manual ps200 eng

Instruction manualDRUM MELTER PS200

MA-5066-E 230712

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.eu

Edition July 2012

© 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.

meler hot-melt adhesive dispensing

MA-5066-E Drum melter manual PS200 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 2-1 Intended use 2-2 Limited use 2-3 Modes of operation 2-3 Identifying the melting equipment 2-4 Main components 2-5 General 2-5 Control panel 2-6 Platen up-down pushbuttons 2-7 Four colors light tower 2-7 Temperature control panel 2-8 Pump speed control panel 2-8 Pneumatic control 2-9 Optional equipment 2-10

3. INSTALLATION 3-1

Preliminary procedures 3-1 Installation requirements 3-1 Free space 3-1 Electrical consumption 3-2 Compressed air 3-2 Other factors 3-3 Unpacking 3-3 Contents 3-3 Equipment placement 3-3 Electrical power connection 3-4 Pneumatic connection 3-4

Table of contents


MA-5066-E Drum melter manual PS200

Hoses and guns connection 3-5 Connecting external I/O 3-5 Drum melter ready (temperatures OK) 3-6 External standby 3-7 Motor start up 3-7 Motor speed set point 3-7 Light tower signals 3-8

4. DRUM MELTER OPERATION 4-1

General information 4-1 Starting up the melter/applicator equipment 4-2 Melter/applicator equipment displays 4-3 Displaying the temperature for each component 4-3 Alarm displays 4-4 Operating speed display and adjustment 4-5 Temperature adjustment 4-5 Programming the melter parameters 4-6 Setting the clock 4-7 Programming the current day and hour 4-8 Programming equipment activation/deactivation 4-9 Disabling the equipment activation/deactivation program 4-10 Programming the equipment’s standby function activation/deactivation 4-11 Disabling the equipment standby function programming 4-12 Special function buttons 4-13 Pump speed control 4-14 Manual mode 4-14 Automatic mode with an internal set point signal 4-15 Automatic mode with an external set point signal 4-16 By-pass valve regulation 4-16 Pneumatic valve adjustment 4-17 Platen movements 4-17 Placing a new drum 4-18 Removing the empty drum 4-20 Removing the drum with manual aeration 4-20 Removing the drum with automatic aeration (optional) 4-21

5. MAINTENANCE 5-1

Equipment cleaning 5-1 System depressurization 5-2


MA-5066-E Drum melter manual PS200 Table of contents

Platen maintenance 5-2 Pump maintenance 5-2 Leak inspection 5-2 Motor and gearbox maintenance 5-3 Cleaning the motor fan 5-3 Changing the lubricant 5-3 Recommended lubricants 5-3 Air fi lter maintenance 5-4

6. TECHNICAL CHARACTERISTICS 6-1

General 6-1

7. ELECTRICAL DRAWINGS 7-1

8. PNEUMATIC DRAWINGS 8-1

9. SPARE PART LIST 9-1

A. ELECTRICAL CABINET COMPONENTS 9-2 B. CONTROL PANEL COMPONENTS 9-4 C. STRUCTURE 9-6 D. PLATEN ENSEMBLE 9-8 E. MANIFOLD ENSEMBLE 9-10 MANIFOLD FOR SINGLE PUMP 9-10 MANIFOLD FOR DOUBLE PUMP 9-12 F. PUMP ENSEMBLE 9-14 G. PRESSURE RELIEF VALVE ENSEMBLE 9-15 H. DRUM AERATION AUTOMATIC VALVE (OPTIONAL) 9-16 I. PNEUMATIC CABINET 9-17

Table of contents



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meler hot-melt adhesive dispensing pag 1-1

Safety guidelinesMA-5066-E Drum melter manual PS200

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 projec-tion. Use thermal protective equipment and glasses.

1. SAFETY GUIDELINES

pag 1-2

Safety guidelines



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 operation; prevent the risk of possible entrapment due to moving mechanical 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 moveable parts by turning off the main switch.

Electrical components

The system operates with three-phase current (3x480 V + N / 50-60 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 placement.

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

Hydraulic components

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

The melter/applicator equipment includes a pressure limit valve. Before each operation, always make sure that the adhesive circuit is completely free of pressure. There is a high risk of hot particle


Safety guidelinesMA-5066-E Drum melter manual PS200

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 200 °C (392 °F). The equipment must be operated using adequate protection (clothing, footwear, gloves and protective glasses) that completely cover exposed parts of the body.

Keep in mind that, due to the high temperatures reached, the heat does not dissipate immediately, even when the power (in this case, electric) source is disconnected. Therefore, use caution, even with the adhesive itself. It may remain very hot, even in a solid state.

In case of burns, 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.

pag 1-4

Safety guidelines





IntroductionMA-5066-E Drum melter manual PS200

Description

‘meler’ PS200 drum melters are melting and pumping systems for thermoplastic materials that directly use their drum containers (with straight sides) for capacities of up to 200 l.

They are designed to be used for applications that require high fl ow levels and speed in supplying the material to the substrate.

Their main advantage is the direct use of the material’s packaging itself, without the need for protective systems when using reactive polyurethanes, since basically only the material being pumped is melted.

2. INTRODUCTION

pag 2-2

Introduction



Essentially, each of these tracker plates have the following characteristics:

- Gear type pump, with easy access for replacement and/or maintenance.

- Single-piece aluminum melting plate, which allows the element to be heated quickly. A special disk is assembled below to select the melting ratio necessities.

- Cartridge resistances housed on the plate. Highly reliable, ensuring thermal stability over the entire surface.

- Temperature control system, using solid-state relays.- Temperature reading by means of RTD probes (one per

element), which ensure perfect temperature stability for the elements.

- Control panel system that is easy to access and use, equipped with particular buttons to control platen movements and pump speed control.

- Plate raising and lowering, machine power and empty drum displays.

- Weekly installation start up and shut down programmer.- Quick drum attachment system.- External connection for the ‘stand-by’, ‘motor start-stop’ and

‘pump revolution speed set point’ signal activation input.- External connection for the ‘temperatures ok’ and ‘empty drum’

signals.

PS200 drum melters are designed to be used with ‘meler’ hoses and guns in hot-melt adhesive applications. Their diverse variations

- line, coating or swirl-spray - cover a wide range of applications, and are very versatile within all the markets where they are used.

Intended use

PS200 tracking plates are intended to be used under the following conditions:

• Hot-melt adhesive melting and pumping at a temperature of up to 200°C (392°F).

• Use of melting equipment with ‘meler’ accessories.



• Installation of melting equipment according to the current safety regulations, as well as the instructions found in this manual (anchoring, electrical connection, hydraulic connection, etc.)

• Use of melting equipment in environments which are not explosive or chemically aggressive.

• The melting equipment is to be used while following the safety instructions found in this manual, as well as the labels found on the equipment, using adequate protective measures in each mode of operation.

