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INSTRUCTIONS MANUAL star PROGRAMMER

1. 22 4 5 Set up of programmer 2 aaa 23 5 MAINTENANCE 2 222 22222222 nne nnn enn nen n enn nnn e nen n ne enn nce e eens ne eenenneeenneee 26 5 1 Outside Cleaning 2 a 26 5 2 Care of connection leads 2 nn nnn enna nn nn nnn nnn nnn en seen nnn nn en seen nennnennnenen 26 5 3 Care of peripherals 2 2222 222 n nnn n nnn nnnnn nn nn nn enn seen nnennnenns 27 5 4 Troubleshooting n n nonane nnn nn nnn mmm 28 6 ACCESSORIES AND SPARES mmm mmm mmm mmm mmm 30 Meler Gluing Solutions S A Vers 1 11 240414 IG 3 106 star Programmer manual General contenis Programming Manual 1 INTRODUCTION 222220 amaaa aaa 35 1 1 Programming Concept 2222222 22 2202020002 a a ese 35 1 2 Programming levelS 020020 0s nee nennnnn nnn nen sens ennenn nen nenneenesnnensesseenns 35 1 3 Programmable fUNCtIONS 22222 22 nn nn maman n 35 2 USER LEVEL mmm amaaa amaaa 37 2 1 COMMON FUNCTIONS 2 22222222 nn nen nn nen nen en nen ne cence nen nenen nen eenensenensensesensenensenencensenensenes 37 2 1 1 Change
2. 75 1 3 2 Connections 77 1 3 3 Programming operating method 77 1 4 Use of cycle Security mmmmmmmmmmmmmmmmmmm mmm mmm 81 1 4 1 Description 81 1 4 2 CONNECH ONS 82 1 4 3 Programming operating method 82 1 5 Use of 0 10 V signal Sift proof 2 2 2nn nn nn nn nnnnnnn nnn nnennnnnnnn 85 1 5 1 Description 85 1 5 2 CONNECTIONS 87 1 5 3 Programming operating method
3. 15 3 2 6 Power supply input 92 nn 22 nnn nnn nn nn nnn nn nnn nn nnn nnn nnn n 15 3 3 Peripherals 22 nn mmm 15 3 3 1 GUINS 16 3 3 2 Photocells 16 3 3 3 Encoder 16 3 3 4 Pressure regulator n 2 2 nnn nnn nn nnn nn mmm 17 4 INSTALLATION AND START UP mmm mmm mmm mmm 18 4 1 Components supplied 22 2 22 22 a 18 4 2 Unpacking n 2 2 nn nn nnn nnn nnn nnn nnn enn nnn ne nn nen e nen n m 18 4 3 Electrical installatiOn 2 222 2222 22 20 4 4 Location of peripherals 2 22 enn nn nnn nnn nnn nnn m 21 4 4 1 Photocell 21 4 4 2 Encoder
4. 88 1 6 Compensation application Longitudinal bead 2 0 00 0 00200200 0 92 1 6 1 Description 92 1 6 2 CONNECTIONS 93 1 6 3 Programming operating method 94 1 7 Encoder setting Four corners 2 22 2222222 0 nen nnn n nen nnnn nnn n enn nnen eens mmm 98 1 7 1 Description 98 1 7 2 CONNECH ONS 99 1 7 3 Programming operating method 100 1 7 4 Encoder setting 102 2 PROGRAMMING MENU TREE mmmmmmmmmmmmmmmmmmm mmm mmm m 104
5. These values are experimental At the end of this manual a table can be consulted for the most common installations with meler guns The values are entered with the numerical keypad confirming each value by pressing ENTER indicates a compensation of 15 ms A The compensation values are programmed in tenths of a millisecond A value of 150 Meler Gluing Solutions S A Vers 1 11 240414 MP 51 106 star Programmer manual Programming Manual 3 Restricted level The restricted level programming can be accessed by entering the relative password in the initial screen after the presentation screens see section 3 7 Front Panel in the User Manual The password is a four figure number that the user can choose through the Change password function see section 3 1 Change restricted password of this manual The default factory defined option is 0000 AN If you change the password you must take note of the new one and keep it in a safe and known place Enter password 0000 The first screen of the restricted level appears The arrow to the right on the right hand side indicates that there are other options on successive screens Press V to advance to other available options Y Y Y The arrow to the left on the right hand side of the screen indicates that there are other options on previous screens Press A to be able to return to other available options 3 1 Chan
6. Supply lead upp y French German and Italian 4 2 Unpacking The star programmer is supplied packed in a cardboard box with all the elements described in the previous section and with an identification label DESC AIPTI H PROGRAMADOR PART MAHE or PC STAR we TM meler M N 1074036740 Www meler es PASSED MU 18 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual User s manual The identification Part number amp Serial n corresponds to the same data contained on the programmer plate Reject any packaging that does not have the relative labels or whose information does not match with that requested V When you unpack the programmer keep the cardboard box and the packaging material in case you wish to move or send the equipment in the future V If any of the components supplied see point 4 1 are missing or damaged inform the meler dealer immediately or the central offices in Pamplona V All the components are packed in their relative bags with their identification labels V Place the programmer on a flat stable surface The legs of the programmer have grooves to secure the legs to the surface using screws V Situate the programmer close to the installation guns photocells encoder etc in order to easily connect the leads The standard length of these leads is 3 m The power supply lead supplied measures
7. The next screen will appear Press 2 and ENTER Enter the Utilities menu Press W The next screen of the menu will appear Press 2 and ENTER Vers 1 11 240414 MU 23 106 star Programmer manual User s manual To select a language press the relative number no and ENTER The texts are automatically displayed in the chosen language To access the other languages on successive screens press W as many times as necessary To access languages from previous screens press A Currently 7 languages have been stored 1 Spanish 2 English 3 French 4 Italian 5 German 6 Dutch 7 Portuguese Return to the initial selection screen pressing ESC several times until you reach it Press 1 and ENTER The following screen will appear Type the program number chosen they are all identical e g 1 and ENTER Press V twice The following screen appears Press 4 and ENTER to access the photocell selection 1 or 2 and assign them to each channel 1 2 3 or 4 In this case photocell 1 T Trigger is assigned to outputs O Output 1 y 2 and photocell 2 to outputs 3 and 4 To change a value go to the relative output with keys gt and d enter the desired value 1 or 2 and press ENTER to memorise the change Return to the general menu screen of the program by pressing ESC several times until you reach it Press V three times The following screen will
8. gt ENTER 2 2 ENTER gt ENTER Y Y i i J wi i p i B ENTER an ENTER _ D gt P gt gt gt a N i i S 000 ENTER GE 5 ENTER N XS 7 Eee gt i dg 6 ENTER 1 ENTER ENTER N Ez N S EN 2 ENTER 1 ENTER EE 2 ENTER S 2 ENTER Y Y Y Y N AS Se a 3 ENTER Y Y AS N NN Meler Gluing Solutions S A Vers 1 11 240414 MP 59 106 star Programmer manual Programming Manual 0000 ENTER 1 ENTER N J CZI 2 ENTER q 3 ENTER a Y Y ETEA A Er S ba ja N R 4 ENTER Y Y NS S 1 ENTER 4 ENTER k J N J 2 ENTER m T Io A 3 ENTER p ENTER Nec eh Pi N io N S MP 60 106 Vers 1 11 240414 Meler Gluing Solutions S A meler GLUING SOLUTIONS EXAMPLES MANUAL star Programmer Manual Examples manual 1 Programming examples The functions of the star programmer are explained in detail in the Progr
9. proportional valve depending on the substrate speed For 0 10 V connection 1 positive voltage signal 0 10 Vcc MU 14 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual User s manual 2 negative voltage signal 3 supply of transducer element 24 Vcc 4 bridge with 2 2 3 5 Input for gun inhibition With the inhibition input and using the external connection of a contact without potential the output signals of the four channels can be annulled so that the installation is protected from undesired patterns It acts as a Safety device if connected to machine access port contacts or to emergency stop buttons To connect inhibition input external signal contact external signal contact bridge with 4 bridge with 3 AUN 2 3 6 Power supply input The power supply connection and the protection fuse connector and lead are supplied to connect the equipm ipment The relative Before making the connection make sure that the mains characteristics coincide with the equipment specifications indicated in the User s Manual and on the identification plate it includes Use the power supply connector fastening flange to secure it This will avoid problems of false contacts and incorrect operation of the equipment The power supply input has a 3 A protection fuse If the equipment fails to come on check the fuse unscrewing the lid that protects it a quarter of a turn Replace it
10. Front panel Encoder activation LED Photocells activation LEDs Channels activation LEDs Control button panel 10 numerical keys Control button panel ESCape key melerW a 5 C Control button panel ENTER key On off switch Control button panel Control button panel Up left cursor key Down right cursor key The on off switch starts up the programmer The entry screen appears after the presentation screens using the password The programmer is totally active in the program selected the last time If the main machine starts to work the pattern cycle starts as well according to the relative parameters programmed The values of the different program parameters are entered with the numerical keypad or the relative submenu is selected within a menu MU 12 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual User s manual E g Type password 000 E g Choose option 1 Select program 1 With the ENTER key we confirm values entered or we access a later submenu With the ESC key we annul values entered or we access a previous menu With the cursor keys we can move within the same menu to display the hidden text lines indicated by means of arrows on screen or choose an output within a channel 3 2 Connections All the electrical connections are on the rear of the equipment mains power supply peripheral connection and inh
11. The high voltage time depends on the type of application gun used Electric guns usually have shorter high voltage times than those ordered pneumatically by solenoid valves To vary the high voltage time of a gun press 4 and ENTER on the Restricted menu submenu screen MP 54 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual The high voltage time modification screen will appear Enter the new value with the numerical keys and press ENTER to confirm 3 5 Program the encoder setting By default the star programmer interprets each impulse received from the outside through the encoder as a millimetre run so the ratio is 1 1 At times this ratio may be different due to the use of a different encoder to that supplied by meler or to the installation of the encoder in places where the substrate displacement speed is not directly measured That is why the star programmer includes a setting function for the impulses received with respect to the millimetres run On the Restricted menu submenu screen press 5 and ENTER The setting screen will appear Press V to be able to advance to other available options V Y 3 5 1 Set value On this screen the ratio of impulses per millimetre used at the present time is displayed regardless of the mode chosen to enter it By default it will be 1 1 Press 1 and ENTER Meler Gluing Solutions S
12. With the numerical keys enter 5 0 Press V to go to the position to enter the activation time With the numerical keys enter 1 5 Press V to access the position to enter the next delay corresponding to the second application The value will appear automatically It corresponds to the sum of the two previous values 50 15 adding one unit to it This value is only valid as reference In our case we are not going to enter any value So we press ENTER to confirm the data entered The value of the second delay disappears and the data entered are stored in memory Press ESC to go to the channel selection screen There are no more pattern data to be programmed Press ESC to go the main screen of program 6 Press 6 and ENTER The compensation value assignment screen will appear Press 1 and ENTER We have to enter the delay compensation values mentioned above expressed in tenths of a millisecond 9 5 ms 95 So with the gt and lt keys go to the data to be modified in this case ON1 ON2 and ON3 and press 9 5 and ENTER to memorise the value Press ESC 2 and ENTER to access the deactivation data Remember enter the delay values expressed in tenths of a millisecond 11 ms 110 So with the P and go to the data to be modified in this case OFF1 OFF2 and OFF3 and press 1 1 0 and ENTER to memorise the valu
13. e g 5 When ENTER is pressed the data contained in the following lines will be cancelled The other option is to erase all the data on the screen This erasure can be done with programmed data of 1 2 3 or 4 lines With lt 4 go to the first delay With the numerical keys enter the value 9999 Press ENTER All the data contained in delays and lengths are cancelled MP 48 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual 2 3 4 Spotting parameters Spotting activation by line It is possible to define a different spotting pattern for each output channel and assign it independently to each line of that channel From the initial screen after selecting the desired program press 2 and ENTER The output channel selection screen to apply the spotting will appear With gt and lt keys go to the desired channel and press ENTER For example channel 3 The spotting parameter screen corresponding to channel 3 will appear Enter the desired value for the spot S Spot in tenths of a millisecond and press DJ to jump to the next parameter Likewise enter the pitch value P Pitch between one spot and the next in mm and press P to jump to the next parameter For example With the numerical keys enter 1 5 0 and gt Then 4 0 and gt With gt and lt go to the line where you wish to spot and select it by pressing ENTER The li
14. etc may make these values vary Summary of parameters to be programmed Programming by encoder Assignment of photocell 1 to outputs 1 and 2 output 1 connector 1 A left bead D delay 35 L activation 290 output 2 connector 2 A right bead D delay 35 L activation 290 spotting left bead L1 S spot 100 P pitch 20 right bead L1 S spot 100 P pitch 20 Compensation times output 1 ON 95 OFF 110 output 2 ON 95 OFF 110 ME 76 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual 1 3 2 Connections The programmer will have the following connections Power supply connection of the star programmer Photocell and encoder connection Two different channels are chosen 1A and 2A to be able to set the beads independently If the exact alignment of the two guns one on each side is guaranteed one single channel could be used 1A and 1B 1 3 3 Programming operating system The parameters will be programmed in program 1 Turn the programmer on with the switch located on the front panel After the presentation screens the password entry screen will appear Enter password 000 by defauli The first user level screen appears From the main menu any of the twenty 20 possible programs that the star program has can be selected To do so press 1 and ENTER and the screen to enter the desired program will appear By default the last progra
15. for the purpose of the application thickness so 0 10V signal is not used The activation and deactivation delays compensation function will be used Meler Gluing Solutions S A Vers 1 11 240414 ME 69 106 star Programmer Manual Examples manual At a speed of 100m min one millimetre represents 0 6 milliseconds 1 millisecond is equal to approx 1 6 mm Therefore the conversion between both units is 1 0 6 The smallest bead to be deposited is 15 mm which means according to the previous ratio a 9 millisecond application Given the response times of the injection system between 5 and 10 ms we should have no problem in achieving the length of 15 mm at a speed of 100 m min The activation and deactivation compensations for a standard system gun with a double acting injector and 24 Vcc 12 7 W solenoid will be 9 5 and 11 ms respectively These are reference values based on tests carried out under certain conditions Any change to those conditions temperatures adhesives control elements etc may make these values vary Summary of parameters to be programmed Encoder programming Assignment of photocell 1 to outputs 1 2 and 3 output 1 connector 1 A bead 1 D delay 100 L activation 40 output 2 connector 2 A bead 2 D delay 50 L activation 15 output 3 connector 3 A bead 3 D delay 50 L activation 15 Compensation times output 1 ON 95 OFF 110 output 2 ON 95 OFF 110 output 3 ON 95 O
