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VALCO MELTON D4 Manual

Hot melt unit
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D4 Hot Melt Unit
Manual Number:
MM147
Revision Date:
6/2018

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Summary of Contents for VALCO MELTON D4

  • Page 1 D4 Hot Melt Unit Manual Number: MM147 Revision Date: 6/2018...
  • Page 2 © Valco Melton All Rights Reserved This manual is provided with the D4 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: D4 Hot Melt Unit Product Name: complies with the following Council Directives: 2006/42/EC Safety of Machinery: 2014/35/EU Low Voltage Equipment: 2014/30/EU...

  • Page 5: Table Of Contents

    MM147 - D4 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 ................... 13 Read Thoroughly Before Handling Equipment .......................
  • Page 6 Table of Contents MM147 - D4 Hot Melt Unit Power On/Off and Standby Mode ........................... 37 Display Contrast Adjustment ........................... 38 User Interface................................39 Navigation ............................... 39 Memory Storage ............................. 39 Thumbwheel vs. Single Digit Edit ......................40 Entering Passwords ..............................41 Set Language ................................
  • Page 7 MM147 - D4 Hot Melt Unit Table of Contents Pump Configuration ..........................77 Number of Pumps ........................77 Pump Configuration for Specific No. Pump ................77 Pump Setup Menu ..........................78 Encoder Setup Menu ............................... 80 PID Setup Menu ..............................81 PID Settings ............................
  • Page 8 D4 Unit, Variable speed, 2 exit (776xx889) .................... 116 D4 Unit, Variable speed, 4 exit (776xx890) .................... 117 D4 Unit, Variable speed, 2 exit (776xx889) - before 5/18 ..............118 D4 Unit, Variable speed, 4 exit (776xx890) - before 5/18 ..............119 D4 Base Unit (776xx392) ............................
  • Page 9 MM147 - D4 Hot Melt Unit Table of Contents Pressure Switch Kit, 50-130 PSI (481xx050) ................137 Pressure Switch Kit, 160-400 PSI (481xx051) ................138 Pressure Switch Kit, 275-850 PSI (481xx052) ................138 Heavy Duty Pressure Gauge (786xx129) ................... 138 Pressure Transducer Assembly (521xx019)................
  • Page 10 Table of Contents MM147 - D4 Hot Melt Unit Module Status LED ........................170 Link/Activity LED ..........................170...

  • 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 D4 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

    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. All units ordered using the S number configuration will have a final selection number engraved on the nameplate.

  • Page 13: Section 2 - Safety And Use

    MM147 - D4 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 14: 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 15: 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 16: Shut Down Safety Information

    MM147 - D4 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 17: What To Do If Contact With Hot Adhesive Occurs

    MM147 - D4 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 18: What To Do If Adhesive-Related Fire Or Explosion Occurs

    Section 2 - Safety and Use MM147 - D4 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 19: Hose Safety Information

    MM147 - D4 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 20 Section 2 - Safety and Use MM147 - D4 Hot Melt Unit...

  • Page 21: Section 3 - Basic Features

    Section 3 - Basic Features Key Features This section describes the basic features of the D-Series Hot Melt Systems. The basic features of the D4 Hot Melt Units are similar, with the exception of the tank capacity of each unit.
  • Page 22 Section 3 - Basic Features MM147 - D4 Hot Melt Unit...

  • Page 23: Section 4 - Installation

    Section 4 - Installation Choosing a Location The D4 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 24: Mounting Footprint

    Section 4 - Installation MM147 - D4 Hot Melt Unit Mounting Footprint Installation Kit An Installation Kit (091xx734) 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 25: 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 D4 hot melt unit can be set up to use one of the following power sources: Power Connector Voltage Plug...
  • Page 26 Section 4 - Installation MM147 - D4 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 27: Connecting The Hoses

    MM147 - D4 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 28 Section 4 - Installation MM147 - D4 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 29: Connecting The Hot Melt Hoses To The Applicators

    MM147 - D4 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 30: Wiring Diagram

    Section 4 - Installation MM147 - D4 Hot Melt Unit Wiring Diagram...

  • Page 31: Wiring Diagram - Before 5/18

    MM147 - D4 Hot Melt Unit Section 4 - Installation Wiring Diagram - Before 5/18...