Limited use

PS200 drum melters must be used in the manner in which they are intended, and never under the following conditions:

• Used with materials that may represent safety or health hazards when heated.

• Use of melting equipment in environments which must be cleaned with water jets.

• Use of melting equipment to heat or melt food products.• Use or handling of melting equipment without adequate safety

protection.

Modes of operation

PS200 drum melters may be used in the modes described below:

Mode of heating system on_ The drum melter keeps all the elements heated at the temperature shown on the display which have been previously set up. The system motor-pump remains enabled waiting the opening action of one or more guns to supply the adhesive.

It is necessary to achieve three conditions for pumping:

1. The pumping system have been activated by the operator (on the front panel with the ON/OFF button).

2. The temperatures pre-set for every element (platen, hoses and guns) have been reached.

3. The delay time pre-set, until the pumping system starts, have been over.

Once the above conditions are done the pumping system can be managed in three different ways.

Manual mode_The melting equipment keeps the hot elements at the pre-selected temperature shown on

pag 2-4

Introduction



the display. The pump remains deactivated, awaiting manual activation, following manual selection of its rotational speed to supply consumable materials through the openings in one or more applicator guns.

Internal automatic mode_The melting equipment keeps the hot elements at the pre-selected temperature shown on the display. The pump remains deactivated, awaiting activation by means of an external signal, following the manual selection of its rotational speed to supply consumable materials through the openings in one or more applicator guns.

External automatic mode_The melting equipment keeps the hot elements at the pre-selected temperature shown on the display. The pump remains deactivated, awaiting activation by means of an external signal, following the automatic selection of its rotational speed (by means of an external variable voltage signal), in order to supply consumable materials through the openings in one or more applicator guns.

Standby mode_The melting equipment remains in a standby status, with the element temperatures kept at a value (programmable) that is below the preselected value. The pump remains deactivated.

Alarm mode_The melting equipment detects a malfunction and warns the operator. The pump remains deactivated.

Stopped mode_The melting equipment remains off,without heating the elements and with the pump deactivated.

Identifying the melting equipment

When ordering replacement parts or requesting assistance from our technical support department, you must know your melting equipment’s model and reference numbers.



This and other technical information may be found on the identifi cation plate, located on the electrical cabinet on the side of the melting equipment.

1. Electro-pneumatic control cabinet 2. Hose-gun electrical connections3. Pneumatic cylinders4. Melting platen5. Pump6. Purge and manual aeration system7. Gear-motor8. Pneumatic bypass valve

9. Drum retainer/Dripping tray10. Automatic aeration valve11. Drum placing system12. Support with springs for guiding hoses13. Five colors ligh tower

7

46

8

101

2

11

9

3

5

12

13

pag 2-6

Introduction



4. Drum aeration pushbutton (‘Air in’)5. Platen down bimanual pushbutton

6. Green ‘Start pump’ pushbutton 7. Main power switch

8. Temperature control panel9. Pump speed control panel10. Bypass valve pressure gauge11. Bypass valve pressure regulator

Main components

General

Control panel

1. ‘Platen up’ illuminated pushbutton2. Emergency stop button3. ‘Platen down’ illuminated pushbutton

1

2

3

4

55

6

7

8

9

10

11



UP DOWNBLINKING LIGHT motion allowed motion allowedLIGHT ON actual sense of motion actual sense of motionLIGHT OFF extreme position reached extreme position reached, but

blinks due to empty drum signal

Four colors light tower

RED: Half empty drum

AMBER: Motor running (pump rotation)

WHITE: Empty drum

GREEN: Drum melter ready (temperatures ok)

pag 2-8

Introduction



1

12

2 43

5

6

7

8

9

11 10Platen up-down pushbuttons

Temperature control panel

13

14

17

16

15

For each motor-pump assembly installed:

13. Pump speed display14. ‘MANUAL / 0 / AUTO’ mode switch15. INTernal / EXTernal set point switch16. Maximum ‘RATIO’ speed control17. Motor ‘R.P.M.’ speed regulation

1. Tank indicator LED2. Gun indicator LED3. Temperature set point4. Actual Temperature5. ON/OFF switch6. Standby function

7. Temperature OK LED8. Pump operation LED9. Time scheduling10. Left/right button - channel selection11. Up/down button - temperature modifi cation12. Hose indicator LED



Pump speed control panel

Pneumatic control

The pneumatic control includes solenoid valve for up-down platen movement and drum aeration system.

1. Intake fi lter 2. Pneumatic cylinder pressure regulator 3. Pneumatic cylinder pressure gauge 4. Bypass valve pressure regulator 5. Bypass valve pressure gauge 6. Drum aeration pressure regulator 7. Drum aeration pressure gauge 8. Drum aeration air pressure relief valve 9. Bypass air pressure relief valve10. Drum aeration solenoid valve11. Pneumatic cylinder solenoid valve12. Drum aeration air shutoff valve (manual option)

2

1

3 6754 9 810 11

13

12

pag 2-10

Introduction



Drum aeration pressure regulator adjusts air pressure to refi ll the empty drum while the platen is been raised up.

It is very important to adjust this pressure with the necessary value: a pressure greater than needed may pressurize the drum and cause a certain explosion when the platen goes outside the drum; a pressure lower than needed may depressurize and crush the drum, impeding the platen going out.

Bypass valve relieves the adhesive circuit pressure when the pump is running but any gun is opened, thus it operates as a safety valve. The pressure MUST NOT BE ADJUSTED without consulting the machine manufacturer.

Ratio between pneumatic pressure supplied and hydraulic pressure generated is 1/15 (as default, we recommended to adjust the valve to 4 bar approximately).

Optional equipment

To increase the performances of the machine it is possible to improve it with the following options:

- Four colors light tower- Circuit pressure automatic discharge- By-pass valve automatic control- Automatic drum aeration system


InstallationMA-5066-E Drum melter manual PS200

3. INSTALLATIONWarning: The drum melters are equipped with up-to-date technology, and have certain foreseeable risks. For this reason, only appropriately trained, experienced employees should be allowed to handle, install or repair this equipment.

Preliminary procedures

PS200 drum melters are delivered with all the parts needed for their installation. However, some components must be provided by the user, depending on the location and the connections at each particular installation:

• Electrical cable for the unit power supply• Pneumatic pipe and connection to the compressed air system• Multi-wire cable for external control functions• Optionally, a gas ventilation system

Installation requirements

Before Installing an PS200 drum melter, make sure there is enough space to position, connect and operate the entire system. Likewise, check that the electrical and pneumatic supplies meet the requirements for the melting equipment being installed.

Free space

A

B

CD

E

F

A

B

F

EE

CD

pag 3-2

Installation



Electrical consumption

In order to install a PS200 drum melter, bear in mind the total consumption of the installation, including the consumption of the hoses and guns that are installed.

