Meler MACRO FOAM Series User manual

MA-5127-ENG 231220
GLUING SOLUTIONS
ADHESIVE
MELTER
MACRO FOAM
SERIES
INSTRUCTIONS
MANUAL

Published by:
Focke Meler Gluing Solutions, S.A.
Pol. Arazuri-Orkoien, c/B, nº3 A
E-31170 Arazuri - Navarra - Spain
Phone: [phone]
[e-mail] - www.meler.eu
Focke Group
Edition December 2020
© 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.
The official language of this manual is only the English language. The
remaining versions of the manual in other languages are mere translations
without any official value or efficacy. In case of discrepancies or contradictions
between the English version of the manual and any other version of the manual
written in another language, the English version will prevail.

TABLE OF CONTENTS MA-5127-ENG MACRO FOAM SERIES MELTER MANUAL
TABLE OF CONTENTS
1. SAFETY GUIDELINES 1-1
General 1-1
Symbols 1-1
Mechanical components 1-2
Electrical components 1-2
Hydraulic components 1-2
Pneumatic components 1-2
Thermal components 1-3
Materials 1-3
Noise emission declaration 1-3
Intended use 1-4
Limited use 1-4
2. INTRODUCTION 2-1
Description 2-2
Intended use 2-2
Limited use 2-2
Modes of operation 2-2
Hot-melt melter identification 2-3
Main components 2-4
Control card components 2-6
Pumping control card components 2-7
Optional Equipment 2-8
Three color ligh beacon 2-8

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
3. INSTALLATION 3-1
Introduction 3-1
Installation requirements 3-1
Free space 3-1
Electrical Consumption 3-2
Compressed air 3-2
Other factors 3-2
Unpacking 3-3
Contents 3-3
Mounting the equipment 3-3
Electrical power connection 3-4
Pneumatic connection 3-5
Hose and applicator connection 3-5
Parameter Programming 3-6
Programming working temperatures 3-6
Selecting the overheating value 3-6
Keeping a component on display 3-7
External I/O connections 3-8
Temperature ok 3-8
External Standby 3-9
Low level (optional) 3-9
Output inhibitor 3-10
Starting up the motor (ok ext) 3-11
Foam pump pressure regulation (ref ext) 3-11
Failures output in pump control card 3-12
Gas low level 3-12
External adhesive feeder 3-13

TABLE OF CONTENTS MA-5127-ENG MACRO FOAM SERIES MELTER MANUAL
4. MELTER OPERATION 4-1
General information 4-1
Filling the tank 4-1
Starting up the melter equipment 4-2
Melter equipment displays 4-3
Displaying the temperature for each component 4-4
Alarm displays 4-5
Hot-melt display level (optional) 4-6
Display and adjustment of the working pressure 4-6
Temperature adjustment 4-6
Programming the applicator parameters 4-7
Setting the clock 4-8
Programming the current day and hour 4-8
Programming equipment activation/deactivation 4-9
Disabling the equipment activation/deactivation program 4-10
Programming the equipment’s standby function activation/deactivation 4-11
Disabling the equipment standby function programming 4-12
Special function buttons 4-13
Pumping control 4-14
Starting up the pump control card 4-14
Pumping safety measures 4-14
Password security 4-15
LED indicators 4-16
Modes of operation 4-17
Mode of operation with internal pumping control and internal pressure control 4-17
Mode of operation with internal pumping control and external pressure control 4-18
Mode of operation with external pumping control and internal pressure control 4-19
Mode of operation with external pumping control and external pressure control 4-20
User configuration menu 4-22

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
Displaying alarms and reset function 4-23
Maximum pressure alarm 4-23
Minimum pressure alarm 4-23
Variator alarm 4-23
Configuring pressure curve 4-23
Programming pressure curve 4-25
Current Vin voltage display 4-26
By-pass valve regulation 4-26
Start up and operation of the loader 4-26
Loader OFF function 4-27
Colourless warning light 4-27
Level sensor adjustments 4-28
Sensitivity adjustment 4-28
Level stabilisation time 4-28
Programmable times using the timer 4-28
Disconnection delay time 4-28
Operating alarms 4-28
Setting programmable times using the timer 4-29
Manual feeding 4-30
Turning off the melter equipment 4-30
Conditions for good performance 4-30
5. MAINTENANCE 5-1
Equipment cleaning 5-1
Depressurizing the system 5-2
Filter maintenance 5-2
Pump filter 5-2
Tank Grating 5-3
Tank filter 5-4
Cleaning the tank 5-4
Changing adhesive type 5-4
Cleaning burnt adhesive 5-5
Emptying the tank 5-5