  • Page 32: Input/Output Connections

    Section 4 - Installation MM147 - D4 Hot Melt Unit 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 33 MM147 - D4 Hot Melt Unit Section 4 - Installation 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 34: Input/Output Connections - Before 5/18

    Section 4 - Installation MM147 - D4 Hot Melt Unit 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 35: Section 5 - Setup

    MM147 - D4 Hot Melt Unit Section 5 - Setup Section 5 - Setup Control Panel...
  • Page 36 Section 5 - Setup MM147 - D4 Hot Melt Unit 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 37: Power On/Off And Standby Mode

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 38: Display Contrast Adjustment

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 39: User Interface

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 40: Thumbwheel Vs. Single Digit Edit

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 41: Entering Passwords

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 42: Set Language

    Section 5 - Setup MM147 - D4 Hot Melt Unit Set Language Continued Next Page...
  • Page 43 MM147 - D4 Hot Melt Unit Section 5 - Setup Set Language - Continued...

  • Page 44: Set Temperature Units

    Section 5 - Setup MM147 - D4 Hot Melt Unit Set Temperature Units...

  • Page 45: Programming Temperatures

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 46: Tank Temperature

    Section 5 - Setup MM147 - D4 Hot Melt Unit Tank Temperature Hose/Valve Temperature Continued Next Page...
  • Page 47 MM147 - D4 Hot Melt Unit Section 5 - Setup Hose/Valve Temperature - Continued...

  • Page 48: System/Pump Ready Temperature Offset

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 49: Ready Delay Time

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 50: Over Temperature Alarm

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 51: Under Temperature Alarm

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 52: Maximum Temperature

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 53: Beacon/Alarm Setup

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 • Pump On • Power On •...
  • Page 54 Section 5 - Setup MM147 - D4 Hot Melt Unit Beacon/Alarm Setup - Continued...

  • Page 55: Beacon 2

    MM147 - D4 Hot Melt Unit Section 5 - Setup Beacon 2...

  • Page 56: Automatic Pump Mode

    Section 5 - Setup MM147 - D4 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 57: Pressure Setup

    MM147 - D4 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 58 Section 5 - Setup MM147 - D4 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 59 MM147 - D4 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 60: Pot Fill Mode

    Section 5 - Setup MM147 - D4 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 61: Level Sensor Setup

    MM147 - D4 Hot Melt Unit Section 5 - Setup Level Sensor Setup Level 1 and 2 There are two level controls typically used with the D-Series Units. The Level 1 sensor can be used inside the tank of the unit to trigger an auto-fill device (see hopper feeder below), or an alarm state. The Level 2 sensor is used for pot fill mode (see Pot Fill Mode - Section 5).

  • Page 62: Filter Change Timer

    Section 5 - Setup MM147 - D4 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 63: Programming Shifts

    MM147 - D4 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 64 Section 5 - Setup MM147 - D4 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 65 MM147 - D4 Hot Melt Unit Section 5 - Setup Moving Through the Shift Time/Day Screens - Continued Press the Clock Button to enable all shift settings (the 7-Day Timer) Do not turn off the main power to the control. The clock/timer will not operate if the power is off.

  • Page 66: Diagnostics

    Section 5 - Setup MM147 - D4 Hot Melt Unit Diagnostics The Diagnostics Screen shows the current software version as well as the current temperature and status of each zone.

  • Page 67: Setback

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 68: Automatic Setback Timeout

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 69: Startup Setup

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 70 Section 5 - Setup MM147 - D4 Hot Melt Unit Sequential Start - Valve...

  • Page 71: History

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 72: User Inputs And Outputs

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 73 MM147 - D4 Hot Melt Unit Section 5 - Setup User Inputs and Outputs - Continued Outputs 1-4 Conditions to Turn Output ON Disabled None Setback On Control is in Setback mode Alarm High Temperature Alarm OR, Low Temperature Alarm OR,...

  • Page 74: Configuration

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 75: Auxiliary I/O

    MM147 - D4 Hot Melt Unit Section 5 - Setup 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 76: Config Comm Menu

    Section 5 - Setup MM147 - D4 Hot Melt Unit Config Comm Menu Comm Menu, located in the Config Menu, allows the user to select Modbus RTU, Ethernet IP, or to disable remote communication. Level 3 is required for all of these settings.

  • Page 77: Pump Configuration

    MM147 - D4 Hot Melt Unit Section 5 - Setup Config Comm Menu - Continued 6. If Modbus RTU is in use, set the Slave ID and Baud Rate for the CPU. Reference Manual MM139 for more information on configuring...

  • Page 78: Pump Setup Menu

    Section 5 - Setup MM147 - D4 Hot Melt Unit Pump Setup Menu The Speed Gain value is adjustable from 0-200%. It scales the pump speed when using Automatic Pump Mode, when the pump speed is determined by the Auto Speed Input. The factory default setting is 100%.
  • Page 79 MM147 - D4 Hot Melt Unit Section 5 - Setup Pump Setup Menu - Continued The Auto Speed Input setting is the type of line speed input used to adjust the pump speed. See the VFD board connections (below) to find the input connectors for the Auto Speed Input. Allowable settings and their corresponding connections are shown below.

