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VALCO MELTON D10 Manual

Hot melt unit
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D10/D16 Hot Melt Unit
Manual Number:
MM113
Revision Date:
8/2019

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Summary of Contents for VALCO MELTON D10

  • Page 1 D10/D16 Hot Melt Unit Manual Number: MM113 Revision Date: 8/2019...
  • Page 2 © Valco Melton All Rights Reserved This manual is provided with the D10/D16 Hot Melt Unit and may be used only in accordance with the terms of purchase. No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Valco Cincinnati, Inc.
  • Page 3 Agustinos calle G, n. 34 Hortonwood 32 Telford TF1 7YN 31160 Orcoyen Navarra, Spain England declares that the product: Product Name: D10/D16 Hot Melt Unit complies with the following Council Directives: Safety of Machinery: 2006/42/EC Low Voltage Equipment: 2014/35/EU 2014/30/EU EMC:...

  • Page 5: Table Of Contents

    MM113 - D10/D16 Hot Melt Unit Table of Contents Table of Contents Table of Contents ....................5 Section 1 - Introduction ..................11 Description ................................11 Nameplate ................................11 S Number Configuration ............................12 Section 2 - Safety and Use ................... 15 Read Thoroughly Before Handling Equipment .......................
  • Page 6 Dimensions - D16 ..............................117 Section 10 - Part Number List ................119 How to Order Parts ..............................119 D10 Unit ................................... 120 D10 Unit, 2 exit (771xx001) ........................123 D10 Unit, 4 exit (771xx002) ........................123 D10 Unit, 6 exit (771xx003) ........................124...
  • Page 7 D10 Unit - Previous Version (before 1/2017 and after 1/2016) ................131 D10 Unit, Fixed speed, 2 exit (776xx703) - Previous Version (before 1/2017 and after 1/2016) ... 133 D10 Unit, Fixed speed, 4 exit (776xx704) - Previous Version (before 1/2017 and after 1/2016) ... 134 D10 Unit, Fixed speed, 6 exit (776xx705) - Previous Version (before 1/2017 and after 1/2016) ...
  • Page 8 Table of Contents MM113 - D10/D16 Hot Melt Unit Pump Kit, Variable, Standard Width (771XX008) - After 5/18 ..............182 Pump Kit, Variable, Standard Width (771XX008) - Before 5/18 and After 1/17 ........183 Pump Kit, Fixed, Half Width (771XX009) ....................184 Pump Kit, Variable, Half Width (771XX010) - After 5/18 ................
  • Page 9 MM113 - D10/D16 Hot Melt Unit Table of Contents Appendix D - Communication Protocols-Modbus ..........217 Appendix E - Communication Protocols-Ethernet IP ..........227 Hot Melt Unit to EthernetIP Communication Protocol .................... 227 Data Packets used for Ethernet/IP communication ....................227 Send Packet (PLC) Frame ........................
  • Page 10 Table of Contents MM113 - D10/D16 Hot Melt Unit...

  • Page 11: Section 1 - Introduction

    ValcoMelton, a division of Valco Cincinnati, Inc., has prepared this manual as an aid for installing, operating, and servicing the D10/D16 hot melt unit. It also contains a list of part numbers for replacement parts. If you need more information, contact your ValcoMelton representative.

  • Page 12: S Number Configuration

    Section 1 - Introduction MM113 - D10/D16 Hot Melt Unit S Number Configuration The S number is used to configure the D4 hot melt unit to meet specific customer needs. All options are add-ons to the base unit assembly and as a result, most of the options can be field installed.
  • Page 13 MM113 - D10/D16 Hot Melt Unit Section 1 - Introduction S Number Configuration - Continued Selection Number – D10/D16 Hot Melt Unit Unit Code Code Description Code Description D10/D16 Base unit prefix Feature 1 2 exits 4 Exits Number of Exits...
  • Page 14 Section 1 - Introduction MM113 - D10/D16 Hot Melt Unit S Number Configuration - Continued Before 12/17 Selection Number – D10/D16 Hot Melt Unit Unit Code Code Description Code Description D10/D16 Base unit prefix Fixed speed, 2 exit Variable speed, 2 exit...

  • Page 15: Section 2 - Safety And Use

    MM113 - D10/D16 Hot Melt Unit Section 2 - Safety and Use Section 2 - Safety and Use Read Thoroughly Before Handling Equipment WARNING! Read and follow all safety precautions, warnings, cautions, and other recommendations in this manual. OTHERWISE, DEATH, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR.

  • Page 16: Owner Responsibilities

    Do not use this equipment for anything other than its intended use. Do not modify, change, or alter the equipment in any way. If you are unsure of the intended use and the limitations of use for the equipment, contact your Valco Melton...

  • Page 17: Installation/Startup/Use Safety Information

    Section 2 - Safety and Use Installation/Startup/Use Safety Information Valco Melton hot melt units, cold glue units, controllers, inspection systems and all related accessories have the following universal safety precautions (this is not intended to be an exhaustive list; follow all instructions and safety...

  • Page 18: Shut Down Safety Information

    MM113 - D10/D16 Hot Melt Unit Shut Down Safety Information Valco Melton hot melt units, cold glue units, controllers, inspection systems and all related accessories have the following universal safety precautions (this is not intended to be an exhaustive list; follow all instructions and safety...

  • Page 19: What To Do If Contact With Hot Adhesive Occurs

    MM113 - D10/D16 Hot Melt Unit Section 2 - Safety and Use WARNING! People with respiratory problems (e.g., asthma, bronchitis, etc.) should not work in the vicinity of molten adhesive. RESPIRATORY PROBLEMS MAY BE AGGRAVATED BY THE FUMES. Do not wear a face mask when working around molten adhesive. THE MASK MAY TRAP THE FUMES AND DEATH OR PERSONAL INJURY COULD OCCUR.

  • Page 20: What To Do If Adhesive-Related Fire Or Explosion Occurs

    Section 2 - Safety and Use MM113 - D10/D16 Hot Melt Unit What to Do if Adhesive-Related Fire or Explosion Occurs During the heating and melting process, the surface of the adhesive will be exposed to air. The mixture of polymer fumes and air can catch fire if the hot melt is overheated.

  • Page 21: Hose Safety Information

    MM113 - D10/D16 Hot Melt Unit Section 2 - Safety and Use Hose Safety Information DO NOT Do not use bindings, wire Do use approved wrapping ties, or unapproved (P/N 775xx827), making fasteners around the sure the wrapping is slightly hoses.
  • Page 22 Section 2 - Safety and Use MM113 - D10/D16 Hot Melt Unit...

  • Page 23: Section 3 - Basic Features

    This section describes the basic features of the D-Series Hot Melt Systems. The basic features of the D10 and D16 Hot Melt Units are similar, with the exception of the tank capacity of each unit. For clarity, only the D10 Hot Melt Unit is shown in this section.
  • Page 24 Section 3 - Basic Features MM113 - D10/D16 Hot Melt Unit...

  • Page 25: Section 4 - Installation

    Section 4 - Installation Choosing a Location The D10/D16 hot melt unit is assembled at the factory. However, the power and the glue hoses must be connected by the customer. This section contains instructions for making the necessary connections. While choosing a location for the unit, keep in mind that: •...

  • Page 26: Installation Kit

    Section 4 - Installation MM113 - D10/D16 Hot Melt Unit Installation Kit An Installation Kit (091xx664) is available for this unit, containing spare fuses, a copy of this manual on CD and warranty information. For details, see Section 10 - Parts List.

  • Page 27: Connecting The Electrical Power

    This unit must be earthed or grounded. Failure to observe could result in personal injury, death, or damage to equipment. The D10/D16 hot melt unit can be set up to use one of the following power sources: Power Connector Voltage Plug...
  • Page 28 Section 4 - Installation MM113 - D10/D16 Hot Melt Unit Connecting the Electrical Power - Continued 4. Attach the appropriate power connector label to the power connector on the 12 zone board (see illustration). 029XX435 Selector Plug Matching Black Label WARNING! The label must be correctly oriented on the power connector.

  • Page 29: Connecting The Hoses

    MM113 - D10/D16 Hot Melt Unit Section 4 - Installation Connecting the Hoses WARNING! Never disconnect the hot melt hoses from a running unit. Hot melt is under high pressure. Turn off the pump, shut off power to the unit, and actuate the gun to relieve residual pressure before removing the hose.
  • Page 30 Section 4 - Installation MM113 - D10/D16 Hot Melt Unit Connecting the Hoses - Continued 5. Attach this end of the glue hose to the fluid outlet fitting in the manifold (Figure 4-2). 6. Using two wrenches, one on the fluid outlet fitting and the other on the hose swivel nut, connect hose ‘one’...

  • Page 31: Connecting The Hot Melt Hoses To The Applicators

    MM113 - D10/D16 Hot Melt Unit Section 4 - Installation Connecting the Hot Melt Hoses to the Applicators WARNING! If hand-held applicators are used, care should be taken to ensure safe operation. Heat protective gloves should be worn. Hot melt is under high pressure at the nozzle tip of the applicator.

  • Page 32: Wiring Diagram (After 5/18)

    Section 4 - Installation MM113 - D10/D16 Hot Melt Unit Wiring Diagram (After 5/18)
  • Page 33 MM113 - D10/D16 Hot Melt Unit Section 4 - Installation Wiring Diagram (After 5/18) - Continued...

  • Page 34: Wiring Diagram - Before 5/18

    Section 4 - Installation MM113 - D10/D16 Hot Melt Unit Wiring Diagram - Before 5/18...

  • Page 35: Input/Output Connections

    MM113 - D10/D16 Hot Melt Unit Section 4 - Installation Input/Output Connections The Input/Output connection interface is on the J-23 & J-24 terminals, on the bottom of the CPU Board. The CPU Board is located directly behind the Keypad. There are four opto-isolated inputs that can be programmed by the user for a variety of options.
  • Page 36 Section 4 - Installation MM113 - D10/D16 Hot Melt Unit Input/Output Connections - Continued INPUT WIRING OPTIONS OUTPUT WIRING INDIVIDUAL DRY CONTACTS DRY CONTACTS WITH COMMON NORMALLY OPEN NORMALLY CLOSED INPUT 1: DRY CONTACT BETWEEN I1 - GND INPUT 1: DRY CONTACT BETWEEN I1 - GND...

