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VALCO MELTON D-90 Manual

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D-90 Hot Melt Unit
D-90 Hot Melt Unit
D-90 Hot Melt Unit
D-90 Hot Melt Unit
D-90 Hot Melt Unit
Manual Number:
Release Date:
MM125
3/2018

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Summary of Contents for VALCO MELTON D-90

  • Page 1 D-90 Hot Melt Unit D-90 Hot Melt Unit D-90 Hot Melt Unit D-90 Hot Melt Unit D-90 Hot Melt Unit Manual Number: MM125 Release Date: 3/2018...
  • Page 2 © Valco Cincinnati, Inc. All Rights Reserved This manual is furnished with the D-90 Hot Melt Unit and may only be used 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 Declaration of Conformity Declaration of Conformity Declaration of Conformity Declaration of Conformity Declaration of Conformity (According to EN 45014) T h e fo llo w in g d e c la ra tio n is is su e d u n d e r th e s o le re s p o n s ib ility o f th e m a n u fa c tu re r: M a n u fa c tu re r: V a lc o M e lto n A d iv is io n o f V a lc o...

  • Page 4: Table Of Contents

    TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS TABLE OF CONTENTS Section 1 - Introduction..........1-1 Description ....................1-1 Section 2 - Safety and Use ..........2-1 Read Thoroughly Before Handling Equipment ........2-1 Symbols ....................2-1 Owner Responsibilities ................
  • Page 5 Table of Contents MM125 - D-90 Hot Melt Unit Section 4 - Installation ............ 4-1 Transport ....................4-1 Choosing a Location ................4-1 Installation Kit ................... 4-2 Routing Low-Voltage Leads ..............4-2 Connecting the Electrical Power .............. 4-2 Electrical Panel ..................4-5 VFD Board - Electrical Cabinet/Terminal Locations ........
  • Page 6 MM125 - D-90 Hot Melt Unit Table of Contents Diagnostics ..................... 5-30 Setback ....................5-31 Setback Temperature ..................5-31 Automatic Setback Timeout ................. 5-32 Startup Setup ..................5-33 Sequential Start – Hose ................5-33 Sequential Start – Valve ................5-34 History .....................
  • Page 7 Reservoir, Collector, Grid, Frame Assembly ..........10-4 Sheet Metal Assembly ................... 10-6 Motor, Pump and Manifold Assembly ............10-9 D-90 Hot Melt Unit (776XX883) - Parts List ......... 10-11 Single Pump Manifold Assembly (776XX299) ........10-13 Dual Pump Manifold Assembly (776XX300) ........10-16 D-90 HMU Electrical Panel Assembly (776XX281) ......

  • Page 8: Section 1 - Introduction

    SECTION 1 - INTRODUCTION ValcoMelton, a division of Valco Cincinnati, Inc., has prepared this manual as an aid for installing, operating, and servicing the D-90 hot melt unit. It also contains a list of part numbers for replacement parts. If you need more information, contact your ValcoMelton representative.

  • Page 9: Section 2 - Safety And Use

    SECTION 2 - SAFETY AND USE SECTION 2 - SAFETY AND USE SECTION 2 - SAFETY AND USE SECTION 2 - SAFETY AND USE SECTION 2 - SAFETY AND USE WARNING! WARNING! WARNING! WARNING! WARNING! Read and follow all safety precautions, warnings, Read cautions, and other recommendations in this manual.
  • Page 10 Section 2 - Safety Information MM125 - D-90 Hot Melt Unit This symbol indicates the need to Unplug/Disconnect All Power Unplug/Disconnect All Power Unplug/Disconnect All Power Unplug/Disconnect All Power Unplug/Disconnect All Power Symbols - Continued Sources Sources Sources Sources Sources and to let them de-energize before attempting any type of work or maintenance.

  • Page 11: Owner Responsibilities

    MM125 - D-90 Hot Melt Unit Section 2 - Safety Information The owner of the equipment is under obligation to manage all safety Owner information. Some examples include: Responsibilities • Examine all safety materials and documents as well as jurisdictional laws and make certain all laws, recommendations, and other safety/hazard laws, certification requirements, training, and instructions are followed and kept current.

  • Page 12: Limitations Of Use

    Valco Melton Representative before handling the equipment. Valco Melton hot melt units, cold glue units, controllers, inspection systems Installation/ and all related accessories have the following universal safety precautions (this is not intended to be an exhaustive list;...

  • Page 13: Shut Down Safety Information

    MM125 - D-90 Hot Melt Unit Section 2 - Safety Information Valco Melton hot melt units, cold glue units, controllers, inspection systems Shut Down 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 14: Hot-Melt-Specific, General Safety Information

    Section 2 - Safety Information MM125 - D-90 Hot Melt Unit Valco Melton hot melt units have the following universal safety precautions in in in in in Hot-Melt- addition to all other universal precautions previously mentioned addition to all other universal precautions previously mentioned...

