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Instructions manual ADHESIVE MELTER MICRON SERIES MA-5039-GB 250906

Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

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Page 1: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

Instructions manualADHESIVE MELTER MICRON SERIES

MA-5039-GB 250906

Page 2: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

Published by:

meler Aplicadores de Hot-melt S.A.P.I. Los Agustinos, calle G, nave D-43E - 31160 ORCOYEN Navarra (Spain)

Phone.: + 34 948 351 110 Fax: + 34 948 351 130e-mail: [email protected] site: www.meler.es

Edition July 2006

© Copyright by 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 specifi cations and information contained in this manual may be modifi ed without prior notice.

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual Table 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 Thermal components 1-3 Noise 1-3 Materials 1-3

2. INTRODUCTION 2-1

Description 2-2 Intended use 2-2 Limited use 2-3 Modes of operation 2-3 Hot-melt melter/applicator identifi cation 2-3 Optional Equipment 2-5

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 gun connection 3-5 Parameter Programming 3-6 Programming working temperatures 3-7 Selecting the overheating value 3-7 Keeping a component on display 3-8

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Table of contents

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

External I/O connections 3-8 Temperature ok 3-9 External Standby 3-9 Low level 3-10 Output inhibitor (optional) 3-11

4. MELTER OPERATION 4-1

General information 4-1 Filling the tank 4-2 Starting up the melter/applicator equipment 4-2 Melter/applicator equipment displays 4-3 Displaying the temperature for each component 4-4 Alarm displays 4-5 Hot-melt display level 4-6 Operational pressure display and adjustment 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 Disabling the equipment activation/deactivation program 4-10 Programming the equipment’s standby function activation/deactivation 4-10 Disabling the equipment standby function programming 4-12 Special function buttons 4-12 Turning off the melter/applicator equipment 4-13

5. MAINTENANCE 5-1

Equipment cleaning 5-1 Depressurizing the system 5-2 Filter maintenance 5-2 Cleaning the tank 5-4 Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6

6. QUICK PROBLEM SOLVING 6-1

7. TECHNICAL CHARACTERISTICS 7-1

General. 7-1

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual Table of contents

Dimensions. 7-2 Accessories. 7-3

8. CIRCUIT DIAGRAMS 8-1

Components list version Pt-100 8-1 Components list version Ni-120 8-1

9. PNEUMATIC DIAGRAM 9-1

Components list 9-1

10. SPARE PARTS LIST 10-1

A. TANK GROUP 10-4 B. DISTRIBUTOR GROUP 10-5 C. PUMP GROUP 10-6 D. PNEUMATIC UNIT GROUP 10-7 E. CHASSIS GROUP 10-8 F. ELECTRONIC GROUP 10-9 G. ELECTRIC GROUP 10-10

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Table of contents

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Safety guidelines

General

The information contained in this section applies not only to every-day machine 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 machine or the rest of the installation.

Before beginning work on the machine, read this manual carefully, and in case of any doubt, contact our Technical Service Center. We are available for any clarifi cation that you might need.

Keep manuals in perfect condition and within reach of personnel that use the machine and perform maintenance on it.

Also provide necessary safety material: appropriate clothing, foot-wear, 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 machine 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 pro-jection. Use thermal protective equipment and glasses.

1. SAFETY GUIDELINES

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Safety guidelines

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

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.

Mechanical components

The melter/applicator equipment installation uses moveable parts that may cause damage or injury. Use the equipment correctly, and do not remove the safety guards while the equipment is in opera-tion; prevent the risk of possible entrapment due to moving mecha-nical parts.

Do not use the machine if the safety devices are not in place or appear to be inadequately installed.

For maintenance or repair operations, stop the movement of mo-veable parts by turning off the main switch.

Electrical components

The system operates with a one-phase current (230 V / 50 Hz) or a three-phase current (3x400 V + N / 50 Hz) at a certain rated 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 place-ment.

Although the system meets EMC requirements, it is inadvisable to use devices that transmit high levels of radiation, i.e., mobile pho-nes or soldering equipment in their vecinity.

Hydraulic components

As this is a pressurized system, precautions related to this type of equipment must be observed.

The melter/applicator equipment includes an automatic valve depressurization system. Before each operation, always make sure that the adhesive circuit is completely free of pressure. There is

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MA-5039-GB micron adhesive melter manual

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Safety guidelines

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 ho-ses when the adhesive cools. When reheated, there is a risk of hot particle projection if the outputs are left open.

Thermal components

The entire system operates with temperatures reaching up to 230 °C (446 °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, immediately cool the affected area with clean, cold water. Seek medical attention as soon as possible from the company’s medical service or the nearest hospital. Do not try to remove the adhesive material from the skin.

Noise

The noise level of the system is well below allowable levels, and therefore does not present a specifi c risk to be taken into conside-ration.

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.

Always use original ‘meler’ components and replacement parts, which guarantee the correct system operation and service.

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.

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Safety guidelines

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MA-5039-GB micron adhesive melter manual

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Introduction

In this manual you will fi nd information about the installation, use and maintenance of the hot-melt adhesive melter/applicator in meler’s micron series.

The ‘micron’ series includes the 4, 8 and 16 liter range of hot-melt adhesive melters/applicators.

Most of the photographs and illustrations that appear in this manual refer to the 4-liter ‘micron’ melter/applicator. 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 ‘micron’ series.

2. INTRODUCTION

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Introduction

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

Description

The ‘micron’ are designed for use with ‘meler’ hoses and guns 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/applicators in the ‘micron’ series are designed to be used in the following conditions:

• Hot-melt adhesive fusion and pumping at temperatures up to 230°C (446°F)

• Use of hot-melt melters/applicators with ‘meler’ accessories

• Installation of hot-melt melters/applicators 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/applicators in non-explosive, non-chemically aggressive environments

• Use of hot-melt melters/applicators 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.

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Introduction

Limited use

The ‘micron’ series hot-melt melters/applicators must be used for their intended uses and never in the following conditions:

• Use with reactive polyurethane- or polyamide-based adhesives or any other material that might cause safety or health risks when heated.

• Use of hot-melt melters/applicators in environments where cleaning is necessary using water jets.

• Use of hot-melt melters/applicators to heat or melt food products.

• Use or operation without adequate safety protection.

Modes of operation

The ‘micron’ series 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 guns are activated.

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.

Stop 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 identifi cation

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.

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Introduction

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

This and other technical information will be found on the identifi cation plate located on the side of the lower part of the hot-melt melter/applicator.

Main components

1. Front control card

2. Access hatch to the electric/pneumatic area and for changing the fi lter

3. Tank access cover

4. Pump air pressure regulator

5. Air pressure gauge

6. Characteristic plate

7. Main switch and electrical hook-up

8. Hose output distributor (up to 6 hydraulic connections)

9. Hose-gun electrical connections

10. Compressed air hook-up (Max. 6 bar)

11. Machine-mounted base plate

1 2 3 8 9

7 10456 11

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Introduction

Optional Equipment

To increase the functionality of the hot-melt melters/applicators, the following optional components may be added:

• Channel control card that allows the activation and deactivation of each output independently from the main machine or an auxiliary control unit

• Pressure compensation control system that allows the regulation of the hot-melt applicator’s pneumatic pressure, and therefore the output fl ow, depending on the application speed variations

• Air fi ltering system for matching the air supply conditions to the hot-melt melter/applicator requirements (clean, dry, and without lubrication)

1. Tank indicator LED

2. Gun indicator LED

3. Temperature set point

4. Actual Temperature

5. ON/OFF switch

6. Standby function

7. Temperature OK LED

8. Pump operation LED

9. Time scheduling

10. Left/right button - channel selection

11. Up/down button - temperature modifi cation

12. Hose indicator LED

12 3 4

56

789

11 10

12

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Introduction

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MA-5039-GB micron adhesive melter manual

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Installation

3. INSTALLATIONWarning: The melters/applicators are equipment with current technology and with certain foreseeable risks. Therefore, only allow qualifi ed personnel with suffi cient training and experience to use, install or repair this equipment.

Introduction

The ‘micron’ series melters/applicators are delivered with all the materials necessary for their installation. However, some components must be provided by the user himself, according to the location and connections in each particular installation:

• Anchoring screws for the melter/applicator equipment• Power cord and plug for electrical power• Pneumatic conduct and connection to the compressed air

system• Multicore cable for external electrical control• Optionally, a gas ventilation system

Installation requirements

Before installing ‘micron’ series melter/applicator equipment, we must make sure that the space assigned to it permits installing, connecting and using the entire system. Similarly, we must check to see that the electrical and pneumatic supplies meet the necessary requirements of the melter/applicator equipment being installed.