  • Page 37: Input/Output Connections - Before 5/18

    MM113 - D10/D16 Hot Melt Unit Section 4 - Installation Input/Output Connections - Before 5/18 The Input/Output connection interface is on the J-23 & J-24 terminals, on the bottom of the CPU Board. The CPU Board is located directly behind the Keypad.

  • Page 38: Section 5 - Setup

    Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Control Panel...
  • Page 39 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Control Panel, Continued ITEM NAME DESCRIPTION ILLUMINATES GREEN WHEN THE SYSTEM REACHES READY SYSTEM READY LED TEMPERATURE WARNING LED ILLUMINATES RED WHEN THE UNIT ENTERS AN ALARM CONDITION PUTS THE UNIT INTO AND OUT OF SETBACK MODE. THIS REDUCES...
  • Page 40 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Power On/Off and Standby Mode The Power On/Off Switch is located on the front of the unit (see picture below). The Power Switch controls the power to the system. The Standby Button controls the power to the Heater circuits. Press the Standby Button once. The display screen will come on and the Standby LED will illuminate green, indicating that the unit is on.
  • Page 41 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Display Contrast Adjustment The display contrast is adjusted for optimal viewing at the factory. If the display is not visible when the Hot Melt Controller powers up, the contrast may need to be adjusted.
  • Page 42 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit User Interface Navigation Navigation symbols on the bottom of the display screen indicate that additional menus are available. Use the indicated button(s) to navigate as follows: Navigation Icons Memory Storage The symbol consisting of two arrows in a circular pattern indicates that a value has been changed but the change is not yet stored in the flash memory.
  • Page 43 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Thumbwheel vs. Single Digit Edit In Thumbwheel Edit, use the Right/Left Arrow Buttons to select the digit position, and the Plus/Minus Arrow Buttons to increase/decrease the value of the selected digit.
  • Page 44 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Entering Passwords Passwords are required to prevent unauthorized access to unit programming. Please see Appendix A - Password Levels for more information. To enter a password: Enter Password (See Thumbwheel vs. Single...
  • Page 45 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Set Language Continued Next Page...
  • Page 46 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Set Language - Continued...
  • Page 47 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Set Temperature Units...
  • Page 48 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Programming Temperatures Press the Temperature Button (if the Temperature LED is not illuminated green) to show the first temperature screen. Temperature Screens The tank temperature screen shows the actual tank temperature and the tank temperature setpoint. For operator convenience, the right side of this screen scrolls through enabled hose / gun zones and displays the actual temperatures as shown.
  • Page 49 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Tank Temperature Hose/Valve Temperature Continued Next Page...
  • Page 50 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Hose/Valve Temperature - Continued...
  • Page 51 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup System/Pump Ready Temperature Offset The System Ready Temperature is relative to the temperature setpoint of each zone. The system is ready (and the System Ready LED illuminates green) when all zones reach their respective temperature setpoints minus the System Ready Temperature Offset.
  • Page 52 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Ready Delay Time When the Ready Delay Time is used, the System Ready LED will illuminate a preset time after all of the zones reach their respective temperature setpoints minus the System Ready Temperature Offset. This feature allows the adhesive in the system to heat for an additional period of time before the pump motor is enabled.
  • Page 53 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Over Temperature Alarm The Over Temperature Alarm setting pertains to all active zones. The number entered on this screen, is the amount of degrees ABOVE each zone’s set temperature that a zone can heat to before activating the Over Temperature Alarm.
  • Page 54 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Under Temperature Alarm The Under Temperature Alarm setting pertains to all active zones. The number entered on this screen, is the amount of degrees BELOW each zone’s set temperature that a zone can cool to before activating the Under Temperature Alarm.
  • Page 55 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Maximum Temperature The Maximum Temperature setting is the maximum value for the setpoint of any zone. The maximum temperature range is 32°F to 446°F (0°C to 230°C). The factory default setting is 446°F (230°C).
  • Page 56 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Beacon/Alarm Setup The Beacon/Alarm Setup allows a specific Beacon, designated by number, to be set to indicate one of several conditions: Ready & Level Level 1 Pump On Level2 Power On...
  • Page 57 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Beacon 2...
  • Page 58 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Automatic Pump Mode When the Automatic Pump Mode is on, the pump will automatically start when the system reaches temperature and the System Ready LED illuminates. If the Ready Delay Time is enabled and set for a preset time (15 minutes), the pump will not start and the unit will not be ready until 15 minutes AFTER the control has gotten to temperature.
  • Page 59 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Pressure Setup If a pump, or multiple pumps, are enabled, Pressure Monitoring can create high or low pressure alarms (Requires pressure transducer[s]) If one pump is enabled: If two pumps are enabled:...
  • Page 60 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Pressure Setup - Continued Pressure-measurement units of can be either bar or PSI (whichever is selected, the CPU will convert every pressure to a related value) Each pressure-monitoring input (1-4) has a user-configuration page: The 1, 2, 3, or 4, above, only shows if the corresponding pump is enabled.
  • Page 61 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Pressure Setup - Continued Example: If pump 1 is enabled and pressure monitor 1 is enabled for the pump, the pump screen (entered by pressing the pump key) will change to the following (this applies to all four pumps):...
  • Page 62 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Pot Fill Mode In this mode of operation, melted glue is pumped into an external pot when the external lever control falls below a set level. The external level control is wired to the external level input on the CPU, J6.
  • Page 63 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Level Sensor Setup Level 1 and 2 There are two types of level control typically used with the D-Series Units, an internal level sensor (Level 1) and an external level sensor (Level 2). The internal level sensor can be used inside the tank of the unit to trigger an auto-fill device (see hopper feeder below), or an alarm state.
  • Page 64 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Filter Change Timer The Filter Change Timer Screen is a countdown timer that shows the time remaining on the currently installed glue filter. When the counter gets down to zero (0), an alarm can be sounded and the filter needs to be changed or cleaned.
  • Page 65 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Shift Times/Setback Times From this screen, use the Up/Down Buttons and the Right/Left Buttons to go through and adjust the shifts and setback times as desired. See the next page for an in-depth review.
  • Page 66 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Programming Shifts - Continued This screen states that on Mondays all three shifts (A, B, and C) will be working. This screen states that on Mondays only Shift A will be working.
  • Page 67 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Moving Through the Shift Time/Day Screens Continue to use the Right/Left, Up/Down, and OK Buttons to set all shift times and what shifts work on each day. Turn the Clock On and your unit is set to work with your shift times and days.
  • Page 68 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Do not turn off the main power to the control. The clock/timer will not operate if the power is off. If the unit is set to ‘Standby’, the clock/timer will operate properly. In Standby, the display will show the status bar with the correct time of day.
  • Page 69 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Diagnostics The Diagnostics Screen shows the current software version as well as the current temperature and status of each zone.
  • Page 70 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Setback Setback Temperature The setback feature is used to reduce the temperatures of all zones by a given temperature differential to allow the hot melt to remain soft but not molten during periods of inactivity.
  • Page 71 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Automatic Setback Timeout If the Automatic Setback Timeout input is enabled and the unit does not see an external input within the automatic setback timeout period, the unit will automatically go into setback.
  • Page 72 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Startup Setup Sequential Start - Hose The Sequential Start function allows the hoses and the valves (guns) to begin heating after the tank reaches a specified temperature offset below the setpoint temperature. This feature is used to reduce adhesive degradation caused from heating adhesive in the hoses and valves for long periods while waiting for the tank to reach temperature.
  • Page 73 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Sequential Start - Valve...
  • Page 74 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit History The Fault History Screen keeps a log of all faults that occur with any zone. The Change History Screen keeps a log of all parameter and setting changes. The Fault History and the Change History are cleared when the unit is turned off.
  • Page 75 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup User Inputs and Outputs There are 4 individual outputs that can be configured to control remote devices as set up by the user. An output relay will turn on when the conditions of the selected feature are met. For example, if Output #1 is programmed for “System Ready”, the output relay will energize when the control reaches temperature and is ready to glue.
  • Page 76 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit User Inputs and Outputs - Continued Outputs 1-4 Conditions to Turn Output ON Disabled None System Ready All zones have reached their respective temperature setpoints minus the System Ready Temperature Offset AND the Ready Delay Time has elapsed.
  • Page 77 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Configuration The Configuration Menu of screens allows the user to set up global parameters for the hot melt control. These configurations are shown below. Zone Configuration Menu Zone Configuration The Zone Configuration is used to set the control for how many hose/gun pairs are being used by the operator and if 1 or 2 tank zones will be enabled.
  • Page 78 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Auxiliary I/O When the Auxiliary I/O is set to “Enabled,” auxiliary I/O devices will be activated. When the Auxiliary I/O is set to “Disabled,” auxiliary I/O devices will be deactivated.
  • Page 79 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Gramage Enable Gramage is ONLY enabled in coating applications where the user wants the unit automatically calculate the pump speed to achieve a desired coat weight. It requires the user to enter the Pump Displacement (cc), Adhesive Density (gram/cc), speed reference values if tach mode is used, coating width (mm), and the desired coating weight (gram/square meter).
  • Page 80 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Config Comm Menu - Continued CAUTION! Load and balance the communication networks properly. If the CPU is the end node in the communication daisy-chain, for each of those protocols, enable the SDO Comm and Modbus RTU resistors.

  • Page 81: Pump Setup Menu

    MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Pump Configuration for Specific No. Pump The Pump Heat Zone is the zone attached to the pump to heat the pump. It is used to make sure the zone is enabled and heating when the pump switch is enabled.
  • Page 82 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Pump Setup Menu - Continued The Maximum Pump Speed is generally set at the factory. It is the motor RPM divided by the reducer size (or pump speed when the motor runs at 100%). It is used to calculate and display the actual speed of the pump on the Pump Status Screens.
  • Page 83 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Pump Setup Menu - Continued VFD Board Connections – Before 5/18 If an Encoder is used for the Auto Speed Input, an additional “Encoder Screen Ref.” screen will appear between “Creep Speed Setting”...

  • Page 84: Vfd Parameters

    Section 5 - Setup MM113 - D10/D16 Hot Melt Unit VFD Parameters After 5/18 Before 5/18...