  • Page 15: What To Do If Contact With Hot Adhesive Occurs

    MM125 - D-90 Hot Melt Unit Section 2 - Safety Information If hot adhesive comes in contact with the skin, , , , , do the following: What to Do if Contact WARNING! WARNING! WARNING! Do not attempt to remove heated hot melt adhesive from...

  • Page 16: What To Do If Adhesive-Related Fire Or Explosion Occurs

    Section 2 - Safety Information MM125 - D-90 Hot Melt Unit 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 What to Do if melt is overheated.

  • Page 17: Hose Safety Information

    MM125 - D-90 Hot Melt Unit Section 2 - Safety Information Hose Safety Do not Do not Do not use bindings, wire ties, or unapproved Do not Do not Information fasteners around the hoses. Do use approved wrapping (P/N 775xx827), making sure the wrapping is slightly snug but not tight.
  • Page 18 Section 2 - Safety Information MM125 - D-90 Hot Melt Unit Hose Safety Information - Do not Do not Do not Do not Do not allow hoses to rub against Continued objects or to come into contact with sharp edges or points.

  • Page 19: Section 3 - Basic Features

    SECTION 3 - BASIC FEATURES SECTION 3 - BASIC FEATURES SECTION 3 - BASIC FEATURES SECTION 3 - BASIC FEATURES SECTION 3 - BASIC FEATURES Overview Figure 3-1. Basic Features ValcoMelton.
  • Page 20 Section 3 - Basic Features MM125 - D-90 Hot Melt Unit Overview - Continued Figure 3-2. Basic Features ValcoMelton...

  • Page 21: Main Power Disconnect

    MM125 - D-90 Hot Melt Unit Section 3 - Basic Features Controls the system main power. Main Power WARNING! WARNING! WARNING! If the main power is switched “off,” anything from the WARNING! WARNING! Disconnect main disconnect to the incoming power is still energized.

  • Page 22: Manifold

    Section 3 - Basic Features MM125 - D-90 Hot Melt Unit Manifold Figure 3-3. Manifold ValcoMelton...

  • Page 23: Filter

    MM125 - D-90 Hot Melt Unit Section 3 - Basic Features The filter reduces the chance of pressurized adhesive becoming contaminated. Clean or replace the filter periodically (see Maintenance Filter section). This valve shuts off adhesive to the manifold for maintenance/parts replacement.

  • Page 24: Dataplates

    Section 3 - Basic Features MM125 - D-90 Hot Melt Unit The dataplates provide more information regarding the system configuration. Dataplates Included information: • Part number • Serial number • Operating voltage • Maximum current • Number of phases •...

  • Page 25: Section 4 - Installation

    The unit may be shipped with the cable track disconnected. The track must be reconnected prior to operation. The D-90 hot melt unit is assembled at the factory. However, the power and Choosing a the glue hoses must be connected by the customer. This section contains instructions for making the necessary connections.

  • Page 26: Installation Kit

    Section 4 - Installation MM125 - D-90 Hot Melt Unit An Installation Kit is available for this unit, containing spare fuses, a copy of this Installation Kit manual on CD and warranty information. For details, see Section 10 - Parts List.

  • Page 27: Connecting The Electrical Power

    MM125 - D-90 Hot Melt Unit Section 4 - Installation The D-90 hot melt unit can be set up to use 380, 400, 440, 480, 575 and 595VAC. Connecting the Electrical Power - All types are three phase and 50/60 Hz. Refer to sheet 1 of the Electrical Continued Schematic for the transformer wiring diagram.
  • Page 28 Section 4 - Installation MM125 - D-90 Hot Melt Unit Connect the power cable leads to the main disconnect switch as Connecting the Electrical Power - shown in sheet 1 of the Electrical Schematic . Continued Figure 4-3. Customer Connections, Main Power Verify that all connectors are fully seated and the terminal block screws are secure.

  • Page 29: Electrical Panel

    MM125 - D-90 Hot Melt Unit Section 4 - Installation Electrical Panel ValcoMelton...

  • Page 30: Vfd Board - Electrical Cabinet/Terminal Locations

    Section 4 - Installation MM125 - D-90 Hot Melt Unit VFD Board - Electrical Cabinet/Terminal Locations Figure 4-4. Electrical Cabinet ValcoMelton...
  • Page 31 MM125 - D-90 Hot Melt Unit Section 4 - Installation VFD Board - Electrical Cabinet/Terminal Locations - Continued “ 1 ” “ 1 ” “ 1 ” “ 1 ” “ 1 ” “ 2 ” “ 2 ” “ 2 ”...

