RubbaFix MELTA Pro User manual

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Operating Instructions
for RubbaFIX®MELTA®Pro
Applicator

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Contents
Disclaimer ...................................................................................................................................................3
1. Meaning of Safety Symbols .....................................................................................................................4
2. Safety and Set Up ...................................................................................................................................5
2.1. Before using your MELTA® Pro ..................................................................................................5
2.2. Basic Electrical Connections (220 VAC) ......................................................................................5
3. MELTA® Pro ............................................................................................................................................6
3.1. Operating Instructions ................................................................................................................6
4. Product Identification ...............................................................................................................................7
4.1. Applicator Gun ..........................................................................................................................8
4.2. Front Control Panels .................................................................................................................8
5. Control Panel Settings ..........................................................................................................................10
6. CAUTION ..............................................................................................................................................11
7. WARNING .............................................................................................................................................11
8. Service and Maintenance .....................................................................................................................12
9. Trouble Shooting ..................................................................................................................................13
10. Compliance ...........................................................................................................................................14
A. Standards applied to this product in full or in part: ......................................................................14
B. RCM Compliance .......................................................................................................................14
C. EU Declaration of Conformity ......................................................................................................14
D. Environmental Protection ...........................................................................................................15
E. Warranty ...................................................................................................................................16
F. Technical Data ..........................................................................................................................17
G. Specifications ...........................................................................................................................17
11. Appendix 1 Electrical Fuse & Relay Chart ..............................................................................................18
12. Appendix 2 Hose & Gun Card ................................................................................................................19

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Disclaimer
To the best of our knowledge, the information contained herein is accurate and reliable as of the date of publication,
however, we do not assume any liability whatsoever for the accuracy and the completeness of the information below. We
make no warranties which extend beyond the description contained herein and any information given does not constitute
any warranty of merchantability or fitness for a particular use. The customers are responsible for the appropriate, safe and
legal process and handling use of our product. In no event will we be liable for any consequential, incidental, indirect or
other damages whatsoever results from the performance or failure to perform under the instructions provided herein.

1. Meaning of Safety Symbols
This symbol indicates that there is, above all, danger to persons, but also to equipment and materials.
To avoid accidents lay the cables so that they will not cause any risk of stumbling.
Wear heat resistant PPE and clothing whenever you work with this equipment.
Electrical Hazard.
Environmental Hazard.
Caution: Hot Surface! Accident prevention regulations VBG 125 – W26 hot surfaces such as machine parts,
tanks or materials, but also hot liquids cannot always be perceived. The utmost caution is advised when
this symbol is attached to a component. Wear protective gloves whenever you have to touch hot surfaces.

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2. Safety and Set Up
2.1. Before using your MELTA® Pro
2.2 Basic Electrical Connections (220 VAC Hz 50/60)
It is your responsibility and obligation to make sure your system:
• Has a pre start check carried out by the operator before each use.
• Has been located in such a way that the controls are away from the operator and that the housing
panel is securely closed at all times.
• Is the right capacity system for the intended use.
• Is connected to the proper power supply (see below).
• Is only used to do what MELTA® Pro is designed to do.
• Is not used by anyone untrained and unable to operate it properly.
• Is only used whilst wearing the correct PPE and clothing.
• Is not used in damp or wet environments.
An independent Risk Assessment should be carried out on this equipment before a decision is made
to use it underground.
• A 10 A 220 VAC electrical supply is required. Performance problems will occur with voltages less than 208 VAC or greater
than 240 VAC.
• Total amperage draw will depend on the final system configuration; length of hose.
• Auto shut off will occur when temperature reaches 218°C.
• Do not allow the system to share the same circuit with other electrical items, a dedicated supply is recommended.
• Do not use an extension cord or power boards.
• Ensure the machine has a current test and tag label.
• Ensure power lead is free from damage.

