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Meler STARBI Instruction Manual

Pattern controller
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GLUING SOLUTIONS
PATTERN
INSTRUCTIONS
MANUAL
CONTROLLER
STARBI
MA-5151-ENG 190919

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  • Page 1 GLUING SOLUTIONS PATTERN INSTRUCTIONS MANUAL CONTROLLER STARBI MA-5151-ENG 190919...
  • Page 2 The specifications and information contained in this manual may be modified without prior notice. This manual is a translation of the original that was written by Focke Meler Gluing Solutions, S. A. in spanish language. If there is any discrepancy between the different versions of this manual, the original written in the spanish language shall prevail.

  • Page 3: Table Of Contents

    Intended use Limited use 2. INTRODUCTION Description Intended use Basic terminology Mods of operation Controller identification Main components Rear connections StarBi 4-6 Outputs Lower connections StarBi 2 Outputs Additional components to the installation Applicators Incremental encoder Pressure regulator Controller bracket...
  • Page 4 Installation requirements Electrical consumption Unpacking Attaching the device Electrical installation Connection of the peripheral components (StarBi 4-6 Outputs) 1. Output for applicators 2. Input for Photocells 3. Input for encoder 4. Input for 0-10 V signal 5. Output for 0-10 V signal 6.
  • Page 5 TABLE OF CONTENTS MA-5151-ENG PATTERN CONTROLLER STARBI 4. USE Start-up and automatic process Manual change from RUNNING mode to STOPPED mode Automatic change from RUNNING mode to STOPPED mode Change from RUNNING mode to STOPPED mode by inhibit signal Temperature OK...
  • Page 6 TABLE OF CONTENTS 5. MANTENANCE General Outside cleaning Connection leads Calibrate the screen 6. TECHNICAL CHARACTERISTICS General Environmental conditions StarBi 2 channels dimensions StarBi 4/6 channels dimensions 7. ACCESSORIES AND SPARE PARTS LIST Spare parts Accessories EC DECLARATION OF CONFORMITY...

  • Page 7: Safety Guidelines

    SAFETY GUIDELINES MA-5151-ENG PATTERN CONTROLLER STARBI 1. SAFETY GUIDELINES General The information contained in this section applies not only to everyday equipment operation, but also to any procedure carried out on it, whether for preventive maintenance or in the case of repairs and the replacement of worn out parts.

  • Page 8: Electrical Components

    FOCKE MELER GLUING SOLUTIONS SAFETY GUIDELINES Electrical components The system works with single-phase of a certain power. Never handle the equipment with the power connected, as this may result in powerful electrical shocks. The installation must be correctly grounded. The installation’s power cable conductors must match the required electric current and voltage.

  • Page 9: Intended Use

    Note: Do not modify the equipment or use components that were not supplied by Focke Meler. For any modification of a component of the equipment or part of the installation, you must firstly consult the After-Sales Service...
  • Page 10 FOCKE MELER GLUING SOLUTIONS SAFETY GUIDELINES This page is intentionally left blank.

  • Page 11: Introduction

    PATTERN CONTROLLER STARBI 2. INTRODUCTION Description Focke Meler’s StarBi pattern controller is a control system for the dispensing and positioning of hot-melt or vinyl glue (cold glue) adhesives in gluing applications. This device has a place in any market related to industrial gluing with hot- melt or cold glue, such as labelling machines, box folding machines, wood lamination, bookbinding…...

  • Page 12: Basic Terminology

    FOCKE MELER GLUING SOLUTIONS INTRODUCTION Basic terminology Some of the terms used in the instruction manual are described below: Channel: pair of homologous outputs through which the activation signals are transmitted to the applicator. Cycle: period of time that includes the process of applying a product or substrate from the start to the end of it.

  • Page 13: Mods Of Operation

    INTRODUCTION MA-5151-ENG PATTERN CONTROLLER STARBI Mods of operation The pattern controller has two modes of operation: Manual mode: to enable purging, cleaning or depressurising of the installation or for checking the correct operation of the applicators. The selected outputs are activated by actuating the corresponding button. If the unit was working in automatic mode, it will be stopped when entering the MANUAL MODE screen.