  • Page 32: Connecting The Hoses

    Section 4 - Installation MM125 - D-90 Hot Melt Unit WARNING! WARNING! WARNING! WARNING! WARNING! Never disconnect the hot melt hoses from a running unit. Connecting Hot melt is under high pressure. Turn off the pump, shut off power to the unit, and actuate the gun to relieve the Hoses residual pressure before removing the hose.
  • Page 33 MM125 - D-90 Hot Melt Unit Section 4 - Installation Connecting the Hoses - Continued Unit connection Gun connection End of glue hose that connects to fluid End of glue hose that connects fitting on unit to fluid fitting on applicator Figure 4-6.
  • Page 34 Section 4 - Installation MM125 - D-90 Hot Melt Unit Using two wrenches, one on the fluid outlet fitting and the other Connecting the Hoses - on the hose swivel nut, connect hose ‘one’ to fluid outlet port Continued ‘one’ of the machine.

  • Page 35: Connecting The Hot Melt Hoses To The Applicators

    MM125 - D-90 Hot Melt Unit Section 4 - Installation WARNING! WARNING! WARNING! WARNING! WARNING! If hand-held applicators are used, care should be Connecting taken to ensure safe operation. Heat protective gloves should be worn. Hot melt is under high the Hot Melt pressure at the nozzle tip of the applicator.
  • Page 36 Section 4 - Installation MM125 - D-90 Hot Melt Unit Connecting the Hot Melt Hoses to the Applicators - Continued Lead assembly with female connector (connects to lead assembly on applicator) End of glue hose that connects to fluid fitting on applicator Figure 4-8.

  • Page 37: Customer Connections

    MM125 - D-90 Hot Melt Unit Section 4 - Installation Customer Connections Units shipped with serial number 18031219 and later ValcoMelton 4-13...
  • Page 38 Section 4 - Installation MM125 - D-90 Hot Melt Unit Units shipped with serial number 18031219 and later - Continued INPUT WIRING OPTIONS OUTPUT WIRING INDIVIDUAL DRY CONTACTS DRY CONTACTS WITH COMMON INPUT 1: DRY CONTACT BETWEEN I1 - GND...

  • Page 39: Units Shipped With Serial Number 18031218 And Prior

    MM125 - D-90 Hot Melt Unit Section 4 - Installation Units shipped with serial number 18031218 and prior ValcoMelton 4-15...

  • Page 40: Section 5 - Setup

    SECTION 5 – SETUP SECTION 5 – SETUP SECTION 5 – SETUP SECTION 5 – SETUP SECTION 5 – SETUP Control Panel Valco Cincinnati, Inc.
  • Page 41 Section 5 – Setup MM125 - D-90 Hot Melt Unit Control Panel, Continued ITEM NAME DESCRIPTION System/Ready LED Illuminates green when the unit reaches ready temperature Warning LED Illuminates red when the unit enters an alarm condition Put unit into and out of setback mode. This reduces the...

  • Page 42: Power On/Off And Standby Mode

    MM125 - D-90 Hot Melt Unit Section 5 – Setup The Power Disconnect Switch is located on the front of the electrical cabinet Power On/Off (see picture below). The Power Disconnect Switch controls the power to the system. and Standby...

  • Page 43: Display Adjustment

    Section 5 – Setup MM125 - D-90 Hot Melt Unit The display contrast is adjusted for optimal viewing at the factory. If the Display display is not visible when the Temperature Controller powers up, the contrast may need to be adjusted.
  • Page 44 MM125 - D-90 Hot Melt Unit Section 5 – Setup Display Adjustment - Continued 5. Adjust the screen position by holding down the “Setup” key on the front panel keyboard, while simultaneously pressing the left or right arrow key, to move the screen left or right, as needed.

  • Page 45: User Interface

    Section 5 – Setup MM125 - D-90 Hot Melt Unit User Interface Navigation symbols on the bottom of the display screen indicate that Navigation additional menus are available. Use the indicated button(s) to navigate as follows: 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 46: Thumbwheel Vs. Single Digit Edit

    MM125 - D-90 Hot Melt Unit Section 5 – Setup When editable information is numerical, the information may be edited with the Plus/Minus Buttons for single digit editing, or the OK Button may be Thumbwheel vs. pressed to bring up a thumbwheel for more detailed editing.

  • Page 47: Entering Passwords

    Section 5 – Setup MM125 - D-90 Hot Melt Unit Passwords are required to prevent unauthorized access to unit programming. Entering Please see Appendix A - Password Levels for more information. To enter a password: Passwords Valco Cincinnati, Inc.