Free space

AB

C

D

E

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Installation

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

Electrical Consumption

In order to install a ‘micron’ series melter/applicator, we should take into consideration the total consumption of the installation, including the consumption of the installed hoses and guns.

Before connecting, make sure that the voltage that is being connected to the melter/applicator is the correct one appearing on the equipment’s characteristics plate.

Connect the machine and check to see if it is well grounded.

Warning: Risk of electrocution. Even when the equipment is turned off, voltage remains in the intake terminals, which may be dangerous during internal equipment manipulations. Install a power switch for disconnecting the melter/applicator equipment from the electrical network.

Compressed air

To install ‘micron’ series melters/applicators, it is necessary to have a dry, non-lubricated compressed air system with a maximum pressure of 6 bar.

The applicator’s internal pneumatic equipment is able to work with a minimum of 0.5 bar, however, pressure lower than this will cause intermittent operational anomalies.

The air consumption is according to the number of stroke made by the pump cylinder, which in turn depends on the adhesive consumption during the application. It is therefore necessary to estimate this consumption in all cases. Generally speaking, we can provide as a maximum consumption value 40-50 l/min for a pressure of 6 bar at maximum pump speed.

Other factors

While installing ‘micron’ series melters/applicators, other practical considerations should be kept in mind:

item description dimensionA EQUIPMENT LENGTH WITH DOOR OPEN 4L 810 mm

8L 886 mmB EQUIPMENT LENGTH 4L 560 mm

8L 636 mmC EQUIPMENT WIDTH 4L 310 mm

8L 310 mmD EQUIPMENT HEIGHT 4L 416 mm

8L 416 mmE EQUIPMENT HEIGHT WITH LID OPEN 4L 550 mm

8L 586 mm

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MA-5039-GB micron adhesive melter manual

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Installation

• Keep the load opening accessible for comfortable melter/applicator fi lling

• Position the melter/applicator equipment in such a way that you can easily see the front panel display where temperatures and possible alarm signals are shown

• As much as possible, try to avoid unnecessarily long hoses that result in elevated electrical energy consumption levels and pressure drops

• Do not install the melter/applicator equipment beside powerful heat or cooling sources that may have distortional effects upon its operation

• Avoid melter/applicator vibrations• Make sure that the melter/applicator maintenance

areas (fi lter, purging valve, tank interior, etc.) are easily accessible

Unpacking

Before proceeding with the installation of the melter/applicator, it should be removed from its location on a pallet and examined in order to detect any possible breakage or deterioration. Communicate any defect, even to the outer packing materials, to your ‘meler’ Representative or to the Main Offi ce.

Contents

The ‘micron’ series packing materials may contain accessories that form part of the same order. If this is not the case, the following are the standard components that accompany the melter/applicator:

• Instruction manual• Guarantee card• Hose couplings• Electrical wall bushing Pg • Connector for external I/O (included on the power card)

Mounting the equipment

‘micron’ series melters/applicators include a mounting base plate for easy mounting.

The base plate allows you to remove and position the melter/applicator equipment easily, without having to touch the fastening screws.

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Installation

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

To mount the base plate, place it on the machine bench and adjust its position. Mark and drill the four holes for the base plate’s M8 fastening screws. The holes may be threaded or non-threaded, depending on the bench to which they are being attached.

Warning: Make sure that the bench where the base plate is fastened is level, free from vibrations and is able to support the weight of the equipment in addition to the full tank load.

Once the base plate is fastened in place on the bench, the melter/applicator should be mounted on top of it.

Insert the fastening tabs on one side and insert the screws as far as possible.

Electrical power connection

‘micron’ series melters/applicators are designed to be connected to the electrical power grid in three possible ways, depending on their power consumption:

• 1-phase 230 VAC• 3-phase 230 VAC without neutral• 3-phase 400 VAC with neutral

A good ground connection is required in all cases.

Consumption fi gures, according to melter/applicator and output confi guration, are included in the table.

Warning: Risk of electrical shock. Carelessness may cause injury or death.

Install the electrical wall bushing Pg 13.5 in the area reserved for them, fastening them to the plate with the appropriate nut.

Open the electric cabinet door as far as possible. Thread the power

EQUIPMENT No. OUTPUTS 1 PHASE 3 PHASES230 VAC 400 VAC

micron 4 2 24.6 A 15.5 A 14.2 A4 35.0 A 19.6 A 14.2 A6 45.5 A 27.2 A 17.7 A

micron 8 2 28.9 A 19.7 A 18.5 A4 39.4 A 23.6 A 18.5 A6 49.8 A 27.9 A 18.5 A

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Installation

cord (Ø6-12 mm) through the electrical wall bushing Pg 13.5 and fasten it to the inside anchor, making sure that the cord reaches the power card connector at the position where it will be installed.

Connect each wire in the power cord to its corresponding place on the power intake connector on the power card.

Pneumatic connection

Before connecting the pneumatic power to the melter/applicator, make sure the pressure regulator is completely closed. To do this, turn the regulator screw located on the equipment base next to the pressure gauge counterclockwise as far as it will go using a 5 mm Allen wrench.

Connect the plant air supply (max. 6 bar) to the melter/applicator intake using fl exible tubing with an outside diameter of 6 mm. The equipment is provided with a quick coupling for this purpose.

Activate the air supply to pass and turn the pressure regulator clockwise. Adjusting to 1 bar of pressure is enough for checking the pump operation.

The pump will not operate and the pressure gauge will show 0 bar until the melter/applicator and the hoses-guns connected to it reach the correct temperature.

Once the pump operation has been checked, you may adjust the pressure to the operational value you wish.

Hose and gun connection

‘micron’ series melters/applicators use standard ‘meler’ components. The entire range of ‘MD/MDR’, ‘MS/MSR’, ‘ND’ and ‘NDS’ hoses and guns may be connected to this equipment.

Up to six hose-gun outputs may be connected to 4 and 8L ‘micron’ melters/applicators.

N3 F3 N1 N2 F2 F1 N F F3 F2 F1 N F3 F2 F1

1 x 230V + N 3 x 230V 3 x 400V + N

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Installation

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

Warning: When connecting hose-gun outputs, verify that the connected power is not above the maximum allowable power for each output. ‘micron’ series melters/applicators are equipped with a six outputs hydraulic distributors. Connect the hoses to the distributor in order, following the numbering in the diagram.

Caution:

• In order to identify each hose-gun, electrically connect them to the connector with the same number as the output they use.

• It is preferable to use couplings at a 90° angle to minimize the space the hoses occupy. Using straight couplings usually results in curves with very small radii that may damage the inside of the hose.

• Save the screw-on caps that are removed from the distributor in order to connect a hose. They may be necessary in the future if a hose is removed from its location.

• Perform the electrical hose and gun connections with the equipment turned off. Failing to do so may result in electrical defects in the connection and the appearance of alarm messages on the melter/applicator display.

Parameter Programming

Once the melter/applicator and its components are installed, you will need to program the operational parameters appropriate for the specifi c application that will be performed.

‘micron’ series melters/applicators simplify this task as much as possible, allowing the operator to modify only those parameters that are necessarily variable for each application.

Among the various parameters, it is necessary to program the set point temperature values for each component connected and the value for overheating warnings. There are two other parameters (weekly start-up and shut-down programming and the standby temperature value) left to program in advanced systems, although the factory default values are perfectly valid for operational purposes.

1 2

3 4

5 6

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Installation

Programming working temperatures

The melters/applicators leave the factory with the following set point temperatures:

• 160 °C (320 °F) for the tank and the distributor• Disconnected (OFF) for hoses and guns

The general process for modifying set up temperature values for any component is described below.

1. Select the component for which you wish to modify the value with the left-right arrow.

The corresponding LED will blink quickly.

2. Using the up-down arrow, select the desired value for the set point temperature.

3. After ten seconds, the LED will stop blinking and the display

will change by default to the set point temperature, saving the changed data.

This simple process must be repeated for each one of the components installed on the melter/applicator.

Selecting the overheating value

1. Press the buttons with the clock symbol and the down arrow at the same time to enter the special menu

The choice of display units (ºC or ºF) will appear on the display.