Before connecting, make sure the voltage that the melting equipment will be connected to is the same as that which appears on the equipment characteristics plate.

Connect and make sure that the installation has a good ground connection.

Warning: Risk of electrocution. Even when the equipment is turned off, voltage is present in the intake terminals, which may be dangerous when performing procedures inside the machine.

PS200 drum melters include a lockable voltage disconnection switch, which isolates the equipment from its power source. It is protected from power surges and short circuits by means of magnetothermic switches and it is equipped with personal protection from branching to mass by way of a differential circuit breaker.

Compressed air

In order to install PS200 drum melters, it is necessary to have a dry, non-lubricated compressed air supply at a maximum pressure of 6 bar.

The air intake connection is installed for a pipe with an outside diameter of 12 mm.

item description dimension

A DOOR OPENING 800 mm

B DRUM MELTER LENGTH W/DOOR OPENED 2600 mm

C DRUM MELTER WIDTH 800 mm

D SPACE TO REMOVE THE DRUM 1600÷2000 mm

E DRUM MELTER HEIGHT AT MIN. POSITION 1600 mm

F DRUM MELTER HEIGHT AT MAX. POSITION 2600 mm



Other factors

Other practical considerations must be taken into account for the installation of PS200 drum melters:

• Keep the drum intake accessible in the equipment for easy replacement.

• Position the drum melter in such a way that its front panel display (which shows temperatures and any possible alarm signals) can be easily seen.

• Try to avoid (as much as possible) unnecessary long hose lengths that result in high electrical power consumptions and high pressure requirements for the pump.

• Do not install the drum melter next to any potential heat or cold sources that might affect its operation.

• Provide easy access to the melting equipment’s maintenance areas (for drum loading, plate cleaning, pressure and fl ow adjustments, the electrical panel, etc.)

Unpacking

Before beginning to install the drum melter, it must be removed from its position on the pallet and inspected in order to detect any possible deterioration or damage. Inform your ‘meler’ agent or the Head Offi ce of any defect, including that to the outside packing materials.

Contents

The drum melter’s shipping packaging may contain accessory items that were requested on the same order. Otherwise, the standard elements that accompany the melting equipment are as follows:

• Instruction manual• Warranty card• Hose connection adapters• Cable gland Pg for power supply connection (on cabinet)• External signals connectors (included on control and power

boards)

Equipment placement

Place the equipment on a horizontal plane in order to prevent uncontrolled movements, Once the unit is at its place of operation, attach the base to the fl oor, if necessary.

pag 3-4

Installation



Electrical power connection

PS200 drum melters are delivered ready to be connected to a 3-phase, 480 VAC 50-60 Hz electrical power supply, according to its power consumption. A good ground connection is always essential.

The maximum consumption values are indicated on the equipment’s characteristics plate.

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

Open the electrical cabinet door as far as possible. Run the power cable (Ø14-18 mm) through the Pg21 cable gland and attach to the inside anchor, making sure that the cable reaches the power intake terminals.

Connect each cable wire at its corresponding position, keeping in mind each cable’s color and function (XA1-XA2-XA3 phase -black or brown- and ground -green/yellow-).

Pneumatic connection

Connect the plant’s air system (maximum of 6 bar) to the drum melter’s intake, using fl exible tubing with an outside diameter of 12 mm. The unit is equipped with a quick adapter for this purpose.

Open the main air valve and turn the cylinder pressure regulator clockwise. A working pressure of 5 bar is enough to operate the plate cylinders. _ +



Hoses and guns connection

PS200 drum melters use standard ‘meler’ components. The entire range of ‘meler’ hoses and guns may be connected to this equipment.

Up to four hose-gun outputs may be connected to drum melter.

Warning: When connecting the hose-gun outputs, verify that the power to which the equipment is connected does not exceed the maximum allowable power for each outlet.

PS200 has a hydraulic manifold with 2 available connections (1 y 2), plus a purge output (3). If you connect only one hose do it in order to facilitate the installation and the connection of the hose. It will be a benefi t for the life of the hose and its correct operation.

Precautions:

• Identify each hose-gun unit according to the electrical connection it uses. This is necessary in order to visually control the temperatures and to observe any possible alarm signals.

• Use the adapters that are the most suitable for each installation, in order to minimize the space taken up by the hoses. Some confi gurations may cause very small radius curves that may cause inside damage to the hose.

• Save the threaded caps that are removed from the distributor to connect the hoses. In the future, they may be necessary if a hose is disconnected from its position.

• Complete the electrical connections for the hoses and guns with the equipment turned off. Failure to do so may result in electrical defects to the connection and cause alarm messages to appear on the melting equipment display screen.

Connecting external I/O

The equipment’s input and output (I/O) signals allow it to communicate with the main machine simply and directly. See Chapter ‘7 . Electrical diagrams’.

Several signals 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.

1122

33

11

22

33

44

pag 3-6

Installation



• External Standby_control input from the standby mode, via a non-voltage contact. The standby function is connected with a closed contact; an open contact disconnects it.

• Motor start up_for each pump installed, the motor start up may be controlled by closing an external non-voltage contact.

• Motor speed set point_for each pump installed, the rotational speed of the motor (and therefore, the pump) may be controlled by means of a 0 to 10V DC external signal.

• Light tower signals_outputs for external option four colors light tower:

- Drum melter ready (temperatures OK-green)- Motor running (pump rotation -amber)- Half empty drum (red)- Empty drum (white)

Also it is possible to connect this signals to the main machine through non-voltage external contacts.

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

Drum melter ready (temperatures OK)

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

2. Open the door of the electrical cabinet as far as possible. Thread the power cord (Ø4-8 mm) through the electrical cable gland Pg13, making sure that the cord reaches the terminal blocks where that signal has to be connected.

3. Insert the wires in XB11/12 terminal blocks and tighten them with the fi xing screws. The terminal block is double so you must to connect every wire in a free hole of the terminal block. It has no polarity so it doesn’t matter the place you connect them.

4. 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.

XB-11XB-11XB-1XB-122



CN4.CN4.22CN4.1CN4.1

External standby


2. Open the door of the electrical cabinet as far as possible. Thread the power cord (Ø4-8 mm) through the electrical cable gland Pg13, making sure that the cord reaches the terminal blocks of the CN4 connector on the control board.

3. Insert the wires in CN4.1/CN4.2 connector terminals and tighten them with the fi xing screws. It has no polarity so it doesn’t matter the place you connect them.



Motor start up



3. Insert the wires in XM3/4 terminal blocks and tighten them with the fi xing screws. The terminal block is double so you must to connect every wire in a free hole of the terminal block. It has no polarity so it doesn’t matter the place you connect them.



Motor speed set point



3. Insert the wires in XM1/2 terminal blocks and tighten them with the fi xing screws. The terminal block is double so you must to connect every wire in a free hole of the terminal block.

