Meler MICRON+ GEAR Series User manual

ADHESIVE
MELTER
MICRON+
GEAR
SERIES
INSTRUCTIONS
MANUAL
GLUING SOLUTIONS
MA-5167-ESP 200519

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 May 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-5167-ENG MICRON+GEAR ADHESIVE MELTERTABLE OF CONTENTS
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 2-1
Modes of operation 2-2
Hot-melt melter/applicator identification 2-2
Main components 2-3
Main components de MICRON+Gear with two motor-pumps 2-4
Control panel components 2-5
Automatic feeder main components (optional) 2-6
General 2-6
MICRON+series range 2-7
Micron+ gear range option accessories 2-8
Automatic feeder option 2-8
Gas injection option 2-8
Air dryer system 2-8
Bypass valve pressure control system 2-8

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
Level control system 2-8
Warning light option 2-8
Optional equipment 2-8
3. INSTALLATION 3-1
Introduction 3-1
Installation requirements 3-1
Electrical Consumption 3-2
Compressed air 3-2
Other factors 3-3
Unpacking 3-3
Contents 3-3
Mounting the equipment 3-3
Electrical power connection 3-4
Pneumatic connection 3-5
Hose and applicator connection 3-6
Parameter Programming 3-6
External I/O connections 3-7
Connecting external inputs and outputs 3-9
Connecting zone inhibition 3-10
External signals of pumping control 3-11
Connection of externar singnals for pumping control 3-11
Automatic feeder assembly 3-12
Pneumatic connection 3-12
Suction tube connection 3-12
Placing the suction tube 3-12
Electrical connections 3-13
4. MELTER OPERATION 4-1
General information 4-1
Filling the tank 4-2

MA-5167-ENG MICRON+GEAR ADHESIVE MELTERTABLE OF CONTENTS
Starting up the melter equipment 4-2
Manual pumping permmision 4-3
Melter equipment display 4-4
General characteristics 4-5
Navigation icons 4-5
Save changes 4-5
Interpretación de las pantallas 4-5
Home display 4-6
General temperature status 4-6
Alarms status 4-7
Calendar status 4-7
Adhesive level status 4-7
Pumping status 4-8
Temperature status 4-8
Temperature and Heating Shortcut displays 4-9
Programming of temperatures 4-10
Programming of statuses 4-10
Menú Calendars 4-10
Units and Lenguage Menu 4-11
Date and time configuration 4-11
Alarms and warnings 4-11
Pumping control menu 4-12
Modes of operation 4-13
‘Pumping safety’ function activated 4-13
‘Pumping safety’ function deactivated 4-13
Operating mode with internal pumping control and internal speed control 4-14
Operating mode with internal pumping control and external speed control 4-15
Operating mode with external pumping control and internal speed control 4-16
Operating mode with external pumping control and external speed control 4-17
Configuring speed ramp 4-18
Main Menu 4-18

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
‘1. Heating’ Menu 4-19
1.1 Heating zones 4-19
1.2 Sequential Heating 4-20
1.3 Inhibitions 4-20
1.4 Auto Standby - OFF 4-21
1.5 Extra temperature settings 4-22
‘2. General settings’ Menu 4-23
2.1 Password management 4-23
2.2 Extra settings 4-24
2.3 Configuration of input and output signals 4-25
2.4 Restore default values 4-25
‘3. Load’ Menu 4-26
Screen 1: Minimum adhesive level sensor 4-26
Screen 2: Automatic adhesive feeder 4-26
Screen 3: Dry air/gas injection 4-26
Screen 4: Pressurisation (only for units with an airtight tank lid) 4-27
‘4. Statistics’ Menu 4-27
Menu ‘5. Pumping’ 4-28
Standby function 4-29
By-pass valve regulation 4-30
Manual valve control 4-30
Adjust pneumatic valve control(DP1 / DP2) (optional) 4-31
Using the air drying system (optional) 4-31
Turning off the melter equipment 4-31
Use of the automatic feeder 4-32
Start up and automatic process 4-32
Sensitivity adjustment 4-33
Positioning of the level sensor 4-33
Application for PC 4-34
5. MAINTENANCE 5-1
Equipment cleaning 5-1

