Meler Micron Gear Series User manual

ADHESIVE
MELTER
MICRON GEAR
SERIES
INSTRUCTIONS
MANUAL
MA-5079-ENG 200718
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 July 2018
© 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.

TABLE OF CONTENTS MA-5079-ENG MICRON GEAR ADHESIVE MELTER
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 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 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
Free space 3-1
Electrical Consumption 3-2
Compressed air 3-3
Other factors 3-3
Unpacking 3-3
Contents 3-3
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) 3-12
Motor speed set point reference (ref ext) 3-12
Failures output in pump control card 3-13

TABLE OF CONTENTS MA-5079-ENG MICRON GEAR ADHESIVE MELTER
4. MELTER OPERATION 4-1
General information 4-1
Filling the tank 4-2
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 level display (optional) 4-7
Display and adjustment of the working speed 4-7
Temperature adjustment 4-8
Programming the applicator parameters 4-9
Programming process 4-9
Timer to switch between 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 standby function activation/deactivation 4-18
Disabling the equipment standby function programming 4-19
Special function buttons 4-20
Pumping control 4-21
Starting up the pump control card 4-21
Pumping safety measures 4-21
Password security 4-22
LED indicators 4-23

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
Modes of operation 4-24
Mode of operation with internal pumping control and internal speed control 4-24
Mode of operation with internal pumping control and external speed control 4-25
Mode of operation with external pumping control and internal speed control 4-26
Mode of operation with external pumping control and external speed control 4-27
User configuration menu 4-28
Displaying alarms 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 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

TABLE OF CONTENTS MA-5079-ENG MICRON GEAR ADHESIVE MELTER
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
6. TROUBLESHOOTING 6-1
Melter 6-2
The unit does not turn on (5, 10 and 20 adhesive melters) 6-2
The unit does not turn on (35 adhesive melter) 6-2
Equipment shortcircuit malfunction 6-3
Tank 6-3
The 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 stop heating (Micron, 1 geared motor) 6-5
The manifold does not stop heating (Micron, 2 geared motores) 6-6
Temperature fluctuations in the manifold/ manifolds 6-6
Melter does not pump 6-6
Problems associated with temperatures 6-6
The pump control board has been switched off 6-6
Pump control board alarms 6-7

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
Check that the machine is working in the correct operating mode 6-7
All of the previous premises are OK but the unit still does not perform any pumping operations 6-7
Level sensor 6-8
The unit does not indicate the absence of adhesive 6-8
Dry air system 6-8
No dry air is fed to the tank 6-8
Hose 6-9
Hose does not heat 6-9
Hose does not stop heating 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 system 7-5
Air drying system for reactives adhesives 7-5
Pneumatic by-pass valve pressure control system 7-5
Level control system 7-5
Warning light option 7-5
Optional equipment 7-6
Wheel system 7-6

TABLE OF CONTENTS MA-5079-ENG MICRON GEAR ADHESIVE MELTER
8. ELECTRICAL DRAWINGS 8-1
9. PNEUMATIC DIAGRAM 9-1
Components list 9-1
Pneumatic by-pass valve control system (optional) 9-1
Air drying 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

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MA-5079-ENG MICRON GEAR ADHESIVE MELTERSAFETY 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: 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.

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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.

MA-5079-ENG MICRON GEAR ADHESIVE MELTERSAFETY GUIDELINES
1-3
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.

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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-5079-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.

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2-2
INTRODUCTION
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 speed _Switches in the position
ok ‘int’ and ref ’int’. 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_Switches in the
position ok ‘int’ and ref ’ext’. 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_Switches in the
position ok ‘ext’ and ref ’int’. This mode of operation is performed
through external pumping 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 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
Technical Service, 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.

INTRODUCTION
2-3
MA-5079-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. Pumping control 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
11109
4
7 8
56
1 2 3

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INTRODUCTION
Main components 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.
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
73
2
84
5
6

INTRODUCTION
2-5
MA-5079-ENG MICRON GEAR ADHESIVE MELTER
Control card components
1. Tank 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

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INTRODUCTION
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.
1
2
3
4
98 5
6
7
121110