XM-3XM-3XM-XM-44

XM-1XM-1XM-XM-22

pag 3-8

Installation



Negative polarity must be connected to the internal free hole (XM1), while positive polarity must be connected to external free hole (XM2).

In order to enable this signal it is necessary to set the reference switch to the external set point position (REF. EXT).



Light tower signals

These signals are internally connected, with the external associated pairs, to the following terminal blocks:

Signal Light tower ExternalDrum melter ready (temperatures OK) XB9/XB10 XB11/XB12Motor running (pump rotation) XB3/XB4 XB17/XB18Half empty drum XB7/XB8 XB15/XB16Empty drum XB5/XB6 XB13/XB14


Drum melter operationMA-5066-E Drum melter manual PS200

In this section we will introduce the method for using the PS200 drum melter. 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 drum melter system installation: the melting unit, the transfer hoses and the application guns. All of these are controlled from the front panel of the drum melter equipment.

The fi rst large group is the platen-distributor ensemble. They form a single heated unit. The distributor, with an independent temperature control, allows you to maintain a uniform temperature throughout the entire adhesive circuit, right up to the hose outputs.

The second group is the hose group. These are identifi ed on the front panel from No. 1 to No. 4 and by a picture of the corresponding hose. Each has its own set point value.

The third group is the gun group. These are identifi ed on the front panel from No. 1 to No. 4 and by a picture of the corresponding gun. Each 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 connection box placed on the drum melter frame.

4. DRUM MELTER OPERATION

pag 4-2

Drum melter operation



Starting up the melter/applicator equipment

Before starting up the drum melter, it is necessary to check it 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 drum has adhesive and that the operational parameters have been programmed.

To start:

1. Connect the drum melter’s switch.

If the control card was turned off the last time the machine was disconnected, it will remain turned 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 is not already activated.

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

The platen (and distributors, hoses and guns connected) heating control LED (green) will light up and the tank will begin to heat.

Once it has reached 3° below the programmed temperature (set point) of the platen, 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. Make sure that the control switches for each of the motors installed is in the correct position (see Chapter ‘2. Introduction. Operating modes’).

5 7 5 7 0 0 77

1 5 7 1 5 7 1 6 0 1 6 0



If it is necessary to disconnect the melting equipment:

1. Push the button ON/OFF on the control panel2. Disconnect the equipment switch located at the front of the unit3. Disconnect the pneumatic power supply from the guns and the

electrical power supply from the control programmer, if there is one

Melter/applicator equipment displays

PS200 drum melter 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.

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 (platen, distributor and each hose and gun) by selecting the component with the cursor.

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

LED display Component heating Component statusconstantly 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

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

simultaneous intermittence from both leds timing in progress, once the tank has reached its set point temperature

pag 4-4




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

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

For these units, the display sequence is the following:

pump manifold<—platen<—hose1<—gun1<—...<—hose4<—gun4pump manifold—>platen—>hose1—>gun1—>...—>hose4—>gun4

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

Alarm displays

PS200 drum melters 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.

Code Source

Actions

Heating Pump Main machine signal

Err 0 platen broken sensor off only platen off offErr 1 hose1 broken sensor off only hose1 off offErr 2 gun1 broken sensor off only gun1 off offErr 3 hose2 broken sensor off only hose2 off offErr 4 gun2 broken sensor off only gun2 off offErr 5 hose3 broken sensor off only hose3 off offErr 6 gun3 broken sensor off only gun3 off offErr 7 hose4 broken sensor off only hose4 off offErr 8 gun4 broken sensor off only gun4 off offErr 13 pump manifold broken sensor off only pump manifold off offErr 100 platen 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 113 pump manifold overheating all components off off off

44 E E r rr r



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.

Operating speed display and adjustment

The speed at which the pump turns (in revolutions per minute) is shown on the control display for each motor in the unit. These revolutions may be adjusted using the potentiometer labeled ‘R.P.M.’ Turning clockwise increases the revolutions, while turning counterclockwise reduces the revolutions. The pump rotation speed has to be adjusted to the consumption needs of the application

Warning: Even though the control allows you to select rotational speeds between 0 and 100 rpm, it is not recommended to work at speeds below than 10 rpm (the fl ow might not be constant, depending on the motor load) or above 80 rpm (with the pump operating at maximum revolutions).

Under the rotational speed adjustment potentiometer, we fi nd the maximum speed control, labeled as ‘RATIO.’ This potentiometer allows us to adjust the full scale of the speed adjustment as a percentage, so that the maximum adjusted speed is 100 rpm (100%) or lower. This regulation affects both the manual speed adjustment and the external set point value for automatic adjustments.

Temperature adjustment

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

• 160 °C (320°F) platen-manifold set point temperature• 150 °C (302°F) hose set point temperature• 160 °C (320°F) gun set point temperature• °C displayed• Overheating value: 20°C• Standby percentage: 40%• Delay time: 10 min• On/Off and stanby programming: OFF

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

pag 4-6




1 0 1 0-- -- --

o f fo f f 40°C

1. Select the component whose value you wish to modify using the left-right arrow.

The corresponding LED will blink rapidly.

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 platen’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 melter 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.

° C° C



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 advance to the next screen, where the level detector activation/deactivation is found (NOT USED IN THESE TYPE OF MELTERS)

10. Use the up-down arrow to select the desired value (ON/OFF). When OFF is selected, neither the on-screen display nor the external signal activation will be operational. If ON is selected, when the level of hot-melt is low the alarm (n - - - ) will be displayed on the screen and the external signal contact will be activated (NOT USED IN THESE TYPE OF MELTERS).

11. Use the right arrow to return to the initial parameter.

12. For any parameter, the left arrow may be used to exit the special menu and display the tank temperatures once again.

To record any parameter, you must always move to the next parameter, using the right arrow.

Setting the clock

PS200 drum melters 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.

5 5 55------

1 01 0ƒƒ

1 1 6 06 0 1 6 0 1 6 0

pag 4-8




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.


Now the dot will appear on the right display.



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



The ‘0’ program appears once again.

0 0

0 2 0 2 . 0 8 . 0 8

22

0 0

0 2 . 0 2 . 0 8 0 8



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


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


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.


The dot changes to the fi nish time.

0 0

22

11 9 . 39 . 30 7 .0 7 . 22

pag 4-10




11 9 . 39 . 30 7 .0 7 . 226. Use the up-down arrow to select the desired value.


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


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.



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.


The status will alternate each time you press the button.


22

00

0 F F0 F F

00 nn



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).



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.

00

1 1

22

11 9 . 39 . 30 7 .0 7 . 22

pag 4-12




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

The dot changes to the fi nish time.



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


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

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.



2. Press the standby function button.

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

11 9 . 39 . 30 7 .0 7 . 22

22

00

1 1



0 F F0 F F

00 nn

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.


The status will alternate each time you press the button.