2. Using the right arrow, we advance to the next screen where the overheating symbol appears.

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Installation

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

3. Select the desired value with the up-down arrow.

The value displayed corresponds to the increase in real temperature over the set point temperature permitted without activating the alarm message.

4. Exit the special menu using the left arrow and the tank temperatures will once again be displayed.

All the special menu values will be saved.

Keeping a component on display

By default, the main display shows the tank temperatures. However, it is possible to display indefi nitely the temperatures of any component for analysis or tracking.

1. Select the component you wish to see permanently with the left-right arrow.

The corresponding LED will blink rapidly.

2. Hold the arrow button down for two seconds, selecting the desired component.

3. The display will now remain on the selected component, without changing.

4. Simple press any left-right arrow button again to restore the default display (tank).

External I/O connections

The melter/applicator’s input and output signals (I/O) allow it to communicate with the main machine simply and directly.

There are four signals that may be used to communicate with the main machine:

• Temperatures ok_an output from a non-voltage contact that communicated to the main machine (or to a warning light beacon) that all the system temperatures have reached 3° below their set point value (and the delay time have fi nished) during start-up, or that their real value is not 20°C below their set point value during operation.

• External Standby_control input from the standby mode, via a non-voltage contact. The standby function is connected

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Installation

with a closed contact; an open contact disconnects it.

• Low level_an output from a non-voltage contact that communicates to the main machine (or to a warning light beacon) that the adhesive fl uid level in the tank has reached the minimum level established.

• Output inhibitor_inhibitor tracking inputs for each hose-gun output via a non-voltage contact. With a closed contact, the output remains activated; with an open contact, it is deactivated (optional).

Warning: Risk of electric shock. Carelessness may cause injuries or death.

Temperature ok

1. If only this signal will be connected, use a 0.5 mm2 two-wire cable.

Install an electrical wall bushing Pg9 on the equipment base plate next to the electrical supply input.

2. Open the door to the electrical cabinet as far as possible. Thread the power cord (Ø4-8 mm) through the electrical wall bushing Pg9 and fasten it to the inside anchor, making sure that the cord reaches the power card connector at the position where it will be installed.

3. Remove the connector from the card and connect the two cable

wires to their corresponding connector terminals:

3 contact NO4 contact NO

4. Reconnect the card connector 5. Make sure that the cable is well connected and that its path

through the electrical cabinet presents no risks of snagging, being cut or any other accidental deterioration.

External Standby

1. If this is the only signal being connected, use 0.5 mm2 two-wire cable.

34

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Installation

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Install an electrical wall bushing Pg9 on the equipment base plate next to the electrical supply input.

2. Open the door to the electrical cabinet as far as possible. Thread the power cord (Ø4-8 mm) through the electrical wall bushing Pg9 and fasten it to the inside anchor, making sure that the cord reaches the power card connector at the position where it will be installed.

3. Remove the connector from the card and connect the two cable wires to their corresponding connector terminals:

1 contact NO2 contact NO

4. Reconnect the card connector 5. Make sure that the cable is well connected and that its path

through the electrical cabinet presents no risks of snagging, being cut or any other accidental deterioration.

Low level

1. If this is the only signal being connected, use 0.5 mm2 two-wire cable.

Install an electrical wall bushing Pg9 on the equipment base plate next to the electrical supply input.

2. Open the door to the electrical cabinet as far as possible. Thread the power cord (Ø4-8 mm) through the electrical wall bushing Pg9 and fasten it to the inside anchor, making sure that the cord reaches the power card connector at the position where it will be installed.

3. Remove the connector from the card and connect the two cable wires to their corresponding connector terminals:

1 contact NO2 contact NO

4. Reconnect the card connector 5. Make sure that the cable is well connected and that its path

through the electrical cabinet presents no risks of snagging, being cut or any other accidental deterioration.

1

2

12

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Installation

Output inhibitor (optional)

1. If this is the only signal being connected, use a seven-wire cable no smaller than 0.22 mm2.

Install an electrical wall bushing Pg9 on the equipment base plate next to the electrical supply input.

2. Open the door to the electrical cabinet as far as possible. Thread the power cord (Ø4-8 mm) through the electrical wall bushing Pg9 and fasten it to the inside anchor, making sure that the cord reaches the power card connector at the position where it will be installed.

3. Remove the connector from the card and connect the two cable wires to their corresponding connector terminals:

1 common + voltage output 2 input for inhibitor output 13 input for inhibitor output 24 input for inhibitor output 35 input for inhibitor output 46 input for inhibitor output 57 input for inhibitor output 6

4. Reconnect the card connector 5. Make sure that the cable is well connected and that its path

through the electrical cabinet presents no risks of snagging, being cut or any other accidental deterioration.

7 6 5 4 3 2 1

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Melter operation

In this section we will introduce the method for using the melter/applicator. Although its operation is very simple, it should not be used by untrained personnel.

Warning: Improper use may cause damage to the machine or injury and even death to the person using it.

General information

There are three large groups of components with thermal control in a hot-melt installation: the fusion unit, the transport hoses and the melter/applicator guns. All of these are controlled from the front panel of the melter/applicator equipment.

The fi rst large group is the tank-distributor group. Combined to form a single unit, they have separate controls even though their set point values are the same. Therefore, when you program a set point value for the tank, for example 170°C, the distributor adopts this same value.

The second group is the hose group. They are identifi ed on the front panel, depending on the equipment model, by number, from No.1 to No.6 and by the corresponding hose picture. Each one has its own set point value.

The third group is the gun group. It is identifi ed on the front panel, depending on the equipment model, by number from No.1 to No.6 and by the corresponding gun picture. Each one has its own set point value.

The hose and gun numbers are automatically assigned to the hose/gun channel they are connected to on the rear part of the melter/applicator.

4. MELTER OPERATION

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Melter operation

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MA-5039-GB micron adhesive melter manual

Filling the tank

The tank is equipped with a fl oating-type low level sensor that warns when the level of hot-melt adhesive drops below a third of the tank’s capacity.

The unit will activate the external signal and, if it is connected, the corresponding warning device.

Warning: Before refi lling the tank, make sure that the adhesive is the same type as that already in the tank. Mixing different types of adhesives can cause damage to the melter/applicator equipment.

To fi ll the tank:

1. Open the tank lid

2. Use a shovel or a ladle to fi ll the tank with adhesive. Do not fi ll the tank above the loading opening level. The lid must be able to close normally.

Warning: Risk of burns. Always refi ll using protective gloves and glasses.

3. Close the lid when you have fi nished refi lling the tank.

MODEL CAPACITY

micron4 4 L 4 kg

micron8 8 L 8 kg

For a density of 1g/cc

Starting up the melter/applicator equipment

Before starting up the melter/applicator equipment, it is necessary to check to see if the unit has been correctly installed and all its input/output and accessory connections are correctly established.

It is also necessary to make sure that the equipment has been fi lled with adhesive and that the operational parameters have been programmed.

To start:

1. Connect the melter/applicator’s switch.

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Melter operation

If the control card was turned off the last time the machine was disconnected, it will remain tuned off when the machine is started up again (time display).

If the control card was on the last time that the machine was disconnected, it will turn on when the machine is started up again.

2. Press the ON/OFF button on the control card to turn it on, if it not already activated.

By default, the set point and real temperature values shown are those corresponding to the tank.

The tank heating control LED (green) will light up and the tank will begin to heat.

One it has reached 3° below the programmed temperature (set point) of the tank, a programmable delay timer starts until, guaranteeing fusion, the pump receives permission to operate and the signal will be sent to the main machine, indicated by the two corresponding (green) LEDs.

While the system is running the delay timer both LEDs remains blinking until the programmed time value has been reached. If then, any other element has not reached 3° below its temperature setting point, the LEDs turn off.

If the system is shut down, for any possible mode, when it is turning on the delay timer only starts again if the tank temperature is 20° below setting point.

3. Use the machine’s pressure gauge to make sure that the generated pressure is adequate. Values below 0.5 bar may cause erratic pump action.

Melter/applicator equipment displays

‘micron’ series melters/applicators have two displays built into their control panel, with three sets of 7 segments each for displaying the temperature values (set point and real temperature), programmable parameters and alarms.