16. it is also possible to lock its reading for a specified distance This latter function will prevent undesired readings from being made whilst a substrate is passing under the photocell caused by changes in colour gloss or grooves holes and flaps of the box that we do not want to detect From the initial screen after selecting the desired program press 4 and ENTER The photocell assignment screen T Trigger will appear for each output channel O Output The selection is made between 1 or You can select the desired channel with keys DJ and lt 4 After positioning the cursor press 1 or 2 as desired and ENTER to confirm If you press gt when positioned on channel O4 you will access the following screen where the security of cycle for each photocell is programmed You can select the desired photocell with keys DJ and lt 4 After positioning the cursor press the numerical keys of the relative value generally the length of a substrate plus five 5 millimetres and ENTER to confirm read four substrates before starting to apply on the first which means that the photocell and the gun can be placed with a considerable distance between them or after defining a distance between photocell and gun the two substrates can be moved as close as possible together The programmer has accumulated reading of up to four substrates per photocell that is it can 2 2 4 Select co
17. 1 and 3 for the application of the long beads and numbers 2 and 4 for the small beads At a speed of 40 m min 1 millimetre is equal to 1 6 milliseconds 1 millisecond is equal to 0 6 mm Therefore the conversion between both units is 1 1 6 At a speed of 80 m min 1 millimetre is equal to 0 77 milliseconds 1 millisecond is equal to 1 3 mm Therefore the conversion between both units is 1 0 77 The smallest bead to be deposited is 12 mm which means according to the previous ratios a application between 9 and 19 milliseconds Given the response times of the injector system between 5 and 10 ms we should have no problem in achieving the length of 12 mm at speeds of 40 80 m min The activation and deactivation compensations for a standard system gun with double acting injector and 24 Vcc 12 7 W solenoid valve will be 9 5 and 11 ms respectively These values are for reference based on tests performed under certain conditions Any change to these conditions temperatures adhesives control elements etc may make these values vary Summary of parameters to be programmed Programming by encoder Assignment of photocell 1 to outputs 1 and 2 and photocell 2 to outputs 3 and 4 output 1 connector 1 A low long bead D delay 30 L activation 90 output 2 connector 2 A low small bead D1 delay 30 L1 activation 12 D2 108 L2 12 output 3 connector 3 A upp long bead D delay 30 L activa
18. 5 m long V Locate the programmer at a height where the display can easily be seen and the programming keypad can be reached Leave sufficient space on the rear so that the connection lead output is not forced and the connection can easily be made 290 120 V Avoid places subject to knocks or vibrations Meler Gluing Solutions S A Vers 1 11 240414 MU 19 106 star Programmer manual User s manual 4 3 Elecirical installation V Avoid connecting the programmer in lines that share the circuit with motors or large devices that might cause fluctuations in the line voltage V Make sure that both the programmer and the installation are far away from potential electromagnetic interference sources frequency variators wireless telephony or public address speakers V Use the yellow green earth lead to connect to the factory installation earth V Connect the programmer to an alternating current source of 230 V 50 Hz Plug the supply lead connector into the rear of the equipment Secure connection with the flange supplied with the lead Connect the other end of the lead to the relative intake according to regulations of each country or to the connection terminals of the main machine A Connect to a 230 V 50 Hz alternating current source with earth tap Connect the peripheral elements guns photocelis encoder 0 10 V signal lead and or gun inhibition signal lead with the 4 pole DIN connectors Fi
19. Below 1 m min the programmer annuls the applications Increase speed above this value The photocell always remains activated V Incorrect sensitivity adjustment Adjust it v An object situated under it reflects the emission of the photocell in the absence of substrate Adjust sensitivity or change the photocell position Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual User s manual The photocell does not detect the substrate at the same time so the application has position variations V The substrate area detected by the photocell has variations in height from one part to another Guide this area when passing through the detection V Some substrates pass out of line or with a lack of material The encoder does not measure the correct machine speed The encoder wheel moves due to lack of pressure on the belt V Verify the grip of the grub screw of the wheel V The encoder has been placed at a different speed point to the displacement of the substrate V An encoder with different impulse displacement ratio to the one selected has been placed Meler Gluing Solutions S A Vers 1 11 240414 MU 29 106 star Programmer manual User s manual 6 Accessories and paris Ref 27000001 COMPLETE PHOTOCELL Ref 10010009 WITH LEAD AND CONNECTOR 3 A FUSE Ref 27000002 OPTICAL FIBRE PHOTOCELL Ref 16000005 AERIAL MALE CONECTOR A pe WITH 3 m LEAD Ref 16000006 3 m LEAD GUN
20. INHIBITION Ref 16020001 COMPLETE CURRENT INTAKE CONNECTOR Ref 16130001 3 m EXTENSI N WITH METAL CONNECTOR PHOTOCELL ENCODER Ref 25010010 25010011 COMPLETE ENCODER SUPPORT FOR BELT COMPLETE ENCODER SUPPORT FOR SHAFT Ref 25010017 ENCODER WHEEL Ref 25010018 ENCODER CONNECTION Ref 25010007 25010008 2501009 COMPLETE INCREMENTAL ENCODER 200 400 1000 PULSES Ref 25010016 ENCODER WHEEL GASKETS MU 30 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Ref 21150002 Complete solenoid valve 5 2 24 Vcc 12 7 W Ref 21120003 Ref 21020003 Ref 21150002 Ref 112000090 Ref 112000010 Ref 112000110 Ref 112000020 Ref 08000004 08000005 PRESSURE VARIATOR ACCESSORY KIT VP 200 PRESSURE VARIATOR ACCESSORY KIT VP 200 WITH AERIAL CONNECTOR Meler Gluing Solutions S A User s manual Complete solenoid valve 3 2 24 Vcc 12 7 W Complete solenoid valve 4 2 24 Vcc 12 7 W Complete solenoid valve 5 2 24 Vcc 12 7 W Complete solenoid valve 3 2 24 Vcc 12 7 W quick connection Complete solenoid valve 4 2 24 Vcc 12 7 W quick connection Complete solenoid valve 5 2 24 Vcc 12 7 W quick connection Complete solenoid valve 5 2 24 Vcc 12 7 W quick connection for adjustable microprecision gun OAC REGULATOR e E N ol FIS i 9 wet amp 3990 eee tee a os E Vers 1 11 240414 MU 31 106 meler GLUING
21. Select output channel 2 mmm 46 2 3 Output channel fUNCTtIONS srmn 46 2 3 1 Delay of each lime 46 2 3 2 Length of each line mma amaaan 47 2 3 3 Partially erase data 48 2 3 4 Spotting parameters Spotting activation by line 49 2 3 5 Compensation values of each channel nm 50 3 RESTRICTED LEVEL mmmm mmm aaa 52 3 1 Change restricted password mnmmmmmmmmmmmm mmm 52 3 2 See USEF paSSWord sarmumunu mann 53 3 3 Change contact phone number mumun 53 3 4 Change high voltage time 2 2 54 3 5 Program encoder Setting srsrmanmamanamamanmamanmamanmanmmanmam anana aaa mame emma 55 3 5 1 Current value mmm 55 3 5 2 Pulses per MM mmm amaaan 56 3 5 3 Product size 7 2 12 56 3 5 4 Line Speed 57 4 PROGRAMMING MENU TREE 2 22 2220c00ennennennnnennennennensennen
22. V 400 To program these values substrates are made to pass at a low speed e g 20 m min With the machine in movement at this speed enter a value in the Min position on the screen e g 10 Vcc and press ENTER The value that we have entered and the speed of the substrate at the time it was entered will appear Observe the thickness of the line applied If it is not sufficient enter a greater voltage value than the current one If the opposite is the case reduce it If the thickness is appropriate increase the speed of the machine e g 100 m min With the machine in movement at this speed enter a value in the Max position on the screen e g 60 Vcc and press ENTER The value that we have entered and the speed of the substrate at the time it was entered will appear Observe the thickness of the line applied If it is not sufficient enter a higher voltage value than the current one If the opposite is the case reduce it If the thickness is appropriate the value programming has finished In this situation variations in speed of the machine will produce an evenly applied line thickness V Meler Gluing Solutions S A Vers 1 11 240414 MP 43 106 star Programmer manual Programming Manual 2 2 3 Select photocell Cycle security A different photoceli of the two possible ones can be assigned to each output channel for the cycle start signal Associated with the working of the photocell
23. Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual User s manual Use the tension system by means of the torsion spring incorporated in the belt support of the encoder ref 25010010 To tighten it gently place in the end position and turn the arm tightening it forwards anti clockwise looking from the wheel side Keep in this position and tighten the screw Do not overtighten There must always be a little play to assume small variations in the surface 4 5 Programmer Set up Place the encoder on smooth surface without joints or protuberances that might make the contact wheel with the belt come out and thus lose reading pulses If any other type of encoder is used ref 25010008 25010009 where the pulse displacement ratio is not 1 1 follow the setting instructions indicated in the Programming manual After installing the programmer and verifying the correct location of all the peripherals start it up with the power on off switch on the front panel After the presentation screens the name of the programmer appears the version and the contact telephone for technical assistance the first interactive screen of the programmer is displayed where the password is requested Meler Gluing Solutions S A The default password factory programmed is O00 This password can be changed in the Utilities menu see Programming manual Press 0 0 0 and ENTER
24. and selection keys It is possible to activate functions such as spotting cycle continues manual output activation the automatic setting of the encoder impulses or the cycle security which allows total control over the applications its reliability and repeatability 1 2 Regulations The star programmer has been designed under European Standards as shown by the EC certification on the characteristics plate vV Directive 92 31 EEC on Electromagnetic Compatibility C 4 v Directive 73 23 EEC on Low Voltage 1 3 Warnings on risk prevention The star programmer is supplied by mains current at 230 V 50 Hz To avoid the risk of electrical shocks do not remove the lid or touch anything on the inside without disconnecting the appliance from the mains Any manipulation on the inside carried out by unauthorized personnel automatically implies the loss of the right to guarantee To avoid the risk of fire or electrical shocks do not expose this product to water or damp To guarantee the electrical safety of the unit the installation must be conforming to applicable regulations and the system must be connected to earth Meler Gluing Solutions S A Vers 1 11 240414 MU 9 106 star Programmer manual User s manual MU 10 106 The electrical connection must coincide with the indications on the characteristics plate rated supply voltage and maximum consumption foreseen For this unit to work co
25. appear Press 5 and ENTER to access the work mode in Timer or Encoder The option between brackets is the selection currently in use To change the option press ENTER Each time it is pressed the selection changes option Working in Timer mode presupposes the use of a cycle activation photocell and parameters expressed in milliseconds ms Working in Encoder mode assumes using a cycle activation photocell a pulse generator to read the speed of the machine and parameters expressed in millimetres mm MU 24 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual User s manual After taking these actions the programmer is set to be able to work in the application defined After this the application values delays and lines must be programmed as well as spotting mode channel selection and values if this function is used 0 10 V output values to regulate the pneumatic pressure if this function is used high voltage time values and compensations depending on the type of gun used setting the encoder pulse displacement ratio if this is not 1 1 etc To program all these parameters and functions you can consult the Programming manual Meler Gluing Solutions S A Vers 1 11 240414 MU 25 106 star Programmer manual User s manual 5 Maintenance For the programmer and its peripherals to work correctly some simple indications for the care and maintenanc
26. be 9 5 and 11 ms respectively These values are for reference based on tests performed under certain conditions Any change to these conditions temperatures adhesives control elements etc may make these values vary Summary of parameters to be programmed Programming by encoder Assignment of photocell 1 to output 1 output 1 connector 1 A longitudinal bead D delay 50 L activation 120 Compensation times output 1 ON 95 OFF 110 1 6 2 Connections The programmer will have the following connections Connection of the power supply of the star programmer Photocell and encoder connection Output connection for solenoid valve 1A Meler Gluing Solutions S A Vers 1 11 240414 ME 93 106 star Programmer Manual Examples manual 1 6 3 Programming operating system The parameters will be programmed in program 1 Turn the programmer on with the switch located on the front panel After the presentation screens the password entry screen will appear Enter password 000 by default The first user level screen appears From the main menu any of the twenty 20 possible programs that the star program has can be selected To do so press 1 and ENTER and the screen to enter the desired program will appear By default the last program selected will flash on and off e g 15 To select the program of example 1 press 1 and ENTER The screen will show the menu of the pro
27. clean and in good conditions If they are deteriorated or extremely soiled replace them ref 25010016 Verify the support pressure of the encoder on the belt to eliminate displacements and loss of control pulses Adjust the support spring if necessary If there is a considerable loss of force of the spring pressure replace it ref 25010020 Meler Gluing Solutions S A Vers 1 11 240414 MU 27 106 star Programmer manual User s manual 5 4 Troubleshooting This section exclusively contemplates the problems caused by connections or positioning errors beyond the programming itself MU 28 106 The star programmer does not come on when the switch is connected v Verify correct connection to mains v Verify power supply lead v Verify fuse situated on the rear of the equipment The system does not activate the application elements v Verify that the guns are connected to the programmed channels and secured with the threaded fastening of the connector v Verify that the channel inhibitor is not activated v Verify the correct assignment of the photocells to each output One or more channels are not activated or they are activated with a brief impulse v Verify the lead of the outputs from that channel Possible internal activation of protection against short circuits Change connection to another channel and verify operation Working at very low speed in encoder mode the application elements are not activated V