Special function buttons

The simplicity of programming PS200 drum melters 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 equipment parameters’). For example, if the platen set point temperature is 160 °C and the standby temperature is programmed as 30 (30%), when you press the standby function button, the platen set point temperature will drop to 112 °C (70% of 160 °C).

The three means for activating the standby function available 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

pag 4-14




1 1 6 06 0 11 2 11 2

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.

Pump speed control

Manual mode

The manual operating mode provides total user control over start-up/stop and the pump rotational speed adjustment.

To operate in this mode, follow these steps:

1. Set the ‘ON-OFF’ switch to the ‘MANUAL’ position.

If there has been a previous speed adjustment made, this value will appear on the display and the pump will start to turn at the speed indicated. If this is not the case:

2. Turn the ‘R.P.M.’ control clockwise and the pump will begin to turn at the revolutions indicated on the display.

3. Set the rotational speed to the value needed for the application.

The full scale for this control is the maximum number of revolutions permitted, 100, although it is recommended to work at speeds that are neither below 10 rpm nor above 80 rpm.

This full scale may be varied using the control labeled ‘RATIO,’ which reduces this value percentage wise. Therefore, with the ‘RATIO’ control at the middle position, the maximum value that can be reached using the ‘R.P.M.’ control is only 50 rpm.

000.00.0

50.050.0



Automatic mode with an internal set point signal

This operating mode permits the user to control the pump rotational speed, but leaving the start-up/stop dependent on an external signal (a contact that is not under voltage), normally from the main machine.


1. Set the ‘REF’ switch to the ‘INT’ position.

2. Set the ‘ON-OFF’ switch to the ‘AUTO’ position.

The system will wait for the start-up signal from the main machine. When this is received, if there has been a previous speed adjustment made, this value will appear on the display and the pump will start to turn at the speed indicated. If this is not the case:

3. Turn the ‘R.P.M.’ control clockwise and the pump will begin to turn at the revolutions indicated on the display.

4. Set the rotational speed to the value needed for the application.

The full scale for this control is the maximum number of revolutions permitted, 100, although it is recommended to work at speeds that are neither below 10 rpm nor above 80 rpm.

This full scale may be varied using the control labeled ‘RATIO,’ which reduces this value percentage wise. Therefore, with the ‘RATIO’ control at the middle position, the maximum value that can be reached using the ‘R.P.M.’ control is only 50 rpm.

Automatic mode with an external set point signal

This operating mode allows the main machine to have total control over the pump start-up/stop (through a contact that is not under voltage) and the pump rotational speed control (by means of a 0-10V DC external signal under voltage).


1. Set the ‘REF’ switch to the ‘EXT’ position.

2. Set the ‘ON-OFF’ switch to the ‘AUTO’ position.

The system will wait for the start-up signal from the main machine. When this is received, if there a previous voltage signal has been

000.00.0

50.050.0

pag 4-16




received, the corresponding speed value will appear on the display and the pump will start to turn at the speed indicated. If this is not the case:

3. Start the main machine so that it sends the appropriate voltage signal.

4. Set the signal to the value needed for the application.

A 10 V DC signal for the speed set point corresponds to the maximum number of revolutions permitted, 100, although it is recommended to work at speeds that are neither below 10 rpm nor above 80 rpm.

The correspondence between the voltage and the rotational speed may be varied using the control labeled ‘RATIO,’ which reduces this value percentage wise. Therefore, with the ‘RATIO’ control at the middle position, the maximum value that can be reached at 10V DC is only 50 rpm.

By-pass valve regulation

The pumping system using a geared pump provides a constant fl ow of adhesive, according to the pump’s rotational speed.

In this type of system, the pressure generated by the pump is the result of the retentions found on the circuit (the length and diameter of the hose, elbows in the connectors, the diameters of the nozzle outputs, etc.) and the adhesive itself (its viscosity).

For safety reasons, this pressure must be discharged when the circuit exceeds the operating value (normally with a closed circuit and the pump activated), which makes the use of a discharge valve or a by-pass valve necessary.

This valve may be a manual adjustment valve, using a threaded screw, or upon request, with pneumatic control, using a pressure regulator and a pressure gauge. In the latter case, the adhesive circuit pressure has a 15:1 ratio to the pressure displayed on the pressure gauge.

Pneumatic valve adjustment

To adjust the pressure with this valve model, follow these steps:

1. Unlock the pressure regulator control by pulling on it gently.

50.050.0



2. Turn it clockwise to increase the pressure. This will be seen refl ected on the pressure gauge located next to it.

Warning: Do not exceed 6 bar of pressure. This corresponds to 90 kg/cm2 on the hydraulic circuit.

Platen movements

To move down the platen, provided that it is outside the drum for safety reasons, you must simultaneously press the bimanual control on each side of the emergency stop and main switch (black buttons).

With the platen in the upper position the amber button ‘Platen down’ is blinking to show the posibility to move down the system. While pushing bimanual control ‘Platen down’ button lights on (the system is moving down) and ‘Platen up’ button blinks (possibility of movement). It is necessary to keep the bimanual control pushed until the platen has reached the inlet edge of the drum (detected by the corresponding sensor on the cam system). At the same time a buzzer sounds warning the operator or third persons about the risk of the movement

As the platen moves downward, if the bimanual control is released at any point, the plate will stop moving. In that case both amber buttons will blink showing the possibility of moving up or down the system.

After this point, the system moves down automatically without the need to keep pushing the bimanual control. The buzzer stops sounding: the risk dosen’t exist already.

Whenever the plate is moving down into the drum, it is necessary to open the manual purge valve to prevent the drum from being pressurized. Once the adhesive is released by the valve, it may be closed and operated as normal.

When the corresponding sensor on the cam system, which position has been selected previously, detects that the adhesive in the drum will end shortly, the system warns by the external signal or the light tower (if it is present —red light—). A new full drum can be prepared to replace the empty one.

When the platen reaches the bottom of the drum (detected by the corresponding sensor on the cam system), the platen stops, also

pag 4-18




the pump and the system is waiting for the order to raise once again. At the same time the buzzer advises of the empty drum (lowest position of the platen). The buzzer can be deactivated by bimanual control.

With the system at the lowest position the amber button ‘Platen up’ blinks showing the possibility to move up the platen. Pushing it the platen moves up until the button is re-push or it reaches the highest position (detected by the corresponding sensor on the cam system), where it stops and the button light goes off.

Automatically, while platen is moving up, the air input for aeration is activated to avoid vacuum efects inside the drum. It is necessary to insert previously the aeration bar (manual system) if the drum melter has not the automatic aeration option installed. Any case it is possible to activate this signal manually by the blue button ‘Air in’.

Placing a new drum

With the platen in the highest position put the new drum placing it on the rounded positioning base. This fi xation avoids horizontal displacements of the drum. The drum must not have dents or deformations.