  • Page 14: Main Components

    4. Button to stop or turn on the program (STOPPED to RUNNING/RUNNING to STOPPED). 5. GREEN LED unit turned on. 6. On/Off button on the screen. 7. Connection for power supply (StarBi 4-6 Outputs). 8. Power input fuse holder. 9. Electrical power supply switch.

  • Page 15: Rear Connections Starbi 4-6 Outputs

    INTRODUCTION MA-5151-ENG PATTERN CONTROLLER STARBI Rear connections StarBi 4-6 Outputs 1. Six inputs for photocells (according to model). 5. One input for encoder. 2. Six outputs for activation channels of solenoid valves, 6. Digital inputs (general inhibition and temperature OK).

  • Page 16: Lower Connections Starbi 2 Outputs

    FOCKE MELER GLUING SOLUTIONS INTRODUCTION Lower connections StarBi 2 Outputs 2 3 2 4 5 1. Input for photocells (PG13). 4. Analogue inputs/outputs (PG13). 2. Digital inputs/outputs (PG9). 5. Output for activation channels of solenoid valves, two per channel 3. Power input (PG13).

  • Page 17: Additional Components To The Installation

    PATTERN CONTROLLER STARBI Additional components to the installation Applicators All Focke Meler applicators controlled by 24 VDC solenoid valves (limited by the output power) can be connected. For other devices, consult the Central Office or your nearest Distributor. Detection systems The most suitable detection system (for presence of substrate or start of pattern) will be connected depending on the work to be carried out.

  • Page 18: Pressure Regulator

    Controller bracket The bracket must be requested separately and there are two types, wall- mounted for 4-6 outputs and articulated wall-mounted for two outputs. Vertical stand StraBi 2 outputs Articulated wall bracket StarBi 2 outputs StarBi wall bracket 4/6 outputs...

  • Page 19: Installation

    INSTALLATION MA-5151-ENG PATTERN CONTROLLER STARBI 3. INSTALLATION Warning: The pattern controllers are installed in equipment provided with current technologies and with certain foreseeable risks. Therefore, only qualified personnel with sufficient training and experience should be allowed to use, install or repair these devices.

  • Page 20: Unpacking

    Remove the pattern controller from its packaging and check for any possible damage or breakage. Communicate any damage, including to the external packaging, to your Focke Meler representative or the Focke Meler Main Office. Warning: Reject any packaging that does not have the corresponding labels or whose information does not match what was requested.
  • Page 21 Make sure that the characteristics of the network match the specifications of the device (see data in this manual and on the nameplate). StarBi 4-6 Outputs: Use the mounting flange of the power connector (supplied with the controller) to avoid false contact problems and the malfunctioning of the unit.

  • Page 22: Connection Of The Peripheral Components (Starbi 4-6 Outputs)

    FOCKE MELER GLUING SOLUTIONS INSTALLATION Connection of the peripheral components (StarBi 4-6 Outputs) 1. Output for applicators Double output per channel. Marked for each channel with the numbering 1.1 and 1.2 (channel 1); 2.1 and 2.2 (channel 2), and so on up to 6 channels.

  • Page 23: Input For Encoder

    INSTALLATION MA-5151-ENG PATTERN CONTROLLER STARBI 3. Input for encoder When using ‘speed reading’ (programming by DISTANCES) it is necessary to have a pulse generator component or analogue input of 0-10 V to know the speed of movement of the substrate.

  • Page 24: Input For General Inhibition And Temperature Ok

    FOCKE MELER GLUING SOLUTIONS INSTALLATION 6. Input for general inhibition and temperature OK The external input of ‘temperature ok’ (1) prevents the operation of the controller (it remains in STOPPED mode) while the working temperature, in an installation with hot-melt equipment, has not been reached.