  • Page 80: Encoder Setup Menu

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 81: Pid Setup Menu

    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 82: Memory Menu

    Section 5 - Setup MM147 - D4 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 83 MM147 - D4 Hot Melt Unit Section 5 - Setup Procedure - Continued 3. Turn on power to the CPU board. 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 84: Hot Melt Cpu Utasker Bootloader (119Xx301) Error Codes

    Section 5 - Setup MM147 - D4 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 85: Initialization Instructions

    MM147 - D4 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 86: Configuring The Unit Type

    Section 5 - Setup MM147 - D4 Hot Melt Unit Configuring the Unit Type 1. 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 87: Selecting The Rtd Type

    MM147 - D4 Hot Melt Unit Section 5 - Setup Selecting the RTD type 1. Use the + or – buttons to select the type of RTDs used in the system. The RTD type can be Ni120 or PT100. All D10/D16 hot melt units use Ni120 RTDs. PT100 should not be selected, this will cause the system to malfunction.

  • Page 88: Selecting The Temperature Units

    Enabling the pattern control when a pattern control is not equipped will result in communication failure. Only enable the pattern control when one is equipped and connected. The Pattern Control is not available with the D4 Hot Melt Unit. Finishing the Configuration When prompted to finish the configuration, use the right arrow button to select ‘Yes,’...

  • Page 89: Adjusting The Pressure Control Valve

    Section 5 - Setup Adjusting the Pressure Control Valve The D4 unit contains a single-stage relief valve (see figure below). Additionally, the D4 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 90: Gramage Feature

    Section 5 - Setup MM147 - D4 Hot Melt Unit 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 91: D Series Variable Frequency Drive Configuration (If Equipped)

    MM147 - D4 Hot Melt Unit Section 5 - Setup D Series Variable Frequency Drive Configuration (If Equipped) 1. Press ‘DSP’ to display ‘F’ number; use arrow keys to reach function to change. 2. Press ‘Data Ent’ to display current value, use arrow keys to change value.

  • Page 92: Before 5/18

    Section 5 - Setup MM147 - D4 Hot Melt Unit Before 5/18 Valco Setting Factory Default Function Range 03.0 05.0 Acceleration Time 00.1 – 999 Seconds 05.0 05.0 Deceleration Time 00.1 – 999 Seconds 000: Fwd/Stop, Rev/Stop External Operation Mode...

  • Page 93: Section 6 - Operation

    MM147 - D4 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 94: Temperature

    Section 6 - Operation MM147 - D4 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 95: Pump Operation

    MM147 - D4 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 96: Variable Speed Unit

    Section 6 - Operation MM147 - D4 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 97: Setback

    MM147 - D4 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 98: Pot Fill - External Low Level Detection

    Section 6 - Operation MM147 - D4 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 99: Filling The Tank

    MM147 - D4 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 100 Section 6 - Operation MM147 - D4 Hot Melt Unit...

  • Page 101: Section 7 - Maintenance

    Section 7 - Maintenance This section contains guidelines and procedures for maintaining the D4 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 102: 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 D4 hot melt unit on and allow 20-30 minutes for hoses and guns to reach temperature. 6. Turn the pump on.
  • Page 103 MM147 - D4 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 104: Parts Replacement

    Section 7 - Maintenance MM147 - D4 Hot Melt Unit Parts Replacement WARNING! If the system is hot, wear insulated gloves and eye protection when disconnecting hoses. Failure to observe could result in personal injury, death, or damage to equipment.

  • Page 105: Changing The Filter

    MM147 - D4 Hot Melt Unit Section 7 - Maintenance 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 106 Section 7 - Maintenance MM147 - D4 Hot Melt Unit...

  • Page 107: Section 8 - Troubleshooting And Repair

    MM147 - D4 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 108 Section 8 - Troubleshooting and Repair MM147 - D4 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 109: Section 9 - Specifications

    MM147 - D4 Hot Melt Unit Section 9 - Specifications Section 9 - Specifications General It is the purchaser’s responsibility to ensure that all local, county, state, and national codes, regulations, rules, and laws relating to safety and safe operating conditions are met and followed.

  • Page 110: Dimensions

    Section 9 - Specifications MM147 - D4 Hot Melt Unit Dimensions...

  • Page 111: Section 10 - Part Number List

    MM147 - D4 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 112: D4 Unit

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit D4 Unit...
  • Page 113 MM147 - D4 Hot Melt Unit Section 10 - Part Number List D4 Unit - Continued...