28. majority of the cases let us assume that there is a distance between the photocell the first to be activated and the gun of for example 40 mm The real value entered as delay D Delay for this application would be 90 mm 50 40 A The position between photocell and gun must remain invariable in time On the contrary the delay values of the application line should be corrected MP 46 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual To enter this value into the programmer press the relative numerical keys and press V The following delay values for application lines 2 3 and 4 will automatically be increased successively by the delay and line length values of the previous lines This is because a second application cannot be superimposed with the first or the others with the previous ones So on going from a length value to the next delay the program automatically executes the sum of the values programmed previously and displays the smallest possible value for the next delay For example When VF is pressed the minimum delay value possible will appear for the second application It is not necessary to continue entering values if only one line is going to be applied Press ENTER to memorise the data and the value suggested disappears 2 3 2 Length of each line The other value associated with an application line is the length of the line
29. marked with the word OFF This word indicates that the system is deactivated If the ENTER key is pressed the word ON will appear indicating that the system is activated and therefore the outputs of the selected channels have been activated Place the cursor on OFF Press ENTER nel or channels will remain activated and their relative led or leds of the front Press the ENTER key again The selected output channel or channels will remain deactivated and their relative led or leds of the front panel will be off In this last position OFF ON the gt key can be pressed permitting access to a new screen On this screen select the 0 10 V signal corresponding to the pressure at which you wish to activate the selected output channels Enter the value in tenths of a volt and confirm with the ENTER key Values from 0 to 100 are permitted MP 40 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual 2 1 4 Production data The star programmer permits reading certain information details about line speed and parts production substrates On the Utilities submenu screen press 4 and ENTER The Line speed information screen will appear indicating the current speed of the pieces substrate Press the gt key to access the Production quant screen which indicates the pieces per hour detected by the photocell connected to in
30. numerical keys enter 1 0 8 Press key V to access the position to enter the application length With the numerical keys enter 1 2 Press V to access the position to enter the next delay corresponding to the third application A value automatically appears in this position As aid the programmer indicates the minimum value that can be entered in this position It corresponds to the sum of the two previous values 108 12 adding one unit to it This value is only valid for reference In our case we are not going to enter any value so press ENTER to confirm the data entered The value of the third delay disappears and the data entered remains stored in the memory Press ESC to go to the channel selection screen With key gt we select output 4 and we press ENTER We repeat the above steps as the beads must be the same unless there are adjustments After entering the data press ESC to go to the channel selection screen There are no more application data to be programmed Press ESC to access the main screen of program 3 Press 6 and ENTER The compensation values assignment screen will appear Press 1 and ENTER We have to enter the delay compensation values mentioned above expressed in tenths of a millisecond 9 5 ms 95 So with the gt and lt keys go to the data to be modified in this case ON1 ON2 ON3 and ON4 and press 9 5 an
31. password 38 2 1 2 Select language 38 2 1 3 Manual activation Drain pressure 2 22 nm 39 2 1 4 Production data 41 2 1 5 Select program 41 2 2 Program FUNCTIONS 2 222222 22 nen nn nnn nen nnn en nen nn nen eeneneenenneneesensenensenensensecensenencensesenes 42 2 2 1 Select spotting mode per channel 22m nn nn nnn nn nn nnn nnn n nn nn nnn nnnnnnenannnanennanncnne 42 2 2 2 0 10V control valUeS 43 2 2 3 Select photocell Cycle security 44 2 2 4 Select control mode Cycle continues 44 2 2 5 Erase memory n nana nana nn nana nn nn nn en ener nn nn nn nn nnnnnnnananananannnnnnenenenanananannnannnananananananansanananacanas 45 2 2 6
32. shown initially The question posed now is what would have happened if he security of cycle had not been programmed The answer can be seen in the figure below ME 84 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual 1 5 Use of the 0 10 V signal Sift proof 1 5 1 Description A frequent application in certain sectors of the industry is the hermetic or sift proof sealing of boxes applicable to any granulated or dusty product These products have traditionally been packed in sealed bags to prevent the product from coming out By sealing the box with the multi strip based system application a sift proof seal is achieved The adhesive application on the box can be seen in the figure The system is comprised of two equal applications sometimes symmetrical depending on the layout of the injectors one for the lower seal of the box before being refilled and another for the upper seal after dispensing the exact quantity of product When the outer lid is finally pressed the adhesive application creates a closed ring of adhesive which totally isolates the product from the outside The guns of a variable design depending on the size of the box have an injector with an independent control which applies the longest bead and the other injectors with one or several controls which apply the shortest beads In general it may be sufficient to use only two control
33. to the sum of the two previous values 100 40 adding one unit to it This value is only valid as reference In our case we are not going to enter any value So we press ENTER to confirm the data entered The value of the second delay disappears and the data entered are stored in memory Press ESC to go to the channel selection screen With gt we select output 2 and press ENTER In this channel we are going to enter the activation data for the second bead Remember 50 delay and 15 application length With the numerical keys enter 5 0 Press V to go to the position to enter the activation time With the numerical keys enter 1 5 Press V to go to the position to enter the next delay corresponding to the second application The value will appear automatically It corresponds to the sum of the two previous values 50 159 adding one unit to it This value is only valid as reference In our case we are not going to enter any value So we press ENTER to confirm the data entered ME 72 106 Ed 1 11 240414 star Programmer Manual Examples manual The value of the second delay disappears and the data entered are stored in the memory Press ESC to go to the channel selection screen With gt we select output 3 and we press ENTER In this channel we are going to enter the activation data for the third bead identical to the second Remember 50 delay and 15 application length
34. 0414 Meler Gluing Solutions S A star Programmer manual User s manual 3 3 4 Pressure regulator When the 0 10V output is used the pneumatic supply pressure of the application pump must be controlled in order depending on the machine speed to apply the necessary hot melt flow volume There is a pneumatic pressure regulation system or proportional valve VP 200 ref 08000005 which transforms the output voltage of the programmer 0 10 Vcc into pneumatic pressure corresponding to the pump 0 6 bar The correspondence is linear and can be programmed from the equipment see Programming Manual or from the actual VP 200 This peripheral requires 24 Vcc electrical supply provided by the star programmer and pneumatic supply max 10 bar through a built in 5u filter The VP 200 has a display that shows the existing pressure at any time To connect any other type of pressure regulator consult with factory Meler Gluing Solutions S A Vers 1 11 240414 MU 17 106 star Programmer manual User s manual 4 Installation and start up To start work with a star programmer the relative hot melt installation is necessary with its guns prepared with the connection 4 pin DIN connector for the programmer 4 1 Components supplied The following components are supplied with a star programmer Inhibition lead star programmer meler 4 eee S88 3 A fuse CD with star programmer manual in five languages Spanish English
35. 3 COMPENSATION VALUE TABLE 22 2 105 Meler Gluing Solutions S A Vers 1 11 240414 IG 5 106 meler GLUING SOLUTIONS USER MANUAL star Programmer manual User s manual 1 Introduction The star pattern programmer is a control system for dispensing and positioning hot melt or cold glue in gluing applications for the markets of Graphic Arts mailing folding machines binding Ceramics high speed boxing Foodstuff labelling or Agriculture agricultural set in high speed forming machines Ideally adapted to the objective market needs it is economical easy to handle and install with reduced dimensions 1 1 Definition of equipment The equipment has four 4 independent channels Each channel can act upon two 2 guns Maximum power with the eight 8 guns connected is 150W It can work in timer mode with photocell activation signal and pattern parameters in milliseconds or in encoder mode with the same activation signal and pattern parameters in millimetres controlled with reading of the speed of the substrate to be glued with an encoder It has a 0 10 V control output to regulate the application pressure with a transducer proportional valve depending on the speed of the substrate The functions are chosen the values are programmed and the different menu levels are displayed using a numerical keypad
36. 90 adding one unit to it This value is only valid for reference In our case we are not going to enter any value so press ENTER to confirm the data entered The value of the second delay disappears and the data entered remains stored in the memory Press ESC to go to the channel selection screen With key gt we select output 3 and we press ENTER We repeat the above steps as the bead must be the same unless there are adjustments After entering the data press ESC to go to the channel selection screen With key gt we select output 2 and we press ENTER In this channel we are going to enter the application data for the smallest beads Remember first strip 30 delay and application length 12 second strip 83 delay and 12 application length With the numerical keys enter 3 0 Press key V to access the position to enter the application length With the numerical keys enter 1 2 Press V to access the position to enter the next delay corresponding to the second application A value automatically appears in this position As aid the programmer indicates the Meler Gluing Solutions S A Vers 1 11 240414 ME 89 106 star Programmer Manual Examples manual minimum value that can be entered in this position t corresponds to the sum of the two previous values 30 12 adding one unit to it This value is only valid as reference In our case the value to be entered is 108 With the
37. A Vers 1 11 240414 MP 55 106 star Programmer manual Programming Manual The display announced will appear A This screen is only for display purposes No value can be entered 3 5 2 Pulses per mm One of the ways to enter the ratio is to program the ratio directly if this is already known Let us assume that this ratio is known and that it is equal to 2 1 that is two pulses for every millimetre On the Setting encoder submenu screen press 2 and ENTER The entry screen for this mode will appear Enter the value with the numerical keypad and press ENTER to confirm If we consult the Set Value screen the new value entered will automatically appear 3 5 3 Product size Another way of knowing the ratio for the encoder setting is to count the pulses received in a known distance for example a complete substrate On the Setting encoder submenu screen press 3 and ENTER A first screen will appear where the pulses are going to be read If the machine is operating and substrates are passing under the photocell the pulse value will update with each new substrate detected Press ENTER to memorise the last pulse value and a second screen will appear where the distance value between two substrates detected will be entered Press ENTER to memorise the values MP 56 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual The programmer makes the relati
38. FF 110 1 2 2 Connections The programmer will have the following connections Power supply connection of the star programmer Photocell and encoder connection Output connection for solenoid valves 1A 2A and 3A ME 70 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual 1 2 3 Programming operating system The parameters will be programmed in program 6 Turn the programmer on with the switch located on the front panel After the presentation screens the password entry screen will appear Enter password 000 by default The first user level screen appears From the main menu any of the twenty 20 possible programs that the star program has can be selected To do so press 1 and ENTER and the screen to enter the desired program will appear By default the last program selected will flash on and off e g 1 To select the program of example 6 press 6 and ENTER The screen will show the menu of the program selected From the initial screen after selecting the desired program press 4 and ENTER The photocell assignment screen will appear T Trigger for each output channel O Output In channel 1 2 and 3 01 O2 03 we will make the selection for photocell 1 Press ENTER to confirm We press DJ several times to jump to a new screen On this screen we will program the cycle security see chapter 2 2 3 Select
39. Its detection distance is 30 cm and it can be used in operation mode with light or in darkness cabled The control output is NPN type For applications in small spaces with difficult access or small sized substrates the photocell for reflection optic fibre can be used directly onto object ref 27000002 with threaded end M6 and self adjusting teaching function Its detection distance is 110 mm and it can be used in operation mode with light or in darkness selector The control output is NPN type To connect any other type of photocell consult with factory 3 3 3 Encoder Three 3 types of encoders are available to users 200 ref 25010007 400 ref 25010008 y 1000 ref 25010009 pulses per revolution with two 2 different fastening versions for belt with running disc for shaft with elastic coupling The 200 pulse model is designed to be placed directly onto the displacement belt of the substrate to be glued so that the programmer works with a ratio of 1 pulse 1 mm In other cases the self adjustment function of the encoder must be used to find the correct ratio All the models work at 15 Vcc with NPN or push pull output The belt support has a tension system with a torsion spring to ensure permanent contact of the wheel on the belt The elastic coupling in the support for shaft has an opening for 10 mm shaft To connect any other type of encoder consult with factory MU 16 106 Vers 1 11 24