LED display Component heating Component status

constantly lit constant low temperature

blinking slowly as needed (according to PID parameters) temperature near set point

blinking rapidly programming or display change in set point values

off not heating temperature reached

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Melter operation

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MA-5039-GB micron adhesive melter manual

They are equipped with LED indicators to display the heating of each component, as well as the pump activations and the main machine connection signal.

They are also equipped with LEDs indicating equipment connection/disconnection and standby function connection/disconnection:

Displaying the temperature for each component

The temperature may be displayed for each component (tank, distributor and each hose and gun) by selecting the component with the cursor.

Press the left-right arrow until the desired component is displayed.

After 10 seconds, the display will return to the default component (the tank).

If you wish to keep the component displayed permanently, press and hold the left-right arrow for 2 seconds while selecting the chosen element.

The following is the display sequence:

distributor<—tank<—hose1<—gun1<—…<—hose6<—gun6distributor—>tank—>hose1—>gun1—>…—>hose6—>gun6

To remove a component from permanent display, simply press either of the left-right arrows.

Led display On/off Standby

constantly lit turned off unit function activated

blinking slowly deactivation programmed for the current day

activation programmed for the current day

blinking rapidly activation/deactivation programming mode

activation/deactivation programming mode

off unit in operation function deactivated

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Melter operation

Alarm displays

‘micron’ series melter/applicator equipment tell the user when a malfunction has occurred in the unit, sending warning messages that may be seen on the control panel display.

When an alarm appears, the control unit takes a series of steps to protect the unit. Simply correct that malfunction and the control unit will reactivate the equipment functions.

Standby function does not generate any alarm.

If a temperature sensor is broken, the system heats all the elements except the one where the failure is located.

In case of overheating the system cuts off inmediately the damaged element. After three minutes if the failure continues all the system will be shut down. After repairing the failure the system starts heating normally.

code source

actions

heating pump main machine signal

Err 0 tank broken sensor only tank off off offErr 1 hose1 broken sensor only hose1 off off offErr 2 gun1 broken sensor only gun1 off off offErr 3 hose2 broken sensor only hose2 off off offErr 4 gun2 broken sensor only gun2 off off offErr 5 hose3 broken sensor only hose3 off off offErr 6 gun3 broken sensor only gun3 off off offErr 7 hose4 broken sensor only hose4 off off offErr 8 gun4 broken sensor only gun4 off off offErr 9 hose5 broken sensor only hose5 off off offErr 10 gun5 broken sensor only gun5 off off offErr 11 hose6 broken sensor only hose6 off off offErr 12 gun6 broken sensor only gun 6 off off offErr 13 distributor broken sensor only distributor off off offErr 100 tank overheating all components off off offErr 101 hose1 overheating all components off off offErr 102 gun1 overheating all components off off offErr 103 hose2 overheating all components off off offErr 104 gun2 overheating all components off off offErr 105 hose3 overheating all components off off offErr 106 gun3 overheating all components off off offErr 107 hose4 overheating all components off off offErr 108 gun4 overheating all components off off offErr 109 hose5 overheating all components off off offErr 110 gun5 overheating all components off off offErr 111 hose6 overheating all components off off offErr 112 gun6 overheating all components off off offErr 113 distributor overheating all components off off off

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Melter operation

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MA-5039-GB micron adhesive melter manual

Hot-melt display level

When the level of hot-melt drops below 1/3 of the tank capacity, the level detector sends a signal to the melter/applicator control unit, which takes the following actions:

It closes a non-voltage output contact where the user will install the required device (horn, light or PLC input).

Simply refi ll the tank and wait for the adhesive to melt enough that the sensor sends the message that the correct level has been reached.

Operational pressure display and adjustment

The air pressure with which the pneumatic pump control device works with is shown on the pressure gauge located on the base of the melter/applicator. The pressure must be adjusted according to the application needs.

Warning: Values below 0.5 bar may cause erratic pump action. Never surpass 6 bar of pressure. The multiplying effect of the pump elevates the hydraulic pressure to dangerous levels for component operation.

To regulate the pressure, use a 5 mm Allen wrench and turn the regulator clockwise (+) or counterclockwise (-) as needed.

Temperature adjustment

The melters/applicators leave the factory with the following set point temperature values:

• 160 °C (320 °F) for the tank and distributor• Disconnected (OFF) for the hoses and guns• °C displayed• Overheating value: 25°C• Standby value: 55%• Delay time: 10 min• On/off and stanby programming: OFF

The general process for adjusting the temperatures of each components is described below.

1. Select the component whose value you wish to modify using the left-right arrow. The tank and the distributor have the same set point value.

The corresponding LED will blink rapidly.

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Melter operation

2. Select the desired set point temperature value with the up-down arrow. Below 40°C the set point value displays ‘OFF’ canceling the heating of that element.

3. After ten seconds, the LED will stop blinking and the display will

show the tank’s set point temperature value by default, saving the modifi ed data.

This simple procedure should be repeated for each of the components whose set point temperature value you wish to modify.

Programming the applicator parameters

1. Simultaneously press the buttons with the clock symbol and the down arrow to enter the special menu.

The choice of temperature display units (°C or °F) will appear on the display.

2. Select the desired value using the up-down arrow.

3. Use the right arrow to move to the next display where the overheating symbol appears.

4. Select the desired value (between 10 and 25) using the up-down

arrow.

The value shown corresponds to the increase in real temperature allowed over the set point temperature without activating the alarm message.

5. Use the right arrow to go to the next display where the standby function symbol appears.

6. Use the up-down arrow to select the desired value (between 25 and 55).

The value shown corresponds to the percent decrease in the real temperature compared to the set point temperature that will occur when this function is activated.

7. Use the right arrow to go to the next display where delay time value appears.

8. Use the up-down arrow to select the desired value (between 0 and 60 min).

9. Use the right arrow to return to the fi rst parameter.

40°C

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Melter operation

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MA-5039-GB micron adhesive melter manual

10. In any parameter, use the left arrow to exit the special menu and see the tank temperatures once more.

All the special menu values are saved.

Setting the clock

‘micron’ series melters/applicators are equipped with a weekly programmable system controlling equipment connection and disconnection and activating and deactivating the standby function.

Before programming these functions, it is necessary to introduce into the control unit data corresponding to the day and hour used to execute these programs.

Programming the current day and hour

1. Press the button with the clock symbol.

A ‘0’ will appear on the display, indicating the program for current day and hour information.

2. Press the button with the clock symbol once again.

On the left display, you will see the time with a dot, indicating that this is the value that may be modifi ed, while the minutes appear on the second display.

3. Use the up-down arrow to select the desired value.

4. Press the button with the clock symbol once again.

Now the dot will appear on the right display.

5. Use the up-down arrow to select the desired value.

6. Press the button with the clock symbol once again.

A number appears, indicating the day of the week (1- Monday / 7- Sunday).

7. Use the up-down arrow to select the desired value.

8. Press the button with the clock symbol once again.

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Melter operation

The ‘0’ program appears once again.

9. Pressing either the left or the right arrow button will exit this program and return to the tank temperature display.

Programming equipment activation/deactivation

You may program an activation and a deactivation time for every day of the week, from Monday (1) to Sunday (7).

Time is expressed in 15 minute increments, so we cycle from 10.0 (10 hours and 0 minutes) to 10.1 (10 hours and 15 minutes) to 10.2 (10 hours and 30 minutes) to 10.3 (10 hours and 45 minutes).

1. Press the button with the clock symbol

A ‘0’ will appear on the display, indicating the program for current day and hour information.

2. Use the up-down arrow to select the value for the desired day of the week, from Monday (1) to Sunday (7).

3. Press the button with the clock symbol once again.

Two times will appear, one in each display. The display on the left shows the start time, while the display on the right shows the fi nish time.

4. The blinking dot next to the start time indicates that this is the value that may be modifi ed. Use the up-down arrow to select the desired value.

5. Press the button with the clock symbol once again.

The dot changes to the fi nish time.

6. Use the up-down arrow to select the desired value.

7. Press the button with the clock symbol once again.

The selected program will appear once again. Use the up-down arrow to select other programs.

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Melter operation

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MA-5039-GB micron adhesive melter manual

8. Pressing either the left or the right arrow button will exit this program and return to the tank temperature display.

The green LED next to the ‘ON/OFF’ button will remain blinking as long as there is an equipment disconnection time programmed for the current day.