  • Page 114: D4 Unit, Fixed Speed, 2 Exit (776Xx887)

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit D4 Unit - Continued D4 Unit, Fixed speed, 2 exit (776xx887) ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D4 776XX392 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT 776XX314...

  • Page 115: D4 Unit, Fixed Speed, 4 Exit (776Xx888)

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List D4 Unit - Continued D4 Unit, Fixed speed, 4 exit (776xx888) ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D4 776XX392 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT 776XX314...

  • Page 116: D4 Unit, Variable Speed, 2 Exit (776Xx889)

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit D4 Unit - Continued D4 Unit, Variable speed, 2 exit (776xx889) ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D4 776XX392 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT 776XX314...

  • Page 117: D4 Unit, Variable Speed, 4 Exit (776Xx890)

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List D4 Unit - Continued D4 Unit, Variable speed, 4 exit (776xx890) ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D4 776XX392 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT 776XX314...

  • Page 118: D4 Unit, Variable Speed, 2 Exit (776Xx889) - Before 5/18

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit D4 Unit - Continued D4 Unit, Variable speed, 2 exit (776xx889) - before 5/18 ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D4 776XX392 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT...

  • Page 119: D4 Unit, Variable Speed, 4 Exit (776Xx890) - Before 5/18

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List D4 Unit - Continued D4 Unit, Variable speed, 4 exit (776xx890) - before 5/18 ITEM DESCRIPTION PART NO. QTY. BASE UNIT ASSY, D4 776XX392 BRACKET MOTOR 776XX313 BRACKET MOUNTING LEFT...

  • Page 120: D4 Base Unit (776Xx392)

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit D4 Base Unit (776xx392)
  • Page 121 MM147 - D4 Hot Melt Unit Section 10 - Part Number List D4 Base Unit (776xx392) - Continued ITEM DESCRIPTION PART NO. QTY. CHASSIS 775XX858 STANDOFF 775XX857 RESERVOIR KIT 916XX808 WASHER 798XX593 798XX301 CABLE ASSY, RESERVOIR RTD 029XX788 SUPPORTING FLANGE...
  • Page 122 Section 10 - Part Number List MM147 - D4 Hot Melt Unit D4 Base Unit (776xx392) - Continued ITEM DESCRIPTION PART NO. QTY. PCB ASSY, 12 ZONE GEAR PUMP 151XX747 WIRE TERMINAL, RING 075XX070 798XX488 PANEL OPERATOR D4 776XX318 OVERLAY ASSY, HM CTRL, D-SERIE...

  • Page 123: D4 Base Unit (776Xx392) - Before 5/18

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List D4 Base Unit (776xx392) - before 5/18 ITEM DESCRIPTION PART NO. QTY. CHASSIS 775XX858 STANDOFF 775XX857 RESERVOIR KIT 916XX808 WASHER 798XX593 798XX301 CABLE ASSY, RESERVOIR RTD 029XX788 SUPPORTING FLANGE...
  • Page 124 Section 10 - Part Number List MM147 - D4 Hot Melt Unit D4 Base Unit (776xx392) - before 5/18 - Continued ITEM DESCRIPTION PART NO. QTY. PCB ASSY, 12 ZONE GEAR PUMP 151XX747 WIRE TERMINAL, RING 075XX070 798XX488 PANEL OPERATOR D4...

  • Page 125: Installation Kit (091Xx734)

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List Installation Kit (091xx734) ITEM DESCRIPTION PART NO. QTY. FUSE 085XX220 FUSE 085XX271 FUSE 085XX289 FUSE; TIME LAG 085XX272 D4 HOT MELT UNIT MANUAL - CD MM147-CD BOX,TRAY 730XX015 WARRANTY CARD; VALCOMELTON LOGO 999XA774-157...

  • Page 126: Option Kits

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit Option Kits The D4 can support a maximum of two level sensors; only two of the following sensors may be selected: • Autofeed • Internal Low-Level • External Pot Fill...
  • Page 127 MM147 - D4 Hot Melt Unit Section 10 - Part Number List Vacuum Feeder Assembly - 776xx305 - Continued ITEM DESCRIPTION PART NO. QTY. LID, RESERVOIR 776XX041 BRACKET,RESERVOIR, D4-E 776XX042 SCREW 784XX491 FEEDER TUBE D050170100 FEEDER TUBE ADAPTER 776XX102 SCREW...

  • Page 128: Pump Control

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit Pump Control Cable Assembly Handgun Pump Control (029xx552) Refer also to Appendix C - Instruction Sheets for Option Kits: IS0161 ITEM DESCRIPTION PART NO. QTY. SLEEVING 755XX077 CONN,SHELL...