40. SOLUTIONS PROGRAMMING MANUAL star Programmer manual Programming manual 1 Introduction It is simple and easy to program the parameters of the star programmer with the aid of the programming menu tree that appears at the end of this manual To have a better understanding of the programming dynamics it is useful to consult the following chapters of this manual where each function its utility and how to program it are explained 1 1 Programming concept The star programmer system is defined based on an options menu that successively folds down from several functions submenus until the final information that the user has to program appears The different submenus make up the programming areas according to the field they include generic programming common to all the programs such as language password or selection of parameters of the manual activation specific programming for each program number such as control mode cycle security values or photocell selection differentiated programming individual for each channel such as delays and lengths of application the spotting activation in the line or compensation values 1 2 Programming levels The programming is divided into two differentiated levels user level with access by password to the majority of the daily programming functions restricted level with access by another password to other generic operation programming parameters and which mu
41. Series 33N electric 38 43 31 35 Pafra Series 33B electric 37 45 26 34 Pafra Systems LTD a LEARY Technology Company ME 106 106 Fd 1 11 240414 Meler Gluing Solutions S A
42. To select the program of example 8 press 8 and ENTER The screen will show the menu of the program selected From the initial screen after selecting the desired program press 4 and ENTER The photocell assignment screen will appear T Trigger for each output channel O Output In channel 1 01 we will make the selection for photocell 1 Press ENTER to confirm We press DJ several times to jump to a new screen On this screen we will program the security of cycle see chapter 2 2 3 Select photocell Security of cycle in the Programming manual We enter the relative value 255 mm Press 2 5 5 and ENTER to memorise the value Press ESC to return to the main menu Press 5 and ENTER The mode selection screen will appear The mode between brackets is the mode currently selected Just press ENTER to change from one working mode to another The selection of the example is Encoder Press ESC to go to the main menu From the initial screen after selecting the desired program press 1 and ENTER The channel selection screen will appear With the gt and lt keys select channel 1 and press ENTER In this channel we are going to enter the application data for no 1 Remember 15 delay and 230 application length With the numerical keys enter 1 5 Meler Gluing Solutions S A Vers 1 11 240414 ME 83 106 star Programmer Manual Exampl
43. alues ME 80 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual 1 4 Use of the cycle security 1 4 1 Description The cycle security consists of giving a value to a parameter that enables us to annul as from the first photocell detection any new detection whilst the value specified in that parameter lasts During the time the application is maintained the shape texture or material of the substrate can cause undesired cycle starts The cycle security parameter guarantees that this is not going to occur until the value indicated in the parameter namely the length of the substrate has elapsed For example in a box with a certain depth you wish to apply an adhesive bead on the inside to glue a dividing wall for example It will start by reading the front edge but after the application cycle has ended a new cycle will begin when it detects the rear edge The distance between photocell and gun is 5mm The length of the box is 250 mm the start delay 10 mm and the application bead length is 230 mm eee eee Ze i To be sure that the photocell will be cancelled when it passes over the rear edge a value is chosen for the cycle security parameter of 255 mm length of the box 250 mm plus 5 mm tolerance These 5 mm depend on the separation that exists between two boxes and can be increased if the distance between them is sufficient A photocell will be used to det
44. amming manual as well as how to use them The aim of this chapter is to show practical examples of applications where these functions are used and to reveal step by step how they must be programmed for the specific data contained in each example 1 1 Timer mode application Container labelling 1 1 1 Description Although the greatest possibilities of the programmer can be achieved by working in the Encoder mode it is also possible to work in the Timer mode where the values entered for the application patterns are expressed in milliseconds see section 2 2 4 Select control mode Cycle continues in the Programming Manual In some applications it is advisable to work in Timer mode either due to the difficulty in installing a line speed reader for the product or because of the application itself which requires almost instantaneous response times A typical application is Container labelling and namely the application of a spiral or swirl on a tin When the tin is introduced into the labelling transfer it begins to rotate and also to move When a photocell detects the tin either sideways or from the top swirling spots are instantaneously applied with self adhesive hot melt the number of spots applied depends on the height of the tin These spots will later permit the label to be attached wrapping it round the tin as well as its extraction from the label holder with adhesive on the e
45. ance 1 Memories 20 Functions v Response time compensation activation deactivation v Erasure of a datum of data from a channel and complete erasure of memory v Selection of a photocell for each channel v Assignment of spotting parameters for each channel v Selection of spotting mode for each line v Cycle locking to avoid false photocell readings v Accumulated reading of up to four substrates per photocell v Independent manual activation for each channel v Activation time adjustment 33 Vcc high voltage for different gun models V Timer encoder work mode selection v Selection of cycle continues for each program after machine stoppage v Automatic flow regulation depending on machine speed 0 10 Voutput for each program v Access to programmings by means of security code V Screen with production data machine speed production per minute total production v Automatic setting of encoder pulses v Electronic protection of output channels electronic fuse automatically resettable v Programming in 10 languages Spanish French English German Italian Portuguese Dutch Others being developed Meler Gluing Solutions S A Vers 1 11 240414 MU 11 106 star Programmer manual User s manual 3 Programmer description The following chapter includes a description of the controls on the front panel the connections on the rear of the equipment and the different peripheral elements that can be connected to the equipment 3 1
46. d ENTER to memorise the value Press ESC 2 and ENTER to access the deactivation data Remember enter the delay values expressed in tenths of a millisecond 11 ms 110 So with the gt and lt keys go to the data to be modified in this case OFF1 OFF2 OFF3 and OFF4 and press 1 1 0 and ENTER to memorise the value Press ESC to access the main screen of program 3 ME 90 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual Press 3 and ENTER The 0 10V signal setting screen will appear The voltage values are expressed in tenths of a volt therefore the current situation is O volts when the machine is stopped this would correspond to 0 bar pressure or to 0 rpm depending on the equipment and 10 volts when the machine has a speed of 400 m min corresponding to maximum pressure standard 6 bar or to maximum rpm 100 The way to enter these values is based on setting the voltages to the maximum and minimum work speeds The other values are automatically interpolated by the star programmer Therefore with the machine at maximum working speed it is set by entering a suitable value in the Wax parameter and visually verifying that the thickness of the bead deposited is as desired For example we enter 6 5 6 5 V and press ENTER The speed it is working at and for which the voltage value has been set is imm
47. d ENTER The photocell assignment screen will appear T Trigger for each output channel O Output In channels 1 and 2 01 O2 we will make the selection for photocell 1 In channels 3 and 4 O3 and O4 the selection for photocell 2 Press ENTER to confirm Press ESC to return to the main menu Press 5 and ENTER The mode selection screen will appear The mode between brackets is the mode currently selected Just press ENTER to change from one working mode to another The selection of the example is Encoder Press ESC to go to the main menu ME 88 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual From the initial screen after selecting the desired program press 1 and ENTER The channel selection screen will appear With the gt and lt 4 keys select channel 1 and press ENTER In this channel we are going to enter the application data for the longest bead Remember 30 delay and 90 application length With the numerical keys enter 3 O Press V to access the position to enter the application length With numerical keys enter 9 0 Press V to access the position to enter the next delay corresponding to the second application A value automatically appears in this position As aid the programmer indicates the minimum value that can be entered in this position It corresponds to the sum of the two previous values 30
48. d If so do so Once adjusted the application will remain as shown in the figure Meler Gluing Solutions S A Vers 1 11 240414 ME 95 106 star Programmer Manual Examples manual If you increase the speed of the machine to the working value of 120 m min the system delay in programming without compensations would affect the application as follows The lighter application area means that the adhesive once it reaches the end of the box would fall on the machine The bead has been moved delay at start and its length has been increased delay at end With the values entered into the programming of the activation and deactivation compensations this effect must be annulled It has already been said that the values are given for reference purposes so they will probably have to be adjusted Let us assume a start and end delay effect as shown in the figure ME 96 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual We access the compensation screen see previous pages Press 1 and ENTER If the bead delays its start this is because the value entered is less than the real delay Let us increase the value for example to 100 Remember 100 10 0 ms Then with the gt and lt 4 keys go to the data to be modified in this case ON1 and press 1 0 0 and ENTER to memorise the value The result is now a correct start but a greater leng
49. e Meler Gluing Solutions S A Vers 1 11 240414 ME 73 106 star Programmer Manual Examples manual It is not necessary to program more data Several boxes are tested with this programming and the application and delay values are set in each case ME 74 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual 1 3 Spotting examples Bookbinding 1 3 1 Description The joint or groove application is a technique used in binding to achieve a better finish when gluing the end leaf to the book covers for these to open easily This application is made with a longitudinal bead all along the book and at times in bead spotting format with the subsequent adhesive saving The parameters defined in a standard installation may be as follows Distance from photocell to gun nozzle 30 mm Book length 300 mm Distance between books 100 mm Approximate belt speed 60 m min Pattern activation two 2 applications with two 2 solenoid valves one for each side of the book Bead delay 5 mm the value to be programmed will be the delay value plus the distance between the photocell and gun that is 5 30 35 Bead length 290 mm This bead will be intermittent with 10 mm spots and a pitch start to start between them of 20 mm The spot must be programmed in tenths of a millisecond therefore at 60 m min 1mm is equal to 1 ms 100 will be the value to be progra
50. e of the system must be followed The periodicity of this care depends on the time of use on the environmental conditions and on possible external aggressions friction splashes of adhesive contact with high temperature areas etc As a general rule it is advisable to carry out a visual inspection once a month 5 1 Outside cleaning To keep the outside of the programmer clean clean the equipment with a soft cloth slightly moistened with water Do not use solvents turpentine benzene etc which may deteriorate the equipment surface AN Before carrying out any intervention to the equipment switch it off and unplug the power supply lead 5 2 Care of connection leads Keep the equipment power supply lead in perfect conditions Replace it ref 16020001 if any deterioration is observed Also keep the leads of peripherals guns photocells encoder etc in excellent conditions Replace them if any damage to them is observed consult spare parts references A Respect the type and section of the leads replaced Not doing so may lead to serious damage to the equipment or to the people handling it MU 26 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual User s manual 5 3 Care of peripheral elemenis Clean the optic lens of the photocell with a soft cloth without scratching it Readjust its sensitivity if necessary Keep the support joints of the encoder on the belt
51. e up it will look like this This example is used to illustrate the way in which the encoder setting can be programmed In general when the encoder supplied by meler is used and it is installed at a point that moves at the speed of the box the ratio between impulses and movement is equal to 1 1 that is each encoder impulse represents a displacement of the box of one millimetre Thus the values programmed are real values in millimetres However at times the encoder may have another number of impulses or it has been installed in a place where its displacement related to the displacement of the box is unknown In these cases it is essential to use the encoder setting function See the example the following parameters are defined in the installation Distance from photocell to gun nozzle 30 mm Box length 200 mm Distance between boxes 50 mm Approximate belt soeed 60 m min Meler Gluing Solutions S A Vers 1 11 240414 ME 99 106 star Programmer Manual Examples manual Pattern activation two 2 applications with one single solenoid vale Delay of first bead 5 mm the value to be programmed will be the delay plus the distance between photocell and gun that is 5 30 35 Length of first bead 20 mm Delay of second bead 175 mm the value to be programmed will be the delay plus the distance between photocell and gun that is 175 30 205 Length of second bead 20 mm A box detection photocell will b
52. e used which will be connected in input 1 of the programmer An encoder will be used to control the speed of the belt conveyor belt to set the parameters in millimetres One of the programmer outputs number 1 will be used to apply the beads At a speed of 60 m min 1 millimetre is equal to 1 millisecond Therefore the conversion between both units is 1 1 The bead to be deposited is 20 mm which means according to the previous ratio an application of 20 milliseconds Given the response times of the injector system between 5 and 10 ms we should have no problem in achieving the length of 20 mm at speeds of 60 m min The activation and deactivation compensations for a standard system gun with double acting injector and 24 Vcc 12 7 W solenoid value will be 9 5 and 11 ms respectively 9 These values are for reference purposes based on tests carried out under certain conditions Any change to those conditions temperatures adhesives control elements etc may make these values vary Summary of parameters to be programmed Programming by encoder Assignment of photocell 1 to output 1 output 1 connector 1 A bead D1 delay 35 L1 activation 20 D2 205 Compensation times output 1 ON 95 OFF 110 1 7 2 Connections The programmer will have the following connections Connection of the power supply of the star programmer ME 100 106 Fd 1 11 240414 Meler Gluing Solu