TABLE OF CONTENTS MA-5127-ENG MACRO FOAM SERIES MELTER MANUAL
Pump maintenance 5-6
Inspecting for leaks 5-6
Changing the pump probe 5-6
Gas injection valve cleaning 5-7
Motor-gear maintenance 5-7
Cleaning the motor fan 5-7
Checking the lubricant 5-7
Recommended lubricants 5-7
Thermostats maintenance 5-8
6. TECHNICAL CHARACTERISTICS 6-1
General 6-1
Dimensions 6-2
7. ELECTRICAL DRAWINGS 7-1
8. PNEUMATIC DIAGRAMS 8-1
Components list 8-1
Pneumatic by-pass valve control system 8-1
9. SPARE PARTS LIST 9-1
A. COVER- TANK ASSEMBLY MACRO FOAM 35 9-2
B. COVER- TANK ASSEMBLY 9-3
C. DISTRIBUTOR ASSEMBLY 9-4
D. FILTER/PURGE AND PRESSURE VALVE ASSEMBLY 9-5
E. GEARED MOTOR-PUMP ASSEMBLY 9-6
F. ELECTRICAL CABINET 9-7
EC DECLARATION OF CONFORMITY 10-1

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

SAFETY GUIDELINES
1-1
MA-5127-ENG MACRO FOAM SERIES MELTER MANUAL
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: Hot zone with high temperatures. Risk of burns. Use thermal
protective equipment.
Warning: System under pressure. Risk of burns or particle projection. Use
thermal protective equipment and glasses.
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.
Warning: Dangerous area. Risk of entrapment. Carelessness may produce
injury or death.

FOCKE MELER GLUING SOLUTIONS
1-2
SAFETY GUIDELINES
Mechanical components
The hot-melt installation, which is installed to this device, requires moving
parts that can cause damage. Use the equipment correctly, and do not remove
the safety guards while the equipment is in operation; prevent the risk of
possible entrapment due to moving mechanical parts.
Do not use the equipment if the safety devices are not in place or appear to be
inadequately installed.
For maintenance or repair operations, stop the movement of moveable parts
by turning off the main switch.
The device has no moving mechanical parts, so it does not pose risks to
consider in this section.
Electrical components
The system works with single-phase or three-phase current 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.
Hydraulic components
As this is a pressurized system, precautions related to this type of equipment
must be observed.
Before each operation, always make sure that the adhesive circuit is
completely free of pressure. There is a high risk of hot particle projection,
along with the corresponding danger of burns.
Use caution with the residual pressure that may remain in the hoses when the
adhesive cools. When reheated, there is a risk of hot particle projection if the
outputs are left open.
Pneumatic components
Some equipment uses compressed air to 6 bar pressure. Before any
manipulation, please ensure that the circuit has lost fully air pressure. The
risk of projection of particles at high speed can cause injury to a certain
severity.
Extreme precautions with the residual pressure that could be contained in the
circuit, before disconnecting any pneumatic feeding tube.

SAFETY GUIDELINES
1-3
MA-5127-ENG MACRO FOAM SERIES MELTER MANUAL
Thermal components
The entire system works 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.
Materials
Meler 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.
When using adhesive, follow the corresponding guidelines found in the
Technical and Safety Sheets provided by the manufacturer. Pay special
attention to the advised work temperatures in order to prevent adhesive
burning and degradation.
Ventilate the work area adequately in order to remove the vapors produced.
Avoid the prolonged inhalation of these vapors.
Always use original Meler components and replacement parts, which
guarantee the correct system operation and service.
Noise emission declaration
The A-weighted emission sound pressure level (LpA) of the unit in operation
does not exceed 70 dB(A) under any circumstances.
The maximum C-weighted sound pressure level (LpCpeak) and the A-weighted
sound power level (LWA) do not exceed values worthy of mention and thus do
not represent a specific risk that must be taken into account.

FOCKE MELER GLUING SOLUTIONS
1-4
SAFETY GUIDELINES
Intended use
The equipment are designed to be used in the following conditions:
• Hot-melt adhesive fusion and pumping at temperatures up to 200 °C
(392 ºF). Consult with Meler technical service to operate with higher
working temperatures.
• Use of equipment with 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 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 products.
• 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 Meler. For any modification of a component of the equipment or part of the
installation, you must firstly consult the After-Sales Service

INTRODUCTION
2-1
MA-5127-ENG MACRO FOAM SERIES MELTER MANUAL
2. INTRODUCTION
In this manual you will find information about the installation, use and
maintenance of the hot-melt adhesive melter in meler’s Macro Foam series.
The Macro series includes the 35, 50 and 120 liter range of hot-melt adhesive
melters.
Most of the photographs and illustrations that appear in this manual refer to
the 35-liter Macro Foam 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
Macro Foam series.