3. MELTA®Pro
3.1 Operating Instructions
The RubbaFIX®MELTA®Pro is designed for the application of RubbaFIX®in operations requiring dispersion of the repair
compound over large surface areas or in other situations where the RubbaFIX®MELTA®Mini is not of size.
• Refer to Caution and Warning Instructions before operating RubbaFIX®MELTA®Pro Applicator.
• Refer to RubbaFIX®Safety Data Sheet (SDS) before operating RubbaFIX®MELTA®Pro Applicator
(website link www.rubbafix.com.au).
• Refer to RubbaFIX®Product Data Sheet (PDS) before operating RubbaFIX®MELTA®Pro Applicator
(website link www.rubbafix.com.au).
• Refer to troubleshooting guide for more information of operating RubbaFIX®MELTA®Pro Applicator.
1. Ensure operators have an adequate work rotation system in place where machine is used for extended periods.
2. Ensure correct PPE is being worn including heat resistant gloves and eye protection.
3. Ensure all combustible materials are removed from the area you are working in.
4. Fill the Tank (3) with the required amount of repair compound (Refer to PDS guideline of use).
5. Ensure power cords and hoses do not create a slip, trip hazard and are off the ground or protected.

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6. Ensure the machine is on stable ground with the foot brake applied.
7. Turn Main Power 1 “ON”.
8. Set required temperature 15 (refer to Control Panel Settings for ideal temperatures for operating RubbaFIX®MELTA®
Pro Applicator).
9. Allow time for machine to heat up and the RubbaFIX®pucks to melt (Time will vary depending on humidity,
environment, amount of product and application).
10. Ensure dispensing hose and gun are placed on the gun hook 11 when not being used.
11. When the ZONE temps meet the target ZONE temps, the system is up to temperature. Do not operate until this has
happened.
12. Turn the Pump Switch 8 “ON”.
13. The pump is activated by the trigger switch 11 which is located on the gun 9.
Note: Gas from moisture or air in lines, MAY cause splattering. It is recommend purging back Rubbafix®into tank to
clear out steam bubbles from hose.
14. The flow control 10 can be adjusted using the Hex key provided, (refer to section 5 for instructions of use).
15. Hold the nozzle approximately 5cm away from the repair area.
16. Aim the nozzle at the area where you want the product to be dispensed and squeeze the trigger (product will
continue to be dispensed as long as the trigger is squeezed).
17. When job is finished hang up gun, turn off machine and leave to cool down.

4. Product Identification
1
2
3
6
7
4
5
8
10
11
14
9
12
13

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4.1 Applicator Gun
4.2 Front Control Panels
12
21
22
18
19
20
5
15
6
16

1. Adjustable Rear Handle:
2. Hinged Lid: The lid has a spring loaded hinge and a lock clip
at the front to ensure the lid is always closed during operation.
3. Tank
4. Adjustable Front Handle
5. Pump Control: "ON/OFF" Switch: Turns pump motor
circuit "ON" or "OFF.
6. Main Power Switch: Turns the system "ON" or "OFF."
7. Control Panel
8. Rear Handle Angle Adjuster: To adjust rear handle release
catches on the bottom of both arms, lower handle to new position
and re-insert catches.
9. Floor lock: To apply brace and lift rear wheels off the ground,
push down on the outer lever. To release the floor lock and return
the rear wheels to the ground push down on the inner lever.
10. Flow Control: Refer to section 4, for full adjustment instruc-
tions.
11. Gun Hook: This is used to rest the applicator gun on when
the gun is not being used.
12. Applicator Gun: The control gun for applying the RubbaFIX®
product.
13. Access Cover: This cover should always be in situ when the
machine is in use.
14. Serial Number Placard: The serial number placard is located
at the lower rear panel of the machine.
15. Set Temperatures: Press and hold the Tank, Hose, or Gun
button for 2 seconds. When the Set Mode light illuminates,
continue to hold the zone button and adjust the set temperature
using the arrow keys. Set temperatures range from 38°C to high
limit in 1°C increments.
16. Standby: All zones are lowered by 50%. Pump will not
operate while in standby.
Auto Standby & Auto Off Timer: When activated, the system
will enter standby after three (3) hours of continuous inactivity,
then off after three (3) more hours. To activate press and hold the
Standby button and turn the system on. Use the arrow buttons to
turn “ON” or "OFF." Turn the main power switch OFF and then
ON to begin operation.
17. Actual Temperatures: During operation the actual
temperatures scan through each zone every five (5) seconds.
Press and release any zone button to display that zone’s actual
temperature.
18. Over Temp: If any zone reaches 15°C above the high limit,
the over temp light will illuminate and the system will shut off.
The temperature display will read "OFF" and the light above the
faulted zone will flash.
19. Pump Ready: The pump will not operate until the actual
tank temperature is within 15°C of set temperature.
20. Set Lock: Lit when feature is “ON."
21. Applicator Nozzle: Hot product comes out of the nozzle
under pressure when the trigger switch is squeezed.
22. Trigger Switch: The trigger switch will allow product to flow
when squeezed.