  • Page 85: Encoder Setup Menu

    MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Encoder Setup Menu If an Encoder is used for the Auto Speed Input, then the Encoder parameters need to be set in this menu. Enter the Pulses per Revolution of the encoder and its circumference in this screen.
  • Page 86 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Valve Setup Menu (pattern control only) 1. Set up the Valve Compensation Times: Ton, Toff and Tmin. 1. Use left/right keys to select time. 2. Use up/down keys to change values.
  • Page 87 Section 5 - Setup PID Setup Menu PID Settings The PID settings are factory set for each zone. The factory PID settings complement Valco Melton’s Tank, Hose, and Gun watt densities (Tank 1 screen shown. Use left/right keys to access other screens). CAUTION! Changing these settings is not recommended.
  • Page 88 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Memory Menu The Memory Menu is used to backup, restore or initialize ALL control parameters. For more information on these functions, see Appendix D - Micro SD Backup & Restore.
  • Page 89 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Procedure - Continued If the USB memory stick mounts successfully, the screen will display the following: If there is a problem with the USB memory stick mounting, the screen will display the error screen with “Error 1” as...
  • Page 90 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Procedure - Continued If the software has the correct name, has been correctly converted for loading, is not corrupted, and is not the same as the version already installed (if a software is already loaded), then the update will continue and the screen will...
  • Page 91 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Initialization Instructions Navigating the Setup Wizard Upon restoring the control to factory settings, the control will launch a wizard that will guide you through a series of control configuration steps. You can navigate the wizard settings using the left and right arrow buttons, and edit the settings using the + and –...
  • Page 92 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit Configuring the Unit Type Use the + and – buttons to select the appropriate unit type. In this case, the unit type should be D Series Variable Speed or D Series Fixed Speed.
  • Page 93 Use the + or – buttons to select the type of RTDs used in the system. The RTD type can be Ni120 or PT100. CAUTION! All D10/D16 hot melt units use Ni120 RTDs. PT100 should not be selected, this will cause the system to malfunction.
  • Page 94 Use the + or – buttons to select the number of pumps on the hot melt unit. CAUTION! All D10/D16 hot melt units use 1 pump. More than 1 pump should not be selected, this will cause the system to malfunction...
  • Page 95 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Selecting the Temperature Units Use the + or – buttons to select the desired temperature units. After selecting the desired temperature units, press the right arrow button to continue. Selecting the Pattern Control Some units are equipped with an internal pattern control for activating up to 6 valve channels.
  • Page 96 MM113 - D10/D16 Hot Melt Unit Adjusting the Pressure Control Valve The D10/D16 unit contains a single-stage relief valve (see figure below). Additionally, the D10/D16 unit can use an optional pneumatic relief valve (707xx212). The single-stage relief valve is a simple safety device which protects the system from excessive pressure. The single- stage relief valve is commonly used for systems that are applying adhesive continuously (laminating).
  • Page 97 MM113 - D10/D16 Hot Melt Unit Section 5 - Setup Gramage Feature The Gramage Feature is ONLY enabled in coating applications where the user wants the unit automatically calculate the pump speed to achieve a desired coat weight. If this feature is used then the following parameters must be set.
  • Page 98 Section 5 - Setup MM113 - D10/D16 Hot Melt Unit...

  • Page 99: Section 6 - Operation

    MM113 - D10/D16 Hot Melt Unit Section 6 - Operation Section 6 - Operation WARNING! It is recommended that Section 5 - Setup is read, understood, and followed before attempting to read this Section and operate the Universal Temperature Control unit. OTHERWISE, DAMAGE TO EQUIPMENT AND PERSONAL INJURY COULD OCCUR.

  • Page 100: Temperature

    Section 6 - Operation MM113 - D10/D16 Hot Melt Unit Temperature The tank temperature screen will show the actual tank temperature and the tank temperature setpoint. For operator convenience, the right side of the display screen alternately displays the Hose & Gun temperatures (see Section 5 –...

  • Page 101: Pump Operation

    MM113 - D10/D16 Hot Melt Unit Section 6 - Operation Temperature Status LEDs - Continued If the temperature set points are not correct or need to be adjusted, select the appropriate zone and adjust the temperature setting (see Section 5 – Setup for setting temperatures). The system is ready (and the System Ready LED illuminates green) when all zones reach their respective temperature setpoints minus the System Ready Temperature Offset.

  • Page 102: Variable Speed Unit

    Section 6 - Operation MM113 - D10/D16 Hot Melt Unit Variable Speed Unit In a Variable Speed Unit the Pump Menu Key allows you to choose the pumps operating mode, manual or automatic. You can also see the pump’s speed input value, the pump RPM, and the individual pump enable.

  • Page 103: Setback

    MM113 - D10/D16 Hot Melt Unit Section 6 - Operation Setback The Setback Temperatures are pre-programmed (see “Setback Temperatures”, Section 5 - Setup). When setback times are set (See “Clock - Shift Times/Setback Times,” Section 5 - Setup) and the clock is on, the unit automatically enters setback during each shift as programmed.

  • Page 104: Pot Fill - External Low Level Detection

    Section 6 - Operation MM113 - D10/D16 Hot Melt Unit Pot Fill - External Low Level Detection Pot Fill is used when the hot melt control is being used to heat the hot melt adhesive and remotely fill a pot. Using the Pot Fill mode, the hot melt control can precisely monitor the pot level and fill the pot on demand from the low level sensor mounted in the pot.

  • Page 105: Filling The Tank

    MM113 - D10/D16 Hot Melt Unit Section 6 - Operation Filling the Tank WARNING! Do not overfill the tank. The adhesive could leak out and damage equipment and cause extensive burns to persons. DAMAGE TO EQUIPMENT AND DEATH OR PERSONAL INJURY COULD OCCUR.
  • Page 106 Section 6 - Operation MM113 - D10/D16 Hot Melt Unit...

  • Page 107: Section 7 - Maintenance

    Section 7 - Maintenance This section contains guidelines and procedures for maintaining the D10/D16 hot melt unit. Your hot melt system will run longer and more consistently if a preventative maintenance program is used. Daily attention to the maintenance of your system is recommended.

  • Page 108: Changing The Adhesive

    3. Manually activate the applicators to relieve any system pressure buildup if the system is hot. 4. Disconnect glue hoses from applicators and collect purged material with appropriate container. 5. Turn the D10/D16 hot melt unit on and allow 20-30 minutes for hoses and guns to reach temperature. 6. Turn the pump on.

  • Page 109: Parts Replacement

    MM113 - D10/D16 Hot Melt Unit Section 7 - Maintenance Flushing the System - Continued 10. Turn the gear pump back on and activate the applicators to purge remaining adhesive through the valve(s). 11. Reset the temperature control to the correct setting for the material you are using.

  • Page 110: Units Produced After August, 2014

    Section 7 - Maintenance MM113 - D10/D16 Hot Melt Unit Units Produced After August, 2014 151XX680 REV M 151xx680 240V Item Fuse Description Part # Quantity Fuse, 2A, 5 x 20 mm 085xx220 Fuse, 6.3A, 5 x 20 mm 085xx271...

  • Page 111: Units Produced Before August, 2014

    MM113 - D10/D16 Hot Melt Unit Section 7 - Maintenance Units Produced Before August, 2014 151xx680 240V (Before August, 2014) Item Fuse Description Part # Quantity Fuse, 2A, 5 x 20 mm 085xx220 Fuse, 6.3A, 5 x 20 mm 085xx271...

  • Page 112: Changing The Filter

    Section 7 - Maintenance MM113 - D10/D16 Hot Melt Unit Changing the Filter WARNING! If the system is hot, wear insulated gloves and eye protection when disconnecting hoses. Trapped air pockets may cause adhesive spray and result in personal injury (burns) or death.

  • Page 113: Section 8 - Troubleshooting And Repair

    MM113 - D10/D16 Hot Melt Unit Section 8 - Troubleshooting and Repair Section 8 - Troubleshooting and Repair Problem Possible Cause Possible Solution 1. Material in 1a. Temperature control 1a. Check indicator lights. reservoir will malfunction or adjustment Reset adjustments.
  • Page 114 Section 8 - Troubleshooting and Repair MM113 - D10/D16 Hot Melt Unit Problem Possible Cause Possible Solution 5. 5. Uneven 6. 5a. Material viscosity too high 7. 5a. flow of 8. -Reservoir temperature too low 9. -Raise reservoir temperature in...

  • Page 115: Section 9 - Specifications

    SECTION 9 - SPECIFICATIONS SECTION 9 - SPECIFICATIONS SECTION 9 - SPECIFICATIONS SECTION 9 - SPECIFICATIONS SECTION 9 - SPECIFICATIONS It is the purchaser’s responsibility to ensure that all local, county, state, and General national codes, regulations, rules, and laws relating to safety and safe operating conditions are met and followed.

  • Page 116: Dimensions - D10

    Section 9 - Specifications MM113 - D10/D16 Hot Melt Unit Dimensions - D10 2 1 . 0 [ 5 3 4 m 1 4 . 3 [ 3 6 2 m 2 9 . 7 [ 7 5 4 m...

  • Page 117: Dimensions - D16

    MM113 - D10/D16 Hot Melt Unit Section 9 - Specifications Dimensions - D16...
  • Page 118 Section 9 - Specifications MM113 - D10/D16 Hot Melt Unit...

  • Page 119: Section 10 - Part Number List

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Section 10 - Part Number List How to Order Parts To order parts, please contact your closest Valco office by mail, phone, or Email: Valco Cincinnati, Inc. 497 Circle Freeway Drive...

  • Page 120: D10 Unit

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit This drawing is referenced by each of the assemblies shown in the table, right, and in the parts lists following this drawing. Items used only on the variable speed model are designated with square balloons.
  • Page 121 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit - Continued...
  • Page 122 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit - Continued...

  • Page 123: D10 Unit, 2 Exit (771Xx001)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10/D16 Unit - Continued D10 Unit, 2 exit (771xx001) ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D10 776XX884 SCREEN; RESERVOIR 776XX113 BRACKET; RESERVOIR LID 776XX110 SCREW 784XX491...

  • Page 124: D10 Unit, 6 Exit (771Xx003)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit, 6 exit (771xx003) ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D10 776XX884 SCREEN; RESERVOIR 776XX113 BRACKET; RESERVOIR LID 776XX110 SCREW 784XX491 LID, RESERVOIR 776XX109 HANDLE, PULL...

  • Page 125: D10 Base Unit (776Xx884)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Base Unit (776xx884)
  • Page 126 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Base Unit (776xx884) - Continued...

