter case, there must always be a configured installation, where the
distances between photocells and solenoid valves, the compensation times
and the reading configuration of the line speed are defined.
The line speed can be known in two different selectable ways: by means of an
incremental encoder (pulse counter) or by an analogue input (0-10 V).
Intended use
The pattern controller must be used exclusively for the functions described in
this manual and under the limitations indicated therein.
Do not modify the installation or use components not supplied by Focke Meler.
For any modification of a component of the unit or part of the installation, you
must firstly consult the manufacturer.
Do not use power ratings greater than those indicated or with devices of
voltages different from those specified.

FOCKE MELER GLUING SOLUTIONS
2-2
INTRODUCTION
Basic terminology
Some of the terms used in the instruction manual are described below:
Channel: pair of homologous outputs through which the activation signals
are transmitted to the applicator.
Cycle: period of time that includes the process of applying a product or
substrate from the start to the end of it.
Input: the connection ports on the rear panel of the controller to introduce
signals into the device, such as the photocell signal, 0-10 V, encoder, etc.
are called inputs. These inputs can be analogue or digital.
Status: functional situation of the controller.
Modbus RTU / Profibus: type of connection with the controller to manage
it remotely.
Pattern: model of adhesive dots and/or beads to be applied, based on a
periodicity and repeatability. Each pattern can be configured with various
beads. A different pattern can be assigned to each applicator.
Product/Substrate: component to be glued and where the corresponding
pattern will be applied.
Output: the connection ports on the rear panel of the controller used to
determine the status of the device, such as the application output, 0-10
V, error or status, are called outputs. These outputs can be analogue or
digital.

MA-5151-ENG PATTERN CONTROLLER STARBIINTRODUCTION
2-3
Mods of operation
The pattern controller has two modes of operation:
Manual mode: to enable purging, cleaning or depressurising of the installation
or for checking the correct operation of the applicators. The selected outputs
are activated by actuating the corresponding button. If the unit was working in
automatic mode, it will be stopped when entering the MANUAL MODE screen.
When leaving the manual mode, the unit changes to the STOPPED status for
safety reasons.
Automatic mode: To execute application programs using patterns in the
different channels. It can be found in three different statuses: RUNNING,
READY or STOPPED.
STOPPED status_ Safety mode where all the outputs are inactive. The
unit starts in this mode; to change to RUNNING status (production), the
following conditions must be met:
- A product must have been selected.
- The unit must be enabled.
- It must be in temperature OK.
- It must have a minimum speed (in products by distances).
READY status_Intermediate status. It is ready to execute the program
and will do so automatically if the following conditions are met:
- It is in temperature OK.
- It has a minimum speed (in products by distances).
In this status all the outputs are turned off.
RUNNING status_Production mode. The pattern controller executes
the selected patterns of the product and where the outputs are
activated or deactivated according to the selected product. If the
temperature OK and minimum speed conditions (in products by
distances) are no longer fulfilled, it will change to the READY or
STOPPED status.
The unit always works in automatic mode except when the user enters the
screen in manual mode.
When in STOPPED or RUNNING, you can change to MANUAL by entering the
user manual on the screen.
Controller identification
When placing orders for replacement parts or requesting help from our
Technical Service, you should know the model and reference number of your
controller.
This and other technical information will be found on the identification plate
located on the side of the lower part of the controller.

FOCKE MELER GLUING SOLUTIONS
2-4
INTRODUCTION
Main components
1. Touchscreen
2. Central light LEDs.
3. RED LED, unit in STOPPED mode.
4. Button to stop or turn on the program (STOPPED to RUNNING/RUNNING
to STOPPED).
5. GREEN LED unit turned on.
6. On/Off button on the screen.
7. Connection for power supply (StarBi 4-6 Outputs).
8. Power input fuse holder.
9. Electrical power supply switch.
9
87
6
1
4
35
2

MA-5151-ENG PATTERN CONTROLLER STARBIINTRODUCTION
2-5
Rear connections StarBi 4-6 Outputs
1. Six inputs for photocells (according to model).
2. Six outputs for activation channels of solenoid valves,
two per channel (according to model).
3. One 0-10 V analogue input for speed reading.
4. Two 0-10 V analogue outputs for regulating pump
pressure or motor speed (one isolated (1) and one
uninsulated (2) that includes a pin with 24V / 100 mA
supply).
5. One input for encoder.
6. Digital inputs (general inhibition and temperature OK).
7. Digital outputs (error and status).
8. An RS485 port with Modbus RTU / Profibus
communication (optional).
1
2
345
7
6
8

FOCKE MELER GLUING SOLUTIONS
2-6
INTRODUCTION
Lower connections StarBi 2 Outputs
1. Input for photocells (PG13).
2. Digital inputs/outputs (PG9).
3. Power input (PG13).
4. Analogue inputs/outputs (PG13).
5. Output for activation channels of
solenoid valves, two per channel
(PG13).
2 3 2 4 5
4
1