  • Page 48: Set Language

    MM125 - D-90 Hot Melt Unit Section 5 – Setup Set Language C O N T I N U E D N E X T P A G E Valco Cincinnati, Inc.
  • Page 49 Section 5 – Setup MM125 - D-90 Hot Melt Unit Set Language - Continued 5-10 Valco Cincinnati, Inc.

  • Page 50: Set Temperature Units

    MM125 - D-90 Hot Melt Unit Section 5 – Setup Temperature Units Valco Cincinnati, Inc. 5-11...

  • Page 51: Programming Temperatures

    Section 5 – Setup MM125 - D-90 Hot Melt Unit Press the Temperature Button (if the Temperature LED is not illuminated green) to show the first temperature screen. Programming Temperatures The tank temperature screen shows the actual tank temperature and the tank Temperature Screens temperature setpoint.

  • Page 52: Grid Temperature

    MM125 - D-90 Hot Melt Unit Section 5 – Setup Grid Temperature Hose/Valve Temperature Valco Cincinnati, Inc. 5-13...
  • Page 53 Section 5 – Setup MM125 - D-90 Hot Melt Unit Hose/Valve Temperature Continued 5-14 Valco Cincinnati, Inc.

  • Page 54: System/Pump Ready Temperature Offset

    MM125 - D-90 Hot Melt Unit Section 5 – Setup The System Ready Temperature is relative to the temperature setpoint of System/Pump each zone. The system is ready (and the System Ready LED illuminates green) when all zones reach their respective temperature setpoints minus the Ready System Ready Temperature Offset.

  • Page 55: Ready Delay Time

    Section 5 – Setup MM125 - D-90 Hot Melt Unit When the Ready Delay Time is used, the System Ready LED will illuminate a Ready Delay preset time after all of the zones reach their respective temperature setpoints minus the System Ready Temperature Offset. This feature allows the...
  • Page 56 MM125 - D-90 Hot Melt Unit Section 5 – Setup Ready Delay Time-Continued Valco Cincinnati, Inc. 5-17...

  • Page 57: Over Temperature Alarm

    Section 5 – Setup MM125 - D-90 Hot Melt Unit The Over Temperature Alarm setting pertains to all active zones. Over 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 Temperature Alarm.

  • Page 58: Under Temperature Alarm

    MM125 - D-90 Hot Melt Unit Section 5 – Setup The Under Temperature Alarm setting pertains to all active zones. Under 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 Temperature Alarm.

  • Page 59: Maximum Temperature

    Section 5 – Setup MM125 - D-90 Hot Melt Unit The Maximum Temperature setting is the maximum value for the setpoint of Maximum any zone. Temperature The maximum temperature range is 32°F to 446°F (0°C to 230°C). The factory default setting is 390°F (199°C).

  • Page 60: Beacon/Alarm Setup

    MM125 - D-90 Hot Melt Unit Section 5 – Setup Beacon/Alarm The Beacon/Alarm Setup allows a specific Beacon, designated by number, to Setup be set to indicate one of six conditions: • Pump On • Ready • Alarm (Zone Faults) •...

  • Page 61: Beacon 2

    Section 5 – Setup MM125 - D-90 Hot Melt Unit Beacon/Alarm Setup - Continued Beacon 2 5-22 Valco Cincinnati, Inc.

  • Page 62: Automatic Pump Mode

    MM125 - D-90 Hot Melt Unit Section 5 – Setup When the Automatic Pump Mode is on, the pump will automatically start Automatic when the system reaches temperature and the System Ready LED illuminates. Pump Mode 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 63: Level Sensor Setup

    Once the filter has been serviced, the timer can be reset for a user set time of up to 2000 hours. The D-90 does not have a filter and, therefore, the factory default timer is OFF. 5-24 Valco Cincinnati, Inc.

  • Page 64: Clock And 7-Day Timer

    MM125 - D-90 Hot Melt Unit Section 5 – Setup Clock and 7- Day Timer The Clock sub menu is used to set the current day and time and to setup shifts with on, off, and setback times/temperatures that are automatically run Set Day and Time by the internal clock.

  • Page 65: Shift Times/Setback Times

    Section 5 – Setup MM125 - D-90 Hot Melt Unit Shift Times/Setback Times Three shifts can be programmed into the unit. Start shift, end shift, and setback times can be pre-programmed for each shift to reduce downtime. Programming Shifts Make certain all desired temperatures are set first (see Programming Temperatures, this section).
  • Page 66 MM125 - D-90 Hot Melt Unit Section 5 – Setup Programming Shifts - C0ntinued This screen states that for Shift C, nothing will be on, since there is no Shift C working. After setting all shift times, program the shifts that will be enabled for each day of the week.