  • Page 129: Pump Kit, Standard Width (561Xx216)

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List Pump Kit, Standard Width (561xx216) Refer also to Appendix C - Instruction Sheets for Option Kits: IS0212 ITEM DESCRIPTION PART NO. QTY. GEAR PUMP, STANDARD WIDTH 561XX308 SCREW...

  • Page 130: Internal Level Sensors

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit Internal Level Sensors Internal Low-Level Sensor Kit (776xx892) Refer also to Appendix C - Instruction Sheets for Option Kits: IS0232 ITEM DESCRIPTION PART NO. QTY. AMPLIFIER, LEVEL SENSOR...

  • Page 131: External Pot Fill

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List External Pot Fill External Pot Fill Kit (776xx757) Refer also to Appendix C - Instruction Sheets for Option Kits: IS0234...
  • Page 132 Section 10 - Part Number List MM147 - D4 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 133: Alarm Beacon

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List Alarm Beacon Alarm Beacon Assembly, 24V (782xx701) Refer also to Appendix C - Instruction Sheets for Option Kits: IS0233...

  • Page 134: Alarm Beacon Replacement Bulb

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit Alarm Beacon Assembly, 24V (782xx701) - Continued ITEM DESCRIPTION PART NO. QTY. BEACON, COVER & BASE 105XX055 SLEEVING, FIBERGLASS 755XX087 WIRE 540XX043 WIRE 540XX040 WIRE 540XX035 WIRE 540XX034...

  • Page 135: Pressure Relief

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List Pressure Relief Pneumatic Pressure Relief Kit (707xx212) ITEM PART NO. DESCRIPTION QTY. 707XX897 VALVE ASSY,PRESSURE RELIEF 755XX054 AIR LINE, 203051 797XX827 MALE CONNECTOR,94929026 594XX160 FILTER REGULATOR-AIR,5-125PSI 786XX001 GAUGE 960LP...

  • Page 136: Relief Valve Assembly (594Xx189)

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit Relief Valve Assembly (594xx189) Refer also to Appendix C - Instruction Sheets for Option Kits: 999XD774-197 Unit Description Part # 707XX897 VALVE ASSY,PRESSURE RELIEF 797XX079 HEX NIPPLE M-M 1/8...

  • Page 137: Pressure Monitoring

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List Pressure Monitoring Pressure Switch Kit, 50-130 PSI (481xx050) Refer also to Appendix C - Instruction Sheets for Option Kits: IS0213 ITEM PART NO. DESCRIPTION QTY. 485XX105 SWITCH; PRESSURE...

  • Page 138: Pressure Switch Kit, 160-400 Psi (481Xx051)

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit Pressure Switch Kit, 160-400 PSI (481xx051) Refer also to Appendix C - Instruction Sheets for Option Kits: IS0213 ITEM PART NO. DESCRIPTION QTY. 485XX107 SWITCH; PRESSURE 792XX340 FITTING ADAPTER...

  • Page 139: Pressure Transducer Assembly (521Xx019)

    MM147 - D4 Hot Melt Unit Section 10 - Part Number List Pressure Transducer Assembly (521xx019) Refer also to Appendix C - Instruction Sheets for Option Kits: IS0377 ITEM DESCRIPTION PART NO. QTY. TRANSDUCER PRESSURE 520XX031 WIRE 540XX160 4.583 WIRE 540XX166 4.583...

  • Page 140: Auxiliary I/O

    Section 10 - Part Number List MM147 - D4 Hot Melt Unit Auxiliary I/O Optional I/O HMU PCB Assembly (098xx134) Refer also to Appendix C - Instruction Sheets for Option Kits: IS0343 ITEM PART NO. DESCRIPTION QTY. 151XX724 PCB ASSY ANYBUS EXPANDED-I/O...

  • Page 141: Section 11 - Warranty

    MM147 - D4 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 142 Section 11 - Warranty MM147 - D4 Hot Melt Unit...

  • Page 143: Section 12 - Service

    MM147 - D4 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 144 Section 12 - Service MM147 - D4 Hot Melt Unit...

  • Page 145: Appendix A - Password Levels

    MM147 - D4 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 146 Appendix A - Password Levels MM147 - D4 Hot Melt Unit Setting Level 0 as Default - Continued...

  • Page 147: Appendix B - Power Requirements

    COULD OCCUR. Power requirements for the D4 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 148 Appendix B - Power Requirements MM147 - D4 Hot Melt Unit...