Disabling the equipment activation/deactivation program

It is possible to disable the equipment activation/deactivation programming without canceling the daily programming. This way the programmed data is saved, but the programming will have no effect on the equipment.

1. Press the button with the clock symbol.

A ‘0’ will appear on the display, indicating the program for current day and hour information.

2. Use the up-down arrow to go past the selection for the last day of the week (7).

The message ‘ON/OFF’ will appear on the display, depending on the current status.

3. Press the button with the clock symbol once again.

The status will alternate each time you press the button.

4. Pressing either the left or the right arrow button will exit this program and return to the tank temperature display.

Programming the equipment’s standby function activation/deactivation

You may program an activation and a deactivation time for every day of the week, from Monday (1) to Sunday (7).

Time is expressed in 15 minute increments, so we cycle from 10.0 (10 hours and 0 minutes) to 10.1 (10 hours and 15 minutes) to 10.2 (10 hours and 30 minutes) to 10.3 (10 hours and 45 minutes).

1. Press the button with the clock symbol.

A ‘0’ will appear on the display, indicating the program for current day and hour information.

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Melter operation

2. Press the standby function button.

A ‘1’ will appear, indicating the fi rst day in the standby function programming.

[Since the current time and date are values common to both programs, the value ‘0’ does not appear in this menu].

3. Use the up-down arrow to select the desired value for the day of the week, Monday (1) to Sunday (7).

4. Press the button with the clock symbol once again.

Two times will appear, one in each display. The left display shows the start time, while the right display shows the fi nish time.

5.The blinking dot next to the start time indicates that this is the time that may be modifi ed.

Use the up-down arrow to select the desired value.

6.Press the button with the clock symbol once again.

The dot changes to the fi nish time.

7. Use the up-down arrow to select the desired value.

8. Press the button with the clock symbol once again.

The selected program appears once again. You may use the up-down arrow to select other programs.

9. Pressing either the left or the right arrow button will exit this program and return to the tank temperature display.

The green LED next to the ‘maintenance’ button will remain blinking as long as there is an equipment standby function activation time programmed for the current day.

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Melter operation

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MA-5039-GB micron adhesive melter manual

Disabling the equipment standby function programming

It is possible to disable the equipment standby function programming without canceling the daily programming. This way the programmed data is saved, but the programming will have no effect on the equipment.

1. Press the button with the clock symbol.

A ‘0’ will appear on the display, indicating the program for current day and hour information.

2. Press the standby function button.

A ‘1’ will appear, indicating the fi rst day in the standby function programming.

3. Use the up-down arrow to go past the selection for the last day of the week (7).

The message ‘ON/OFF’ will appear on the display, depending on the current status.

4. Press the button with the clock symbol once again.

The status will alternate each time you press the button.

5. Pressing either the left or the right arrow button will exit this program and return to the tank temperature display.

Special function buttons

The simplicity of programming ‘micron’ series melters/applicators reduces the use of the special function buttons to only the standby function.

This manual function allows you to alternate between the operational mode and the standby mode. Using the standby function during periods of melter/applicator inactivity helps save energy and allows the heated elements to return quickly to their set point temperatures once you return to the operational mode.

When the standby function is activated, the set point temperature for all the heated components is lowered to a certain value, according to the programmed parameter (see ‘Programming melter/applicator equipment parameters’). For example, if the tank

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Melter operation

set point temperature is 160 °C and the standby temperature is programmed as 30 (30%), when you press the standby function button, the tank set point temperature will drop to 112 °C (70% of 160 °C).

The three means for activating the standby function available with ‘micron’ melters/applicators have the following priority protocols:

1° manual standby function button2° standby function external signal3° standby function activation/deactivation programming

Therefore, if the function is activated by any of the three means, it may always be deactivated using the manual button. On the other hand, if it was activated using the manual button, it may not be deactivated by either of the other two means. The weekly programming may not deactivate a standby function that has been activated by either of other two means.

The following criteria are suggested for standby function use:

- If the period of inactivity is less than 2 hours, allow the melter applicator equipment to heat as normal.

- If the period of inactivity is more than 2 hours and less than 4 hours, use the standby function.

- If the period of inactivity is over 4 hours, use one of the following two options: turn off the equipment if you do not plan on using it for the rest of the day or keep the standby function on if you plan on using the equipment during that same day.

Turning off the melter/applicator equipment

If you need to disconnect the melter/applicator equipment:

1. Turn off the equipment switch, located on the side next to the power input.

The depressurization valve frees pressure from the hydraulic circuit, returning the adhesive to the tank.

2. Disconnect the pneumatic power to the guns and the electrical power to the control unit programmer, if there is one.

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Melter operation

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Maintenance

Warning: The melter/applicator equipment is equipped with current technology, but has certain foreseeable risks. Therefore, only allow qualifi ed personnel with enough training and experience to operate install or repair this equipment.

The following table briefl y summarizes the indications for adequate melter/applicator equipment maintenance. Always read the corresponding section carefully.

If the equipment does not work or works incorrectly, you may refer to the next chapter ‘6. Quick problem solving’.

Equipment cleaning

To continue to take advantage of the melter/applicator’s benefi ts and to ensure the perfect mobility of its components, it is necessary to keep all its parts clean, especially the ventilation grate on the upper part of the machine.

Warning: Risk of electric shock. Carelessness may result in injury or death. Clean the exterior using a cloth moistened with water. Do not use fl ammable liquids or solvents.

External cleaning:

Use cleaning products compatible with polyamide materials.

Apply the cleaning product with a soft cloth.

Do not use sharp tools or scrapers with sharp edges.

5. MAINTENANCE

Operation Frecuency Refer toExternal cleaning Daily Equipment cleaning

System depressurization Before performing maintenance tasks and repairing the hydraulic system Depressurizing the system

Filter cleaning or changing - As needed (once a year minimum)- With each adhesive change Filter maintenance

Emptying and cleaning the tank - When burnt adhesive is present- With each adhesive change Tank cleaning

Equipment change - Equipment change or repair Dettaching equipment from base

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Maintenance

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MA-5039-GB micron adhesive melter manual

Removing and changing exterior panels:

1. Disconnect the melter/applicator equipment.

2. Disconnect the compressed air from the equipment intake.

3. Remove the screws fastening the various side panels (A, B, C) and the upper panel (D).

4. Remove each panel sliding it in the direction shown in the fi gures.

5. To replace the panels, follow steps 1 through 4 in the reverse order.

[Panels A, B and C must be disassembled in this order and assembled in the reverse order.]

Depressurizing the system

‘micron’ series melters/applicators are equipped with a safety valve that allows you to depressurize the system whenever the equipment is pneumatically or electrically disconnected.

Before disconnecting any hydraulic component or opening any distributor output, it is necessary to follow these steps:

1. Disconnect the equipment switch located on the side next to the power input.

The depressurization valve releases the pressure from the hydraulic circuit, returning the adhesive to the tank.

2. Purge all guns that have been used either manually or with the corresponding program command.

Filter maintenance

‘micron’ series melter/applicator equipment is equipped with a 100 mesh pump fi lter. The fi lter prevents impurities and burnt adhesive remains from being pushed out from the tank by the pump.

Warning: It is a good idea to also use a fi lter in the tank intake valve. This fi lter performs a fi rst-step fi ltration, preventing impurities resulting from burning in the tank and other impurities that may enter from the outside from passing through.

AB

C

D

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 5-3

Maintenance

The adhesive fl ows from the inside to the outside of the fi lter, with impurities being trapped inside it.

When the fi lter is removed from its housing, all the impurities remain trapped inside, and the inside of the distributor stays perfectly clean. The fi lter may be cleaned or replaced directly with a new one.

No rule exists for determining when to change the fi lter. Several factors infl uence this decision:

• the type and purity of the adhesives used• the adhesive work temperatures• adhesive consumption in relation to the time it spends in the

tank• changes in the type of adhesive used

In any case, we recommend checking and cleaning the fi lter at least every 1000 hours of operation (melter/applicator equipment turned on).

Warning: Always use protective gloves and glasses. Risk of burns.

To change the fi lter:

1. Depressurize the system.

2. Using a 15 mm wrench, unscrew the hexagonal fi lter cap and remove it.

3. Unscrew the fi lter cartridge in a clockwise direction.

4. Depending on the dirt inside the cartridge, clean it or dispose of it directly, abiding by any existing waste regulations.