53. ect the boxes connected in the input 1 of the programmer An encoder will be used to control the box conveyor belt speed to set the parameters in millimetres A programmer output number 1 will be used to apply the bead Meler Gluing Solutions S A Vers 1 11 240414 ME 81 106 star Programmer Manual Examples manual Summary of parameters to be programmed Programming by encoder Assignment of photocell 1 to output 1 output 1 connector 1 A bead D delay 15 L activation 230 Cycle security 255 5 mm greater than the length of the box Compensation times output 1 ON 95 OFF 110 1 4 2 Connections The programmer will have the following connections Photocell and encoder connection Output connection for solenoid valve 1A 1 4 3 Programming operating system The parameters will be programmed in program 8 Turn the programmer on with the switch located on the front panel After the presentation screens the password entry screen will appear Enter password 000 by default The first user level screen appears From the main menu any of the twenty 20 possible programs that the star program has can be selected ME 82 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual To do so press 1 and ENTER and the screen to enter the desired program will appear By default the last program selected will flash on and off e g 3
54. ediately displayed 80 m min After setting this value the operation is repeated for the minimum working speed value 40 m min For example we enter 2 8 2 8 V and press ENTER The speed it is working at and for which the voltage value has been set is immediately displayed 40 m min AN Speed values cannot be entered These values appear automatically when ENTER is pressed after having entered a voltage value The final situation expressed in a graph would be as follows rpm bar y 100 6 4 OW gi 65 28 Meler Gluing Solutions S A Vers 1 11 240414 ME 91 106 star Programmer Manual Examples manual 1 6 Compensation application Longitudinal bead 1 6 1 Description The longitudinal bead is used in any case type box to form the box before it is filled and later sealed A bead of adhesive is applied to one of the flaps which is glued to the opposite end thus forming the box lt a The application is simple its difficulty lies in the fact that these cases are usually processed at high and variable machine speeds around 120 to 150 m min Under these conditions the accuracy of the application is essential and it is not possible for the bead to move due to variations in the machine speed For these cases the correct use of the delay compensation function of the system is essential The parameters defined in a standard installation may be as follows Distance from photocell to gun n
55. en the star programmer is turned on a phone number appears to contact the meler Technical Service This number corresponds to the head offices in Spain The contact number can be changed depending on the Country or Autonomous community in the case of Spain where it is used This means that the user always has the phone of the nearest Technical Service and can contact them immediately On the Restricted menu submenu press 3 and ENTER Meler Gluing Solutions S A Vers 1 11 240414 MP 53 106 star Programmer manual Programming Manual The screen to enter the new number will appear Enter the desired number with the numerical keys and press ENTER to confirm E g 00390542358731 Press ENTER to change the number to the new one entered This number is fictitious and does not respond to any Technical Service of meler 3 4 Change High Voltage Time To speed up the application gun opening and closing response times the voltage signal of the output channels is not a 24 Vcc amplitude rectangular wave There is an initial high voltage peak of limited duration and programmable and a maintenance voltage below the rated 24 Vcc F4 High voltage De Rated voltage Maintenance voltage Dey 7 y Oe aA i High voltage time 2 e bkm NN we i Cycle time A
56. es manual Press V to access the position to enter the application length With numerical keys enter 2 3 0 Press V to access the position to enter the next delay corresponding to the second application A value automatically appears in this position As aid the programmer indicates the minimum value that can be entered in this position It corresponds to the sum of the two previous values 15 230 adding one unit to it This value is only valid for reference In our case we are not going to enter any value so press ENTER to confirm the data entered The value of the second delay disappears and the data entered remains stored in the memory Press ESC twice to go to the initial screen Press 6 and ENTER The compensation values assignment screen Press 1 and ENTER We have to enter the delay compensation values mentioned above expressed in tenths of a millisecond 9 5 ms 95 So with the gt and lt keys go to the data to be modified in this case ON1 and press 9 5 and ENTER to memorise the value Press ESC 2 and ENTER to access the deactivation data Remember enter the delay values expressed in tenths of a millisecond 11 ms 110 So with the DJ and lt keys go to the data to be modified in this case OFF1 and press 1 1 0 and ENTER to memorise the value It is not necessary to program more data With these parameters we will obtain the application
57. esnennensensenennences 58 IG 4 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual General contenis Examples manual 1 PROGRAMMING EXAMPLES m mmmmmmmmmmmmmmmmm mmm mmm 63 1 1 Timer mode application Container labelling 63 1 1 1 Description 922 n nnn nnn nn nnn nn nnn nnn nnn nnn nnn nnn nnn mmm 63 1 1 2 Connections 65 1 1 3 Programming operating method 65 1 2 Encoder mode application Lockbottom Carton 2 20 02200 2000e20ee200200 68 1 2 1 Description 22 n nnn nnn nn nnn nnn nn nnn nnn nnn nnn nnn nnn mmm 68 1 2 2 Connections 70 1 2 3 Programming operating method 71 1 3 Spotting example Bookbinding 0 02 002 00022 2 5 75 1 3 1 Description
58. f the four lines of the channel selected are displayed on the screen 2 3 Output channel functions Just like the functions that are common to the whole program have been described in section 2 2 Program functions in this section the functions that are specific for each channel are going to be described and which therefore can be programmed differently for each one of them 2 3 1 Delay of each line The pattern values screen has already been shown in section 2 2 6 Select output channel Here four sets of dots appear placed in two rows where the values corresponding to four possible patterns of a program can be entered A This screen is accessed from the program selection in the first place with the pattern secondly and later with the select output channel The delay of a line or strip of adhesive applied is given by the position where you wish to start the application of the relative line As the photocell element that starts the cycle and the application gun element that supplies the adhesive are not usually in the same perpendicular with respect to the movement of the substrate this delay is increased by the length that separates both elements So a cardboard box for example on which you wish to start an application line 50 mm from the reading edge would have a delay value of 50 working in encoder mode if the photocell and the gun were in line As this is not possible in the
59. for reference In our case we are not going to enter any value so press ENTER to confirm the data entered The value of the third delay disappears and the data entered remains stored in the memory Press ESC to go to the channel selection screen Press ESC to go to the channel selection screen There are no more pattern data to be programmed Press ESC to access the main screen of program 10 ME 102 106 Ed 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Press 6 and ENTER The compensation values assignment screen will appear Press 1 and ENTER We have to enter the delay compensation values mentioned above expressed in tenths of a millisecond 9 5 ms 95 So with the gt and lt keys go to the data to be modified in this case ON1 and press 9 5 and ENTER to memorise the value Press ESC 2 and ENTER to access the deactivation data Remember enter the delay values express in tenths of a millisecond 11 ms 110 So with the gt and lt keys go to the data to be modified in this case OFF1 and press 1 1 0 and ENTER to memorise the value Press ESC to access the main screen of program 10 It is not necessary to program more data We press ESC three 3 times to go to the initial access screen 1 7 4 Encoder setting Examples manual The encode settings can be found in a restricted access menu see chap
60. g Solutions S A star Programmer Manual Examples manual 2 Programming menu tree Some pages are included in the Programming Manual see 4 which show all the screens of the star programmer and the access to each one them It is useful to have these sheets at hand when carrying out new programmings or as reference to access data that we wish to modify Meler Gluing Solutions S A Vers 1 11 240414 ME 105 106 star Programmer Manual 3 Compensation values table Examples manual The compensation values times expressed in tenths of a millisecond shown on the table below are given as guidance and are carried out in standard conditions Any variation to the installation conditions temperature or working pressure will affect the compensation values which must be adjusted GUN MODEL CONTROL TYPE ON COMP OFF COMP meler MDR 1 pneumatic 4 2 24Vcc 5 4 W 115 115 meler MDR 1 pneumatic 4 2 24Vcc 12 7 W 95 110 meler MDR 1 pneumatic 5 2 24Vcc 5 4 W 110 140 meler MDR 1 pneumatic 9 2 24Vcc 12 7 W 85 120 meler MSR 1 pneumatic 3 2 24Vcc 5 4 W 105 195 meler MSR 1 pneumatic 3 2 24Vcc 12 7 W 95 200 meler microprecision pneumatic 5 2 24Vcc 16 W 105 95 meler microprecision pneumatic 4 2 24Vcc 12 7 W 100 90 meler microprec adjustable pneumatic 5 2 24Vcc 12 7 W 95 105 Pafra Series 86 electric 110 60 Pafra Series 87 pneumatic 70 60 Pafra Series 88 pneumatic 85 60 Pafra Series 22 electric 40 35 65 Pafra
61. ge restricted password On the submenu screen Restricted menu press 1 and ENTER A new screen appears Enter the four new digits and press ENTER The cursor will go to the second bracket to confirm the password chosen MP 52 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual Enter the four digits again and press ENTER The password will automatically be registered The program returns to the previous screen If you make a mistake when entering the digits the invalidation screen appears Press ESC to return to the previous screen Take note of the new password and keep it in a place where it can be consulted if forgotten The programmer does not permit access if the correct password is not entered 3 2 See user password Contrary to that set out in section 2 1 1 Change password if the user password is lost or forgotten the process is not irreversible For authorised personnel those having the restricted password this negligence can be corrected recuperating the value of this password by reading the restricted menu On the screen of the Restricted menu submenu press 2 and ENTER The screen with the last user password memorised will appear factory programmed 000 A If the restricted password has been lost or forgotten contact the Technical Service of meler 3 3 Change contact phone number In the initial presentation wh
62. gram selected From the initial screen after selecting the desired program press 4 and ENTER The photocell assignment screen will appear T Trigger for each output channel O Output In channel 1 01 we will make the selection for photocell 1 Press ENTER to confirm Press ESC to return to the main menu Press 5 and ENTER The mode selection screen will appear The mode between brackets is the mode currently selected Just press ENTER to change from one working mode to another The selection of the example is Encoder Press ESC to go to the main menu From the initial screen after selecting the desired program press 1 and ENTER The channel selection screen will appear With the gt and lt keys select channel 1 and press ENTER In this channel we are going to enter the application data for the longest bead Remember 50 delay and 120 application length With the numerical keys enter 5 0 ME 94 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual Press V to access the position to enter the application length With numerical keys enter 1 2 0 Press V to access the position to enter the next delay corresponding to the second application A value automatically appears in this position As aid the programmer indicates the minimum value that can be entered in this position It corresponds to the sum of the two pre
63. has been selected The data is validated by selecting E and pressing ENTER Press ESC to go to the previous screen We repeat the steps for output 2 After programming the data we return to the initial screen f we now access the output selection menu 1 ENTER the letter S appears next to output 1 and 2 indicating that the spotting mode function has been activated for these two outputs Press ESC to access the main screen of the program Press 6 and ENTER The compensation values assignment screen will appear Press 1 and ENTER We have to enter the delay compensation values mentioned above expressed in tenths of a millisecond 9 5 ms 95 So with the gt and lt keys go to the data to be modified in this case ON1 and ON2 and press 9 5 and ENTER to memorise the value Meler Gluing Solutions S A Vers 1 11 240414 ME 79 106 star Programmer Manual Examples manual Press ESC 2 and ENTER to access the deactivation data Remember enter the delay values expressed in tenths of a millisecond 11 ms 110 So with the gt and lt keys go to the data to be modified in this case OFF 1 and OFF2 and press 1 1 0 and ENTER to memorise the value It is not necessary to program more data Several books are tested with this programming and the application and delay values are set as well as the spotting mode and compensation v
64. hot melt application points are indicated on the drawing in a lighter tone aca Once glued the box is folded for later assembly before being filled When assembling it press the sides from the side the base is automatically closed ME 68 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual The parameters defined in a standard installation may be as follows Distance from photocell to gun nozzle 0 mm in line Box length 255 mm Distance between boxes 80 mm Approximate speed of the belt 100 m min Pattern activation three 3 applications with three 3 solenoid valves Bead delay 1 100 mm Bead length 1 40 mm Bead delay 2 and 3 50 mm Bead length 2 and 3 15 mm ae ee ee ee ee ee m may am wf ee eee ees eee ee eee he ee oi oo eee ee eet m nade enn ethane m m m mm m ese ee ing ole ww nn nn na fn nn nn nnn nn lo wn nn nn on on nn nn nn on nn ne nn nn nn ee ew ee ne nnn nn nnn nen nnn nee A box detection photocell connected to input 1 will be used An encoder will be used to control the speed of the box conveyor belt to set the parameters in millimetres Three programmer outputs will be used number 1 for the longitudinal seal bead application bead 1 number 2 for the application of the first seal bead of the bottom flap bead 2 and number 3 for the second seal bead bead 3 The belt speed variation is assumed to be irrelevant