  • Page 149: Appendix C - Instruction Sheets For Option Kits

    MM147 - D4 Hot Melt Unit Appendix C - Instruction Sheets for Option Kits Appendix C - 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 150 Appendix C - Instruction Sheets for Option Kits MM147 - D4 Hot Melt Unit...

  • Page 151: Appendix D - Micro Sd Backup & Restore

    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. Remove the quick-disconnect ground wire from the top of the case. Valco Melton...

  • Page 152: Error Codes

    Remove any other connections that are holding the case to the chassis. Remove the case. Carefully remove the three (3) circular knockouts from the top of the case. Carefully remove the circular knockout on the center bulkhead in the case. Valco Melton...

  • Page 153: Appendix E - Communication Protocols-Modbus

    15. Install the reed sensors into the appropriate knockout on the top 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" from the top of the case. Valco Melton...

  • Page 154: Parameter List

    22. Replace the wiring insert back into the connector. Make sure the fiberglass sleeving is held by the strain relief in the bottom of the connector. 23. Route the cable assembly through the cable clamp on the back of the valve. Valco Melton...
  • Page 155 This will ensure that the tank does not crush the wires when the case is reinstalled. Route Cable through Clamp 24. Attach the terminal strip to the side of the case using two (2) M3 x 16 socket-head cap screws. Valco Melton...
  • Page 156 32. Reattach the rectangular connector to the air valve. 33. Remove the yellow cap from the end of the feeder tube. 34. Attach the hose to the feeder inlet, using a Phillips-head screwdriver to tighten the hose clamp. Valco Melton...
  • Page 157 39. Connect the flying leads, with the white ferrules, to the feeder location on the temperature control board. 40. Attach the flying terminal ring from the cable assembly to one of the grounding studs on the base of the chassis. Valco Melton...
  • Page 158 47. 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 159 CAUTION! CAUTION! CAUTION! CAUTION! CAUTION! Check the adhesive level periodically to confirm the sensor is working properly. 53. Reinsert the protective screw into the amplifier box. 54. Close the front operator panel. To adjust the sensor delay time: Valco Melton...
  • Page 160 57. Access the setting screen by pressing again. 58. Access the “System” screen. 59. Select Internal ON Delay, based on the desired sensor, and adjust the time for your application. The default time for the sensor is 5 seconds. Valco Melton...
  • Page 161 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 162 ‘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 163: Appendix F - Communication Protocols-Ethernet Ip

    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 164: Bit Definitions For Control Byte 0

    Turn off power to unit and open lid to electronics cabinet. Locate Power Board (151xx606/151xx616), mounted in the base of the cabinet. From underneath the D4-E unit, run the flying lead end of the Handgun Switch Cable assembly through an available cord grip into the electronics cabinet of the unit.

  • Page 165: Data Index Byte 2

    P in 7 (IN 2 + ) : B r o w n J u m p e r a n d Y e llo w Input Setup Connect the power and turn the D4-E unit ON. Press the Setup Button and unlock the system using password “6550.”...

  • Page 166: Data Value Byte 4 And 5

    IS0161 Handgun Switch Kit Installation and Operation Testing Connect the hose/handgun to the D4- E Unit. Connect the 4-pin circular connector from the Handgun Switch Cable installed, to the mating connector from the hose. Turn ON the unit and wait for all zones to reach temperature and for the System Ready light to come on.

  • Page 167: Data Index Byte 2

    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 168: Current Alarm Types

    Pull the handgun trigger to activate the pump. Testing is pump activating. Also, if there is glue in the successful when the pump is enabled during the time the trigger system, the handgun is held. will dispense glue. Valco Melton...

  • Page 169: Error Codes

    Failure TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO EQUIPMENT. If changing the pump in a D4 Unit, the tank must be drained before Before Replacing proceeding, to prevent glue leakage. the Pump If changing the pump in a D10 or D16 Unit, it is not necessary to drain the tank.