  • Page 67: Moving Through The Shift Time/Day Screens

    Section 5 – Setup MM125 - D-90 Hot Melt Unit Moving Through the Shift Time/Day Screens 5-28 Valco Cincinnati, Inc.
  • Page 68 MM125 - D-90 Hot Melt Unit Section 5 – Setup Press the Clock Button to enable all shift settings (the 7-Day Timer) Moving Through the Shift Time/ Day Screens - Continued Do not turn off the main power to the control.

  • Page 69: Diagnostics

    Section 5 – Setup MM125 - D-90 Hot Melt Unit The Diagnostics Screen shows the current software version as well as the Diagnostics current temperature and status of each zone. 5-30 Valco Cincinnati, Inc.

  • Page 70: Setback

    MM125 - D-90 Hot Melt Unit Section 5 – Setup Setback The setback feature is used to reduce the temperatures of all zones by a Setback Temperature given temperature differential to allow the hot melt to remain soft but not molten during periods of inactivity.

  • Page 71: Automatic Setback Timeout

    Section 5 – Setup MM125 - D-90 Hot Melt Unit 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 Automatic Setback automatically go into setback.

  • Page 72: Startup Setup

    MM125 - D-90 Hot Melt Unit Section 5 – Setup Startup Setup The Sequential Start function allows the hoses and the valves (guns) to begin heating after the upper platen (referred to as the Tank, below) reaches a Sequential Start –...

  • Page 73: Sequential Start - Valve

    Section 5 – Setup MM125 - D-90 Hot Melt Unit Sequential Start – Valve 5-34 Valco Cincinnati, Inc.

  • Page 74: History

    MM125 - D-90 Hot Melt Unit Section 5 – Setup The Fault History Screen keeps a log of all faults that occur with any zone. History 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: User Inputs And Outputs

    Section 5 – Setup MM125 - D-90 Hot Melt Unit There are 4 individual outputs that can be configured to control remote User Inputs 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 and Outputs programmed for “System Ready”, the output relay will energize when the...

  • Page 76: Configuration

    MM125 - D-90 Hot Melt Unit Section 5 – Setup The Configuration Menu contains screens that allow the user to setup global Configuration parameters for the hot melt control. These configurations are shown below. The number of hoses is used to set the control for how many hose/gun pairs Number of Hose are being used by the operator.

  • Page 77: Number Of Pumps

    Section 5 – Setup MM125 - D-90 Hot Melt Unit The total number of pumps for the unit can be configured in this screen. For this unit, the number is one. This setting will be set at the factory before Number of Pumps shipment.

  • Page 78: Pump Setup Menu

    MM125 - D-90 Hot Melt Unit Section 5 – Setup 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 Section 5 – Setup MM125 - D-90 Hot Melt Unit The Auto Speed Input setting is the type of line speed input used to adjust the Pump Setup Menu - Continued pump speed. See the VFD board connections (below) to find the input connectors for the Auto Speed Input.

  • Page 80: Encoder Setup Menu

    MM125 - D-90 Hot Melt Unit Section 5 – Setup If an Encoder is used for the Auto Speed Input, then the Encoder parameters Encoder need to be set in this menu. Enter the Pulses per Revolution of the encoder and its circumference in this screen.

  • Page 81: Autotune Feature

    MM125 - D-90 Hot Melt Unit The PID settings are factory set for each zone. The factory PID settings PID Settings - Continued complement Valco Melton’s Tank, Hose, and Gun watt densities (Tank 1 screen shown. Use left/right keys to access other screens). CAUTION!

  • Page 82: Initialize Screen

    MM125 - D-90 Hot Melt Unit Section 5 – Setup The Init or Initialize Screen is used to reset ALL of the control parameters Initialize back to the factory settings. When “OK” is selected to Initialize ALL Data, the set up wizard will take the user through the control initialization to reconfigure Screen the hot melt control as if it were a brand new installation.

  • Page 83: Adjusting The Pressure Control Valve

    MM125 - D-90 Hot Melt Unit The D-90 unit contains a single-stage, external, manually adjustable relief Adjusting the valve (see figure below). Additionally, the D-90 unit can use an optional pneumatic relief valve, Uniflow 12 and Uniflow 24V (contact Valco Melton for Pressure details).

  • Page 84: Gramage Feature

    MM125 - D-90 Hot Melt Unit Section 5 – Setup The Gramage Feature should ONLY be enabled in coating applications Gramage 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...
  • Page 85 Section 5 – Setup MM125 - D-90 Hot Melt Unit The Application Width and Gramage (Application Weight) must be set in the Gramage Feature - Continued “Pump Menu”. This parameter can be accessed in Password Level 1 or higher (see Appendix A Password Level).