5. Screw back the cartridge back onto the fi lter cap in a counterclockwise direction.

6. Replace the fi lter seal if damaged.

7. Place the assembly inside the distributor once more and tighten as much as possible.

8. Continue with normal operation.

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pág 5-4

Maintenance

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

Cleaning the tank

The hot-melt tank must be cleaned on occasion to maintain its fusion and anti-adherence properties. The tank is covered on the inside with PTFE and inclined enough to aid unloading the hot-melt and to avoid it from being retained inside when consequential burning occurs.

Furthermore, when adhesives are mixed, reactions may occur between them, causing a degeneration and thus problems in unloading in the direction of the pump.

Therefore, it is recommended to clean the deposit every time that:

• a change is made to a different type of hot-melt.• too much burnt material is generated in its interior.

Changing adhesive type.

1. Use up as much of the adhesive as possible.

If it is necessary to unload the adhesive without having used it up as much as possible, follow the instructions in the section ‘Emptying the tank’.

2. Clean the remains of hot-melt adhesive on the inside of the tank.

Warning: Use appropriate protective equipment for high temperatures.

3. Add the appropriate type and quantity of the new adhesive, wait for it to melt and pump at least one full tank through the system (hoses and guns).

Cleaning burnt adhesive.

1. Empty the tank directly (see the section ‘Emptying the tank’) to prevent the burnt material from passing through the pump circuit.

2. Clean the adhesive remains and burnt material inside the tank. Do not use sharp objects that might damage the inside coating.

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MA-5039-GB micron adhesive melter manual

pág 5-5

Maintenance

Warning: Use appropriate protective equipment for high temperatures.

3. Add the appropriate type and quantity of adhesive and wait for it to melt.

4. Remove the fi lter cartridge and clean it, if necessary (see the

section ‘Filter maintenance’).

5. Reassemble the fi lter without the cartridge.

6. Pump a minimum of one tank through the distributor output marked number 1.

7. Remove the fi lter and attach it to the corresponding cartridge. Reinstall it in the distributor.

8. Refi ll the tank with adhesive, wait for it to melt and continue working as usual.

Warning: Whenever you handle the fi lter or any other element subject to pressure, you must always perform a system depressurization fi rst (see the corresponding section)

Emptying the tank

During normal maintenance activities, it is recommended, and sometimes necessary to empty the tank directly, without passing the adhesive through the pump system.

To do so, follow these instructions:

1. Maintain the tank at operating temperature. 2. Remove the side shroud cap.

3. Lower the discharge ramp located next to the tank and put an appropriate container in place.

4. Unscrew the emptying plug and allow the adhesive to fl ow freely into the container.

5. Once completely empty, clean the any remaining adhesive from around the output hole and ramp.

6. Replace the plug.

7. Raise the discharge ramp and replace the side shroud cap.

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pág 5-6

Maintenance

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

Warning: Use appropriate protective equipment for high temperatures.

Dettaching the equipment from its base

For more thorough equipment maintenance, it is necessary to remove it from its present location to be able to perform operations more comfortably and with greater accessibility.

To do this, the equipment should be removed from its base in the following manner:

1. Disconnect the equipment electrically from the main switch.

2. Depressurize the system.

3. Disconnect the hoses connected to the distributor outputs both electrically and hydraulically.

4. Disconnect the power input and the ground connection.

5. Unscrew the screws fastening the equipment to the base: on the left side, in a clockwise direction, on the right side in the opposite direction (counterclockwise).

6. Slide the equipment forward and raise it off its base.

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-1

Quick problem solving

6. QUICK PROBLEM SOLVING

This chapter shows basic help for solving simple problems without intervention from ‘meler’ technical personnel.

It is very important to respect the security instructions in this manual at all times. Failure to do so may result in personal injury and/or damage to the machine or to the rest of the installation.

Warning: The melter/applicator equipment is equipped with current technology, but with certain foreseeable risks. Therefore, only allow appropriate personnel with enough training and experience to use, install or repair this equipment.

Each observed problem corresponds to a chapter section. There are four different columns in each one:

• possible causes • verifi cation to be performed • actions • useful observations The system is simple. Locate the chapter section that corresponds to the observed problem. Starting with the column on the left, follow horizontally along the second and third columns. By the time you reach the a text in bold type (action) in the third column, the pro-blem should have been resolved. If you reach a text in italics (go to), the help section tells us to see another chapter section. If you do not reach either text, follow along vertically to the next cause, or if there is none, to the next problem.

If you are unable to solve the problem with the help provided in this chapter, contact your Area Technical Service Center or ‘meler’ headquarters directly.

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pág 6-2

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

This page is intentionally left blank.

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-3

Quick problem solving

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pág 6-4

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-5

Quick problem solving

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Page 54: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 6-6

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-7

Quick problem solving

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Page 56: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 6-8

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-9

Quick problem solving

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LY

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AN

UA

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ION

)

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EC

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ATIC

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IT C

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VA

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ATE

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MO

VE

INC

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AS

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ATE

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AN

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IT F

OR

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ED T

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SEE

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ENT

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OR

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LY A

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ING

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N

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ES

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EC

KIN

GA

CTI

ON

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IC U

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NC

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Page 58: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 6-10

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

SE

NS

OR

MA

LFU

NC

TIO

N

DE

FFE

CTI

VE

PLA

CE

ME

NT

DE

FFE

CTI

VE

CO

NN

EC

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N

CH

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K R

EA

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ER

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RE

CH

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K S

EN

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MA

KE

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IT IS

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RR

EC

TLY

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TED

IN IT

S

HO

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ING

CH

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K S

EN

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NN

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NS

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AN

GE

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CH

AN

GE

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TIFY

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CH

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GE

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AR

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OR

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ES

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KIN

GA

CTI

ON

SC

OM

ME

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UR

E M

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UN

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ON

Page 59: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-11

Quick problem solving

SE

NS

OR

MA

LFU

NC

TIO

N

DE

FFE

CTI

VE

PLA

CE

ME

NT

DE

FFE

CTI

VE

CO

NN

EC

TIO

N

CH

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K R

EA

L TE

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ER

ATU

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CH

EC

K S

EN

SO

R

MA

KE

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IT IS

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RR

EC

TLY

INS

DE

RTE

D IN

ITS

H

OU

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G

CH

EC

K S

EN

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CO

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EC

TIO

NS

CH

EC

K E

XTE

RN

AL

EFF

EC

TS

CH

AN

GE

SEN

SOR

CH

AN

GE

SEN

SOR

REC

TIFY

REC

TIFY

REC

TIFY

CH

AN

GE

SEN

SOR

BO

AR

D

SE

NS

OR

BO

AR

D C

N1

CO

NN

EC

TOR

PO

INTS

3

AN

D 4

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CU

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TS, P

NE

UM

ATIC

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UP

LIN

G

LEA

KS

, ETC

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CA

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KIN

GA

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SC

OM

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ALF

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Page 60: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 6-12

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

SE

NS

OR

MA

LFU

NC

TIO

N

DE

FFE

CTI

VE

CO

NN

EC

TIO

N

EX

TER

NA

L C

OO

LIN

G

PO

WE

R B

OA

RD

MA

LFU

NC

TIO

N

PO

WE

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OA

RD

CH

AN

NE

L M

ALF

UN

CTI

ON

CH

EC

K R

EA

L TE

MP

ER

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RE

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FFE

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SO

R

CH

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K H

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S

CH

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QU

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CH

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NS

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EC

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POW

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DO

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INTS

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LIN

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GA

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Page 61: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-13

Quick problem solving

SE

NS

OR

MA

LFU

NC

TIO

N

DE

FFE

CTI

VE

CO

NN

EC

TIO

N

EX

TER

NA

L C

OO

LIN

G

PO

WE

R B

OA

RD

MA

LFU

NC

TIO

N

PO

WE

R B

OA

RD

CH

AN

NE

L M

ALF

UN

CTI

ON

CH

EC

K R

EA

L TE

MP

ER

ATU

RE

CH

EC

K A

FFE

CTE

D S

EN

SO

R

CH

EC

K G

UN

CO

NN

EC

TIO

NS

CH

EC

K H

OS

E C

ON

NE

CTI

ON

S

CH

EC

K E

QU

IPM

EN

T C

ON

NE

CTI

ON

S

CH

EC

K S

EN

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R B

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CO

NN

EC

TIO

NS

CH

EC

K E

XTE

RN

AL

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TS

CH

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K H

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UN

AS

SE

MB

LY O

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CH

AN

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K A

NO

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MB

LY O

N

DE

FFE

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VE

CH

AN

NE

L

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AN

GE

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AN

GE

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TIFY

REC

TIFY

REC

TIFY

REC

TIFY

CH

AN

GE

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AR

D

REC

TIFY

CA

RD

DO

ES N

OT

REG

ULA

TE. C

HA

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E PO

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B

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CH

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TE. C

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D

CO

NN

EC

TOR

PIN

S 3

AN

D 4

MA

LE C

ON

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CTO

R P

INS

5 A

ND

6 A

ND

FE

MA

LE

CO

NN

EC

TOR

PIN

S 3

AN

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CO

NN

EC

TOR

PIN

S 5

AN

D 6

CN

2/C

N3/

CN

4/C

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CN

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N7

PO

INTS

3 A

ND

4 O

N

THE

SE

NS

OR

BO

AR

D

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RR

EN

TS, P

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PLI

NG

LE

AK

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TC.

