Meler PS200 User manual

MA-5066-ENG 250220
GLUING SOLUTIONS
ADHESIVE
MELTER
PS200
DRUM
UNLOADER
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
A Focke Group Company
Edition February 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.
This manual is a translation of the original that was written by Focke Meler
Gluing Solutions, S. A in english language. If there is any discrepancy between
the different versions of this manual, the original written in the english
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-5066-ENG PS200 DRUM 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 2-1
Intended use 2-2
Limited use 2-3
Modes of operation 2-3
Identifying the melting equipment 2-4
Main components 2-4
General 2-4
Control panel 2-5
Platen up-down pushbuttons 2-6
Four colors light tower 2-6
Control card components 2-7
Pumping control card components 2-8
Pneumatic control 2-9
Optional equipment 2-10

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 3-3
Unpacking 3-3
Contents 3-3
Equipment placement 3-3
Electrical power connection 3-4
Pneumatic connection 3-4
Hoses and applicators connection 3-5
Parameter Programming 3-5
Programming working temperatures 3-5
Selecting the overheating value 3-6
Keeping a component on display 3-7
External I/O connections 3-7
Temperature ok 3-8
External Standby 3-8
Output inhibitor 3-9
Starting up the motor (ok ext) 3-10
Motor speed set point reference (ref ext) 3-10
Failures output in pump control card 3-10
Light tower signals 3-11
4. MELTER OPERATION 4-1
Información general 4-1
Starting up the melter equipment 4-2
Melter equipment displays 4-3

TABLE OF CONTENTS MA-5066-ENG PS200 DRUM MELTER MANUAL
Displaying the temperature for each component 4-4
Alarm displays 4-4
Display and adjustment of the working speed 4-5
Temperature adjustment 4-5
Programming the applicator parameters 4-6
Timer to switch between ON - Standby - OFF modes 4-10
Password to access parameter programming 4-11
Total equipment service hours counter 4-11
Counter that warns of the need to change the adhesive agent filter 4-12
Setting the clock 4-13
Programming the current day and hour 4-13
Programming equipment activation/deactivation 4-14
Disabling the equipment activation/deactivation program 4-15
Programming the equipment’s standby function activation/deactivation 4-15
Disabling the equipment standby function programming 4-16
Special function buttons 4-17
Pumping control 4-18
Starting up the pump control card 4-18
Pumping safety measures 4-18
Password security 4-19
LED indicators 4-20
Modes of operation 4-21
Mode of operation with internal pumping control and internal speed control 4-21
Mode of operation with internal pumping control and external speed control 4-22
Mode of operation with external pumping control and internal speed control 4-23
Mode of operation with external pumping control and external speed control 4-24
User configuration menu 4-25
Displaying alarms and reset function 4-26
Maximum rpm alarm 4-26
Minimum rpm alarm 4-26

FOCKE MELER GLUING SOLUTIONS TABLE OF CONTENTS
Variator alarm 4-26
Configuring speed ramp 4-27
Programming speed ramp 4-28
Current Vin voltage display 4-29
By-pass valve regulation 4-29
Pneumatic valve adjustment 4-29
Placing a new drum 4-30
Removing the empty drum 4-31
Removing the drum with manual aeration 4-31
Removing the drum with automatic aeration (optional) 4-33
5. MAINTENANCE 5-1
Equipment cleaning 5-1
Depressurizing the system 5-2
Platen maintenance 5-2
Pump maintenance 5-2
Inspecting for leaks 5-2
Motor-gear maintenance 5-3
Cleaning the motor fan 5-3
Checking the lubricant 5-3
Recommended lubricants 5-3
Safety Thermostat 5-4
Air filter maintenance 5-4
6. TECHNICAL CHARACTERISTICS 6-1
General 6-1
Dimensions 6-2
Accessories 6-2
Light tower system 6-2
Automatic air injection for platen pulling out 6-2
7. ELECTRICAL DRAWINGS 7-1

TABLE OF CONTENTS MA-5066-ENG PS200 DRUM MELTER MANUAL
8. PNEUMATIC DIAGRAMS 8-1
Pneumatic drawing with manual aereation system 8-1
Pneumatic drawing with automatic aereation system 8-1
9. SPARE PARTS LIST 9-1
A. STRUCTURE 9-2
A. STRUCTURE 9-3
B. PLATEN ENSEMBLE 9-4
B. PLATEN ENSEMBLE 9-5
C. SIMPLE MANIFOLD ENSEMBLE 9-6
C. SIMPLE MANIFOLD ENSEMBLE 9-7
C. DOUBLE MANIFOLD ENSEMBLE 9-8
D. DOUBLE MANIFOLD ENSEMBLE 9-9
E. PUMP ENSEMBLE 9-10
F. PRESSURE RELIEF VALVE ENSEMBLE 9-11
G. DRUM AERATION AUTOMATIC VALVE (OPTIONAL) 9-12
H. PNEUMATIC CABINET 9-13
I. ELECTRICAL CABINET COMPONENTS 9-14
I. ELECTRICAL CABINET COMPONENTS 9-15
J. CONTROL PANEL COMPONENTS 9-16
J. CONTROL PANEL COMPONENTS 9-17
EC DECLARATION OF CONFORMITY 10-1

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

SAFETY GUIDELINES
1-1
MA-5066-ENG PS200 DRUM 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-5066-ENG PS200 DRUM 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-5066-ENG PS200 DRUM MELTER MANUAL
2. INTRODUCTION
Description
Meler PS200 drum melters are melting and pumping systems for
thermoplastic materials that directly use their drum containers (with straight
sides) for capacities of up to 200 L.
They are designed to be used for applications that require high flow levels and
speed in supplying the material to the substrate.
Their main advantage is the direct use of the material’s packaging itself,
without the need for protective systems when using reactive polyurethanes,
since basically only the material being pumped is melted.