  • Page 25: Additional Configuration

    INSTALLATION MA-5151-ENG PATTERN CONTROLLER STARBI Additional configuration Enable / disable temperature ok The option to ENABLE / DISABLE the temperature OK input has been added. This permits operation without connecting the melter used to send the signal when the correct temperature has been reached and operation with a cold glue unit.

  • Page 26: Connection Of The Peripheral Components (Starbi 2 Outputs)

    FOCKE MELER GLUING SOLUTIONS INSTALLATION Connection of the peripheral components (StarBi 2 Outputs) To connect the peripherals in the unit, it is necessary to pass the cable through the corresponding PG cable gland and connect it to the appropriate terminal.

  • Page 27: Location Of The Peripheral Components

    To use another type of photocell or presence of substrate sensor, consult your Focke Meler representative or the Focke Meler Main Office. Encoder The positioning and length of the lines of application and their precision,...

  • Page 28: Pressure Regulator

    (max. 10 bar), through a built-in filter of 5 µ. The VP-200 has a display that shows the existing pressure at any given moment. To connect other types of devices, consult your Focke Meler Representative or the Focke Meler Main Office. 3-10...

  • Page 29: Use

    MA-5151-ENG PATTERN CONTROLLER STARBI 4. USE This section explains how to use the pattern controller. Although its operation is very user-friendly, it should not be used by untrained personnel. Warning: Improper use may damage the unit itself or injure the person using it.

  • Page 30: Change From Running Mode To Stopped Mode By Inhibit Signal

    FOCKE MELER GLUING SOLUTIONS Change from RUNNING mode to STOPPED mode by inhibit signal If the ‘Enable inhibit signal’ option is connected and activated, you can switch RBI. between both modes from an external signal of a PLC or main machine (24 V ->...

  • Page 31: Operating Anomalies

    MA-5151-ENG PATTERN CONTROLLER STARBI Operating anomalies When the unit detects an anomalous situation, but not enough to switch to STOPPED mode, the YELLOW LED is activated. The GREEN LED stays on if the unit is in RUNNING mode. If the cause of the anomaly disappears, the YELLOW LED turns off and the unit continues in RUNNING mode.

  • Page 32: Save Changes

    FOCKE MELER GLUING SOLUTIONS Save changes The ‘SAVE CHANGES’ icon, located in the upper right part of the screen, appears in the data entry and programming screens. If the data shown on the screen is stored, the icon appears with a blue background. If the data has not been stored, the icon is shown with a green background.