  • Page 127: After 5/18

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Base Unit (776xx884) - Continued After 5/18 ITEM DESCRIPTION PART NO. QTY. CHASSIS 776XX117 STANDOFF; RESERVOIR 776XX108 RESERVOIR 776XX114 SCREW 884XX244 NUT FLANGE 884XX243 VALVE; RESERVOIR SHUTOFF...
  • Page 128 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit After 5/18 - Continued ITEM DESCRIPTION PART NO. QTY. 798XX488 WIRE TERMINAL; RING 075XX070 SCREW 798XX428 POWER SUPPLY 148XX076 SCREW 784XX259 PANEL; OPERATOR 776XX119 LOCK WASHER 798XX776 OVERLAY ASSY, HM CTRL, D-SERIE 137XX029 SWITCH;...

  • Page 129: Before 5/18 And After 1/17

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Base Unit (776xx884) - Continued Before 5/18 and After 1/17 ITEM DESCRIPTION PART NO. QTY. CHASSIS 776XX117 STANDOFF; RESERVOIR 776XX108 RESERVOIR 776XX114 SCREW 884XX244 NUT FLANGE 884XX243 VALVE;...
  • Page 130 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Before 5/18 and After 1/17- Continued ITEM DESCRIPTION PART NO. QTY. CABLE ASSY; DC SUPPLY TO 12 Z 029XX568 LANYARD 782XX311 SCREW 798XX188 ELECTRICAL CONNECTIONS STICKER 917XX811 HARNESS ANCHOR 067XX002 ILLUSTRATION DWG, WIRING DIA.

  • Page 131: D10 Unit - Previous Version (Before 1/2017 And After 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit - Previous Version (before 1/2017 and after 1/2016) This drawing is referenced by each of the assemblies shown in the table, below, and in the parts lists following this...
  • Page 132 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit - Previous Version (before 1/2017 and after 1/2016) – Continued...

  • Page 133: D10 Unit, Fixed Speed, 2 Exit (776Xx703) - Previous Version (Before 1/2017 And After 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit, Fixed speed, 2 exit (776xx703) - Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D10 BASE UNIT ASSY 776XX884 BRACKET MOTOR 776XX313...

  • Page 134: D10 Unit, Fixed Speed, 4 Exit (776Xx704) - Previous Version (Before 1/2017 And After 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit, Fixed speed, 4 exit (776xx704) - Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D10 BASE UNIT ASSY 776XX884 BRACKET MOTOR 776XX313...

  • Page 135: D10 Unit, Fixed Speed, 6 Exit (776Xx705) - Previous Version (Before 1/2017 And After 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit, Fixed speed, 6 exit (776xx705) - Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D10 BASE UNIT ASSY 776XX884 BRACKET MOTOR 776XX313...

  • Page 136: D10 Unit, Variable Speed, 2 Exit (776Xx706) - Previous Version (Before 1/2017 And After 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit, Variable speed, 2 exit (776xx706) - Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D10 BASE UNIT ASSY 776XX884 BRACKET MOTOR 776XX313...

  • Page 137: D10 Unit, Variable Speed, 4 Exit (776Xx707) - Previous Version (Before 1/2017 And After 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit, Variable speed, 4 exit (776xx707) - Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D10 BASE UNIT ASSY 776XX884 BRACKET MOTOR 776XX313...

  • Page 138: D10 Unit, Variable Speed, 6 Exit (776Xx708) - Previous Version (Before 1/2017 And After 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit, Variable speed, 6 exit (776xx708) - Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D10 BASE UNIT ASSY 776XX884 BRACKET MOTOR 776XX313...

  • Page 139: D10 Unit - Previous Version (Before 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit - Previous Version (before 1/2016) This drawing is referenced by each of the assemblies shown in the table, below, and in the parts lists following this drawing.
  • Page 140 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit - Previous Version (before 1/2016) - Continued...
  • Page 141 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit - Previous Version (before 1/2016) - Continued...
  • Page 142 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit - Previous Version (before 1/2016)- Continued...

  • Page 143: D10 Unit, Fixed Speed, 2H/2G (776Xx853) - Previous Version (Before 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit, Fixed speed, 2H/2G (776xx853) - Previous Version (before 1/2016) ITEM DESCRIPTION PART NO. QTY. MANIFOLD 776XX111 FILTER ASSY 593XX499 VALVE, PRESSURE RELIEF 707XX222 HEX PLUG 799XX127...
  • Page 144 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit, Fixed speed, 2H/2G (776xx853) - Previous Version (before 1/2016) - Continued ITEM DESCRIPTION PART NO. QTY. CABLE ASSY; HOSE/GUN 029XX546 NUT,HEX M3 ZINC 798XX489 WIRE TERMINAL; RING...

  • Page 145: Coupling Assembly (Units Produced Before 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit, Fixed speed, 2H/2G (776xx853) - Previous Version (before 1/2016) - Continued ITEM DESCRIPTION PART NO. QTY. PHMS M3 X 8 ZINC 784XX259 PLUG, RESERVOIR 776XX125 O` RING...

  • Page 146: D10 Unit, Fixed Speed, 4H/4G (776Xx859) - Previous Version (Before 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit, Fixed speed, 4H/4G (776xx859) - Previous Version (before 1/2016) ITEM DESCRIPTION PART NO. QTY. D10 HOT MELT UNIT ASSY 776XX853 UPGRADE KIT 4 EXITS 776XX140 NAMEPLATE, SHURE-GLUE SYSTEMS...
  • Page 147 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D10 Unit, Variable speed, 2H/2G (776xx858) - Previous Version (before 1/2016) - Continued ITEM DESCRIPTION PART NO. QTY. CABLE ASSY; RESERVOIR RTD 029XX549 CABLE ASSY; RESERVOIR HEATER 029XX550 SHCS,M5 X 8.0 LNG,B.O.

  • Page 148: D10 Unit, Variable Speed, 4H/4G (776Xx861) - Previous Version (Before 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D10 Unit, Variable speed, 2H/2G (776xx858) - Previous Version (before 1/2016) - Continued ITEM DESCRIPTION PART NO. QTY. RIVET, BLIND, 1/8 DIA X 1/4 LG 091XX517 INSULATOR; FISH PAPER...

  • Page 149: D16 Unit

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit This drawing is referenced by each of the assemblies shown in the table, below, and in the parts lists following this drawing. Items used only on the variable speed model are designated with square balloons.
  • Page 150 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit - Continued...
  • Page 151 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit - Continued...

  • Page 152: D16 Unit, 2 Exit (771Xx004)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit, 2 exit (771xx004) ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D16 776XX885 SCREEN, RESERVOIR 776XX152 BRACKET; RESERVOIR LID 776XX153 SCREW 784XX491 LID; RESERVOIR 776XX154 HANDLE, PULL...

  • Page 153: D16 Unit, 6 Exit (771Xx006)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit, 6 exit (771xx006) ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D16 776XX885 SCREEN, RESERVOIR 776XX152 BRACKET; RESERVOIR LID 776XX153 SCREW 784XX491 LID; RESERVOIR 776XX154 HANDLE, PULL...

  • Page 154: D16 Base Unit (776Xx885)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Base Unit (776xx885)
  • Page 155 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Base Unit (776xx885) - Continued...

  • Page 156: Before 5/18

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Base Unit (776xx885) - Continued Before 5/18 ITEM DESCRIPTION PART NO. QTY. CHASSIS 776XX117 STANDOFF; RESERVOIR 776XX108 RESERVOIR 776XX146 SCREW 884XX244 NUT FLANGE 884XX243 VALVE; RESERVOIR SHUTOFF...

  • Page 157: Before 5/18 And After 1/17

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Base Unit (776xx885) - Continued Before 5/18 and After 1/17 ITEM DESCRIPTION PART NO. QTY. CHASSIS 776XX117 STANDOFF; RESERVOIR 776XX108 RESERVOIR 776XX146 SCREW 884XX244 NUT FLANGE 884XX243 VALVE;...

  • Page 158: D16 Unit-Previous Version (Before 1/2017 And After 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit-Previous Version (before 1/2017 and after 1/2016) This drawing is referenced by each of the assemblies shown in the table, below, and in the parts lists following this...
  • Page 159 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit - Previous Version (before 1/2017 and after 1/2016) - Continued...

  • Page 160: D16 Unit, Fixed Speed, 2 Exit (776Xx774) - Previous Version (Before 1/2017 And After 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit, Fixed Speed, 2 exit (776xx774) - Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D16 BASE UNIT ASSY 776XX885 BRACKET MOTOR 776XX313...

  • Page 161: D16 Unit, Fixed Speed, 4 Exit (776Xx775)-Previous Version (Before 1/2017 And After 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit, Fixed Speed, 4 exit (776xx775)-Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D16 BASE UNIT ASSY 776XX885 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT...

  • Page 162: D16 Unit, Fixed Speed, 6 Exit (776Xx776)-Previous Version (Before 1/2017 And After 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit, Fixed Speed, 6 exit (776xx776)-Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D16 BASE UNIT ASSY 776XX885 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT...

  • Page 163: D16 Unit, Variable Speed, 2 Exit (776Xx777)-Previous Version (Before 1/2017 And After 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit, Variable Speed, 2 exit (776xx777)-Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D16 BASE UNIT ASSY 776XX885 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT...

  • Page 164: D16 Unit, Variable Speed, 4 Exit (776Xx778)-Previous Version (Before 1/2017 And After 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit, Variable Speed, 4 exit (776xx778)-Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D16 BASE UNIT ASSY 776XX885 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT...

  • Page 165: D16 Unit, Variable Speed, 6 Exit (776Xx779)-Previous Version (Before 1/2017 And After 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit, Variable Speed, 6 exit (776xx779)-Previous Version (before 1/2017 and after 1/2016) ITEM DESCRIPTION PART NO. QTY. D16 BASE UNIT ASSY 776XX885 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT...

  • Page 166: D16 Unit - Previous Version (Before 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit - Previous Version (before 1/2016) This drawing is referenced by each of the assemblies shown in the table, below, and in the parts lists following this drawing.
  • Page 167 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit - Previous Version (before 1/2016) - Continued...
  • Page 168 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit - Previous Version (before 1/2016) - Continued...
  • Page 169 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit - Previous Version (before 1/2016) - Continued 48 49...

  • Page 170: D16 Unit, Fixed Speed, 2H/2G (776Xx864) - Previous Version (Before 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit, Fixed Speed, 2H/2G (776xx864) - Previous Version (before 1/2016) ITEM DESCRIPTION PART NO. QTY. MANIFOLD 776XX111 FILTER ASSY 593XX499 VALVE, PRESSURE RELIEF 707XX222 HEX PLUG 799XX127...
  • Page 171 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit, Fixed Speed, 2H/2G (776xx864) - Previous Version (before 1/2016) - Continued ITEM DESCRIPTION PART NO. QTY. NUT,HEX M3 ZINC 798XX489 WIRE TERMINAL; RING 075XX179 LOCK WASHER M5...