Place the drum retainer to adjust its the vertical fi xation when the platen moves up out of the drum.



Apply a light layer of grease on the plate closure seal.

Unscrew the threaded rod from the purge hole (turning it ¼ turn to the left) and put the PTFE-coated collection pan in place. Slowly lower the platen using the bimanual control, until the seal is inserted inside the drum.

From this point on, the platen will move down automatically. Wait until the adhesive comes out of the purge hole. Make sure that there is no air trapped in the drum.

Screw in the rod (turning it 1/4 turn to the right) and clean the PTFE-coated collection pan (the cleaning process is much easier once the pan has cooled, as you are able to remove all of the solidified adhesive).

Activate the pump green button. The system is ready to operate.

1/4

1/4

pag 4-20




Removing the empty drum

A warning (‘Platen down’ button light blinking) on the control panel or an external signal to the light tower or the main machine informs you that drum is empty. When this happens, the pump will remain deactivated.

You can activate the pump manually pushing continuously the green button to assure the drum is completely empty (althought the system stops the pump 3 min after the empty drum sensor is activated for that reason).

Removing the drum with manual aeration

Unscrew the threaded rod from the purge hole, turning it ¼ turn to the left.

Insert the rod with the air tube, turning it ¼ turn to the right.

The system must be connected to the air supply and the valve must be open.

It is recommended to make sure that air comes out of the tube by pressing the ‘Air in’ button on the panel. ANY MALFUNCTION IN

1/4

1/4



THE AIR SUPPLY MAY DAMAGE THE DRUM AND PREVENT REMOVING THE PLATEN.

Push the amber button ‘Platen up’ and it starts moving up. Automatically it is activated the drum aeration input. When the platen reaches the highest position the amber light ‘Platen up’ goes off while the amber light ‘Platen down’ blinks waiting a new order to move down the platen.

Remove the drum retainer and take out the empty drum.

If a new drum is not going to be placed immediately, put the dripping tray below the platen to collect any adhesive that might drip out. Unscrew the rod and the air tube and replace the threaded rod in the purge hole.

When inserting the dripping tray, a detection system indicates its presence to the machine, preventing the platen from being moved down while the tray is underneath it.

If the system is not going to be used for several hours, clean any remaining adhesive stuck to the platen with an absorbent cloth.

pag 4-22




Removing the drum with automatic aeration (optional)

The system inserts automatically compressed air into the drum while the platen is moving up after the operator pushes the amber button ‘Platen up’.

Automatically the drum aeration system is activated.

Warning: Excess air will pressurize the inside of the drum.

The pressure of the aeration air may be regulated according to the speed with which the plate is moved up (maximum pressure is limited to 1.5 bar). The air is necessary to prevent depressions inside the drum. By default it is adjusted to 1 bar. Inside the pneumatic cabinet there are the pressure regulator, pressure gauge and pressure relief valve for the system.

_ +


MaintenanceMA-5066-E Drum melter manual PS200

Warning: Drum melters are equipped with up-to-date technology, and have certain foreseeable risks. For this reason, only appropriately trained, experienced employees should be allowed to handle, install or repair this equipment.

The following table provides a brief summary of the instructions for the correct maintenance of the tracker plate. Read each section carefully.

If the equipment does not work or does not work correctly, please contact ‘meler’ Technical Service or your local Agent.

Equipment cleaning

In order to maintain all the functions of the melting equipment and the complete mobility of all its components, it is important to keep all its parts clean, particularly the electrical panel’s ventilation grate.

Warning: Risk of electrical shock. Carelessness may result in injury or death. Clean the outside with a cloth moistened with water. Do not use flammable liquids or solvents.

External cleaning:

Use non-abrasive cleaning products, which are free of solvents.

Apply the product with a soft cloth.

Do not use sharp tools or scrapers with sharp edges.

5. MAINTENANCE

Operation Frequency Refer toExternal cleaning Daily Equipment cleaning

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

Plate cleaning - As needed (once a year, minimum)- With each drum change Plate maintenance

Checking for leaks in the pump Depending on the work hours and temperature and speed parameters (min. once a month) Pump maintenance

Cleaning and changing the oil (motor and gearbox)

Depending on the temperature and usage conditions (max. 8000 h) Gearbox maintenance

Compressed air filter- Purge condensed water (weekly)

- Clean filter (at least every six months)Air filter maintenance

pag 5-2

Maintenance



System depressurization

Warning: System pressurized at a high temperature. Before any procedure, disconnect the hoses and guns, completely depressurizing the system. Failure to follow these precautions may lead to serious personal injury.

1. Disconnect the motor.2. Place a container under the application nozzles.3. Activate the solenoid valve (automatic guns) electrically or

manually or press the trigger (manual guns) until no adhesive flows from the nozzles.

Platen maintenance

It is necessary to discharge the circuit using a cleaning product whenever the equipment will remain unused for several days or when changing the type of adhesive.

Contact the adhesive manufacturer to choose the best cleaning product and to obtain instruction on its use. Request and read carefully the technical specifications for the product.

When restarting production, remove cleaning product remains with the new adhesive.

The platen has a PTFE coating to improve its non-stick property. This means that platen cleaning is relatively easy. Cold material may be removed by pulling on it gently. If necessary, the platen may be heated to 60-80ºC to make adhesive removal easier.

Warning: Do not use sharp tools or scrapers with sharp edges.

Regarding to the platen seals is recommended cover it with grease after the drum change or after work to preserve it and prevent cracks.

Pump maintenance

Leak inspection

The pump has a gasket system on the axle to prevent adhesive from leaking through it. Some adhesive may occasionally leak out, which is why it is necessary to retighten the nut or replace the gasket.


MaintenanceMA-5066-E Drum melter manual PS200

Warning: The pump should be hot when replacing the gasket.

Dismount the coupling from the pump axle. Retighten or remove the nut that holds the gasket in place. Replace the gaskets and reassemble everything once again.

Due to system heating-cooling cycles, it may occasionally be necessary to retighten the nuts holding the assembly in place.

Warning: Always wear gloves and protective goggles. Risk of burns.

Motor and gearbox maintenance

Cleaning the motor fan

Periodically check the condition of the motor fan and its ventilation grate.

If any dust has accumulated, blow it clean with air (removing the protective cover, if necessary).

Changing the lubricant

The gears are delivered filled with synthetic oil. This will provide ‘lifetime’ lubrication (if there is no outside contamination). Ambient temperature 0 ÷ 40 °C, with peaks as low as -20 °C and as high as +50 °C.

Use only those lubricants recommended by the manufacturer. Using other types may cause premature wear or damage the reduction gears.

This reducer model holds approximately 1.6 L of lubricant.

Recommended lubricants

BRAND TYPE OF OILKLÜBER Klübersynth GH 6-220SHELL Tivela Oil S 220MOBIL Glygoyle 30

pag 5-4

Maintenance



Air filter maintenance

The air regulator-filter is used at the equipment’s air intake to clean the air of any impurities, remove condensation humidity and regulate the maximum working pressure.