  • Page 33: Description Of Screens

    MA-5151-ENG PATTERN CONTROLLER STARBI Description of screens 1. HOME screen. This is the start screen. When it starts, the system displays this screen with STARBI. the main data of the device. A- Name of the product selected to work. Access to ‘Product selection’.
  • Page 34 FOCKE MELER GLUING SOLUTIONS STARBI. 2. MENU screen. Menu Product Installation Manual mode Settings Statistics Alarms 3. INSTALLATION screen. To work with products by distances, it is necessary to determine an installation STARBI. STARBI. before starting. It is selected from the MENU screen.
  • Page 35 MA-5151-ENG PATTERN CONTROLLER STARBI 4. NEW INSTALLATION screen. After selecting NEW INSTALLATION a screen will open to enter the name; STARBI. STARBI. then go to the EDIT INSTALLATION screen. Installation New installation Installation 1 Edit installation installation Copy Delete installation...
  • Page 36 FOCKE MELER GLUING SOLUTIONS 6. EDIT SELECTED INSTALLATION screen. 6 tabs appear, one for each channel (EV). Each tab allows you to edit the distance between the applicator of that channel and each photocell. It also STARBI. allows you to set the ON and OFF compensation times of that applicator.
  • Page 37 MA-5151-ENG PATTERN CONTROLLER STARBI 8. ENCODER screen. There are 3 options to configure the encoder and only one of them can be ARBI. STARBI. active. Installation 2 Installation 2 Current information saved Saved pulses per meter 1285 Encoder Data for new configuration:...
  • Page 38 FOCKE MELER GLUING SOLUTIONS 9. ANALOGUE INPUT screen. The following screen will appear where you can configure a ramp with 5 dots, defining the conversion between input voltage and line speed. STARBI. STARBI. The maximum input voltage cannot exceed 10 V.
  • Page 39 MA-5151-ENG PATTERN CONTROLLER STARBI 10. COPY INSTALLATION screen. Select the installation to copy. A confirmation message will appear and then a screen will open to enter the name of the new installation. STARBI. STARBI. Copy installation Installation Are you sure...
  • Page 40 FOCKE MELER GLUING SOLUTIONS 12. PRODUCT screen. STARBI. It is selected from the MENU screen. Menu Product Edit product Product Installation New product Manual mode Settings Copy product Delete product Statistics Alarms 13. SELECT PRODUCT screen. Selected directly from the HOME screen. The list of products to select appears.
  • Page 41 MA-5151-ENG PATTERN CONTROLLER STARBI 14. NEW PRODUCT screen. It is selected from the PRODUCT screen. Once the type of product is selected, RBI. STARBI. an editing screen is opened depending on the type of product chosen. Product New product Time product...
  • Page 42 FOCKE MELER GLUING SOLUTIONS 16. COPY PRODUCT screen. It is selected from the PRODUCT screen. A confirmation message will appear and then a screen will open to enter the name of the new product. STARBI. Copy product Product Product 0...
  • Page 43 MA-5151-ENG PATTERN CONTROLLER STARBI 18. EDITING PRODUCT BY TIME screen. The screen appears when you name a new product from the NEW PRODUCT screen or if you select an existing one from the EDIT PRODUCT screen. The ARBI. STARBI. first step is to select the photocell and then edit the pattern.
  • Page 44 FOCKE MELER GLUING SOLUTIONS 20. ADVANCED PARAMETERS screen. Other parameters can be configured in addition to the patterns. The keyboard ARBI. opens when pressing on the text boxes. After entering the value it will be visible in the text box.
  • Page 45 MA-5151-ENG PATTERN CONTROLLER STARBI 22. ADVANCED PARAMETERS screen. Other parameters can be configured in addition to the patterns. The keyboard opens when pressing on the text boxes. After entering the value it will be ARBI. visible in the text box.
  • Page 46 FOCKE MELER GLUING SOLUTIONS 24. ADVANCED PARAMETERS screen. Other parameters can be configured in addition to the patterns. The keyboard opens when pressing on the text boxes. After entering the value it will be RBI. visible in the text box.
  • Page 47 MA-5151-ENG PATTERN CONTROLLER STARBI 26. ADVANCED PARAMETERS screen. These parameters are configured in the same way as the products by times STARBI. but with values in millimetres (mm). The analogue outputs are configured in ramp mode to have a variable output depending on the speed.
  • Page 48 FOCKE MELER GLUING SOLUTIONS 28. ADVANCED PARAMETERS screen. These parameters are configured in the same way as the products by times but with values in millimetres (mm). The analogue outputs are configured in ramp mode to STARBI. have a variable output depending on the speed.
  • Page 49 MA-5151-ENG PATTERN CONTROLLER STARBI 30. ADVANCED OPTIONS screen. These parameters are configured in the same way as the products by times but with values in millimetres (mm). The analogue outputs are configured in STARBI. ramp mode to have a variable output depending on the speed.
  • Page 50 FOCKE MELER GLUING SOLUTIONS 32. MANUAL MODE screen. Here each of the outputs can be activated and deactivated manually. This mode enables purging, cleaning or depressurising the installation, or checking the correct operation of the applicators. Manual mode A- In manual mode the output channels can be enabled individually.
  • Page 51 MA-5151-ENG PATTERN CONTROLLER STARBI 34. Selection of CONFIGURATION screen. STARBI. STARBI. It is selected from the MENU screen. Menu Configuration Product Installation Password Extra settings Manual mode Settings Restore default Statistics Alarms 35. LANGUAGE screen. The language selection menu can be accessed directly from the HOME screen.
  • Page 52 FOCKE MELER GLUING SOLUTIONS 36. DATE AND TIME screen. From the HOME screen, the ‘Date and Time’ menu can be accessed directly. The following screen will appear where you can see and modify the date and STARBI. STARBI. time of the system. It also shows the software version and a QR code to access the equipment manual.