  • Page 172: Coupling Assembly (Units Produced Before 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Coupling Assembly (units produced before 1/2016) ITEM DESCRIPTION PART NO. QTY. COUPLING ASSY 783XX212 D16 Unit, Fixed Speed, 4H/4G (776xx865) - Previous Version (before 1/2016) ITEM DESCRIPTION PART NO.

  • Page 173: D16 Unit, Variable Speed, 2H/2G (776Xx867) - Previous Version (Before 1/2016)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit, Variable Speed, 2H/2G (776xx867) - Previous Version (before 1/2016) ITEM DESCRIPTION PART NO. QTY. MANIFOLD 776XX111 FILTER ASSY 593XX499 VALVE, PRESSURE RELIEF 707XX222 HEX PLUG 799XX127...
  • Page 174 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit, Variable Speed, 2H/2G (776xx867) - Previous Version (before 1/2016) - Continued ITEM DESCRIPTION PART NO. QTY. NUT,HEX M3 ZINC 798XX489 WIRE TERMINAL; RING 075XX179 LOCK WASHER M5...
  • Page 175 MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List D16 Unit, Variable Speed, 2H/2G (776xx867) - Previous Version (before 1/2016) - Continued ITEM DESCRIPTION PART NO. QTY. STANDOFF, M3 X 18MM LONG, F- 091XX666 PHMS M3 X 8 ZINC...

  • Page 176: D16 Unit, Variable Speed, 4H/4G (776Xx868) - Previous Version (Before 1/2016)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit D16 Unit, Variable Speed, 4H/4G (776xx868) - Previous Version (before 1/2016) ITEM DESCRIPTION PART NO. QTY. D16 HOT MELT UNIT ASSY 2H/2G 776XX867 UPGRADE KIT 4 EXITS 776XX140...

  • Page 177: Option Kits

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Option Kits AutoFeed Vacuum Feeder Assembly 776xx157 Refer also to Appendix B - Instruction Sheets for Option Kits: IS0231 If the Autofeed is selected, the low-level sensor cannot be selected.
  • Page 178 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Vacuum Feeder Assembly 776xx157 Continued ITEM PART NO. DESCRIPTION QTY. 776XX159 LID RESERVOIR 776XX158 BRACKET RESERVOIR LID D10 784XX491 BHCS,M6 X 10.0 LG,S.S. D050170100 FEEDER TUBE 776XX102 THREADED FEEDER TUBE...

  • Page 179: Split Lid Kits

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Split Lid Kits 776xx610 ITEM DESCRIPTION PART NO. QTY. LID, OUTER, SPLIT 776XX199 LID, REAR INNER, SPLIT 776XX200 LID, FRONT INNER, SPLIT 776XX201 STANDOFF 091XX681 HANDLE, PULL 104XX135...

  • Page 180: Pump Control

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pump Control Cable Assembly Handgun Pump Control (029xx553) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0161 ITEM PART NO. DESCRIPTION QTY. 755XX077 SLEEVING;FIBERGLASS,#6,BLACK 061XX033 CONN;SHELL,4P,RECEPT,SIZE11...

  • Page 181: Pump Kit, Fixed, Standard Width (771Xx007)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Pump Kit, Fixed, Standard Width (771XX007) ITEM DESCRIPTION PART NO. QTY. GEAR PUMP ASSEMBLY 561XX308 O-RING 745XX035 SCREW 784XX341 WASHER 784XX476 BLANKET, PUMP INSULATION 776XX061 MANIFOLD 776XX111 HEX PLUG...

  • Page 182: Pump Kit, Variable, Standard Width (771Xx008) - After 5/18

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pump Kit, Variable, Standard Width (771XX008) - After 5/18 ITEM DESCRIPTION PART NO. QTY. GEAR PUMP ASSEMBLY 561XX308 O-RING 745XX035 SCREW 784XX341 WASHER 784XX476 BLANKET, PUMP INSULATION 776XX061...

  • Page 183: Pump Kit, Variable, Standard Width (771Xx008) - Before 5/18 And After 1/17

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Pump Kit, Variable, Standard Width (771XX008) - Before 5/18 and After 1/17 ITEM DESCRIPTION PART NO. QTY. GEAR PUMP ASSEMBLY 561XX308 O-RING 745XX035 SCREW 784XX341 WASHER 784XX476 BLANKET, PUMP INSULATION...

  • Page 184: Pump Kit, Fixed, Half Width (771Xx009)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pump Kit, Fixed, Half Width (771XX009) ITEM DESCRIPTION PART NO. QTY. GEAR PUMP ASSEMBLY 561XX330 O-RING 745XX035 SCREW 784XX341 WASHER 784XX476 BLANKET, PUMP INSULATION 776XX061 MANIFOLD 776XX111 HEX PLUG...

  • Page 185: Pump Kit, Variable, Half Width (771Xx010) - After 5/18

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Pump Kit, Variable, Half Width (771XX010) - After 5/18 ITEM DESCRIPTION PART NO. QTY. GEAR PUMP ASSEMBLY 561XX330 O-RING 745XX035 SCREW 784XX341 WASHER 784XX476 BLANKET, PUMP INSULATION 776XX061...

  • Page 186: Pump Kit, Variable, Half Width (771Xx010) - Before 5/18 And After 1/17

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pump Kit, Variable, Half Width (771XX010) - Before 5/18 and After 1/17 ITEM DESCRIPTION PART NO. QTY. GEAR PUMP ASSEMBLY 561XX330 O-RING 745XX035 SCREW 784XX341 WASHER 784XX476 BLANKET, PUMP INSULATION...

  • Page 187: Pump Kit, Fixed, Double Width (771Xx011)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Pump Kit, Fixed, Double Width (771XX011) ITEM DESCRIPTION PART NO. QTY. GEAR PUMP, DOUBLE WIDTH 561XX218 O-RING 745XX035 SCREW 784XX381 WASHER 784XX476 BLANKET, PUMP INSULATION 776XX061 MANIFOLD 776XX699...

  • Page 188: Pump Kit, Variable, Double Width (771Xx012) - After 5/18

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pump Kit, Variable, Double Width (771XX012) - After 5/18 ITEM DESCRIPTION PART NO. QTY. GEAR PUMP, DOUBLE WIDTH 561XX218 O-RING 745XX035 SCREW 784XX381 WASHER 784XX476 BLANKET, PUMP INSULATION...

  • Page 189: Pump Kit, Variable, Double Width (771Xx012) - Before 5/18 And After 1/17

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Pump Kit, Variable, Double Width (771XX012) - Before 5/18 and After 1/17 ITEM DESCRIPTION PART NO. QTY. GEAR PUMP, DOUBLE WIDTH 561XX218 O-RING 745XX035 SCREW 784XX381 WASHER 784XX476...

  • Page 190: Pump Kit, Fixed, Quad Width (771Xx013)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pump Kit, Fixed, Quad Width (771XX013) ITEM DESCRIPTION PART NO. QTY. GEAR PUMP, QUAD WIDTH 561XX219 O-RING 745XX035 SCREW 884XX496 WASHER 784XX476 BLANKET, PUMP INSULATION 776XX061 MANIFOLD 776XX699...

  • Page 191: Pump Kit, Variable, Quad Width (771Xx014) - After 5/18

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Pump Kit, Variable, Quad Width (771XX014) - After 5/18 ITEM DESCRIPTION PART NO. QTY. GEAR PUMP, QUAD WIDTH 561XX219 O-RING 745XX035 SCREW 884XX496 WASHER 784XX476 BLANKET, PUMP INSULATION...

  • Page 192: Pump Kit, Variable, Quad Width (771Xx014) - Before 5/18 And After 1/17

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pump Kit, Variable, Quad Width (771XX014) - Before 5/18 and After 1/17 ITEM DESCRIPTION PART NO. QTY. GEAR PUMP, QUAD WIDTH 561XX219 O-RING 745XX035 SCREW 884XX496 WASHER 784XX476...

  • Page 193: Pump Type - Previous (Before 1/2017)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Pump Type - Previous (before 1/2017) Pump Kit, Standard Width (560xx886) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0212 ITEM PART NO. DESCRIPTION QTY.

  • Page 194: Pump Kit, Double Width (561Xx221)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pump Kit, Double Width (561xx221) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0212 ITEM PART NO. DESCRIPTION QTY. 561XX218 GEAR PUMP, DOUBLE WIDTH 798XX175...

  • Page 195: Internal Level Sensors

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Internal Level Sensors Internal Low-Level Sensor Kit (776xx745) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0232 ITEM PART NO. DESCRIPTION QTY. 098XX106 AMPLIFIER, LEVEL SENSOR, PNP...

  • Page 196: Internal High-Level Sensor Kit (776Xx748)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Internal High-Level Sensor Kit (776xx748) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0232 ITEM PART NO. DESCRIPTION QTY. 098XX106 AMPLIFIER, LEVEL SENSOR, PNP 098XX107...

  • Page 197: External Pot Fill

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List External Pot Fill External Pot Fill Kit (776xx757) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0234...
  • Page 198 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit External Pot Fill Kit (776xx757) - Continued ITEM PART NO. DESCRIPTION QTY. 026XX317 ENCLOSURE, MODIFICATION 026XX318 MOUNTING PLATE, INTERNAL 784XX945 SHCS,M3 X 5MM LONG,S.S. 098XX106 AMPLIFIER, LEVEL SENSOR, PNP 798XX188 SHCS - M4 X 8MM, S.S.

  • Page 199: Alarm Beacon

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Alarm Beacon Alarm Beacon Assembly, 24V (782xx701) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0233 ITEM DESCRIPTION PART NO. QTY. BEACON, COVER & BASE...

  • Page 200: Alarm Beacon Replacement Bulb

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Alarm Beacon Replacement Bulb 105XX050, 24V, 5W Siren Element Kit (776xx762) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0233 ITEM PART NO. DESCRIPTION QTY.

  • Page 201: Relief Valve Assembly (594Xx189)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Relief Valve Assembly (594xx189) Refer also to Appendix B - Instruction Sheets for Option Kits: 999XD774-197 Unit Description Part # 707XX211 VALVE ASSY,PRESSURE RELIEF 797XX079 HEX NIPPLE M-M 1/8...