  • Page 86: Section 6 - Operation

    SECTION 6 - OPERATION SECTION 6 - OPERATION SECTION 6 - OPERATION SECTION 6 - OPERATION SECTION 6 - OPERATION WARNING! WARNING! WARNING! WARNING! WARNING! It is recommended that Section 5 – Setup is read, understood and followed before attempting to read this section and operate the unit.
  • Page 87 Section 6 - Operation MM125 - D-90 Hot Melt Unit If the power disconnect switch is on but there is nothing on the Unit Startup - Continued display, the unit is in Standby mode. Push the Standby key on the control and ensure the LED changes from orange to green.

  • Page 88: Filling The Tank

    MM125 - D-90 Hot Melt Unit Section 6 - Operation If filling the Reservoir manually (using bricks, pillows or pellets), Filling the open the lid and fill the Reservoir to the desired level. Tank WARNING! WARNING! WARNING! WARNING! WARNING! Do not overfill the tank! Allow the adhesive to melt, and check the adhesive level before adding more adhesive.

  • Page 89: Dispensing Adhesive

    Section 6 - Operation MM125 - D-90 Hot Melt Unit WARNING! WARNING! WARNING! WARNING! WARNING! Make sure all heating zones are at the correct Dispensing temperature. The Pump Ready light should be on. Adhesive Make sure all hoses and fittings/connections are secured properly to prevent adhesive leaks.

  • Page 90: Section 7 - Maintenance

    Periodically clean the exterior of the D-90 hot melt unit. • Inspect the exterior of the unit for any noticeable damage that may cause a system malfunction. To clean the exterior of the D-90 hot melt unit, follow these steps: Cleaning the CAUTION! CAUTION!

  • Page 91: Filter Replacement

    Section 7 – Maintenance MM125 - D-90 Hot Melt Unit Filter Replacement See Figure 7-2 See Figure 7-3 Valco Melton...

  • Page 92: Replacing The Tank Inlet Filter

    MM125 - D-90 Hot Melt Unit Section 7 – Maintenance The optional tanlk inlet filter should be cleaned or replaced periodically to Replacing the prevent adhesive flow restriction, due to debris buildup. Tank Inlet Clean or replace the filter as follows: Filter Turn the Drum Unloader pump OFF.

  • Page 93: Replacing The Manifold Filter

    Section 7 – Maintenance MM125 - D-90 Hot Melt Unit The procedure for replacing the Replacing the manifold filter is similar to that of replacing the Inlet Filter. Manifold Filter Turn off the D-90 pumps. WARNING! WARNING! WARNING! WARNING! WARNING! Make sure pressure gauge reads 0 psi.

  • Page 94: Changing The Adhesive

    MM125 - D-90 Hot Melt Unit Section 7 – Maintenance CAUTION! CAUTION! CAUTION! CAUTION! CAUTION! When changing adhesives, always consult adhesive Changing the suppliers to check compatibility between adhesives. Failure to comply could result in damage to the Adhesive equipment.

  • Page 95: Parts Replacement

    Section 7 – Maintenance MM125 - D-90 Hot Melt Unit Manually activate the applicators to relieve any system pressure Flushing the System - Continued buildup if the system is hot (if applicable). Disconnect glue hoses from applicators/unit, and collect purged material with an appropriate container.

  • Page 96: Changing Fuses

    MM125 - D-90 Hot Melt Unit Section 7 – Maintenance In the event that a fuse must be replaced, simply remove one of the spare fuses from the included installation kit and insert the fuse in the appropriate Changing Fuses socket.

  • Page 97: Section 8 - Troubleshooting And Repair

    TO THE EQUIPMENT COULD OCCUR. This section includes some of the common faults that can occur with the S- drum hot melt unit. If the problem can not be solved with the information in this manual, contact your Valco Melton representative. Problem Possible Cause...
  • Page 98 Section 8 - Troubleshooting and Repair MM125 - D-90 Hot Melt Unit Troubleshooting - Continued Problem Possible Cause Possible Solution Loosen the pressure relief valve adjustment screw until the desired Adhesive pressure is too high Pressure relief valve set too high pressure is obtained.
  • Page 99 MM125 - D-90 Hot Melt Unit Section 8 - Troubleshooting and Repair Troubleshooting - Continued Problem Possible Cause Possible Solution Raise the Castings, manifold, hoses and Adhesive temperature is too applicators temperatures in accordance with Cold adhesive on product adhesive manufacturer’s specifications.

  • Page 100: Repair

    Section 8 - Troubleshooting and Repair MM125 - D-90 Hot Melt Unit WARNING! WARNING! WARNING! WARNING! WARNING! All of these operations should be performed with the Repair machine switched off at the main breaker and disconnected from the incoming air, making sure the system has been duly bled and depressurized.
  • Page 101 MM125 - D-90 Hot Melt Unit Section 8 - Troubleshooting and Repair Replacing the Pump - Continued Valco Cincinnati, Inc.