  • Page 53: Password Management

    Whenever there is activity on the screen, the system remains in this mode. If the end of this 15 minutes is reached, the unit returns to USER mode. If you forget the EXPERT level password, contact the Focke Meler main offices to find out how to proceed to recover it.
  • Page 54 FOCKE MELER GLUING SOLUTIONS • Continue after the Reset: This activated option disables the STOPPED mode so that is not necessary to press the STOP key to switch to RUNNING mode. This option is used when the unit is in an inaccessible area to the operator.
  • Page 55 MA-5151-ENG PATTERN CONTROLLER STARBI 40. Selection of STATISTICS screen. It is selected from the MENU screen. it shows the total amount of products produced and the total and partial amount of a specific product produced. It STARBI. STARBI. also allows you to reset these values.

  • Page 56: Modbus Communications

    FOCKE MELER GLUING SOLUTIONS ModBus communications The unit comes with the option of an RS485 port for MODBUS RTU communications. The tables are as follows: IMPUT Address Description MAGNITUDE Read / Write TYPE Register 30001 ALWAYS 0x1111 number 65535 Uint16...

  • Page 57: Modbus Connections

    MA-5151-ENG PATTERN CONTROLLER STARBI Values: 1 ----- 1: StarBi / 2: Micron Pump / 3: Micron Gear / 4: PS 20 NS / 5:Macro 4 ----- 0: OFF / 1:ON 5 ----- 0: OFF / 1:ON 6 ----- 0: OFF / 1:ON 7 ----- 0: OFF / 1:ON 8 ----- Bit0: FC1 Bit1:FC2 …...

  • Page 58: Comunicaciones Profibus

    FOCKE MELER GLUING SOLUTIONS Comunicaciones Profibus The unit comes with the option of an RS485 port for Profibus communications. The table is as follows: Data Description Read / Write Data Description Read / Write Host Cmd R / W reserved 40...

  • Page 59: Profibus Connections

    8 ----- 0:English, 1:Spanish … 9 ----- STATUS: STOPPED (0), READY (1), RUNNING (2), MANUAL (3). 51 ---- 1: StarBi / 2: Micron Pump / 3: Micron Gear / 4: PS 20 NS / 5:Macro 54 ---- 0: OFF / 1:ON...
  • Page 60 FOCKE MELER GLUING SOLUTIONS Profibus interface Signal In/Out Description Conenct to n. c. Not connected n. c. Not connected PB_B PROFIBUS B-Line PB-Interface PB_RTS Request-To-Send PB-Interface GND_ISO Ground (isolated) PB-Interface VCC_ISO VCC 5V (isolated) PB-Interface n. c. Not connected PB_A...

  • Page 61: Application For Pc

    • Update the IOC board software. • Make a complete backup of the system. • Restore a complete backup of the system. (*) http://www.meler.eu/media/S00900010_PC_App_Installer.zip Warning: For more information consult your Focke Meler Representative or the Focke Meler Main Office. 4-33...

  • Page 62: Mantenance

    Do not replace the cable with another one of a type that is different from that provided by the equipment or recommended by Focke Meler. If in doubt, please check with your Focke Meler Representative or the Focke Meler Main Office.

  • Page 63: Calibrate The Screen

    FOCKE MELER GLUING SOLUTIONS MANTENANCE Calibrate the screen If necessary, it is possible to calibrate the touchscreen. Disconnect the power supply from the equipment. Open the front door to access the HMI card. Lower microswitch 8 on the HMI card to the OFF position.