  • Page 202: Pressure Monitoring

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pressure Monitoring Pressure Switch Kit, 50-130 PSI (481xx050) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0213 ITEM PART NO. DESCRIPTION QTY. 485XX105 SWITCH; PRESSURE...

  • Page 203: Pressure Switch Kit, 275-850 Psi (481Xx052)

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Pressure Switch Kit, 275-850 PSI (481xx052) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0213 ITEM PART NO. DESCRIPTION QTY. 485XX106 SWITCH; PRESSURE 792XX340 FITTING ADAPTER...

  • Page 204: Pressure Transducer Assembly (098Xx134)

    Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit Pressure Transducer Assembly (098xx134) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0377 ITEM DESCRIPTION PART NO. QTY. TRANSDUCER PRESSURE 520XX031 WIRE PTFE 22 AWG BRN 540XX160 4.583...

  • Page 205: Auxiliary I/O

    MM113 - D10/D16 Hot Melt Unit Section 10 - Part Number List Auxiliary I/O Optional I/O HMU PCB Assembly (098xx134) Refer also to Appendix B - Instruction Sheets for Option Kits: IS0343 ITEM DESCRIPTION PART NO. QTY. PCB ASSY ANYBUS EXPANDED-I/O...
  • Page 206 Section 10 - Part Number List MM113 - D10/D16 Hot Melt Unit...

  • Page 207: Section 11 - Warranty

    MM113 - D10/D16 Hot Melt Unit Section 11 - Warranty Section 11 - Warranty Warranty Information Valco Cincinnati, Inc. warrants its equipment worldwide against defects in material and workmanship as outlined in this section. Liability of the company is limited to repair of the product, or replacement of any part shown to be defective, and does not extend to defects caused by accidents, misuse, abuse, neglect, tampering or deterioration by corrosion.
  • Page 208 Section 11 - Warranty MM113 - D10/D16 Hot Melt Unit...

  • Page 209: Section 12 - Service

    MM113 - D10/D16 Hot Melt Unit Section 12 - Service Section 12 - Service If a problem with your system persists, contact a ValcoMelton Technical Support representative. If your need is urgent, we encourage you to contact our corporate office in Cincinnati, Ohio, U.S.A. at (513) 874-6550. If the problem cannot be resolved, Valco Cincinnati, Inc.
  • Page 210 Section 12 - Service MM113 - D10/D16 Hot Melt Unit...

  • Page 211: Appendix A - Password Levels

    MM113 - D10/D16 Hot Melt Unit Appendix A - Password Levels Appendix A - Password Levels The Unit has multiple security levels to protect important information against unauthorized access. The levels are enabled with different PIN codes when entering the ‘Setup menu’. The following list includes the PIN codes for the different levels and describes the difference between them.
  • Page 212 Appendix A - Password Levels MM113 - D10/D16 Hot Melt Unit Setting Level 0 as Default - Continued...

  • Page 213: Appendix B - Power Requirements

    COULD OCCUR. Power requirements for the D10/D16 System (unit, hoses and guns) must be calculated before hooking up power, to verify that the hoses and guns do not exceed the power rating for the D Series unit. Personnel injury, as well as serious equipment damage, can result from overloading the system.
  • Page 214 Appendix B - Power Requirements MM113 - D10/D16 Hot Melt Unit...

  • Page 215: Appendix C - Micro Sd Backup & Restore

    MM113 - D10/D16 Hot Melt Unit Appendix C - Micro SD Backup & Restore Appendix C - Micro SD Backup & Restore Functions Backup (Level 3 Permission Required): • Deletes any existing backup on the micro SD card • Lookup and copy object IDs and their values to the card (all user configurable parameters) •...

  • Page 216: Error Codes

    Appendix C - Micro SD Backup & Restore MM113 - D10/D16 Hot Melt Unit Error Codes Code 1: SD card failed to initialize • It is likely there is not a card installed, it is damaged, or it is not formatted as FAT32...

  • Page 217: Appendix D - Communication Protocols-Modbus

    MM113 - D10/D16 Hot Melt Unit Appendix D - Communication Protocols-Modus Appendix D - Communication Protocols-Modbus Communication Specifications 1) The CPU board only supports Modbus RTU Baud Rate is defaulted to 19200 but has the option to run at 9600 or 19200 configurable in the settings menu.
  • Page 218 Appendix D - Communication Protocols-Modus MM113 - D10/D16 Hot Melt Unit Hardware Considerations - Continued With jumpers installed on JP1-4 (currently installed), the board is configure for 2-wire RTU. Can also be configured for 4-wire (without jumpers JP1-4). From RJ45 port (J2 on CPU board) Pin 1 is the Negative “A” comm. line and Pin 2 is the Positive “B”...
  • Page 219 MM113 - D10/D16 Hot Melt Unit Appendix D - Communication Protocols-Modus Parameter List - Continued Modbus Hex Address Short Name Write/Read Description Comments (Melton) (NC Spec) 0x010F Guns Standby % Not Used by Valco CPU 0x0110 Access level 0x0111 Temperature Units 0 = ºC, 1 = ºF...
  • Page 220 Appendix D - Communication Protocols-Modus MM113 - D10/D16 Hot Melt Unit Parameter List - Continued Modbus Hex Address Short Name Write/Read Description Comments (Melton) (NC Spec) 0x0132 W/R Monday Minute OFF 2 Not Used by Valco CPU 0x0133 W/R Monday...
  • Page 221 MM113 - D10/D16 Hot Melt Unit Appendix D - Communication Protocols-Modus Parameter List - Continued Modbus Hex Address Short Name Write/Read Description Comments (Melton) (NC Spec) 0x0155 W/R Thursday Hour OFF 2 Not Used by Valco CPU 0x0156 W/R Thursday...
  • Page 222 Appendix D - Communication Protocols-Modus MM113 - D10/D16 Hot Melt Unit Parameter List - Continued Modbus Hex Short Name Address Write/Read Description Comments (Melton) (NC Spec) 0x0178 W/R Sunday Type ON 2 Not Used by Valco CPU 0x0179 W/R Sunday...
  • Page 223 MM113 - D10/D16 Hot Melt Unit Appendix D - Communication Protocols-Modus Parameter List - Continued Modbus Hex Short Name Address Write/Read Description Comments (Melton) (NC Spec) 0x019A Spare Not Used by Valco CPU 0x019B Tank 2 Temperature All Temperatures in ºC w/ 25 ºC offset added...
  • Page 224 Appendix D - Communication Protocols-Modus MM113 - D10/D16 Hot Melt Unit Parameter List - Continued Modbus Hex Short Name Address Write/Read Description Comments (Melton) (NC Spec) 0x01BC Sequential Start Hose Temp Offset All Temperatures in ºC 0x01BD Sequential Start Gun On/Off...
  • Page 225 MM113 - D10/D16 Hot Melt Unit Appendix D - Communication Protocols-Modus Parameter List - Continued Modbus Hex Short Name Address Write/Read Description Comments (Melton) (NC Spec) 0x01DB Zone 5 Enable/Disable 0x01DC Zone 6 Enable/Disable 0x01DD Zone 7 Enable/Disable 0x01DE Zone 8 Enable/Disable...
  • Page 226 Appendix D - Communication Protocols-Modus MM113 - D10/D16 Hot Melt Unit...

  • Page 227: Appendix E - Communication Protocols-Ethernet Ip

    MM113 - D10/D16 Hot Melt Unit Appendix E - Communication Protocols-Ethernet IP Appendix E - Communication Protocols-Ethernet IP Hot Melt Unit to EthernetIP Communication Protocol The Melter Communication Interface Ethernet/IP module is configured to use a consistent 16 bytes of process data.

  • Page 228: Bit Definitions For Control Byte 0

    Appendix E - Communication Protocols-Ethernet IP MM113 - D10/D16 Hot Melt Unit Bit Definitions for Control Byte 0 These are control bits executed with each message by the Melter. When in remote mode, these functions are controlled only by the PLC, and cannot be updated at the Melter. In local mode, this byte is ignored, and full control is at the Melter.

  • Page 229: Data Index Byte 2

    MM113 - D10/D16 Hot Melt Unit Appendix E - Communication Protocols-Ethernet IP Data Index Byte 2 The Data Index is equal to the Melter Parameters that may be accessed through the Ethernet/IP protocol. Only those parameters listed can be accessed through remote mode. Parameters that require a system restart, including most setup parameters, will still need to be accessed at the Melter.

  • Page 230: Data Value Byte 4 And 5

    Appendix E - Communication Protocols-Ethernet IP MM113 - D10/D16 Hot Melt Unit Data Value Byte 4 and 5 This is the data that the PLC sends to the Melter to update a given parameter. This value is limited to the range listed in the Data Index table, and will return an Outside Range fault otherwise.

  • Page 231: Data Index Byte 2

    MM113 - D10/D16 Hot Melt Unit Appendix E - Communication Protocols-Ethernet IP Data Index Byte 2 This is the same Data Index as in Send Packet. This is used as an acknowledgement back to the PLC, to confirm the message.

  • Page 232: Current Alarm Types

    Appendix E - Communication Protocols-Ethernet IP MM113 - D10/D16 Hot Melt Unit Current Alarm Types When Reading the Current Alarm Type (Data Index 23), a specific code is returned on Read Data (Byte 4, 5). For Zone Errors, The Zone with the error is returned in Byte 4.

  • Page 233: Error Codes

    MM113 - D10/D16 Hot Melt Unit Appendix E - Communication Protocols-Ethernet IP Error Codes On an Error, the Status (byte 0, 1) will send back a 0x4000 hex, indicating an error has occurred. When this occurs, the Data Index (byte 2) will be set to the corresponding error code:...

  • Page 234: Status Indicators

    Appendix E - Communication Protocols-Ethernet IP MM113 - D10/D16 Hot Melt Unit Status Indicators 1 – Network Status LED 2 – Module Status LED 3 – Link/Activity LED port 1 4 – Link/Activity LED port 2 Network Status LED LED State...