65. ibition signal Input for gun inhibition Input for photocells Output for guns Input for encoder Output for regulation 0 10 V two per channel Meler Gluing Solutions S A Vers 1 11 240414 MU 13 106 star Programmer manual User s manual 3 2 1 Output for guns The outputs for gun connection are grouped together two by two in each channel Thus for channel 1 there is output 1A and 1B for IA channel 2 2A and 2B and so on The connection is carried out with a four 4 threaded pins DIN connector To connect guns 1 Positive voltage signal 24 Vcc 33 V 10 V 2 Negative voltage signal 3 2 2 Input for photocells Up to two photocells can be connected in their relative connections so that each one of them controls the cycle start of different guns C E The connection is made with a four 4 threaded pins DIN connector To connect photocells 1 Positive voltage signal 15 Vcc 2 Negative voltage signal 3 Switch over signal type NPN 3 2 3 Input for encoder element to read the substrate movement speed This generator encoder is coupled to its relative connection When the encoder mode is used there must be a pulse generator Ke To connect the encoder 1 positive voltage signal 15 Vcc 2 negative voltage signal 3 switch over signal type NPN 3 2 4 Outout for regulation 0 10 V The Q 10 V signal is used to regulate the application pressure using a transducer
66. in question This value is entered on the same screen as the delays in the row defined as L L Length and it defines the real length of the line to be applied from start with the relative delay to finish Meler Gluing Solutions S A Vers 1 11 240414 MP 47 106 star Programmer manual Programming Manual In applications in encoder mode it will be sufficient to measure on the substrate to be glued the real application distance and transcribe it to the relative programming Each line length from 1 to 4 is independent from the other three and obviously it cannot be greater than the delay value of the next line Altogether regardless of whether 1 2 3 or 4 lines are programmed the total application value cannot exceed 9999 ms timer mode or 9999 mm encoder mode Any programming of lines delays and lengths must end by pressing ENTER for the programmer to memorise the data entered 2 3 3 Partially erase data In the normal programming process isolated data will logically have to be erased without having to access the general erase memory process For these cases there are two ways of erasing data partially The first case is when you wish to eliminate one line in a programming For example The last two lines programmed are intended to be erased With gt go to the delay of the line where you wish to eliminate data With the numerical keys enter a lower value than the initial delay 90
67. ing at a later time That is why the Erase memory function has been incorporated as it cancels the pattern data and selects default values in the other parameters From the initial screen after selecting the desired program press 7 and ENTER The erase screen of the selected program will appear Press ENTER to cancel the data of that program A screen informs us of the action taken Press ESC to quit the erase submenu The data of the erased program are cancelled and the other parameters become preset values Pattern values cancelled Selection of spotting mode channels cancelled Assignment of photocells to 1 Preset security of cycle value Preset control mode Preset cycle continues The spotting mode values do not undergo any modification and they remain programmed However the spotting mode has no effect when all the channel or line selections are cancelled with the function of Erase memory The compensation values and the 0 10 V output values remain unaltered Meler Gluing Solutions S A Vers 1 11 240414 MP 45 106 star Programmer manual Programming Manual 2 2 6 Select output channel From the initial screen after selecting the desired program press 1 and ENTER The channel selection screen will appear With keys DJ and lt q select the channel and press ENTER The data if any of the delay values D Delay and the pattern length L Length for each one o
68. ion A value automatically appears in this position As aid the programmer indicates the minimum value that can be entered in this position It corresponds to the sum of the two previous values 35 290 adding one unit to it This value is only valid for reference In our case we are not going to enter any value so press ENTER to confirm the data entered The value of the second delay disappears and the data entered remains stored in the memory Press ESC to go to the channel selection screen ME 78 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual With the gt key we select output 2 and we press ENTER We repeat the previous steps as the bead must be the same unless there are adjustments After programming the data we return to the initial screen Press 2 and ENTER The spotting mode screen is reached A different spotting mode can be selected for each channel For channel 1 with the gt key we select output 1 and we press ENTER The values to be programmed are S 100 and P 20 With the numerical keys enter 1 0 0 With the DJ key select parameter P and enter the value 2 0 As each programmer output can apply up to four 4 strips of adhesive the strip or strips we wish to spot must be selected In this case only one strip With gt select L1 and press ENTER An asterisk will appear next to the selection indicating that it
69. justment screw can be used In clockwise direction the sensitivity increases In the opposite direction it decreases In the case of the photocell for optical fibre ref 27000002 apply the teach key and follow the procedure If the photocell must be placed in the opposite position with the lens upwards prevent any light from the main machine installation falling upon it Although the photocells detect infrared light some fluorescent lights might activate them accidentally In hot melt application systems do not place the photocell very close to the guns The heat that these give off may affect and even destroy them The distance between the photocell and the gun in the substrate displacement line is a determining factor when applying certain formats at certain machine speeds The recommendations to avoid problems with this position are described in the Programming manual The installation can be started with a distance of 50 mm sufficient in the majority of the applications 4 4 2 Encoder The encoder ref 25010007 must be placed in a position where it can read the substrate displacement speed Avoid placing it on transfers or pressure accumulator belts controlled by NOK other motors than that of the main belt Do not place the encoder on tension wheels of the contact area At those points the belt undergoes tensions that modify its speed with respect to the rest of the belt MU 22 106
70. lines Spotting values per output channel Activate spotting mode per line Partially erase data Compensation values meler Z nHoE Baa Mlele ole AN MP 36 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual 2 User level The user level programming can be accessed by entering the relative password on the initial screen after the presentation screens see section 3 7 Front panel in the User manual The password is a three figure number that the user can choose using the Change password function see section 2 7 1 Change password of this manual The default option defined in factory is O00 AN If the password is changed the new one must be noted down and kept in a safe and known place Enter password 000 The first user level screen appears 2 1 Common functions The common functions of the programmer can be accessed from this first screen We press the numerical key 2 and ENTER to enter the Utilities submenu The submenu screen appears with the first selection The arrow to the right on the right hand side indicates that there are other options on successive screens Press V to be able to advance to other available options V Y The arrow to the left on the right hand side of the screen indicates that there are other options on previous screens Press A to be able to return to other available option
71. m selected will flash on and off e g 3 Meler Gluing Solutions S A Vers 1 11 240414 ME 77 106 star Programmer Manual To select the program of example 1 press 1 and ENTER The screen will show the menu of the program selected mM D V D 3 lt From the initial screen after selecting the desired program press 4 and ENTER The photocell assignment screen will appear T Trigger for each output channel O Output In channel 1 and 2 01 O2 we will make the selection for photocell 1 Pulsar ENTER to confirm Press ESC to return to the main menu Press 5 and ENTER The mode selection screen will appear The mode between brackets is the mode currently selected Just press ENTER to change from one working mode to another The selection of the example is Encoder Press ESC to go to the main menu From the initial screen after selecting the desired program press 1 and ENTER The channel selection screen will appear With the gt and lt keys select channel 1 and press ENTER In this channel we are going to enter the application data for bead no 1 Remember 35 delay and 290 application length With the numerical keys enter 3 5 Press V to access the position to enter the application length With numerical keys enter 2 9 0 Press V to access the position to enter the next delay corresponding to the second applicat
72. meler GLUING SOLUTIONS star PROGRAMMER INSTRUCTIONS MANUAL MA 5028 ENG vers 1 11 240414 star Programmer manual General contenis General contenis User manual 1 INTRODUCTION mmm mmm mmm mmm mmm mmm 9 1 1 Definition of equipment 2 2 n 9 1 2 Regulations 2 22 2 nen n nnn nnnnn nnn nn nnn nese nn sneer nnn nnn 9 1 3 Warnings on risk prevention 92 nn nnn nn nnn n nn nn nnn nnn nn nnn nnn nn ennnnnennnnens 9 2 TECHNICAL SPECIFICATIONS mmm mmm mmm mmm mmm 11 3 DESCRIPTION OF PROGRAMMER mmmmmmmmmmmm mmm mmm mmm mmm 12 3 1 Front panel 2 2 nn nnn nnn 12 3 2 CONNECHIONS 9 22 22 mmm nena nnn nnn nnn aa 13 3 2 1 Output for guns 14 3 2 2 Input for photocells 14 3 2 3 Input for encoder 14 3 2 4 0 10 V adjustment output 14 3 2 5 Input for gun inhibition
73. mmed A photocell will be used to detect the books and which will be connected in input 1 of the programmer An encoder will be used to control the speed of the book conveyor belt to set the parameters in millimetres Meler Gluing Solutions S A Vers 1 11 240414 ME 75 106 star Programmer Manual Examples manual Two programmer outputs will be used number 1 for the application of the bead on the left hand side of the book and number 2 for the application of the bead on the right hand side of the book The belt speed variation belt is assumed to be irrelevant for the purpose of the application thickness so 0 10V signal is not used The activation and deactivation delays compensation function will be used At a speed of 600m min a millimetre represents 1 millisecond Therefore the conversion between both units is 1 1 The spot to be deposited is 10 mm which means according to the previous ratio a application of 10 milliseconds Given the response times of the injection system between 5 and 10 ms we should have no problem in achieving the length of 10 mm at a speed of 60 m min The activation and deactivation compensations for a standard system gun with a double acting injector and 24 Vcc 12 7 W solenoid will be 9 5 and 11 ms respectively These are reference values based on tests carried out under certain conditions Any change to those conditions temperatures adhesives control elements
74. mmer Manual Press ESC to go to the main menu From the initial screen after selecting the desired program press 1 and ENTER The channel selection screen will appear With the gt and lt keys select channel 1 and press ENTER In this channel we are going to enter the application data for the longest bead Remember 35 delay and 20 application length With the numerical keys enter 3 5 Press V to access the position to enter the application length With numerical keys enter 2 0 Press V to access the position to enter the next delay corresponding to the second application A value automatically appears in this position As aid the programmer indicates the minimum value that can be entered in this position It m O D V 3 D 3 lt corresponds to the sum of the two previous values 30 20 adding one unit to it This value is only valid for reference In our case the value to enter is 205 With the numerical keys enter 2 0 5 Press V to access the position to enter the application length With numerical keys enter 2 0 Press V to access the position to enter the next delay corresponding to the third application A value automatically appears in this position As aid the programmer indicates the minimum value that can be entered in this position It corresponds to the sum of the two previous values 205 20 adding one unit to it This value is only valid
75. n of adhesive D delay 85 L activation 15 output 2 connector 2 A swirl air D delay 75 L activation 25 1 1 2 Connections The programmer will have the following connections Connection of the power supply of the star programmer Output connection for solenoid valves 1A and 2A 1 1 3 Programming operating system The parameters will be programmed in program 1 Turn the programmer on using the switch situated on the front panel After the presentation screens the password entry screen will appear Enter password 000 by default The first user level screen appears From the main menu any of the twenty 20 possible programs of the star programmer can be selected To do so press key 1 and ENTER and the screen to enter the desired program appears By default the last program selected will appear e g 5 Meler Gluing Solutions S A Vers 1 11 240414 ME 65 106 star Programmer Manual To select the program of example 1 press 1 and ENTER The screen will show the menu of the selected program mM O D V a D 3 From the initial screen and after selecting the desired program press 4 and ENTER The photocell assignment screen will appear T Trigger for each output channel O Output In channel 1 and 2 01 O2 we will make the selection for photocell 1 Press ENTER to confirm From the initial screen after selecting the desired program
76. nd edge for it to be finally attached The schematic layout of the application may be as expressed in the figure TRANSFER BELT CONTAINER TIN REAL MOVEMENT OF TIN SWIRL GUN Meler Gluing Solutions S A Vers 1 11 240414 ME 63 106 star Programmer Manual Examples manual The application on the container will try to achieve due to the characteristics of the tin used three spiral or swirl spots centred on the side surface The parameters defined in a standard installation may be as follows Distance from photocell to gun nozzle 50 mm Tin diameter 70 mm Approximate belt soeed 60 m min Pattern activation three 3 applications with one 1 single solenoid valve Swirl air activation with independent signal solenoid valve Analysing the data and if some rapid calculations are made we will obtain A photocell will be used to detect the tin connected in input 1 of the star programmer Encoder will not be used for the reasons set out at the beginning of this chapter Two programmer outputs will be used number 1 for the adhesive applications common solenoid valve for the three applications and number 2 for the swirl air As the application is carried out at fixed speed the 0 10 V signal is not used The inhibition input of the guns must be used to prevent undesired applications due to the accidental activation of the photocell A switch can be placed on the actual machine control to i