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Page 62: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 6-14

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

ER

R 0

ER

R 1

ER

R 2

ER

R 3

ER

R 4

ER

R 5

ER

R 6

ER

R 7

ER

R 8

ER

R 9

ER

R 1

0

ER

R 1

1

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R 1

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R 1

3

ER

R 1

00

ER

R 1

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ER

R 1

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ER

R 1

03

ER

R 1

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R 1

05

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11

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TAN

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SO

R

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SE

1 B

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2 B

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R

GU

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SE

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OR

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SE

3 B

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4 B

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EN

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OR

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SE

5 B

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EN

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R

GU

N5

BR

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EN

SE

NS

OR

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SE

6 B

RO

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R

GU

N6

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SE

NS

OR

DIS

TRIB

UTO

R B

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R

TAN

K O

VE

RH

EAT

ING

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SE

1 O

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ING

GU

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OV

ER

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ATIN

G

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2 O

VE

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ER

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G

HO

SE

3 O

VE

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EAT

ING

GU

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ER

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G

HO

SE

4 O

VE

RH

EAT

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ER

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5 O

VE

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ER

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G

HO

SE

6 O

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DIS

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SC

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AR

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UR

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OR

Page 63: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-15

Quick problem solving

PU

MP

PLU

G L

EA

KS

PU

MP

SH

AFT

LE

AK

S

LEA

KS

BE

TWE

EN

PU

MP

AN

D T

AN

K

CO

MP

EN

SAT

ION

VA

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LE

AK

S

PU

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CO

UP

LIN

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EA

KS

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ED

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IGH

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AN

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S

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MP

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Page 64: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 6-16

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

HO

SE

CO

NN

EC

TIO

N M

ALF

UN

CTI

ON

EQ

UIP

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WE

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UP

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MA

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MA

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EQ

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Page 65: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-17

Quick problem solving

EQ

UIP

ME

NT

PO

WE

R S

UP

PLY

MA

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Page 66: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 6-18

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

GU

N C

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MA

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Page 67: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 6-19

Quick problem solving

TAN

K T

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PE

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UR

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Page 68: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 6-20

Quick problem solving

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

This page is intentionally left blank.

Page 69: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 7-1

Technical characteristics

Tank capacity

Pump rate

Melt rate

Outputs

Temperature range

(optional)

Temperature control

Maximum working pressure(at 6 bar)

Maximum power supply(at 230V)

External functions

Electrical requirements

(optional)

Electrical installation class

Workplace temperature

Dimensions

WeightPeso

(*) Under standard conditions

4 liters

29,3 kg/h (*) pump 7 cc/cycle

6,0 kg/h (*)

2, 4 ó 6

40 a 200°C (100 a 392°F)

230°C (450°F)

RTD ±0.5°C (±1°F)Pt-100 o Ni-120

81,6 bar (1183 psi)

5200 W (2 outputs)7600 W (4 outputs)10000 W (6 outputs)

temperatures ok outputlow level signalstandby input

230V 1~ 50/60 Hz + N + PE230V 3~ 50/60 Hz + PE 400V 3~ 50/60 Hz + N + PE400V 3~ 50/60 Hz + PE

class II

0 to 40°C

560 x 308 x 416

48 kg (empty)

8 liters

29,3 kg/h (*) pump 7 cc/cycle

11,2 kg/h (*)

2, 4 ó 6

40 a 200°C (100 a 392°F)

230°C (450°F)

RTD ±0.5°C (±1°F)Pt-100 o Ni-120

81,6 bar (1183 psi)

6200 W (2 ouputs)8600 W (4 outputs)11000 W (6 outputs)

temperatures ok outputlow level signalstandby input

230V 1~ 50/60 Hz + N + PE230V 3~ 50/60 Hz + PE 400V 3~ 50/60 Hz + N + PE400V 3~ 50/60 Hz + PE

class II

0 to 40°C

636 x 308 x 416

52,7 kg (empty)

7. TECHNICAL CHARACTERISTICS

General.

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pág 7-2

Technical characteristics

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

Dimensions.

560 (4) / 636 (8)308 (4) / 308 (8)

416

(4) /

416

(8)

BASE PLATE micron4

Page 71: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 7-3

Technical characteristics

Accessories.

VP-200 automatic pressure control system

Permits controlling the application fl ow, by means of a proportional valve, according to the variation in the machine speed.

External outlet inhibitor control system

Permits controlling the activation/deactivation of the output channels from the main machine via the NO (normally open) contacts without voltage.

400 VAC connection system without neutral

Transformer box for connection to three-phase 400 V systems without neutral. Only compatible with melters/applicators that are prepared for this type of connection.

Air fi ltering system

For adapting the air supply conditions to the hot-melt melter/applicator requirements (clean, dry, and without lubrication).

BASE PLATE micron8

Page 72: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 7-4

Technical characteristics

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

This page is intentionally left blank.

Page 73: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 8-1

Circuit diagrams

-A01 Power card (2, 4 or 6 outputs)-A02 Power supply card-A03 Sensor card (2, 4 or 6 outputs)-A04 Control card-B01 Level sensor-B02 240ºC safety thermostat -B03 Pt-100 tank temperature sensor -B04 Pt-100 distributor temperature sensor-S01 ON-OFF switch-Y01 Pneumatic group solenoid valve-R01 Tank resistance 2000W 230V (4) / 3000W 230V (8)-R02 Distributor resistance 1 400W 230V-R03 Distributor resistance 2 400W 230V-X0 Tank connection ceramic lead-X1 Distributor connection ceramic lead-X2 Level sensor connection ceramic lead-X3 8-pole channel 1 connector-X4 8-pole channel 2 connector-X5 8-pole channel 3 connector-X6 8-pole channel 4 connector-X7 8-pole channel 5 connector-X8 8-pole channel 6 connector-F1 Channel 6 fuse (hose-gun) 6A 250V F-F2 Channel 2 fuse (hose-gun) 6A 250V F-F3 Channel 1 fuse (hose-gun) 6A 250V F-F4 Distributor fuse 6A 500V gG-F5 Channel 3 fuse (hose-gun) 6A 250V F-F6 Tank fuse 16A 500V gG-F7 Low level signal fuse (F.H.M.) 2A 250V F-F8 Channel 5 fuse (hose-gun) 6A 250V F-F9 Channel 4 fuse (hose-gun) 6A 250V F-F13 DC Power supply fuse (F.F.A.) 0.5A 250V T

8. CIRCUIT DIAGRAMS

Components list version Pt-100

-A01 Power card (2, 4 or 6 outputs)-A02 Power supply card-A03 Sensor card (2, 4 or 6 outputs)-A04 Control card-B01 Level sensor-B02 240ºC safety thermostat -B03 Ni-120 tank temperature sensor -B04 Ni-120 distributor temperature sensor-S01 ON-OFF switch-Y01 Pneumatic group solenoid valve-R01 Tank resistance 2000W 230V (4) / 3000W 230V (8)-R02 Distributor resistance 1 400W 230V -R03 Distributor resistance 2 400W 230V-X0 Tank connection ceramic lead-X1 Distributor connection ceramic lead