  • Page 235: Appendix F - Instruction Sheets For Option Kits

    MM113 - D10/D16 Hot Melt Unit Appendix F - Instruction Sheets for Option Kits Appendix F - Instruction Sheets for Option Kits The attached Instruction Sheets apply to the Option Kits listed in the table below. Some of the Instruction Sheets associated with this system also contain information for other systems.
  • Page 236 Follow these instructions for all units, and then follow unit-specific instructions: Installation For unit drawings and parts lists, refer to “Parts List,” Pg.14. Disconnect power to the unit. Proceed according to the unit: Unit Series Page Start D4-E/D4/D10/D16 Flexmelt 50 Valco Melton...
  • Page 237 IS0231 Vacuum Feeder Assembly Instructions Open the back hose and front operator panels. D10/D16 Remove the two (2) M4 x 12 socket head cap screws holding the lanyards to the top of the case. Remove the quick-disconnect ground wire from the top of the case.
  • Page 238 Vacuum Feeder Assembly Instructions IS0231 D10/D16 - Continued File down any sharp metal edges that occur as a result of removing the knockouts. 10. Turn the case on its side. For D4 hot melt units, proceed to step 13. 11. Install the mounting bracket to the center bulkhead, using the two (2) socket head cap screws.
  • Page 239 13. For D4 hot melt units only: For D4 hot melt units only: For D4 hot melt units only: D10/D16 - Continued Install the level sensor amplifier box to the center bulkhead,using the two (2) M4 hex nuts. 14. Attach the terminal ring from the amplifier box to the grounding stud on the top of the case.
  • Page 240 IS0231 16. Install the reed sensors into the appropriate knockout on the top D10/D16 - Continued of the case. The reed sensor number is indicated by a label on one of the lead wires. The top of the sensors need to be .218" - .060"/+.100"...
  • Page 241 Vacuum Feeder Assembly Instructions 25. Using the two (2) ty-raps included in the kit, attach the cable to the D10/D16 - Continued case walls. This will ensure that the tank does not crush the wires when the case is reinstalled.
  • Page 242 Vacuum Feeder Assembly Instructions IS0231 27. Attach the three (3) flying leads from the amplifier box to the D10/D16 - Continued terminal block. 28. Attach the three (3) flying leads from the included cable assembly to the other side of the terminal block.
  • Page 243 Remove the panel holding the lid. Remove the current lid from the unit by removing the two (2) socket head cap acting as the hinge. Discard the old lid. Drill a hole into the back side of the panel as indicated below. Valco Melton...
  • Page 244 11. Route the cable out of the bottom of the unit and back up into the electrical cabinet. 12. Snap the cord grip shut. 13. Drill and tap the base of the electrical cabinet as detailed below. 14. Mount the amplifier box using two (2) M4 socket head cap screws. Valco Melton...
  • Page 245 17. Attach the other end of the ground wire to the grounding strip. 18. Attach the sensor cable to the amplifier box. 19. Route the amplifier box power cable and the valve cable along the side of the operator panel. Valco Melton...
  • Page 246 Attachments Attach the 10 mm tubing to the push-in 90° swivel fitting on the air valve. Connect the three (3) pin, white JST connector from the amplifier box to the temperature control board. Valco Melton...
  • Page 247 Connect the flying leads, with the white ferrules, to the feeder location on the temperature control board. Attach the flying terminal ring from the cable valve assembly to one of the grounding studs on the base of the chassis. Valco Melton...
  • Page 248 Once the vacuum feeder has stopped, open the lid, and make sure the unit is filled and the adhesive level is about 1.5"±0.25" from the top of the tank. Valco Melton...
  • Page 249 10. Allow the unit to refill. Make sure the light is green and the adhesive is at the appropriate level. If the adhesive is not at the appropriate level, repeat step 8. CAUTION! CAUTION! CAUTION! CAUTION! CAUTION! Check the adhesive level periodically to confirm the sensor is working properly. Valco Melton...
  • Page 250 Vacuum Feeder Assembly Instructions IS0231 Parts List External Vacuum SEE DETAIL "A" Feeder – D10/D16 (776XX157) SEE NOTE #3 REMOVE CIRCULAR KNOCKOUT (2) PLACES SEE DETAIL "B" PORT 1 PORT 3 PORT 2 DETAIL 'B' DETAIL 'A' Valco Melton...
  • Page 251 IS0231 Vacuum Feeder Assembly Instructions Item Part # Description External Vacuum Feeder - D10/D16 (776XX157) - Continued 776XX159 LID RESERVOIR 776XX158 BRACKET, RESERVOIR LID, D10 784XX491 SCREW D050170100 FEEDER TUBE 776XX102 THREADED FEEDER TUBE 784XX008 SCREW 776XX160 VALVE MOUNTING BRACKET...
  • Page 252 Vacuum Feeder Assembly Instructions IS0231 External Vacuum Feeder - D4-E/D4 (776XX305) SEE DETAIL "A" SEE DETAIL "B" PORT 1 PORT 3 PORT 2 DETAIL 'B' DETAIL 'A' Valco Melton...
  • Page 253 JUMPER CABLE ASSY 067XX154 CABLE TIE 075XX392 CONNECTOR, 4 PIN TERMINAL 784XX598 SCREW IS0274 IS, VACUUM FEEDER OPERATION 781XX629 LABEL,WARNING-HOT SURFACE 066XX075 CABLE CLAMP 784XX359 SCREW 799XX574 NUT,LOCK,STEEL 782XX707 MOUNTING PLATE, LEVEL SENSOR 798XX488 IS0231 IS, VACUUM FEEDER Valco Melton...
  • Page 254 Vacuum Feeder Assembly Instructions IS0231 External Vacuum Feeder - FlexMelt 50 (776XX568) Valco Melton...
  • Page 255 INTERNAL LEVEL SENSOR KIT 029XX584 JUMPER CABLE ASSY 104XX135 HANDLE, PULL 784XX300 SCREW 784XX568 FLAT WASHER 781XX629 LABEL,WARNING-HOT SURFACE 067XX154 TY-RAP 066XX217 CORD GRIP 799XX479 CONV UNION 755XX485 TUBING IS0231 IS, VACUUM FEEDER K051701002 ASSEMBLY,FEEDER TUBE 776XX243 LEVEL PROBE GUARD Valco Melton...
  • Page 256 4; then run a jumper wire from where the Orange wire is landed to the other input you want to use (I1-Pin 2, I2-Pin 5, I3-Pin 8, or I4-Pin 11). Valco Melton...
  • Page 257 ‘Pump On/Off’ will activate the pump when the handgun trigger is pulled. ‘Auto Setback’ resets the Auto Setback Timer when the trigger is pulled. If Auto Setback is enabled (see manual), when the Auto Setback Timer expires, the unit goes into setback due to inactivity. Setup is complete. Valco Melton...
  • Page 258 To tell if the pump is enabled when the trigger is held, listen for the sound of the pump activating. Also, if there is glue in the system, the handgun will dispense glue. Valco Melton...
  • Page 259 If you want to use one handgun switch for two different functions (ie Pump On/ Off and Auto Setback), then you can connect the cable as follows. Valco Melton...
  • Page 260 ‘Pump On/Off’ will activate the pump when the handgun trigger is pulled. ‘Auto. Setback’ resets the Auto Setback Timer when the trigger is pulled. If Auto Setback is enabled (see manual), when the Auto Setback Timer expires, the unit goes into setback due to inactivity. Setup is complete. Valco Melton...
  • Page 261 To tell if the pump is enabled when the trigger is held, listen for the sound of the pump activating. Also, if there is glue in the system, the handgun will dispense glue. Valco Melton...
  • Page 262 On J13 Customer Connector If you use two handguns and want both to activate an input, install the yellow Pin 5 (Remove Box GND): Orange and orange wires from each cable in Pin 6 (Remote Box Sig): Yellow parallel. Valco Melton...
  • Page 263 3. SW1 is in the FIX position. See figure below. Setup is complete. Connect the hose/handgun to the D10 Unit. Testing Connect the 4-pin circular connector from the Handgun Switch Cable installed, to the mating connector from the hose.
  • Page 264 Pump If changing the pump in a D10 or D16 Unit, it is not necessary to drain the tank. These units include a tank-connection shut-off plug that can be opened or closed, using a screwdriver (see below). Turn the plug to CLOSED (slot to horizontal position).
  • Page 265 Warning! Turn the unit on its side. Cut the tie wrap as shown in the figure, below. Remove motor bracket bolts Motor bracket bolts Slide the motor forward out of the way. The coupling will come apart easily. Valco Melton...
  • Page 266 - Continued Center Disk Slide Motor and Bracket this way Remove the coupling half from the pump. Remove the pump jacket (if installed). Remove the 4 pump mounting bolts. Pump Mounting Bolts Jacket Coupling Half 10. Remove the pump. Valco Melton...
  • Page 267 Double-width Pump Standard-width Pump Caution! Caution! Caution! Caution! Caution! Install by cross-tightening the four (4) mb x 90 socket- head cap screws. This will ensure the pump has a uniform seal with the manifold, and will not leak. Valco Melton...
  • Page 268 Hortonwood 32 D-15749 Gallun, Germany TEL: (1) 513-874-6550 31160 Orcoyen, Navarra, Spain Telford TF1 7YN England TEL: (49) 33764 8700 FAX: (1) 513-874-3612 TEL: (34) 948-321-580 TEL: (44) 1952-677911 FAX: (49) 33764 87070 FAX: (34) 948-326-584 FAX: (44) 1952-677945 Valco Melton...
  • Page 270 IS0230 - Pattern Control Instructions IS0230 - Pattern Controller Instructions Version 4/18 Important Information WARNING! Read and follow all instructions, warnings, tag, and label before operating the equipment. Only qualified personnel should perform this procedure. USE OF THIS EQUIPMENT IN A MANNER OTHER THAN DESCRIBED IN THIS INSTRUCTION SHEET AND FAILING TO FOLLOW ALL INSTRUCTIONS COULD RESULT IN PERSONAL INJURY, DEATH, OR DAMAGE TO EQUIPMENT.
  • Page 271 IS0230 - Pattern Control Instructions Installation To install a pattern control in a D series unit: 1. Disconnect the power. 2. Carefully remove the five (5) knockouts from the front of the operator panel. 3. File down any sharp metal edges that occur as a result of removing the knockouts. 4.
  • Page 272 IS0230 - Pattern Control Instructions 6. Disconnect the spades on the top of the power supply. 7. Remove the current power supply (148xx076) by removing the two (2) M3 X 8 socket head cap screws on the top and bottom of the power supply. If the power supply is replaced at the factory, write this power supply into stock as 148xx076.
  • Page 273 IS0230 - Pattern Control Instructions To install a pattern control in an EC series unit: 14. Disconnect the power. 15. Open the front operator panel. 16. Remove the three (3) M4 hex nuts and three (3) M4 lock washers from the control board shown in the picture below.
  • Page 274 IS0230 - Pattern Control Instructions 23. Screw one of the M3 socket head cap screws half way into the bottom hole. 24. Place the new power supply onto the bottom screw. 25. Insert the other M3 socket head cap screw into the top hole for the power supply. 26.