MA-5167-ENG MICRON+GEAR ADHESIVE MELTERTABLE OF CONTENTS
System depressurisation 5-3
Access to the interior of the equipment 5-3
Access to distributor 5-3
Access to pump gear- motor 5-3
Filter maintenance 5-4
Cleaning the tank 5-5
Changing adhesive type 5-5
Cleaning burnt adhesive 5-5
Emptying the tank 5-6
Pump maintenance 5-7
Inspecting for leaks 5-7
Gear motor maintenance 5-7
Cleaning the motor fan 5-7
Checking the lubricant 5-7
Recommended lubricants 5-8
Safety Thermostat 5-8
Air dryer filter maintenance 5-8
Remove the equipment from its base 5-9
Automatic feeder maintenance 5-10
Cleaning of the unit 5-10
Pneumatic system 5-10
Control of the load sensor 5-11
Inspection of the aspiration tube 5-11
Filter maintenance 5-11
Control of pneumatic vibrator 5-11
6. TECHNICAL CHARACTERISTICS 6-1
Generals 6-1
Dimensions 6-3
Micron+ gear range option accessories 6-5
Automatic feeder system 6-5
Air drying system for reactives adhesives 6-5

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
Pneumatic by-pass valve pressure control system 6-5
Level control system 6-5
Warning light option 6-5
Optional equipment 6-6
Wheel system 6-6
7. ELECTRICAL DRAWINGS 7-1
8. PNEUMATIC DIAGRAM 8-1
Components list 8-1
Pneumatic by-pass valve control system (optional) 8-1
Air drying system (optional) 8-1
Double pressure system (opcional) 8-2
9. SPARE PARTS LIST 9-1
A. TANK ASSEMBLY 9-4
B. DISTRIBUTOR UNIT 9-5
C. DISTRIBUTOR SIMPLE/ DOUBLE ASSEMBLY 9-6
D. GEARED MOTOR-PUMP ASSEMBLY 9-7
E. CHASSIS ASSEMBLY 9-8
F. ELECTRIC ASSEMBLY 9-9
G. ELECTRONIC ASSEMBLY 9-10
H. PNEUMATIC COMPONENTS 9-11
I. GAS INJECTION ASSEMBLY (OPTIONAL) 9-11
J. AIR DRYER ASSEMBLY (OPTIONAL) 9-12
K. AUTOMATIC FEEDER. FILTER- SENSOR ASSEMBLY 9-13
L. AUTOMATIC FEEDER. SUCTION TUBE 9-14
M. AUTOMATIC FEEDER. VALVE ASSEMBLY 9-15
EC DECLARATION OF CONFORMITY 10-1

SAFETY GUIDELINES
1-1
MA-5167-ENG MICRON+GEAR ADHESIVE MELTER
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-5167-ENG MICRON+GEAR ADHESIVE MELTER
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-5167-ENG MICRON+GEAR ADHESIVE MELTER
2. INTRODUCTION
In this manual you will find information about the installation, use and
maintenance of the hot-melt adhesive melter in Meler’s ‘Micron+ gear’ series
(hereinafter also referred only as Micron+).
This melters series includes the 5, 10, 20 and 35 liter range of hot-melt
adhesive melters.
Most of the photographs 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 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.

FOCKE MELER GLUING SOLUTIONS
2-2
INTRODUCTION
Modes of operation
The hot-melt melters/applicators may be used in all of the following modes:
Work mode_The hot-melt melter/applicator 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
application applicators are activated.
Internal control of pumping and speed _ In this mode of
operation, the user has full control of pumping and the set speed
of the pump rotation.
Control of internal pumping and external speed_ This mode of
operation is performed through internal pumping control and
speed control by means of an external 0-10 V signal sent from the
main machine.
Control of external pumping and internal speed_ This mode of
operation is performed through external pumping control and
manual speed control.
Control of external pumping and speed_ 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/applicator 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/applicator detects a malfunction
and warns the operator of this event. The pump remains deactivated.
OFF mode_The hot-melt melter/applicator 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/applicator 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/applicator.
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.
MICRON+ ENGRANE
75 rpm
50 rpm
50 rpm
49 rpm
53 rpm
PUMP 1
Real speed:
External reference 1
External permission 1
Switch 1
Real speed:
External reference 2
External permission 2
Switch 2
PUMP 2