  • Page 102: Replacing The Motor

    Section 8 - Troubleshooting and Repair MM125 - D-90 Hot Melt Unit If the motor needs to be replaced, proceed as follows: Replacing the Motor Turn off the unit and disconnect the power. Open the electrical box on the motor.

  • Page 103: Replacing The Pressure Relief Valve

    MM125 - D-90 Hot Melt Unit Section 8 - Troubleshooting and Repair Turn on the unit and allow it to reach the operating temperature. Replacing the Pressure Relief Valve Relieve any pressure in the system. Remove the pressure relief valve from the manifold.

  • Page 104: Replacing The Beacon Light Bulb

    Section 8 - Troubleshooting and Repair MM125 - D-90 Hot Melt Unit Turn off the unit and disconnect the power. Replacing the Beacon Light Bulb Twist the beacon that needs to be replaced counter-clockwise and remove. Twist the light bulb inside of the beacon case clockwise a quarter turn and discard the bulb.

  • Page 105: 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 106 Section 9- Specifications MM125 - D-90 Hot Melt Unit Dimensions - D-90 Figure 9-1. Working Profile – Front View Figure 9-2. Working Profile – Top View Valco Cincinnati, Inc.

  • Page 107: Section 10 - Part Number List

    Melton S.L.U. Pol. Industrial Agustinos Spain: calle G, n. 34 31160 Orcoyen, Navarra, Spain Tel: (34) 948-321-580 Fax: (34) 948-326-584 Valco Melton France Valco Melton France Valco Melton France Valco Melton France Valco Melton France Technoparc des Hautes Faventines France:...

  • Page 108: Hot Melt Unit (776Xx883)

    Section 10 - Part Number List MM125 - D-90 Hot Melt Unit D-90 Hot Melt Unit (776XX883) Overall Assembly 776XX883-01.dwg 10-2 ValcoMelton...
  • Page 109 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List Overall Assembly - Continued 776XX883-01.dwg ValcoMelton 10-3...

  • Page 110: Reservoir, Collector, Grid, Frame Assembly

    Section 10 - Part Number List MM125 - D-90 Hot Melt Unit Reservoir, Collector, Grid, Frame Assembly 776XX883-02 10-4 ValcoMelton...
  • Page 111 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List Reservoir, Collector, Grid, Frame Assembly - Continued 776XX883-02 ValcoMelton 10-5...

  • Page 112: Sheet Metal Assembly

    Section 10 - Part Number List MM125 - D-90 Hot Melt Unit Sheet Metal Assembly 776XX883-03 10-6 ValcoMelton...
  • Page 113 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List Sheet Metal Assembly - Continued 776XX883-03 ValcoMelton 10-7...
  • Page 114 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit Sheet Metal Assembly - Continued 776XX883-03 10-8 ValcoMelton...

  • Page 115: Motor, Pump And Manifold Assembly

    MM125 - D-90 Hot Melt Unit Section 10 - Part Number List Motor, Pump and Manifold Assembly A further breakdown of the Dual Pump Manifold Assembly is shown on Page 10-16 . A further breakdown of the Single Pump Manifold Assembly is shown on Page 10-13 .
  • Page 116 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit Motor, Pump and Manifold Assembly - Continued 776XX882-04 10-10 ValcoMelton...
  • Page 117 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List ITEM DESCRIPTION PART # D-90 Hot Melt FRAME 776XX274 CASTER-ALTERATION 794XX886 Unit NUT,FLANGE 798XX699 INSULATION PAD 782XX509 (776XX883) - COLLECTOR 776XX273 Parts List CABLE ASSY, COLLECTOR RTD 029XX708...

  • Page 118: Hot Melt Unit (776Xx883) - Parts List

    Section 10 - Part Number List MM125 - D-90 Hot Melt Unit PART # ITEM DESCRIPTION D-90 Hot Melt Unit (776XX883) - Parts List - Continued CORD GRIP 066XX191 SETTINGS, VFD PARAMETERS 999XB776-20 CABLE ASSY, VFD-MTR D90/D180 029XX720 PANEL, BACK; D180...

  • Page 119: Single Pump Manifold Assembly (776Xx299)

    MM125 - D-90 Hot Melt Unit Section 10 - Part Number List Single Pump Manifold Assembly (776XX299) ValcoMelton 10-13...
  • Page 120 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit Single Pump Manifold Assembly (776XX299) - Continued 776XX299-02.dwg. 10-14 ValcoMelton...
  • Page 121 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List Item Description Part Number Single Pump Manifold Assembly (776XX299) - Continued MANIFOLD, SINGLE PUMP 776XX254 O` RING 745XX002 SCREW 884XX348 BLOCK, FILTER 776XX253 O-RING 745XX385 SCREW 884XX272 CAP,FILTER,MNFD ASSY.