77. ne is marked with an asterisk If you wish to annul any selection with gt and lt d go to the line that you wish to cancel and press ENTER In this way the asterisk marking it will disappear To confirm and memorise the data go to letter E situated between brackets and press ENTER Quit the submenu by pressing ESC Application of four lines WITHOUT spotting D4 ee i L 4 HL _ NN D2 D1 iman U U S eee eee L1 L2 L3 L4 re T A n eee T M m a a aaa T 7 re es 4 Meler Gluing Solutions S A Vers 1 11 240414 MP 49 106 star Programmer manual Programming Manual Application of four lines WITH spotting at L2 and L3 Spotting parameters S and P 2 3 5 Compensation values of each channel The compensation values are used to correct the delay effect produced between the moment when the programmer gives the order to activate or deactivate the output channels and the moment when the application system executes this order This delay is due to multiple factors such as the type of activation electrical or pneumatic the activation force voltage or air pressure viscosity of adhesive used pattern height adhesive output diameter etc When the installation is defined this value is constant in time until any of the factors mentioned above are changed On being a dela
78. nhibit the outputs At a speed of 60m min one millimetre means one millisecond Therefore the conversion between both units is 1 1 The application delay to be programmed will be 85 mm 50 70 2 that is 85 ms An injection system solenoid valve and injector module in non continuous applications takes between 5 and 10 ms to carry out a complete cycle opening and closing A minimum time is required for the O application in order to achieve the greatest possible swirl concentration see drawing For example the application to be programmed may initially be 15 ms For the swirl to be effective both at the start prevent drops of adhesive and at the end threads in the machines of the application the swirl air must be programmed so that it is activated a short time before the adhesive is applied and is deactivated shortly afterwards Thus the delay of the swirl air activation may be 75 ms and the activation time 25 ms 10 ms before the start of the application and 10 ms after this has finished In applications made in Timer mode the programming of compensations has no effect as it lacks an element the encoder which enables us to know the line speed of the machine ME 64 106 Ed 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual Summary of parameters to be programmed Programming by timer Assignment of photocell 1 to outputs 1 and 2 output 1 connector 1 A applicatio
79. ntrol mode Cycle continues You can work in two different modes with the star programmer in timer mode with programming in milliseconds it acts as a timer and in encoder mode with programming in millimetres it acts as an impulse counter In this second case a second screen enables you to select if in the case of a machine stoppage the cycle should be annulled and a new one should start with a new photocell detection Cycle continues NO or on the contrary it is stored in memory so that it can end when the machine starts up again Cycle continues YES From the initial screen after selecting the desired program press 5 and ENTER The mode selection screen will appear The mode between brackets is the mode currently selected Just press ENTER to change from one working mode to another MP 44 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual With the gt key you go to the next screen where the cycle continues mode is selected in the same way as the working mode Just press ENTER to change from Yes cycle continues to No cycle continues and vice versa 2 2 5 Erase memory Sometimes the data contained in a program can be obsolete or not valid for any job to be carried out Erasing each one of the data independently is an insecure and tiresome task as you may forget to cancel parameters that may lead to erroneous programm
80. ozzle 30 mm Box length 160 mm Distance between boxes 40 mm Approximate belt soeed between 120 m min and 150 20 Pattern activation one 1 application with one 1 solenoid valve Bead delay 20 mm the value to be programmed will be the delay plus the distance between photocell and gun that is 20 30 50 Bead length 120 mm ME 92 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual A photocell will be used to detect the boxes which is connected in input 1 of the programmer An encode will be used to control the sped of the box conveyor belt to set the parameters in millimetres One of the programmer outputs will be used number 1 At a speed of 120 m min 1 millimetre is equal to 0 5 milliseconds 1 millisecond is equal to 2 mm Therefore the conversion between both units is 1 0 5 At a speed of 150 m min 1 millimetre is equal to 0 4 milliseconds 1 millisecond is equal to 2 5 mm Therefore the conversion between both units is 1 0 4 The bead to be deposited is 120 mm which means according to the previous ratios an application of between 48 and 60 milliseconds Given the response times of the injector system between 5 and 10 ms we should have no problem in achieving the length of 120 mm at speeds of 120 150 m min The activation and deactivation compensations for a standard system gun with double acting injector and 24 Vcc 12 7 W solenoid valve will
81. photocell Cycle security in the Programming Manual We enter a value corresponding to the length of the box 255 mm plus 5mm This value must never exceed the sum of the length of the box 255 mm and the space between this and the next one 80 mm Press 2 6 0 255 5 and ENTER to memorise the value Press ESC to return to the main menu Press 5 and ENTER The mode selection screen will appear The mode between brackets is the mode currently selected Just press ENTER to change from one working mode to another The selection of the example is Encoder Press ESC to go to the main menu Meler Gluing Solutions S A Vers 1 11 240414 1106 star Programmer Manual Examples manual From the initial screen after selecting the desired program press 1 and ENTER The channel selection screen will appear With the gt and lt q keys select channel 1 and press ENTER In this channel we are going to enter the application data for bead 1 Remember 100 delay and 40 application length With the numerical keys enter 1 0 0 Press V to go to the position to enter the application time With the numerical keys enter 4 0 Press V to go to the position to enter the next delay corresponding to the second application A value automatically appears in this position As aid the programmer indicates the minimum value that can be entered in this position It corresponds
82. press 5 Control mode and ENTER The mode selection screen will appear The mode between brackets is the mode currently selected Just press ENTER to change from one working mode to another The selection of the example is Time Press ESC to go to the main menu From the initial screen after selecting the desired program press 1 Pattern and ENTER The channel selection screen will appear With keys DJ and lt q select channel 1 and press ENTER In this channel we are going to enter the adhesive pattern data Remember delay 85 and application time 15 With the numerical keys enter 8 5 Press V to access the application time entry position With the numerical keys enter 1 5 Press V to access the position to enter the next delay corresponding to the second application In this position a value appears automatically As aid the programmer indicates the minimum value that can be entered in this position It corresponds to the sum of the two previous values 85 15 adding one unit to it This value is only valid as reference In our case we are not going to enter any value So we press ENTER to confirm the data entered The value of the second delay disappears and the data entered are stored in the memory Press ESC to quit the channel selection screen With key gt we select output 2 and we press ENTER ME 66 106 Fd 1 11 240414 Meler Gluing Solution
83. put number 1 Press the gt key to access the Production quant which indicates the pieces per hour detected by the photocell connected to input number 2 Press the gt key to access the Total production screen which indicates the total pieces detected by the photocell connected to input number 1 from the last time the counter was erased Letter R permits resetting the counter pressing ENTER Press the gt key to access the Total production screen which indicates the total pieces detected by the photocell connected to input number 2 from the last time the counter was erased Letter R permits resetting the counter pressing ENTER By pressing ESC on any of the screens you can access the initial screen 2 1 5 Select program From the main menu you can select any of the twenty 20 possible programs that the star programmer incorporates To do so press key 1 and ENTER and the introduction screen of the desired program will appear By default the last program selected will appear flashing on and off e g 5 To select another program e g 8 press 8 and ENTER The screen will show the menu of the selected program Once you have chosen the program this becomes the active program the one which is executed and also the edited program permits carrying out settings and changes to the parameters of this program Meler Gluing Solutions S A Vers 1 11 240414 MP 41 106 star P
84. ress 6 and ENTER The programmer will immediately present the screen with the translation in the language chosen 2 1 3 Manual activation Purge pressure Manual activation permits directly activating and deactivating each one of the four output channels by pressing the ENTER key Itis possible select one or more guns to carry out this function It is also possible on a second screen to select the 0 10 V signal corresponding to the pressure with which the output channels are going to be activated in a system with proportional regulation of the application pressure On the Utilities submenu screen press 3 and ENTER The channel selection screen will appear as well as their activation deactivation The cursor will flash on channel number 1 If you press the ENTER key this channel is selected to be activated deactivated An asterisk will appear next to the channel number indicating that this has been selected For example select channel 3 With the gt arrow go to number 3 and press the ENTER key Channel 3 is selected As many channels as you wish can be selected with this Meler Gluing Solutions S A Vers 1 11 240414 MP 39 106 star Programmer manual Programming Manual procedure To eliminate the selection do the same with the numbers that already have an asterisk After selecting the channels to activate deactivate them the cursor must be placed with the gt arrow on the position
85. rmly screw in the check nut Make sure that each peripheral is connected into its relative place MU 20 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual User s manual 4 4 Location of the peripheral elements For the system to work perfectly it is advisable to place the photocell so that it detects the substrate correctly without false readings and enabling the hot melt to be applied from the start of the actual substrate The positioning and length of the application lines and their precision independent from the changes in speed of the machine mean that certain considerations must be taken into account when situating the encoder avoiding erroneous readings or displacement of the wheel on the substrate displacement belt 4 4 1 Photocell The photocells must be placed so that it detects the substrate to be glued but when this is not present there must not be any reflecting surface that might activate it The actual detection distance of each photocell must be taken into account and its activation margin respected There must be a clear contrast between the substrate to be detected and the absence of this substrate For example a white surface could be detected if when this is not present the existing surface were to be black Meler Gluing Solutions S A Vers 1 11 240414 MU 21 106 star Programmer manual User s manual To adjust the sensitivity of the photocell ref 27000001 the ad
86. rogrammer manual Programming Manual 2 2 Program functions For each program number once selected according to the procedure described in section 2 1 5 Select program there are some functions defined globally regardless of which channel or channels are being used Press the W key to access the successive screens of the menu Y Y Y Y Y Y 2 2 1 Select spotting mode per channel From the initial screen after selecting the desired program press 2 and ENTER The channel selection screen to apply the spotting mode will appear The cursor will flash on channel number 1 If you press ENTER this channel is selected to program the spotting parameters see section 2 3 4 Spotting parameters Spotting activation by line With the gt and lt 4 keys you can select the desired channel After positioning the cursor press ENTER to access it MP 42 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual 2 2 2 Control values 0 10V This function is used when the installation includes a proportional application pressure regulator depending on the substrate displacement speed From the initial screen after selecting the desired program press 3 and ENTER The screen to select the 0 10V output values assigned to the maximum and minimum work speed will appear These two values generate a proportional voltage speed interpolation
87. rrectly only use original accessories and parts If you wish to use components of other makers consult the manufacturer This appliance is usually used with elements subject to high temperatures Prevent the connection leads from being damaged due to contact with these elements If the installation is going to be manipulated disconnect the appliance or use the built in output inhibition signal Possible untimely applications will be avoided Before the initial start up it is advisable to carefully read the installation and handling instructions contained in this manual It is also advisable to read the handling instructions of the Main Unit or dispensing and pumping system that is going to be used Above all the warnings due to risks derived from high temperatures and pressure Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual User s manual 2 Technical specifications Power supply 230 Vac 50 Hz Output power 35 W channel Output voltage 24 Vcc 33 Vcc high voltage 10 Vcc maintenance Output 0 10 V 24 Vcc power supply 0 to 10 Vcc signal Photocell encoder 15 Vcc power supply 15 Vcc output NPN signal Channels 4 Guns per channel 2 A B Lines per channel 4 Photocells 2 Encoder 1 Channel inhibition 1 Maximum speed main machine 400 m min Minimum application speed 1 m min Programming range encoder 2 9999 mm Programming range times 2 9999 ms Programming toler
88. s Meler Gluing Solutions S A Vers 1 11 240414 MP 37 106 star Programmer manual Programming Manual 2 1 1 Ghange password On the screen of the Utilities submenu press 1 and ENTER A new screen appears Enter the three new digits and press ENTER The cursor will go to the second bracket for you to confirm the password chosen Enter the three digits again and press ENTER The password is automatically registered The program returns to the previous screen lf you make a mistake when typing the digits the invalidation screen appears Press ESC to return to the previous screen Take note of the new password and keep it in a place where you can consult it if you forget it The programmer does not permit access if the correct password is not entered 2 1 2 Select language The star programmer permits selecting the screen language from a list of 10 possibilities currently only seven of them have been activated On the Utilities submenu screen press 2 and ENTER The screen appears with the list of languages Press key V to be able to advance to other available options Y MP 38 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual Y Y Y The star programmer is factory selected in the Spanish language To select a new language press the relative number and ENTER For example to select the Dutch language P