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5. Control Panel Settings
Set Temperatures:
Press and hold the Zone button (Tank, Hose or Gun) for 2 seconds. When the Set Mode light illuminates, continue to hold
and adjust the set temperature up or down using the arrow keys.
Set temperatures cannot be adjusted when the Set Lock is activated. Set temperatures range from 38°C – 204°C, in 1°C
increments.
Ideal Temperatures:
Optimal product application temperature is 190°C. To achieve this we recommend the Tank temperature to be set
between 160°C – 170°C, the Hose temperature at 180°C and the Gun temperature at 200°C.
In a cold environment the temperature of the tank and hose may need to be adjusted higher to achieve the ideal product
temperature. The belt also needs to be preheated using a hot air gun to maximise product adhesion.
Actual Temperature:
During operation, actual zones scan every five (5) seconds. To read the actual temperature of any zone, press the Zone
button (15) and the actual temperature will be displayed.
Standby:
Press the Standby Button to lower the set temperature in each zone by 50%. While in Standby, the pump will not operate.
Pump Ready:
The pump will operate when the actual tank temperature is within -4°C of the set temperature. The pump will not
operate if the system is in Standby or if the actual tank temperature drops -4°C from the set temperature.
Over Temperature Protection:
If any zone reaches 218°C, the Over Temp light will illuminate and the system will shut off. The Temperature
Display will read “OFF” and the light adjacent to the faulted zone will flash red.

6. CAUTION
7. WARNING
The RubbaFIX®MELTA®Pro can cause severe injury if incorrectly used. Those who use and maintain the system should
be trained on its proper use warned of its dangers and should read the entire manual before attempting to set up, operate
or adjust the machine.
• Do not squeeze the trigger switch on the gun when the system is cold.
• Do not adjust the Flow Control Knob when the system is cold.
• Do not allow the pump motor to stall. A prolonged stall will cause the motor to go into thermal overload.
• Do not connect or disconnect electrical connectors or remove components with the power on, This will prevent
arcing of electrical contacts and possible failure of components.
• Always close and secure the control panel access cover 13 to protect internal electrical components.
• Always operate the system with the tank lid Closed.
• Foot brake must always be on when machine is in use.
• Refer to RubbaFIX®Safety Data Sheet (SDS) for the following Warning instructions before using RubbaFIX®MELTA®
Pro Applicator.
• RubbaFIX®Pty Ltd recommends an independent Risk Assessment should be carried out on this equipment before a
decision is made to use it underground.
• Working on or around the RubbaFIX®MELTA®Pro and equipment can cause severe burns.
• Use eye protection, Thermal gloves and protective clothing while operating.
• Before using any RubbaFIX®MELTA®Pro equipment, determine proper electrical requirements as per all applicable
codes.
• Ensure hazardous material(s) that are toxic, heat or fire sensitive are not located in the immediate vicinity of the
RubbaFIX®MELTA®Pro as fire, explosion, personal injury, property and/or equipment damage can result.
• The RubbaFIX®MELTA®Pro system is equipped with over temperature protection as a necessary safety device.
• Run-away heating can cause hot melt materials to exceed their flash point.
At RubbaFIX®Pty Ltd, we pay special attention to the needs of operators and service personnel when designing equipment,
but molten repair compounds are dangerous and can cause severe burns. Extreme care must be exercised to insure
personnel safety.