The air humidity condensation is collected in a cup inside the filter-regulator.

To purge it, open the small purging valve located on the bottom of the cup.

Depending on how dirty the air used is, it is recommended to clean the inside of the filter of any particles once every six months. To do this, first purge the collector cup, cut off the air pressure intake and unscrew the cup from the body of the filter in order to remove the filter cartridge. Wash it with soapy water, rinsing it well.

Replace the cartridge and screw the cup back on.


Technical characteristicsMA-5066-E Drum melter manual PS200

6. TECHNICAL CHARACTERISTICS

General

Drum capacityDrum capacity 200 l200 lDrum dimensionsDrum dimensions ØØ571 x 950 mm (max.)Melting typeMelting type platen with embedded resistorsplaten with embedded resistorsPlaten optionsPlaten options smoothsmooth axialaxial parallelparallelMelting ratio (*)Melting ratio (*) 30 kg/h30 kg/h 130 130 kg/hkg/h 165165 kg/h kg/hSSensor typeensor type RTD Pt100 / Ni120Pump (1 per unit)Pump (1 per unit) 1, 2.5, 4, 8, 15, 20, 30 cc/rev simple

0.6, 1.2, 2.4, 4.8 cc/rev dobleNo. hydraulic outputsNo. hydraulic outputs 2 per pump (thread 3/4’ UNF)2 per pump (thread 3/4’ UNF)No. electrical outputsNo. electrical outputs up to 4 outputs (1200W per output)up to 4 outputs (1200W per output)Motor powerMotor power 250W / 375W / 1100W (depends on the

pump)Pump speedPump speed 7-100rpm (10-80rpm recommended)7-100rpm (10-80rpm recommended)Temperature rangeTemperature range 40 to 200°C40 to 200°CPower supplyPower supply 400V 3~ 50/60 Hz + N + PEAmbient temperatureAmbient temperature 10°C min / 10°C min / 40°C max40°C maxMax. working pressureMax. working pressure 85 bar85 bar (70 bar recommended)(70 bar recommended)Bypass valve typeBypass valve type pneumatic (manual regulation)pneumatic (manual regulation)Max. unit powerMax. unit power 7.850W (1 single pump/2 outputs) 7.850W (1 single pump/2 outputs)

10.250W (1 double pump/4 outputs)10.250W (1 double pump/4 outputs)External functionsExternal functions Temperatures OK output signalTemperatures OK output signal

Empty drum output signalEmpty drum output signalStandby activation input signalStandby activation input signalMotor on/off external controlMotor on/off external controlMotor speed external controlMotor speed external control

OptionsOptions Automatic drum aeration systemAutomatic drum aeration systemDrum retainer and dripping trayDrum retainer and dripping trayFour colors light towerFour colors light towerSupport with springs for guiding hosesSupport with springs for guiding hoses

Dimensiones (LxAxH) 1795 x 800 x 1592mm (plato abajo) x 2624mm (plato arriba)

Unit weightUnit weight 780780 kg (without adhesive drum) kg (without adhesive drum)(*) depending on adhesive type, melting platen and working conditions(*) depending on adhesive type, melting platen and working conditions

pag 6-2

Technical characteristics





Electrical drawingsMA-5066-E Drum melter manual PS200

7. ELECTRICAL DRAWINGS

pag 7-2

Electrical drawings





Pneumatic drawingsMA-5066-E Drum melter manual PS200

8. PNEUMATIC DRAWINGS

Pneumatic drawing with manual aereation system

- 1 Drum aeration valve system- 2 Intake filter - 3 Drum aeration control 3/2 solenoid valve- 4 Drum aeration pressure regulator- 5 Drum aeration pressure gauge- 6 Drum aeration pressure relief valve- 7 Bypass valve pressure regulator- 8 Bypass valve pressure gauge- 9 Bypass valve pressure relief valve- 10 Pneumatic cylinder 5/3 solenoid valve- 11 Pneumatic cylinder pressure regulator- 12 Pneumatic cylinder pressure gauge- 13 Pneumatic cylinder flow regulator- 14 Pneumatic cylinder

Pneumatic drawing with automatic aereation system

- 1 Drum aeration valve system- 2 Intake filter - 3 Drum aeration control 3/2 solenoid valve- 4 Drum aeration pressure regulator- 5 Drum aeration pressure gauge- 6 Drum aeration pressure relief valve- 7 Bypass valve pressure regulator- 8 Bypass valve pressure gauge- 9 Bypass valve pressure relief valve- 10 Pneumatic cylinder 5/3 solenoid valve- 11 Pneumatic cylinder pressure regulator- 12 Pneumatic cylinder pressure gauge- 13 Pneumatic cylinder flow regulator- 14 Pneumatic cylinder

pag 8-2

Pneumatic drawings



P: 6

bar

ØEX

T 10

mm

6 ba

r max

.

P: 0

.5 b

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/ DRU

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N MA

NUAL

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P: 6

bar

6 ba

r max

.

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PS20

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2

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98

7

1112

10 13

14


Pneumatic drawingsMA-5066-E Drum melter manual PS200

P: 6

bar

ØEX

T 10

mm

6 ba

r max

.

P: 0

.5 b

ar

1 ba

r max

.

/ DRU

M ME

LTER

INYE

CCIÓ

N AU

TOMÁ

TICA

DE A

IRE

2/05

/13

P: 6

bar

6 ba

r max

.

MAN

OM

ETE

R

MAN

OM

ETE

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PLAT

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UP

PLAT

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UM

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1.0

2.0

1.02

2.02 2.03

1.03

1.1

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0.1

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4.04

4.02

4.1

3.0

4.0

4.2

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pag 8-4

Pneumatic drawings






pag 9-1

Spare part list

A list of the most common replacement parts used for 200 kg drum melter equipment appears in this chapter to provide a quick, reliable guide for their selection.

The replacement parts are naturally arranged in several groups, in the same manner in which they are found on the equipment.

General pictures of the parts are included as a visual aid, and are numbered to make them easier to identify in the list.

The lists include the reference number and part name.