INTRODUCTION
2-3
MA-5167-ENG MICRON+GEAR ADHESIVE MELTER
Main components
1. Front control card.
2. Access door to the electric/pneumatic area.
3. Tank access lid.
4. Main switch ON/OFF.
5. Gear motor
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.
13. I/O card pumping control
11
109
4
7 85 6
1 2 3
12
13

FOCKE MELER GLUING SOLUTIONS
2-4
INTRODUCTION
For each motor-pump assembly installed:
1. Gear motor 1
2. Gear motor 2
3. Pressure regulator 1
4. Pressure regulator 2
5. Hoses output 1
6. Hoses output 2
Main components de MICRON+Gear with two motor-
pumps
Marking of the Micron+ gear components is the same for all models with two
motor-pumps. In this case the pictures refers to the 20-liter model.
13
245
6

INTRODUCTION
2-5
MA-5167-ENG MICRON+GEAR ADHESIVE MELTER
Control panel components
1. Touch screen.
2. Status central leds (GREEN, YELOW, RED).
3. RED led ‘pumping OFF’.
4. STOP RED Button ‘Start/Stop Pump’.
5. Touch screen ON/OFF button.
6. GREEN led ‘power ON’.
1
2
3
4 5
6

FOCKE MELER GLUING SOLUTIONS
2-6
INTRODUCTION
Automatic feeder main components (optional)
General
1. Flexible Load Tube
2. Rotary fitting
3. Unload Filter
4. Load Sensor
5. Tank access lid
6. Output air supply to the suction area
7. Electric load valve
8. Input air supply (from the grid)
9. Junction box
10. Level sensor amplifier
11. Sensor and power supply connector
12. Pneumatic vibrator
13. Suction area
14. Air feeding tube
16
4
11
12 13 14
2
3
10
4
7
5
8
9

INTRODUCTION
2-7
MA-5167-ENG MICRON+GEAR ADHESIVE MELTER
MICRON+series range
(1) In case of simple pump up to 6 outputs but in case of double pump up to 4.
(2) The 230°C version and the version with the tank lid featuring gas or dry air intake do not allow the use of float
detectors.
(3) In the case of two single pumps or two double pumps, place a 2 before the pump type (SX or DX). In the case
of one single pump and a double pump, place the single pump (SX) first followed by the double pump (DX). The
maximum number of pumps is two per equipment.
MICRON+ 5 2 M01 200 BE S8 V A0 PC LD2 B0 0B SW
serie MICRON+
tank capicity -
5: 5kg / 10: 10kg / 20: 20 kg / 35: 35 kg
no. electric outputs (1)-
2 / 4 / 6
connection -
M01: Pt100 / N01: Ni120 / R01: NTC (R)
pumping type-
BE: engranaje
maximum temperature (2)-
200: 200°C / 230: 230°C
pumping type (3) -
S: simple / D: doble
cover model - V: standard / CG:automatic feeder /
G: standard with gas inlet / CL: liquid charge
air dryer system -
A0: no dryer system / A1: air dryer system
level sensor (4) - LD0: w/o / LD1: float switch
/ LD2: capacitive / LD3: capacitive high-low
low level warning light (5) -
B0: no warning light / B1: with
warning
communications -
0B: without/ PB:Profibus /
PN: Profinet / EN: Ethernet IP
bypass valve pressure control system - PC: pneuma-
tic / MC: mechanic / DP1: Double pressure / DP2: VP
SW: with Switch
connector Pump
ON/OFF

FOCKE MELER GLUING SOLUTIONS
2-8
INTRODUCTION
Micron+ gear range option accessories
If some of the different machine configuration options have been chosen, 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.
Gas injection option
There is the possibility of preparing the equipment with an air or gas input
into the reservoir. This entrance is done from the top and the equipment is
prepared from the factory.
Air dryer system
The air dryer system must be requested separately and is the same for the 5,
10, 20 and 35l machines.
Bypass valve pressure control system
Pressure control can be effected through pneumatic or mechanical regulation.
By default, the equipment is fitted with pneumatically regulated pressure
control.
Level control 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 be requested separately. There is a choice of the low
level and colourless (white) indicator light or the low level and temperature OK
indicator light (green). They are both the same for all machines.
Optional equipment
To increase the functionality of the melter machines, the following optional
elements can be incorporated:
• Wheels: these can be fitted to all the machines.