Components list version Ni-120

Page 74: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 8-2

Circuit diagrams

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

-X2 Level sensor connection ceramic lead-X3 12-pole channel 1 connector-X4 12-pole channel 2 connector-X5 12-pole channel 3 connector-X6 12-pole channel 4 connector-X7 12-pole channel 5 connector-X8 12-pole channel 6 connector-F1 Channel 6 fuse (hose-gun) 6A 250V F-F2 Channel 2 fuse (hose-gun) 6A 250V F-F3 Channel 1 fuse (hose-gun) 6A 250V F-F4 Distributor fuse 6A 500V gG-F5 Channel 3 fuse (hose-gun) 6A 250V F-F6 Tank fuse 16A 500V gG-F7 Low level signal fuse (F.H.M.) 2A 250V F-F8 Channel 5 fuse (hose-gun) 6A 250V F-F9 Channel 4 fuse (hose-gun) 6A 250V F-F13 DC Power supply fuse (F.F.A.) 0.5A 250V T

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Page 76: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM
Page 77: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM
Page 78: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM
Page 79: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM
Page 80: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM
Page 81: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 9-1

Pneumatic diagrams

- 1 Innlet fi lter (fi ltering disk)- 2 Solenoid valve 3/2 manual override (230V 50 Hz 1.5VA)- 3 Pressure regulator 1-8 bar- 4 Pressure gauge 0-10 bar- 5 Pneumatic valve 5/2- 6 Pneumatic valve 5/2 (pilot priority)- 7 Pneumatic cylinder double acting double chamber Ø50x50 (7cc pump)- 8 Exhaust port fi lter- 9 Pressure discharge valve

9. PNEUMATIC DIAGRAM

Components list

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Page 83: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 10-1

Spare parts list

The most common spare parts list of the micron series adhesive melters is shown in this chapter to give you a quick and sure guideline to choose them.

The spare parts are listed by groups in a natural order as they are located on the units.

As a visual help the manual includes drawings of the components with a drawing number to easy fi nd them through the list.

The list gives you the part number and description, showing if it is necessary, if the part number belongs to a 4 or 8 liters unit.

10. SPARE PARTS LIST

Page 84: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 10-2

Spare parts list

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

This page is intentionally left blank.

Page 85: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 10-3

Spare parts list

E

B

F

G

D

C

ATANK GROUP

ELECTRONIC GROUP

DISTRIBUTORGROUP

PUMP GROUP

PNEUMATIC UNIT GROUP

ELECTRIC GROUP

CHASSIS GROUP

Page 86: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 10-4

Spare parts list

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

A. TANK GROUP

2Nº Ref. Description1 150021750 Complete tank assembly micron41 150022100 Complete tank assembly micron81.1 150021670 PTFE coated tank micron41.1 150021680 PTFE coated tank micron82 150021610 Insulation mantle micron42 150021620 Insulation mantle micron83 150021630 Tank gasket micron43 150021640 Tank gasket micron84 150021650 Tank port housing micron44 150021660 Tank port housing micron85 10100070 Flat tank fi lter5 10100085 Flat tank fi lter, extra-thick5.1 10100071 Flat tank fi lter screen5.1 10100086 Flat tank fi lter screen, extra-thick6 10030009 Safety thermostat 240°C7 150022640 Tank RTD sensor Pt-100 micron7 150022650 Tank RTD sensor Ni-120 micron8 10030007 Tank hook-up fi tting-electrical

lead9 150022090 Inlet valve fi tting micron10 150021790 Drain plug with o-ring10.1 150021730 Drain plug o-ring11 150021910 Level detector assembly micron411 150021860 Level detector assembly micron811.1 150021920 Level detector micron

3

4

11.1

5

6

10

8

9

7

1

11

Page 87: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 10-5

Spare parts list

B. DISTRIBUTOR GROUP

Nº Ref. Description1 150022660 Distributor RTD sensor Pt-100

micron1 150022670 Distributor RTD sensor Ni-120

micron2 150021710 Heating element 10x160 400W3 150021720 Tank-distributor seating o-rings

kit4 150021740 Distributor fi lter assembly micron 4.1 150021760 Distributor fi lter body with o-ring

micron4.2 150021770 Distributor fi lter body o-ring

micron4.3 150021780 Distributor fi lter cartridge micron5 150021820 Compensation valve assembly

micron5.1 150021830 Compensation valve piston-

plunger assembly micron5.2 10100096 Compensation valve spring6 150022110 Compensation valve plug with

o-ring 7 150022080 Pressure discharge valve

assembly7.1 150021900 Pressure discharge valve o-rings

kit

4.1

1

2

3

4.2

4.3

4

7

5

6

5.2

5.1

7.1

Page 88: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 10-6

Spare parts list

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

C. PUMP GROUP

Nº Ref. Description1 150021800 7cc pump body with braces and

fi ttings micron2 10100011 Pump shaft3 150021810 Pump seating o-rings kit micron4 10100013 Pump shaft guide tips and fi ttings

assembly4.1 10100105 Kit pump shaft retainer fi ttings5 10100082 Pump plug with o-ring5.1 10100083 Pump plug o-ring6 150021870 Pump holding support micron7 150022120 Pump-distributor tube cross-over

micron8 150020590 Pump shaft short hinge joint

5

5.1

6

8

1

3

2

4.14

7

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

pág 10-7

Spare parts list

IDENT FECHA MODIFICACIONMATERIAL/MATERIAL TRATAMIENTO/TREATMENT CERTIFI

Nota: Las cotas indicadas en el plano son desse les debe de aplicar corrección de medida a

D. PNEUMATIC UNIT GROUP

Nº Ref. Description1 150022680 Pneumatic unit assembly with fi lter1.1 150020490 Differential valve with gasket1.2 150020500 Slide pilot valve with gasket1.3 150020510 Pneumatic unit valves gasket kit1.4 150020520 Intake solenoid valve (220V AC)1.5 150020540 Pneumatic unit fi ttings kit1.6 10110051 Pneumatic unit exhaust silencer1.7 150020560 Pneumatic unit fi ltering disc (2)1.8 150020570 Pneumatic cylinder with seating gaskets1.9 150021700 Pneumatic unit insulator plate1.10 150020580 Pneuamtic unit cylinder gasket kit1.11 150020620 Pneumatic unit manifold1.12 150020630 Connector 2P+T 15x152 150021850 Pressure regulator3 150021690 Manometer micron4 10120021 Quick air input fi tting

1

1.8

32

4

1.21.41.12

1.1

1.3

1.5

1.6

1.5

1.7

1.9

1.10

1.101.11

Page 90: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

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meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

E. CHASSIS GROUP

Nº Ref. Denominación1 150021980 Control board door housing micron2 150021990 Power board door housing micron3 150021970 Front movable housing micron44 150022060 Front movable housing micron85 150022000 Rear fi xed housing micron6 150021960 Rear movable housing micron47 150022050 Rear movable housing micron88 150021950 Right side movable housing micron49 150022040 Right side movable housing micron810 150022020 Lid assembly micron411 150022030 Lid assembly micron812 150022010 Cover housing micron413 150022070 Cover housing micron8

5

7

9

41

2

3

6

8

1110

1312

Page 91: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

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Spare parts list

F. ELECTRONIC GROUP

Nº Ref. Description1 150021440 Control board micron2 150021450 Power board micron 2 outlets3 150021460 Power board micron 4 outlets4 150021470 Power board micron 6 outlets5 150021480 Sensor board Pt100/Ni120 micron 2 outlets6 150021490 Sensor board Pt100/Ni120 micron 4 outlets7 150021500 Sensor board Pt100/Ni120 micron 6 outlets8 150021510 AC/DC power supply +12/-12/+5 V DC

1 2 53 4 6 7

8

Page 92: Instructions manual - powerbond.co.uk · Changing adhesive type. 5-4 Cleaning burnt adhesive. 5-4 Emptying the tank 5-5 Dettaching the equipment from its base 5-6 6. QUICK PROBLEM

pág 10-10

Spare parts list

meler hot-melt adhesive dispensing

MA-5039-GB micron adhesive melter manual

G. ELECTRIC GROUP

Nº Ref. Description1 10010300 Fuse 6A2 150021530 Fuse 6A 10x38 gG type3 150021540 Fuse 16A 10x38 gG type4 150021550 Control to power board ribbon cable assembly5 150021560 Control to sensor board ribbon cable assembly6 16010003 Female connector 8 pin (base housing)7 150020720 Female connector 12 pin (base housing)8 10140040 Cable gland Pg13

9 150021590 Cable gland Pg910 150021600 Main switch

7 6

1

5

42

3

8 910