89. s S A star Programmer Manual Examples manual In this channel we are going to enter the spiral shape or swirl air activation data Remember delay 75 and application time 25 With the numerical keys enter 7 5 Press V to access the position to enter the activation time With the numerical keys enter 2 5 Press V to access the position to enter the next delay corresponding to the second application The value appears automatically It corresponds to the sum of the two previous values 75 25 adding one unit to it This value is only valid as reference In our case we are not going to enter any value so we press ENTER to confirm the data entered The value of the second delay disappears and the data entered are stored in the memory Press ESC to go to the channel selection screen It is not necessary to program more data Several tins are tested with this programming and the application and delay values are set in each case Meler Gluing Solutions S A Vers 1 11 240414 ME 67 106 star Programmer Manual Examples manual 1 2 Application using the encoder Lockbottom carton 1 2 1 Description The lockbottom carton is a very common application when making boxes The lower part of a box is glued so that depending on the die casting of the box board when unfolded it is automatically made up and ready for filling Before being glued the box has a similar aspect to the one in the figure The
90. s and this is what will be considered in this example In the figure on the next page you can see a standard layout of multi strip nozzles and the resulting application on the box This example is used as stated in the title for the use of the 0 10V signal More information can be obtained about this function in the Programming Manual see chapter 2 2 2 0 10 Control values Meler Gluing Solutions S A Vers 1 11 240414 ME 85 106 star Programmer Manual Examples manual If inan multi strip application and in general for any application we obviously increase or decrease the machine speed the application beads are affected in two different ways J Q CM ELL in their length and position YUMYNNY VYN EN OEY in their thickness 1 l CE The first aspect is solved by the delay J il 4 compensations function see Programming Manual and its chapter 2 3 5 Compensation values of each channel already used in previous examples The second aspect is solved by using a pressure variator device proportional valve in piston equipment or by means of motor speed variators z for gearing equipment In both cases a set point signal is required which depending on the speed of the machine transmits the relative order to the variator to set the relative parameter pressure or soeed This necessar
91. st not be handled by the normal user but by experienced personnel 1 3 Programmable functions The programmable functions are grouped together as mentioned in section 1 1 Programming Concept into three differentiated groups Common general functions independent from the program used Change password User menu restricted menu Change language User menu Manual activation of outputs User menu Select purge pressure User menu Display production data User menu Line speed User menu Current production 1 and 2 User menu Total production 1 and 2 User menu Meler Gluing Solutions S A Vers 1 11 240414 MP 35 106 star Programmer manual Programming Manual Display user password Restricted menu Change service phone Restricted menu High voltage time setting Restricted menu Encoder setting Restricted menu Pulses per mm Restricted menu Product size Restricted menu Line speed Restricted menu Program selection User menu Program functions from the user menu assigned independently to each program Select output channel Select spotting mode per output channel Output values 0 10 V Assign photocell to each output channel Cycle security value for each photocell Select control mode Time or Encoder Select cycle continues Erase memory Output channel functions from user menu assigned independently to each output channel Delay of up to four application lines Length of up to four application
92. ter 3 Restricted level of the Programming manual Enter 0000 by defauli Access the main screen of this menu Press 5 and ENTER The encoder setting screen appears We are going to set this parameter using method number 3 produce size Press 3 and ENTER With the machine running make two consecutive boxes pass under the photocell Meler Gluing Solutions S A Vers 1 11 240414 ME 103 106 star Programmer Manual Examples manual Stop the machine immediately afterwards to have access to the box sizes later Press ENTER The pulses recorded between the start of one box and the start of the next are memorised and the following screen is displayed The box measures 200 mm long and the distance between boxes is 50 mm These values must be measured directly on the boxes that are used to measure the pulses AN The measurements must be as accurate as possible The accuracy of the pulse millimetre ratio depends on this and therefore the whole programme size control system Enter the measured value 2 5 0 When you press ENTER the screen of the previous menu appears again If we press 1 and ENTER we can display the resulting ratio 500 250 2 AN This setting must be made in the encoder installation and it remains in use until the number of pulses of the encoder or the position of the encoder in the machine are changed ME 104 106 Fd 1 11 240414 Meler Gluin
93. th as the deactivation compensation has not been modified AN If the bead start position is moved forward higher activation compensation values are advised If the start position is moved backward lower values are suggested 20 We access the compensations screen See previous pages Press 2 and ENTER If the bead delays its start this is because the value entered is less than the real delay Let us increase the value for example to 130 Remember 130 13 0 ms Then with the gt and lt 4 keys go to the data to be modified in this case ON1 and press 1 31 0 and ENTER to memorise the value Meler Gluing Solutions S A Vers 1 11 240414 ME 97 106 star Programmer Manual Examples manual The result is now a correct start and a correct end The compensation setting has ended and therefore if the speed is increased to 150 m min the result must be the same AN If the bead end position is moved forward higher activation compensation values are advised If the end position is moved backward lower values are suggested ME 98 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual 1 7 Encode setting Four corners 1 7 1 Description The four corner application is used when making up base lid type boxes shirts shoes etc With the injector guns two strips are applied on each side to glue the four corners Once the box has been glued and mad
94. tion 90 output 4 connector 4 A upp small bead D1 delay 30 L1 activation 12 D2 108 L2 12 Compensation times output 1 ON 95 OFF 110 output 2 ON 95 OFF 110 output 3 ON 95 OFF 110 output 4 ON 95 OFF 110 1 5 2 Connections The programmer will have the following connections Connection of the power supply of the star programmer Connection of two photocells upper connectors Connection of encoder and 0 10V signal ower connectors Meler Gluing Solutions S A Vers 1 11 240414 ME 87 106 star Programmer Manual Examples manual Output connectors for solenoid valves 1A 2A 3A 4A 5 ii T x F an gt POTE 4 We v4 Da pe v a z ir 1 5 3 Programming operating system The parameters will be programmed in program 3 Turn the programmer on with the switch located on the front panel After the presentation screens the password entry screen will appear Enter password 000 by default The first user level screen appears From the main menu any of the twenty 20 possible programs that the star program has can be selected To do so press 1 and ENTER and the screen to enter the desired program will appear By default the last program selected will flash on and off e g 1 To select the program of example 3 press 3 and ENTER The screen will show the menu of the program selected From the initial screen after selecting the desired program press 4 an
95. tions S A star Programmer Manual Examples manual Photocell and encoder connection Output connection for solenoid valve 1A 1 7 3 Programming operating system The parameters will be programmed in program 10 Turn the programmer on using the switch situated on the front panel After the presentation screens the password entry screen will appear Enter password 000 by default The first user level screen appears From the main menu any of the twenty 20 possible programs that the star program has can be selected To do so press 1 and ENTER and the screen to enter the desired program will appear By default the last program selected will flash on and off e g 1 To select the program of example 10 press 1 0 and ENTER The screen will show the menu of the program selected From the initial screen after selecting the desired program press 4 and ENTER The photocell assignment screen will appear T Trigger for each output channel O Output In channels 1 01 we will make the selection for photocell 1 Pulsar ENTER to confirm Press ESC to return to the main menu Press 5 and ENTER The mode selection screen will appear The mode between brackets is the mode currently selected Just press ENTER to change from one working mode to another The selection of the example is Encoder Meler Gluing Solutions S A Vers 1 11 240414 ME 101 106 star Progra
96. ve calculation so that if we consult the Set value screen it will appear automatically with the new value entered The more exact the measurements the more exact the calculation of the pulse mm ratio A will be 3 5 4 Line speed The third way of entering the pulse mm ratio value is by programming the substrate displacement line speed Using a tachometer this speed can be determined at the time of programming and it can be entered into the programmer so that this calculates this ratio by counting the encoder pulses On the Setting encoder submenu screen press 4 and ENTER The screen where the speed value is entered will appear Press ENTER to memorise the data The programmer makes the relative calculation so that if we consult the Set value screen it will appear automatically with the new value entered The more exact the measurements the more exact the calculation of the pulse mm ratio A will be Meler Gluing Solutions S A Vers 1 11 240414 MP 57 106 star Programmer manual Programming Manual 4 Programming menu tree All the screens of the star programmer are shown on the following pages as weli as the access to each one of them It is useful to have these pages at hand when programming or to consult about accessing data that we wish to change MP 58 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming Manual 1 ENTER 1 a 20 ENTER 1 ENTER
97. vious values 50 120 adding one unit to it This value is only valid for reference In our case we are not going to enter any value so press ENTER to confirm the data entered The value of the second delay disappears and the data entered remains stored in the memory Press ESC to go to the channel selection screen There are no more application data to be programmed Press ESC to access the main screen of program 3 Press 6 and ENTER The compensation values assignment screen will appear Press 1 and ENTER We have to enter the delay compensation values mentioned above expressed in tenths of a millisecond 9 5 ms 95 So with the gt and lt keys go to the data to be modified in this case ON1 and press 9 5 and ENTER to memorise the value Press ESC 2 and ENTER to access the deactivation data Remember enter the delay values express in tenths of a millisecond 11 ms 110 So with the gt and lt keys go to the data to be modified in this case OFF1 OFF2 OFF3 and OFF4 and press 1 1 0 and ENTER to memorise the value Press ESC to access the main screen of program 1 It is not necessary to enter more data With these parameters some boxes are tested at low speed e g 20 m min where the effect of the delays even without compensations is minimal You will probably wish to adjust the position and length of the bea
98. with another one of the same value if it has blown A For the equipment to work correctly it is essential to connect the electrical system earth tap 3 3 Peripheral elements There are different peripheral elements that can be connected to a star programmer Maintaining the order in which the connections of the previous chapter have been analysed we can define Meler Gluing Solutions S A Vers 1 11 240414 MU 15 106 star Programmer manual User s manual 3 3 1 Guns All the MAC solenoid valve controlled meler guns 24 Vcc version limited by the output power can be connected bead coating swirl or spray guns in their simple acting MS or double acting version MD microprecision and adjustable microprecision guns and compact series guns also in both the single MS or double acting MD versions Pafra guns for cold glue controlled by MAC solenoid valves 24 Vcc version limited by the output power guns series 87 and series 88 Pafra guns for cold glue controlled by electromagnet limited by output power guns series 86 and series 33 To connect any other type of guns consult with factory 3 3 2 Photocells Two types of photocells are supplied depending on the work to be carried out In the majority of the applications it is sufficient to use the reflection photocell directly onto the object ref 27000001 with threaded body M18x1 to make anchorage easy This has a sensitivity adjustment screw
99. y its value is expressed in tenths of a millisecond to achieve greater precision There is a delay for the activation and a delay for the deactivation which are independent and in the majority of the installations different The greatest advantage of using these values is due to the use of variable working speeds in a high percentage of machines As the delay is a fixed value this has greater incidence at high speeds than at low speeds so the application results without correction without compensation are very different and in the majority of the cases unacceptable If these values are suitably programmed the star programmer corrects these effects automatically so that when there are variations in the substrate speed the application positioning remains constant From the initial screen after selecting the desired program press 6 and ENTER The compensation selection screen will appear activation or deactivation Press the relative numerical key 1 or 2 and ENTER MP 50 106 Vers 1 11 240414 Meler Gluing Solutions S A star Programmer manual Programming manual For each output channel 1 2 3 or 4 we can assign a different delay value to be corrected in the activation activation compensation ON The same for the deactivation For each output channel 1 2 3 or 4 we can assign a different delay value to be corrected in the deactivation deactivation compensation OFF
100. y setting between machine speed T al a values and pressure values or applicator p a equipment rotation speed is carried out by the Output 0 10V function The parameters defined in an installation of this kind can be the following Distance from photocell to gun nozzle 25 mm Box length 100 mm Distance between boxes 100 mm Approximate belt soeed between 40 m min and 80 m min Pattern activation two 2 applications with two 2 solenoid valves for each gun lower seal upper seal Long bead delay 5 mm the value to be programmed will be the delay plus the distance between photocell and gun that is 5 25 30 Long bead length 90 mm Delay of first strip of small beads 5 mm value to be programmed 5 25 30 Length of first strip of small beads 12 mm Delay of second strip of small beads 83 mm value to be programmed 83 25 108 Length of second strip of small beads 12 mm Two photocells will be used to detect the boxes which are connected in inputs 1 and 2 of the programmer ME 86 106 Fd 1 11 240414 Meler Gluing Solutions S A star Programmer Manual Examples manual An encoder will be used to control the speed of the box conveyor belt to set the parameters in millimetres and for the 0 10V signal Four programmer outputs will be used number

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