  • Page 170: Status Indicators

    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 171 - 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 172 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 173 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 174 Both 776xx892* *For D4/D4E Hot Melt units only. (For D4/D4E Hot Melt Units Only. Otherwise, proceed to (For D4/D4E Hot Melt Units Only. Otherwise, proceed to (For D4/D4E Hot Melt Units Only. Otherwise, proceed to (For D4/D4E Hot Melt Units Only. Otherwise, proceed to (For D4/D4E Hot Melt Units Only.
  • Page 175 10. 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 176 14. Thread the sensor into the tank so that the tip of the sensor is 1.5 inches from the wall of the tank. 15. Feed the cable with the Lemo connector through the holes in the chassis, as shown below. Valco Melton...
  • Page 177 16. Reattach the case to the chassis by reversing steps 2-6. 17. Attach the Lemo connector to the bottom of the appropriate Rechner amplifier box. 18. Attach the JST connector from the assembly to the appropriate position as shown below. Internal High (Ext. Level) Internal Low (Int. Level) Valco Melton...
  • Page 178 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 179 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 180 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 181 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 182 If the cord grip was not installed, route the System cable into the parent machine’s electrical enclosure so that the JST connector is inside. Attach the four-pin JST connector to the universal control on the parent machine. Valco Melton...
  • Page 183 Insert the sensor into the mounting bracket, using the two (2) jam nuts from the previous step. The bottom of the sensor should be about 0.75" above the desired adhesive level. The minimum sensing distance for this sensor is 2mm, and the maximum is 50mm. Valco Melton...
  • Page 184 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 185 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 186 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 187 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 188 (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 189 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 190 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 193 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 194 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 195 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 196 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 197 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 198 IS0377 - D Series Pressure Transducer Instructions IS0377 - D Series Pressure Transducer Instructions 4/18 Important Information 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 EQUIPMENT DAMAGE.
  • Page 199 IS0377 - D Series Pressure Transducer Instructions Installation 1. Remove the pressure gauge and plug for the transducer from the back of the manifold. 2. Install the 1/4 npt pipe plug into the pressure gauge port. Ensure the plug is wrapped with Teflon tape. 3.
  • Page 200 IS0377 - D Series Pressure Transducer Instructions Installation - Continued 4. Route the cable along the side of the unit and through the support bracket on the chassis. 5. Route the cable into the electrical cabinet through the “D” shaped hole on the chassis. 6.
  • Page 201 IS0377 - D Series Pressure Transducer Instructions Setup 1. Access the Setting screen by pressing the button. 2. Press the “OK” button and unlock the control using the level 3 password, 6550. 3. Access the Pressure screen by pressing the button three times, followed by the “OK”...
  • Page 202 IS0377 - D Series Pressure Transducer Instructions Setup - Continued 5. Press the right arrow button and set the delay times for low and high pressure fault alarms if desired. 6. Press the right arrow button to get to the next screen and enable the pressure monitoring by pressing the “+”...
  • Page 203 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.
  • Page 204 · All equipment must be properly grounded and fused in accordance with rate current consumption (refer to the equipment identification plate) · Gauge and insulation for the power supply must be adequate to handle rated current consumption. Valco Melton...
  • Page 205 Check the electrical cabinet to make sure everything is connected, and the power is hooked up correctly. Turn the unit on. Verify the auxiliary I/O board is receiving power by checking that the “24V” led is on. Access the setting screen by pressing Valco Melton...
  • Page 206 Return to the setting screen by pressing again. Access the Configuration screen. Select Auxiliary I/O and press the ‘up’ arrow to enable it. 10. Return to the setting screen by pressing again. 11. Select input or output, depending on your application. Valco Melton...
  • Page 207 Use the diagram below to hook up an input or output. 4 Opto Isolated Inputs See the table on the following page for input wiring options See the table on the following page for output wiring options 4 Output Relay Contacts Valco Melton...
  • Page 208 Anybus Installation IS0343 Installation - Continued Valco Melton...
  • Page 209 IS0344 Anybus Installation and Setup IS0344 - Anybus Installation and Setup 2/18 Description The Melter Communication Interface PCB is a communication interface between the Hot Melt Unit and a parent- machines PLC. This interface allows the user to set and monitor parameters and data from the Hot Melt Unit. For a list of accessible parameters, see the Data Index and Control Byte sections in Section 3 - Configuring the Melt Unit .
  • Page 210 IS0344 Anybus Installation and Setup Physical Installation - Continued ITEM NO. DESCRIPTION PART NO. QTY. PCB ASSEMBLY; ANYBUS I/O EXTEND BJK0347 MODULE, ANYBUS, ETHERNET/IP, JTS0021 098XX123 SPACER, PCB 14MM LONG, SNAP IN NYLON 091XX644 STANDOFF,6MM HEX, M3 X 0,5 THREAD 091XX563 SCREW BUTTON HEAD CAP M3 X 6 784XX541...
  • Page 211 IS0344 Anybus Installation and Setup RSLogix 5000 Setup 1. In communication tree, choose “New Module” under the Ethernet port. 2. Select “Generic Ethernet Module” from the list of available modules. ValcoMelton...