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8. Service and Maintenance
1. If the power supply cord is damaged, it must be replaced by the manufacturer, its service agent or a similarly qualified
person in order to avoid a hazard.
2. Never fill the tank of your MELTA®Pro with contaminated material. If you observe all advice given in the operating
manual, the applicator should not need cleaning.
3. Never clean the applicator with solvent, benzene, toluene, acetone and turpentine etc., risk of explosion!
4. The MELTA®Pro is to be inspected by skilled personnel on a regular basis. The frequency of maintenance depends on
usage. Checks and maintenance should include, but are not limited to, functionality of the lid latch, the wire stand and
the power cord.
5. Ensure, at a minimum of every 6 months, the access cover 13 is removed from the machine after the power has been
turned off and the plug removed from the wall socket and the inside area is de-dusted.
6. While the access cover 13 is off, ensure all nuts, bolts and screws are checked for tightness and ensure all nuts and
screws are fitted.
7. Check and ensure all cables and hoses are in good condition and not damaged or frayed (replace if required).
8. Ensure tip is free from any hardened material.
9. Check and ensure correct operation of Floor lock 9 by applying and releasing the mechanism to ensure it holds the
unit firm.

9. Trouble Shooting
PROBLEM CHECKLIST POSSIBLE SOLUTIONS
MELTA®Pro won’t power up
Tank not reaching temperature
Hose not reaching temperature
Gun not reaching temperature
Material not dispensing at all
Flow of Rubbafix®is low
• Check power cable is not damaged, plugged in and
power source turned on.
• Check on/off switch is turned on.
• Check that circuit boards and connectors have not
dislodged in transit.
• Check tank temperature settings.
• Check tank fuse.
• Check hose temperature settings.
• Check hose for damage.
• Check hose power cable connection.
• Check hose fuse.
• Check gun temperature settings.
• Check gun and hose for damage.
• Check hose power cable connection.
• Check gun fuse.
• Check that zones have reached operating
temperature.
• Check pump switch.
• Check that machine is not in standby mode.
• Check motor shear coupling.
• Check that tank has Rubbafix®material.
• Check nozzle for blockage.
• Check hose for blockages or damage.
• Check that tank has Rubbafix®material.
• Check hose feed connector for leaks.
• Adjust to required temperature.
• If fuse is blown, contact your Rubbafix®
representative to arrange repair.
• Replace hose if damaged.
• Adjust to required temperature.
• If fuse is blown, contact your Rubbafix®
representative to arrange repair.
• Replace hose if damaged
• Wait until zone temperatures are reached as
specified in the manual. Turn on pump switch and
confirm that “pump ready” light is on.
• Replace shear coupling
• If pump motor can be heard running but shear
coupling does not turn, replace pump motor.
• Remove nozzle and dispense Rubbafix®, if flow
returns, replace with new nozzle. If flow is still
restricted, check tank for blockage. If no tank
blockage, replace hose.
• Adjust to required temperature.
• If fuse is blown, contact your Rubbafix®
representative to arrange repair.
• Replace power lead by licenced electrician if
damaged.

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10. Compliance
B. RCM Compliance
C. Environmental Protection
AS/NZS 3820, AS/NZS 60335.1IEC 61032,
AS/NZS 60990:2002 Method of measurement of touch current and protective
conductor current, IEC 61180-1.
This is to certify that the above applicator in the design marketed is in conformity with the following EMC
guidelines AS/NZS 61000.6.3:
16/6 Gladstone Rd, Castle Hill, NSW.
Please dispose in accordance with the regulations in your country
Packing material used for this product can be recycled completely.
Please take instructions for the disposal of RubbaFIX®products from the respective safety data sheets.
A. Standards applied to this product in full or in part:

D. EU Declaration of Conformity
1. Product Name: RubbaFIX®MELTA®Pro Applicator
Type: XP215-HVR4
2. Name and address of the manufacturer or his authorised representative:
Rubbafix Pty Ltd
Unit 16/6 Gladstone Rd
Castle Hill 2154
NSW Australia
ACN 159 441 871
[phone]
Compliance@rubbafix.com.au
3. This is to certify that the above applicator in the design marketed by us are in conformity
with the following EC Directives:
Low Voltage Directive (LVD) 2014/35/EU,
Electromagnetic Compatibility Directive (EMC) 2014/30/EU, Restriction of Hazardous
Substances (RoHS) Directive 2011/65/EU, WEE Directive 2012/19/EU,
4. Standards
EN61010-2-010:2014
EN 61000-6-3:2007/A1:2011
EN 61000-6-3:2007/A1:2011/AC: 2012
EN 61000-6-1
IEC 61000-6-3:2006
5. Regulations
764/2008/ECU
765/2008/ECU
768/2008/ECU
6. This declaration of conformity shall become invalid, if the product is modified, extended, or otherwise changed
without express written approval of RubbaFIX®Pty Ltd and/or
• other components than accessories of RubbaFIX® Pty Ltd are fitted, and/or
• if the product is not connected or used as intended.
Russell Eggers, June 18th 2017
Chief Executive Officer
Rubbafix Pty Ltd

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E. Warranty
RubbaFIX®warrants that the MELTA®Pro shall be free from defects in materials and workmanship. The
Purchaser acknowledges, agrees and warrants that as the Purchaser’s intended use of the MELTA®Pro is
outside the control of RubbaFIX®, the Purchaser is satisfied that the MELTA®Pro when supplied shall be fit for
purpose.
In the event that it is proven to the satisfaction of RubbaFIX®that all or part of the MELTA®Pro does not perform
in accordance with this Warranty, then RubbaFIX®shall, at its discretion:
i. replace the MELTA® Pro; or
ii. Credit the purchaser the amount of the purchase price.
The Purchaser’s sole and exclusive remedy for breach of warranty shall be such replacement or credit. In the
event of a claim, the purchaser shall make available to RubbaFIX®or its nominees, servants or agents any
records reasonably required by RubbaFIX®to verify the claim.
A claim of defect in materials or workmanship in any MELTA®Pro shall be allowed only when it is submitted in
writing within 14 days after discovery of the defect and in any event, no later than twelve (12) months after
delivery of the MELTA®Pro to the Purchaser. No such claim shall be allowed in respect of a MELTA®Pro which
has been injected with non-RubbaFIX®approved products, neglected or improperly stored, transported, handled,
installed, connected, operated, used or maintained. In the event of unauthorised modification of the MELTA®Pro
including use of non-RubbaFIX®authorised products, no claim shall be allowed.
The Purchaser shall keep RubbaFIX®, its servants and agents, indemnified against all costs, claims, demands,
expenses and liabilities of whatsoever nature (including those by any third party), including but not limited to
claims of death, personal injury, damage to property and consequential loss (including loss of profit) which may
be made against the Purchaser or which the Purchaser may sustain, pay or incur as a result of or in connection
with the sale and use of the MELTA®Pro unless such costs, claim demanded, expense or liability shall be directly
and solely attributable to any breach of contract or guarantee by, or negligence of RubbaFIX®or its duly
authorised officers and/or agents.
It is the Purchaser’s responsibility to ensure that all applicable health and safety regulation are complied with
and appropriate steps are taken in relation to the storage, handling and the use of the goods and where the
RubbaFIX®supplies information to the purchaser on the potential hazards relating to the MELTA®Pro, such
information must be brought to the attention of its employees, agents, sub-contractors, visitors and customers.