  • Page 64: Technical Characteristics

    Supply voltage 100-240V ±10% Frequency 50/60Hz Protection fuse StarBi 2 outputs: 2A FF 6.3x32 • StarBi 4/6 outputs: 3.15A FF 6.3x32 StarBi 6 Outputs ---- 154W Total Power StarBi 4 Outputs ---- 104W StarBi 2 Outputs ---- 54W Channel Power...

  • Page 65: Environmental Conditions

    FOCKE MELER GLUING SOLUTIONS TECHNICAL CHARACTERISTICS Environmental conditions Interior use Altitude up to 2,000m. Room temperature between 5ºC and 40ºC Relative maximum humidity of 80% for temperatures up to 31ºC, decreasing linearly to 50% relative humidity to 40ºC Voltage fluctuations of the supply NETWORK which do not surpass ±10%...

  • Page 66: Starbi 2 Channels Dimensions

    PROGRAMADOR DISPAROS STARBI-2-PNP-I0-0B HOJA Nº/ SUS. A/ REPLAC SHEET NUMBER 1 de 1 CATEGO RATE Este plano es propiedad exclusiva de MELER GLUING SOLUTIONS Todos los derechos reservados. This drawing is owned sole of MELER GLUING SOLUTIONS All rights reserved.

  • Page 67: Starbi 4/6 Channels Dimensions

    REFERENCIA/ RE SHEET NUMBER 1 de 1 2203 Este plano es propiedad exclusiva de MELER APLICADORES DE HOT - MELT S.A. Todos los derechos reservados. This drawing is owned sole of MELER APLICADORES DE HOT- MELT S.A. All rights reserved.

  • Page 68: Accessories And Spare Parts List

    ACCESSORIES AND SPARE PARTS LIST MA-5151-ENG PATTERN CONTROLLER STARBI 7. ACCESSORIES AND SPARE PARTS LIST The list of the most common spare parts in the time controller device appears in this chapter in order to provide a quick and reliable guide to choosing them.

  • Page 69: Spare Parts

    FOCKE MELER GLUING SOLUTIONS ACCESSORIES AND SPARE PARTS LIST Spare parts Nº Ref. Description 150030490 Fuse 3.15 A 6.3x32 (for units with 4 or 6 outputs) 150025640 Fuse 2 A 6.3x32 (for units with 2 outputs) 150030600 Power supply 24 VDC 8.4 A (6 outputs) 150030610 Power supply 24 VDC 6.5 A (4 outputs)

  • Page 70: Accessories

    150060140 Solenoid valve cable 5/2 UF 10 m connection to terminals 150030400 * Solenoid valve cable 5/2 UF 3 m M12 connection (Starbi 4/6 outputs) 150030820 * Solenoid valve cable 5/2 UF 6 m M12 connection (Starbi 4/6 outputs) 150031050 * Solenoid valve cable 5/2 UF 9 m M12 connection (Starbi 4/6 outputs) (*) Only for Solenoid valve cable 5/2 24DVC 12W UF ref.
  • Page 71 VP-200 pressure regulator accessory kit 150030480 VP-200 pressure regulator accessory kit M12 connection (Starbi 4/6 outputs) 150031250 Aerial connector VP-200 Starbi connection M12 with 3m of cable (Starbi 4/6 outputs) 115002450 Extension 3m. applicator series 33A Starbi M12 (Starbi 4/6 outputs) 150123770...

  • Page 72: Ec Declaration Of Conformity

    EC DECLARATION OF CONFORMITY Original Declaration Product: PATTERN CONTROLLER The manufacturer: Focke Meler Gluing Solutions, S.A. Pol. Los Agustinos, c/G, nave D-43 E-31160 Orkoien, Navarra - Spain — A Focke Group Company — This declaration of conformity is issued under the sole responsibility of the manufacturer.
  • Page 73 For more information speak with your Focke Meler representative: Focke Meler Gluing Solutions, S. A. Pol. Los Agustinos, c/G, nave D-43 E-31160 Orkoien - Navarra - Spain Phone: +34 948 351 110 Fax: +34 948 351 130 info@meler.eu - www.meler.eu...

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