  • Page 212 IS0344 Anybus Installation and Setup RSLogix 5000 Setup - Continued 3. Name the module, and set up the Comm Format and Connection parameters as shown. 4. Set the module to the appropriate IP address. The new modules Output connection will be “Send Packet,” as described in Data Packets used for Ethernet/IP communication, below, and the new module Input connection will be “Receive Packet.”...
  • Page 213 IS0344 Anybus Installation and Setup Modules Input Connection 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. When the Ethernet is enabled, the Melter control will initiate configuration setup with the Ethernet/IP module, and configure the module, using the addresses stored in the setup menus.
  • Page 214 IS0344 Anybus Installation and Setup Send Packet (PLC) Frame Command Channel Pump1 speed% Pump3 speed% Not Used Byte0 Byte1 Byte2 Byte3 Byte4, 5 Byte6, 7 Byte8, 9 Byte10, 11 Byte12, 13 Byte14, 15 Control Data Index Data Value Pump2 speed% Pump4 speed% Bit Definitions for Control Byte 0 These are control bits executed with each message by the Melter.
  • Page 215 IS0344 Anybus Installation and Setup 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 216 IS0344 Anybus Installation and Setup Channel Byte 3 This is the location targeted within parameters having multiple zones. For example - In Data Index 182 (Pump Speed): Sending a read to channel 0, the Melter will send back the value for the Pump 1 current pump speed (channel 1 = Pump 2, etc.) Data Value Byte 4 and 5 This is the data that the PLC sends to the Melter to update a given parameter.
  • Page 217 IS0344 Anybus Installation and Setup 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. Channel Byte 3 This is the same Channel as in Send Packet. This is used as an acknowledgement back to the PLC, to confirm the message.
  • Page 218 IS0344 Anybus Installation and Setup 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: Error Code Description 0x00...
  • Page 219 IS0344 Anybus Installation and Setup 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 Description NO POWER OR IP ADDRESS GREEN ONLINE WITH CONNECTIONS ESTABLISHED...
  • Page 220 (refer to the equipment identification plate) · Gauge and insulation for power supply must be adequate to handle rated current consumption. · Protective clothing and gear should be worn at all times when performing hot-melt tasks. Valco Melton...
  • Page 221 Connect the green Phoenix connector on the 5/6 zone board to the main power board. Fix the board to the electrical panel using two (2) M4 X 6 pan head machine screws. Connect the 5/6 zone power cable to both of the boards. Valco Melton...
  • Page 222 10. Attach the flanged connector to the inside of the hose panel using four (4) M3 lock washers and four (4) M3 hex nuts into the appropriate numbered slot. 11. Attach the flying connectors in the operator panel to the appropriate position on the board. Valco Melton...
  • Page 223 16. Turn on the unit. 17. Go to the setting screen by pressing 18. Unlock the control by using the level 3 password “6550”. 19. Go to the setting screen by pressing again. 20. Go the “Config” screen. Valco Melton...
  • Page 224 22. Attach the new hose(s) to the manifold and back hose panel. 23. Turn on the new hose and gun and set to the desired temperature. 24. Verify that the hose and gun heat up and maintain temperature. Valco Melton...
  • Page 225 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 226 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 227 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 228 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 229 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 230 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 231 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 232 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 233 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.
  • Page 234 MM147 - D4 Hot Melt Unit Appendix D - Micro SD Backup & Restore Appendix D - 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 235 Appendix D - Micro SD Backup & Restore MM147 - D4 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 236 MM147 - D4 Hot Melt Unit Appendix E - Communication Protocols-Modus Appendix E - 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 237 Appendix E - Communication Protocols-Modus MM147 - D4 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 238 MM147 - D4 Hot Melt Unit Appendix E - 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 239 Appendix E - Communication Protocols-Modus MM147 - D4 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 240 MM147 - D4 Hot Melt Unit Appendix E - 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 241 Appendix E - Communication Protocols-Modus MM147 - D4 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 242 MM147 - D4 Hot Melt Unit Appendix E - 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 243 Appendix E - Communication Protocols-Modus MM147 - D4 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 244 MM147 - D4 Hot Melt Unit Appendix E - 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 245 Appendix E - Communication Protocols-Modus MM147 - D4 Hot Melt Unit...
  • Page 246 MM147 - D4 Hot Melt Unit Appendix F - Communication Protocols-Ethernet IP Appendix F - 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 247 Appendix F - Communication Protocols-Ethernet IP MM147 - D4 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 248 MM147 - D4 Hot Melt Unit Appendix F - 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 249 Appendix F - Communication Protocols-Ethernet IP MM147 - D4 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 250 MM147 - D4 Hot Melt Unit Appendix F - 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 251 Appendix F - Communication Protocols-Ethernet IP MM147 - D4 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 252 MM147 - D4 Hot Melt Unit Appendix F - 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 253 Appendix F - Communication Protocols-Ethernet IP MM147 - D4 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...

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