FOCKE MELER GLUING SOLUTIONS, S.A.
2-2
INTRODUCTION
Essentially, these tracker plates have the following characteristics:
- Gear type pump, with easy access for replacement and/or
maintenance.
- Single-piece aluminum melting plate, which allows the element to be
heated quickly. A special disk is assembled below to select the melting
ratio necessities.
- Cartridge resistances housed on the plate. Highly reliable, ensuring
thermal stability over the entire surface.
- Temperature control system, using solid-state relays.
- Temperature reading by means of RTD probes (one per element), which
ensure perfect temperature stability for the elements.
- Control panel system that is easy to access and use, equipped with
particular buttons to control platen movements and pump speed
control.
- Plate raising and lowering, machine power and empty drum displays.
- Weekly installation start up and shut down programmer.
- Quick drum attachment system.
- External connection for the ‘stand-by’, ‘motor start-stop’ and ‘pump
revolution speed set point’ signal activation input.
- External connection for the ‘temperatures ok’ and ‘empty drum’
signals.
PS200 drum melters are designed to be used with Meler hoses and
applicators in hot-melt adhesive applications. Their diverse variations - line,
coating or swirl-spray - cover a wide range of applications, and are very
versatile within all the markets where they are used.
Intended use
PS200 tracking plates are intended to be used under the following conditions:
• Hot-melt adhesive melting and pumping at a temperature of up to
200°C (392°F).
• Use of melting equipment with Meler accessories.
• Installation of melting equipment according to the current safety
regulations, as well as the instructions found in this manual
(anchoring, electrical connection, hydraulic connection, etc.)
• Use of melting equipment in environments which are not explosive or
chemically aggressive.
• The melting equipment is to be used while following the safety
instructions found in this manual, as well as the labels found on the
equipment, using adequate protective measures in each mode of
operation.

INTRODUCTION
2-3
MA-5066-ENG PS200 DRUM MELTER MANUAL
Limited use
PS200 drum melters must be used in the manner in which they are intended,
and never under the following conditions:
• Used with materials that may represent safety or health hazards when
heated.
• Use of melting equipment in environments which must be cleaned with
water jets.
• Use of melting equipment to heat or melt food products.
• Use or handling of melting equipment 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 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.

FOCKE MELER GLUING SOLUTIONS, S.A.
2-4
INTRODUCTION
Identifying the melting equipment
When ordering replacement parts or requesting assistance from our technical
support department, you must know your melting equipment’s model and
reference numbers.
This and other technical information may be found on the identification plate,
located on the frontal side of the electrical cabinet.
Main components
General
1. Electro-pneumatic control cabinet .
2. Hose-applicator electrical connections.
3. Pneumatic cylinders.
4. Melting platen.
5. Pump.
6. Purge and manual aeration system.
7. Gear-motor.
8. Pneumatic bypass valve.
9. Automatic aeration valve.
10. Drum placing system.
11. Support with springs for guiding.
12. Light tower.
72
12
11
1
6
8
10
4
9
3
5

INTRODUCTION
2-5
MA-5066-ENG PS200 DRUM MELTER MANUAL
Control panel
1. ‘Platen up’ illuminated pushbutton.
2. ‘Platen down’ illuminated pushbutton.
3. Emergency stop button.
4. Drum aeration pushbutton (‘Air in’).
5. Green ‘Start pump’ pushbutton.
6. Platen down bimanual pushbutton.
7. Main power switch.
8. Temperature control card.
9. Pumping control card.
10. Bypass valve pressure gauge (two, in case of double pump).
11. Bypass valve pressure regulator (two, in case of double pump).
11
10
1
2
4
5
6
37
6
9
8

FOCKE MELER GLUING SOLUTIONS, S.A.
2-6
INTRODUCTION
Platen up-down pushbuttons
Up Down
BLINKING LIGHT motion allowed motion allowed
LIGHT ON actual sense of motion actual sense of motion
LIGHT OFF extreme position reached extreme position reached, but blinks due to empty
drum signal
Four colors light tower
RED: Alarms.
AMBER: Motor running (pump rotation).
FIXED WHITE: Empty drum.
BLINKING WHITE: Half empty drum.
GREEN: Drum melter ready (temperatures ok).

INTRODUCTION
2-7
MA-5066-ENG PS200 DRUM MELTER MANUAL
Control card components
1. Melting platen 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

FOCKE MELER GLUING SOLUTIONS, S.A.
2-8
INTRODUCTION
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.