9. SPARE PART LIST

pag 9-2

Sparie part list



A. ELECTRICAL CABINET COMPONENTS

15

13

11

16

17

18

7

6

10

5

4

20

22

23

24

25

26

14

123

9

8

12

29 28 27

19

21



pag 9-3

Spare part list

A. ELECTRICAL CABINET COMPONENTS

Nº Ref. Description1 150110690 80A 4P 24V DC contactor2 150024450 Residual current swith 4P-63A-300mA3 150024440 Circuit breaker, 63A 4-pole4 150024120 Siemens Sitop Smart 5A DC power supply5 150110680 40A solid state relay6 150110710 Control to sensor board cable ensemble 500mm7 150024710 Sensor board Pt100/Ni120 micron/macro8 150112570 Fuse 16A 10x38 ultra fast9 150112560 Fuse 6,3A 6x32 ultra fast10 150110720 Control power board to power supply cable 500mm11 150024690 Power board 6 outputs micron/macro12 150028150 Control to power board ribbon cable ensemble13 150112410 Fuse 6,3A 5x20 ultra fast

14150090500 Motor inverter 230V AC 0.375kW150090710 Motor inverter 230V AC up to 2.2kW

15 150025630 Buzzer 24V DC16 150110660 Programmable relay omron zen 20 I/O17 150110670 Programmable relay expansion 18 150024150 Siemens 24VDC emergency relay19 150024140 Siemens safety combination 24V DC20 150110650 Memory ribbon to omron zen21 150024270 2-contact relay socket22 150029760 0-10V/0-10V converter23 150090420 220V AC 2-contact relay24 150090430 24V DC 2-contact relay25 150024110 Circuit breaker, 4A 1-pole 26 150024060 Circuit breaker, 6A 2-pole27 150024100 Circuit breaker, 6A 1-pole28 150028170 Circuit breaker, 32A 2-pole29 150110700 Circuit breaker, 32A 3-pole

pag 9-4

Sparie part list



B. CONTROL PANEL COMPONENTS

1

2

3

5

11

4

16

12

14

10

17

15

13

9

8

7

6

4

18

19



pag 9-5

Spare part list

B. CONTROL PANEL COMPONENTS

Nº Ref. Description

1 150022480 Illuminated amber pushbutton2 150022500 Blue pushbutton3 150022450 Illuminated green pushbutton4 150022510 Black pushbutton5 150022440 Emergency stop6 150024480 Device control three padlocks7 150090480 Three-position switch8 150021600 Two-position switch9 150090470 Potentiometer handle10 150090450 Motor speed display11 150024720 Control board micron12 150022490 Amber Led13 150022520 Contact base14 150022530 Contact N/O15 150022460 Green Led16 150090460 Linear potentiometer 2K (20K)17 150022540 Contact N/C18 150024470 3-pole base block 63A19 150024460 Neutral pole 63-80A

pag 9-6

Sparie part list



C. STRUCTURE

2

6

10

8

7

5

3

9

1

2

4



pag 9-7

Spare part list

C. STRUCTURE

Nº Ref. Description1 150024360 Flow regulator ‘L-type’ male-female G3/8” Ø10 2 150023780 M5 PNP inductive sensor3 150023530 Limit swith cable 4- pole 5m

4150028080 0,375kW gear-motor with fan150110880 1,1kW gear-motor with fan

5 150110910 Hose protection spring ensemble for drum melter PS200 6 150023660 Hose protection spring for drum melter PS2007 150023670 Lobed wheel M12x508 150023680 Dipping tray9 150023520 Limit swith angle mov.

10150023760 Elbow connector socket base150020720 Female 12-pole base connector

pag 9-8

Sparie part list



D. PLATEN ENSEMBLE

2 3 4

5

6

1

7

8

9



pag 9-9

Spare part list

D. PLATEN ENSEMBLE

Nº Ref. Description1 150110800 Embedded resistor drum melter platen2 150110810 Smooth melting disk PS2003 150110820 Axial melting disk PS2004 150110830 Parallel melting disk PS2005 150021220 High temperature platen seal6 R0005031 Pt100 sensor (encapsulated Ø 4,8 mm)7 150090300 Ni120 sensor8 150023560 M32x1.5 metalic cable gland9 10030009 Safety thermostat 240 ºC

pag 9-10

Sparie part list



E. PUMP ENSEMBLE

2

1

3

4



pag 9-11

Spare part list

Nº Ref. Description

1150110870 Single gear pump 30cc/rev150026030 Single gear pump 20cc/rev150026020 Single gear pump 15cc/rev

2150025970 Single gear pump 8cc/rev150025930 Single gear pump 4cc/rev150025960 Single gear pump 1cc/rev

3 150026430 Single pump seat o-rings4 150028050 Double pump seat o-rings

E. PUMP ENSEMBLE

pag 9-12

Sparie part list



E. MANIFOLD ENSEMBLE

7

2

6

4

1

3

5

12

8

11109 13 14



pag 9-13

Spare part list

Nº Ref. Description 1 150044040 Resistance 250W 230V Ø12.61x71 2 150028050 Simple pump seat o-rings 3 10100082 9/16’ pump plug 4 10100083 Pump plug o-ring 5 150110840 O-ring Ø35x2 6 150090360 O-ring Ø37x2 7 150110860 Drain collecting bucket 8 150023690 Ball valve H-G3/8 H-G3/8 9 150025420 Drum aeration set ensemble10 150024430 O-ring 13x311 150110850 Drum air drain rod ensemble12 150027960 3/4” 16h UNF plug with o-ring13 150041920 O-ring for fitting 3/4

14R0005031 Pt100 sensor (encapsulated Ø 4,8 mm)150090300 Ni120 sensor

E. MANIFOLD ENSEMBLE

pag 9-14

Sparie part list



F. PRESSURE RELIEF VALVE ENSEMBLE

12

3



pag 9-15

Spare part list

F. PRESSURE RELIEF VALVE ENSEMBLE

Nº Ref. Description1 150026270 Pressure relief valve complete ensemble2 150026300 Pressure relief valve o-rings3 150026060 Pressure relief valve closing tip

pag 9-16

Sparie part list



G. PNEUMATIC CABINET

3

7

4

8

6

5

2

9

10

2

12

11

3

1



pag 9-17

Spare part list

G. PNEUMATIC CABINET

Nº Ref. Description1 150110730 6 bar 1/8 pressure limiting valve2 150023730 0.3-7 bar G1/4 pressure regulator3 10110030 ‘meler’ air pressure gauge4 150110780 0.3-3.5 bar G1/4 pressure regulator5 150110770 0-4 bar air pressure gauge6 150023750 1 bar pressure limiting valve7 150110790 5/3 24VDC solenoid valve8 150060040 22 mm DIN 43650B solenoid valve connector9 150024410 Fan 119x119x3810 150023700 G3/8 air filter11 150023710 3/2 24VDC aeration solenoid valve12 150060050 32 mm DIN 43650A solenoid valve connector

pag 9-18

Sparie part list



I. DRUM AERATION AUTOMATIC VALVE (OPTIONAL)

2

1

3

4



pag 9-19

Spare part list

I. DRUM AERATION AUTOMATIC VALVE (OPTIONAL)

Nº Ref. Description1 150110890 Drum aeration automatic valve2 150011950 O-ring 14x2 (*)3 150023950 O-ring 24x2 (*)4 150110900 Drum aeration o-rings set(*) The same o-ring is used in the drum melter without this option (blind cap).

pag 9-20

Sparie part list




manual ps200 eng

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