MA-5151-ENG PATTERN CONTROLLER STARBIINTRODUCTION
2-7
Additional components to the installation
Applicators
All Focke Meler applicators controlled by 24 VDC solenoid valves (limited by
the output power) can be connected. For other devices, consult the Central
Office or your nearest Distributor.
Detection systems
The most suitable detection system (for presence of substrate or start
of pattern) will be connected depending on the work to be carried out. A
detection system can be a photocell, an inductive sensor, mechanical switch,
pedal, etc.
The connection will always be of the PNP type (switching to positive +).
The most common device used is the photocell (optical sensor). Two types of
photocells are mainly supplied:
It is sufficient to use the reflection photocell in most applications. Its detection
distance is 30 cm and it can be used in light or dark operation mode (wired).
The photocell with reflection optical fibre (direct reflection on the object) can
be used for applications with limited space, difficult access or with small-
sized substrates. Its detection distance is 110 cm and it can be used in light or
dark operation mode (switch).
To connect other types of devices, consult your Focke Meler Representative or
the Focke Meler Main Office.
Incremental encoder
An incremental encoder (pulse counter) is sufficient to read the line speed; it
does not need to pass through zero or need rotational direction.
Three types of encoder are available to users (200, 400 and 1000 pulses per
revolution) with two different attachment versions: for conveyor, with rolling
disc; for shaft, with elastic coupling. The conveyor bracket has a tension
system, using a torsion spring, to ensure permanent contact of the wheel on
the conveyor.
The 200 pulse model is designed to be placed directly on the conveyor of the
substrate to be glued, so that the controller works with a ratio of 1 pulse = 1
mm. In other cases, the auto-adjustment function of the encoder needs to be
used to find the right ratio.
The connection will always be of the PNP type (switching to positive +).
To connect other types of devices, consult your Focke Meler Representative or
the Focke Meler Main Office.

FOCKE MELER GLUING SOLUTIONS
2-8
INTRODUCTION
Pressure regulator
It is connected to the 0-10 V output (output without isolation) and is used when
a pneumatic supply pressure control is required:
- For the application pump (in the case of piston pumping units)
- For the pressure by-pass valve, in gear pumping
The necessary adhesive flow rate is applied depending on the speed of the
main machine.
This device transforms the output voltage of the controller (0-10 Vdc) into the
corresponding adjustable pneumatic pressure of the pump (0-6 bar).
It can also be used to control the speed of the motors, in gear pumps with a
variable speed through a frequency inverter.
Note: This peripheral needs 24 Vdc power supply.
Controller bracket
The bracket must be requested separately and there are two types, wall-
mounted for 4-6 outputs and articulated wall-mounted for two outputs.
1. Vertical stand StraBi 2 outputs 2. Articulated wall bracket StarBi 2 outputs
3. StarBi wall bracket 4/6 outputs

INSTALLATION
3-1
MA-5151-ENG PATTERN CONTROLLER STARBI
3. INSTALLATION
Warning: The pattern controllers are installed in equipment provided with
current technologies and with certain foreseeable risks. Therefore, only
qualified personnel with sufficient training and experience should be allowed
to use, install or repair these devices.
Introduction
The pattern controllers are supplied with the complete 5 metre power cable
(except the pattern controller with 2 outputs) and the manual on a USB device.
The rest of the accessories will be requested apart.
Installation requirements
- Have the corresponding adhesive installation, with its applicators
prepared with the connection for the controller
- Ensure that the space set aside for this device enables the location,
connection and use of the entire system.
- Check that the electrical supply meets the requirements of the device
to be used.
Electrical consumption
Before connecting the pattern controller:
- Take into account the total consumption of the installation and provide
a current supply for the power rating indicated.
- Make sure that the voltage to which the device is to be connected is the
same as that indicated on the nameplate of the unit.
- Connect and check that the installation has a good ground connection.
Warning: Risk of electrocution. Even when the unit is turned off, tension
remains in the input terminals, which could be dangerous for internal
manipulation of the unit.
- Install a circuit breaker to protect against short-circuits and a residual
current device as personal protection against earth leakages.
- The power associated with these protections is indicated on the
nameplate of the controller.

FOCKE MELER GLUING SOLUTIONS INSTALLATION
3-2
Unpacking
Remove the pattern controller from its packaging and check for any possible
damage or breakage. Communicate any damage, including to the external
packaging, to your Focke Meler representative or the Focke Meler Main Office.
Warning: Reject any packaging that does not have the corresponding labels or
whose information does not match what was requested.
Attaching the device
- Place the controller on a flat and stable surface.
- Fix the base to the desired location by means of the holes indicated for
M6 screws.
Other types of fixings are available, to adapt to different locations or needs.
Consult your Focke Meler Representative or the Focke Meler Main Office.
- Place the controller near the installation (applicators, photocells,
encoder, etc.) so that the cables can be connected easily.
- Place the device at a height where the screen is easily visible and
accessible.
- Leave enough space so that the output of the connection cables is not
forced and can be implemented comfortably.
- The equipment must be positioned in such a way that the disconnection
device is visible and easy to access.
- Avoid places exposed to knocks or vibrations.
Warning: Make sure the bench on which the base is mounted is level, free
from vibrations and able to support the weight of the device.
Electrical installation
The pattern controllers are supplied to be connected to the 230 VAC
single phase power supply network with neutral, according to their power
consumption.
Good ground connection is always essential.
The maximum consumption values are indicated on the nameplate of the
device.
Warning: Risk of electric shock. Carelessness may cause injury or death.
Warning: Avoid connecting the controller on lines that share the circuit with
motors or large devices that may cause fluctuations in the line voltage.
Warning: Make sure that both the controller and the installation are kept away
from potential sources of electromagnetic interference (frequency inverters,
wireless telephony or public address speakers).