F. Technical Data
G. Specifications
Tank Capacity 7 Litres Approx.
Number of Hoses/Guns 1 Hose/1 Handgun
Electrical 220 VAC, 10 amp Hz 50/60
Drive Motor All-electric, fractional HP
Length of Electric Cord 1.8 Metres
Pump Cast iron with steel gears
Temperature Control Micro Processor
Dimensions 28 cmx 61 cm x 51 cm high (approx. 27.2Kgs.)
Warranty One year limited warranty
Article Number
*Rates will vary depending on adhesive type and viscosity

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Appendix 1 Electrical Fuse & Relay Chart
Hose/Gun Card (241-217)
HOSE/GUN BOARD
TANK FUSES 7.5 AMP
TANK
RTD
HOSE
RTD
GUN
RTD
L2
L1
TANK HEATER
PUMP READY
MOTOR FUSE 5 AMP
PUMP
SWITCH
MOTOR
H5
H6
H7
H4
H3
A4
A6
L2 L1 +24 COM
T
A5
A7
M3 M4
AIR BAG
HOSE RELAY
GUN RELAY
F2
G
N
D
SET LOCK
DEGREES C
ON
DO NOT INSTALL OR REMOVE CARD WITH POWER ON
HOSE/GUN FUSE
8 AMP
F1
5
7
4
6
Accessory
Connector
9-pin
5
6
7
4
3
Hose
Connector
14-pin
Motherboard
(241-216)
TANK
AIR BAG
TANK
RELAY
(213-052)
M
Tank Heaters
Main Power
Breaker
L1
Pump
Switch
Display Board (241-213)
PLUG INTO MOTHERBOARD
FAULT HOSE GUN
8910 11
Hose Connector
14-pin
Ribbon
Cable
(220-053)
FUSE CHART
F2
HOSE/GUN
FUSE 8 AMP
H2
2
F3
L1 L1 L2 L2
1 2
TANK
CYCLE
L2
GROUND
Hose/Gun Card, 220 VAC (241-217)
Fuse # Description Fuse Rating
F1 Hose/Gun Fuse 8 AMP, 250 V [GMA]
Part #
214-108
XP215-HVR2 Motherboard, 220 VAC (241-216)
Fuse # Description Fuse Rating
Tank Fuse 7.5 AMP, 250 V [AGC]
Part #
214-207
F2 Motor Fuse 5 AMP, 250 V [GMA] 214-105
F2 Hose/Gun Fuse 8 AMP, 250 V [GMA] 214-108
F3 Motor Fuse 5 AMP, 250 V [GMA] 214-105
Tank Fuse 7.5 AMP, 250 V [AGC] 214-207
Wiring Diagram
6
Pin
Number
2-Wire, 220 VAC
220 Volt Tank Heaters Only
L1 220V L2
Power Connection
Caution
M
RTD Temperature Sensor
Motor
Breaker Switch
Heater
Switch
Wired to Connector

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Appendix 2 Hose & Gun Card
L2L1
ON/OFF BREAKER
TANK
FUSE
TANK
AIR BAG 2
1
2
1
TANK
RTD
HOSE
RTD
GUN
RTD
C1-8 C1-9 C1-10 C1-11
TANK HEATERS
CR1 Relay (Normally Open)
PUMP
READY
RELAY
PUMP
SWITCH
H7
GUN
INPUT H6
A7 A6
M4 M3
C1-7 C1-6
C2-4 C2-3
HOSE/GUN
FUSE (F1)
AIR
BAG
L2
C1-2
HOSE HEATER
C1-5
TANK HEATERS
C1-4
GUN HEATER
HOSE
RELAY
H2
H5
ACC.
INPUT
C3-7 C3-6
POWER SWITCH
POWER SWITCH
TANK
RELAY
TANK
RELAY
L1 GUN
RELAY
TRIGGER
OUT
HOSE/GUN BOARD
A5 A4
ACC.
OUTPUT
C3-5 C3-4
ON/OFF BREAKER
POWER SWITCH
POWER SWITCH
TANK
FUSE
C1-3
H3
H4 HOSE/GUN
FUSE (F2)
MOTOR
FUSE (F3)
T
MOTOR
FUSE (F2)
CR3
CR1
CR1
CR2
Power Connection
2-Wire, 220 Volts
L1 220 V L2
220 Volt Heaters Only
Electrical
Caution
220 VAC Schematic