FOCKE MELER GLUING SOLUTIONS, S.A.
2-2
INTRODUCTION
Description
The Macro Foam series are designed for use with Meler hoses and applicators
in hot-melt adhesive applications. Their different variations – line, coating or
swirl-spray – cover a wide range of applications, being very versatile in all
markets where they are used.
Intended use
The hot-melt melters in the Macro Foam series are designed to be used in the
following conditions:
• Hot-melt adhesive fusion and pumping at temperatures up to 200°C.
• Use of hot-melt melters with Meler accessories.
• Installation of hot-melt melters according to the security regulations
currently in force and the instructions provided in this manual
(anchoring, electrical connection, hydraulic connection, etc).
• Use of hot-melt melters in non-explosive, non-chemically aggressive
environments.
• Use of hot-melt melters 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 Macro Foam series hot-melt melters must be used for their intended
uses and never in the following conditions:
• Use with adhesives or any other material that might cause safety or
health risks when heated.
• Use of hot-melt melters in environments where cleaning is necessary
using water jets.
• Use of hot-melt melters to heat or melt food products.
• Use or operation without adequate safety protection.
Modes of operation
These melters may be used in all of the following modes:
Work mode_The hot-melt melter keeps materials hot at the pre-
selected temperature indicated on the display. The pump is kept
activated, waiting for the consumption command when one or more
applicators are activated.
Internal control of pumping and pressure _Switches in the
position ok ‘int’ and ref ’int’. In this mode of operation, the user
has full control of pumping and the set work pressure of the
pump.

INTRODUCTION
2-3
MA-5127-ENG MACRO FOAM SERIES MELTER MANUAL
Control of internal pumping and external pressure_Switches
in the position ok ‘int’ and ref ’ext’. This mode of operation is
performed through internal pumping control and pressure
control by means of an external 0-10 V signal sent from the main
machine.
Control of external pumping and internal pressure_Switches
in the position ok ‘ext’ and ref ’int’. This mode of operation
is performed through external pumping control and manual
pressure control.
Control of external pumping and pressure_Switches in the
position ok ‘ext’ and ref ’ext’. In this working mode, both pumping
and pressure are controlled from the main machine. Pressure 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 values below the
pre-selected value. The pump remains deactivated.
Alarm mode_The hot-melt melter detects a malfunction and warns
the operator of this event. The pump remains deactivated.
Stop mode_The hot-melt melter remains off, without heating the
materials and with the pump deactivated. The electrical and pneumatic
supply remains activated between the network and the system,
however.
Hot-melt melter identification
When placing orders for replacement parts or requesting help from our
service center, you should know the model and reference number of your hot-
melt melter.
This and other technical information will be found on the identification plate
located on the side of the lower part of the hot-melt melter.

FOCKE MELER GLUING SOLUTIONS, S.A.
2-4
INTRODUCTION
Main components
9
1
2
3
4
5
6
8
10
11
12
15
16
18 19 20 18 19 20
7
18
17
14
13
21

INTRODUCTION
2-5
MA-5127-ENG MACRO FOAM SERIES MELTER MANUAL
1. Access door to the electronic section and connections.
2. Front control card.
3. Pumping control card 1.
4. Pumping control card 2.
5. Control system of the external adhesive feeding (optional).
6. Main power switch.
7. Electrical main supply input.
8. Auxiliary I/O signals input.
9. Warning beacon system (optional).
10. Tank access cover.
11. Gas pressure regulator to pump 1.
12. Gas pressure regulator to pump 2.
13. Unit transport wheels.
14. External adhesive feeding inlet (optional).
15. Pneumatic by-pass valve pressure control with pressure gauge pump 1.
16. Pneumatic by-pass valve pressure control with pressure gauge pump 2.
17. Hose-applicator electrical connections. Right side or rear placed.
18. Hose output distributor. Right side or rear placed.
19. Pump filter and purge valve set.
20. By-pass valve pressure regulator with pressure gauge.
21. Tank-distributor shut off valve.

FOCKE MELER GLUING SOLUTIONS, S.A.
2-6
INTRODUCTION
Control card components
1. Temperature OK LED and pumping allow.
2. Tank indicator LED.
3. Distribuitors indicators LEDS.
4. Temperature set point.
5. Real temperature.
6. ON/OFF switch.
7. Standby function.
8. Time scheduling.
9. Pumps indicators LEDS.
10. Left/right button - channel selection.
11. Up/down button - temperature modification.
12. Applicator indicator LED.
13. Hose indicator LED.
1
2
3
6
7
8
9
10
4 5
111213

INTRODUCTION
2-7
MA-5127-ENG MACRO FOAM SERIES MELTER MANUAL
1
2
3
4
98 5
6
7
121110
Pumping control card components
1. Main switch ON/OFF.
2. External start-stop LED.
3. External speed control LED.
4. Pumping permission LED.
5. Up/down 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.

FOCKE MELER GLUING SOLUTIONS, S.A.
2-8
INTRODUCTION
Optional Equipment
In order to provide the melting equipment with more functions, the following
optional elements may be added:
• Low melted adhesive level detection system.
• Light tower system.
• Automatic tank filling system.
Three color ligh beacon
RED: Gas bottle empty.
WHITE: Low adhesive level.
GREEN: Temperature OK.