  • Page 275 IS0230 - Pattern Control Instructions To install the communication cable for fixed speed D series units or EC series units: 29. Attach the four-conductor, four-pin connector to J4 on the pattern control board (152xx671). 30. Attach the two-conductor, four-pin connector to J1 on the temperature control board (152xx746). 31.
  • Page 276 IS0230 - Pattern Control Instructions 32. Proceed to step 38. To install communication cable for variable speed D series units: 33. Attach the four-pin connector to J4 on the pattern control board (152XX671).
  • Page 277 IS0230 - Pattern Control Instructions 34. Attach the eight-pin connector to the J7 on the VFD board (151XX701). 35. Route the wires to the side panel using ty-raps and wire harnesses that were included with the assembly. DO NOT route the wires from the pattern control parallel with the wires from the switch.
  • Page 278 IS0230 - Pattern Control Instructions 37. Attach the spades on the included cable assembly to the remaining slots on the top of the power supply, following the labels on the wires. 38. Close the operator panel. To enable pattern control. 39.
  • Page 279 IS0230 - Pattern Control Instructions 43. Select “Pattern Control” and press the up arrow to enable it. 44. Go over one more screen to the right and select “Pattern Control Overlay”. Press the up arrow to enable it. DO NOT enable the overlay if it is an EC series unit. 45.
  • Page 280 IS0230 - Pattern Control Instructions 51. Check the cable connections by verifying the connectors are not damaged. 52. Reinsert the two pattern control connectors into the appropriate locations. 53. Turn on the unit. 54. Repeat step 45-48, if the problem continues please contact Technical Service. To change the pattern control to speed or time based: 55.
  • Page 281 Both Turn off the unit and disconnect the power. Installation Open the back hose and front operator panels. Remove the two (2) M4 X 12 socket head cap screws holding the lanyards to the top of the case. Valco Melton...
  • Page 282 Attach the amplifier box to the appropriate mounting location on the center bulkhead using two (2) M4 X 8 socket head cap screws as shown below. Valco Melton...
  • Page 283 13. Thread the sensor into the tank so that the tip of the sensor is 1.5 inches from the wall of the tank. 14. Feed the cable with the Lemo connector through the holes in the chassis, as shown below. Valco Melton...
  • Page 284 14. Reattach the case to the chassis by reversing steps 2-6. 15. Attach the Lemo connector to the bottom of the appropriate Rechner amplifier box. 16. Attach the JST connector from the assembly to the appropriate position as shown below. Internal High Internal Low Valco Melton...
  • Page 285 Fill the tank with adhesive until the adhesive level is in the center of the desired sensor. On the amplifier box, if the sensor light is green, carefully turn the screw clockwise until the light changes to amber. Valco Melton...
  • Page 286 Close the front operator panel. Go to the setting screen by pressing Adjusting the Sensor Time Delay Unlock the control by using the level 3 password “6550”. Go to the setting screen by pressing again. Go to the “System” screen. Valco Melton...
  • Page 287 IS0232 Select Internal (low) or External (high) ON Delay based on the Adjusting the Sensor Time Delay - desired sensor and adjust the time depending on your Continued application. The default time for either sensor is 5 seconds. Valco Melton...
  • Page 288 5: step 5: step 5: step 5: Remove one of the knockouts from the front of the chassis. File down any remaining metal chips from the knockout hole. Attach the provided cord grip to the new mounting hole. Valco Melton...
  • Page 289 If the cord grip was not installed, route the cable into the parent machine’s electrical enclosure so that the System JST connector is inside. Attach the four-pin JST connector to the universal control on the parent machine. Valco Melton...
  • Page 290 Fill the pot to the desired adhesive level. Slide the sensor into the compression fitting, on the mounting bracket, until the bottom of the sensor is 0.50" below the desired adhesive level. Valco Melton...
  • Page 291 15. Unlock the control by using the level-3 password, “6550”. 16. Return to the setting screen by pressing again. 17. Access the “System” screen. 18. Select “Pot Fill Mode,” and press the up arrow to enable it. 19. Enable the “External On Delay.” Valco Melton...
  • Page 292 Verify that the pump on the parent machine turns off after the unit is filled to the desired level. CAUTION! CAUTION! CAUTION! Check the level of adhesive periodically to ensure the CAUTION! CAUTION! sensor is working properly. Valco Melton...
  • Page 293 12. Return to the setting screen by pressing again. 13. Access the “System” screen. 14. Select External ON Delay, based on the desired sensor, and adjust the time, dependent on the application. The default time for either sensor is five seconds. Valco Melton...
  • Page 294 The beacon does not need to be installed to the top of the unit. If the beacon is installed on an alternative surface, a new female five-pin Turck cable will need to be purchased separately. Valco Melton...
  • Page 295 (4) M5 X 8 socket head cap screws. Attach the female connector, included in the bag, to the beacon assembly. Attach the three (3) flying leads to the universal control, as shown below. Wire Locations Pin 1 Pin 2 White Blue Brown Valco Melton...
  • Page 296 Close the front operator panel. Turn the unit on. Enabling the Beacon Access the setting screen by pressing Unlock the control using the level-3 password, “6550”. Return to the setting screen by pressing again. Access the “System” screen. Valco Melton...
  • Page 297 2 and 3. If the jumper is still connected, reattach the beacon assembly. If the jumper is missing, install a new jumper. Verify that the beacon is working. The siren will start when the second beacon light is on. Valco Melton...
  • Page 300 Operating Range (psi) 481XX050 50-130 481XX051 160-400 481XX052 275-850 These pressure switches are to be installed into the back or side of hot-melt units. The fittings included with this kit are for 9/16" hose ports and 1/4" NPT gauge ports. Valco Melton...
  • Page 301 Remove the hex plug from side of the manifold as shown below. Installing the Pressure Switch into the Side of a Manifold Attach the adapter fitting to the open port on the side of the manifold. Connect the desired pressure switch to the adapter fitting. Valco Melton...
  • Page 302 Connect the brown wire into “GND” for the desired input. If a pressure rise is desired, connect the blue wire to the center pin. If a pressure drop is desired, connect the red wire to the center pin. Valco Melton...
  • Page 303 14. Close the front operator panel. Close the front operator panel. Enabling Pressure Switch Input Turn the unit on, if it is not already. Go to the setting screen by pressing Unlock the control, using the level-3 password, “6550”. Valco Melton...
  • Page 304 Hortonwood 32 D-15749 Gallun, Germany TEL: (1) 513-874-6550 31160 Orcoyen, Navarra, Spain Telford TF1 7YN England TEL: (49) 33764 8700 FAX: (1) 513-874-3612 TEL: (34) 948-321-580 TEL: (44) 1952-677911 FAX: (49) 33764 87070 FAX: (34) 948-326-584 FAX: (44) 1952-677945 Valco Melton...
  • Page 305 IS0299 - D Series Coupling Upgrade Procedure IS0299 - D Series Coupling Upgrade Procedure 1/16 Important Information: Read Before Use WARNING! Read and follow all instructions, warnings, tags, and labels before operating the equipment. Only qualified personnel should perform this procedure. Use of this equipment in a manner other than described in this instruction sheet and failing to follow all instructions could result in personal injury, death, or damage to equipment.
  • Page 306 IS0299 - D Series Coupling Upgrade Procedure Parts Included The jaw coupling upgrade kit for the D series hot melt units (776XX490) contains the following components: 776XX313 1.000 BRACKET MOTOR 783XX370 1.000 HUB JAW COUPLING 1/2” BORE 783XX371 1.000 HUB JAW COUPLING 3/4" BORE 783XX372 1.000 SPIDER JAW COUPLING...
  • Page 307 IS0299 - D Series Coupling Upgrade Procedure Installing the Coupling 1. With the tank completely empty and the unit disconnected from power, gently lay the unit on its side. 2. Using a pair of wire snips, cut the tie wrap securing the motor cable to the chassis as shown in the figure below.
  • Page 308 IS0299 - D Series Coupling Upgrade Procedure 3. Using a ratchet, drive extension, and 10mm socket, remove the (4) M6 hex head cap screws securing the motor bracket to the chassis as shown in the figure below. 4. Slide the motor forward out of the way. The coupling should separate easily. Remove the black center disk and set it aside.
  • Page 309 IS0299 - D Series Coupling Upgrade Procedure 6. Using a ratchet and 7/16 socket, remove the (4) 1/4-28 hex head cap screws securing the motor to the motor bracket. Remove the motor bracket and set it aside. 7. Using a ratchet and 13mm socket, remove ONLY the (2) M8 hex head cap screws and washers that secure the pump to the manifold, as shown in the figure below.
  • Page 310 IS0299 - D Series Coupling Upgrade Procedure CAUTION! Remove only the (2) M8 hex head cap screws shown. Removing all of the bolts is not necessary unless replacing the pump at the same time. If the pump insulation blanket interferes with the installation of the motor bracket, remove it and if desired, reinstall after completeing this procedure.
  • Page 311 IS0299 - D Series Coupling Upgrade Procedure The right hand mounting bracket is shown in the figure below. The left hand mounting bracket is mounted to the same bolt pattern on the opposite side of the new motor bracket. 12. Place the new ½” bore jaw coupling (783XX370) on the pump shaft. Use the .040” feeler gauge provided (782XX596) to position the hub on the pump shaft .040”...
  • Page 312 IS0299 - D Series Coupling Upgrade Procedure 14. Replace the key in the motor shaft if removed earlier. 15. Place the new ¾” bore jaw coupling hub (783XX371) on the motor shaft. Do not tighten the set screw yet, as the motor side hub needs to be positioned after assembly. 16.
  • Page 313 No part of this document may be reproduced without express permission from Valco Cincinnati, Inc. All rights reserved. Designs and other information may change without notice. Valco Cincinnati Incorporated Melton S.L.U. Valco Cincinnati, Ltd. Valco Cincinnati GmbH Valco Melton France 411 Circle Freeway Drive Pol. Industrial Agustinos Unit 7-8 Bonnerstrasse 349 Technoparc des Hautes Faventines Cincinnati, Ohio 45246, USA calle G, n.

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