  • Page 122: Dual Pump Manifold Assembly (776Xx300)

    Section 10 - Part Number List MM125 - D-90 Hot Melt Unit Dual Pump Manifold Assembly (776XX300) 10-16 ValcoMelton...
  • Page 123 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List Dual Pump Manifold Assembly (776XX300) - Continued 776XX300-02.dwg. ValcoMelton 10-17...
  • Page 124 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit Item Description Part Number Dual Pump Manifold Assembly (776XX300) - Continued MANIFOLD, DUAL PUMP 776XX295 O` RING 745XX002 SCREW 884XX348 BLOCK, FILTER 776XX253 O-RING 745XX385 SCREW 884XX272 CAP,FILTER,MNFD ASSY.

  • Page 125: Hmu Electrical Panel Assembly (776Xx281)

    MM125 - D-90 Hot Melt Unit Section 10 - Part Number List D-90 HMU Electrical Panel Assembly (776XX281) ValcoMelton 10-19...
  • Page 126 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit D-90 HMU Electrical Panel Assembly (776XX281) - Continued 10-20 ValcoMelton...
  • Page 127 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List ITEM DESCRIPTION PART # D-90 HMU Electrical Panel Assembly (776XX281) - PANEL, ELECTRICAL 776XX257 Continued PCB ASSY 151XX680 STANDOFF 091XX706 HEX NUT 798XX299 SWITCH, DISCONNECT, FUSIBLE 485XX121 SCREW...
  • Page 128 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit ITEM ITEM DESCRIPTION PART # D-90 HMU Electrical Panel Assembly (776XX281) - SCREW 784XX604 Continued LABEL, GROUND SYMBOL 781XX110 COVER, RELAY 160XX150 SHAFT EXTENSION 485XX123 CONTACTOR 160XX293 FUSE...

  • Page 129: D90 Hot Melt Unit (Eqm0690)

    MM125 - D-90 Hot Melt Unit Section 10 - Part Number List D90 Hot Melt Unit (EQM0690) E Q M 0 6 9 0 - 0 1 . d w g ValcoMelton 10-23...
  • Page 130 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit D90 Hot Melt Unit (EQM0690) - Continued E Q M 0 6 9 0 - 0 2 . d w g 10-24 ValcoMelton...
  • Page 131 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List D90 Hot Melt Unit (EQM0690) - Continued E Q M 0 6 9 0 - 0 3 . d w g ValcoMelton 10-25...
  • Page 132 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit D90 Hot Melt Unit (EQM0690) - Continued E Q M 0 6 9 0 - 0 4 . d w g 10-26 ValcoMelton...
  • Page 133 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List ITEM DESCRIPTION PART # D90 Hot Melt Unit (EQM0690) - Continued FRAME EQM0684 CASTER-ALTERATION 794XX886 NUT,FLANGE 1/2-13 798XX699 INSULATION PAD 782XX509 COLLECTOR MODIFICATION EQM0680 PLATE, DIVERTER 776XX276 O-RING...
  • Page 134 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit ITEM DESCRIPTION PART # D90 Hot Melt Unit (EQM0690) - Continued GEAR PUMP, DOUBLE WIDTH 561XX218 SHCS M8 X 100 BLACK 784XX381 O-RING 745XX035 COUPLING ASSY HEAVY DUTY 783XX322 MOTOR;...

  • Page 135: Recommended Spare Parts For Eqm0690

    MM125 - D-90 Hot Melt Unit Section 10 - Part Number List ITEM DESCRIPTION PART # Recommended Spare RECHNER LEVEL SENSORS 098XX107 Parts for EQM0690 MECHANICAL PRESSURE RELIEF 707XX222 PNEUMATIC RELIEF VALVE ASSY DJD3453 PRESSURE GAUGE 0-1000PSI 786XX122 DOUBLE WIDTH PUMP, VARISEAL...

  • Page 136: Electrical Panel Assembly

    Section 10 - Part Number List MM125 - D-90 Hot Melt Unit Electrical Panel Assembly E Q M 0 6 9 4 . d w g 10-30 ValcoMelton...
  • Page 137 MM125 - D-90 Hot Melt Unit Section 10 - Part Number List ITEM DESCRIPTION PART # Electrical Panel Assembly - PANEL; ELECTRICAL EQM0693 Continued PCB ASSY, 12 ZONE GEAR NI-120 151XX680 STANDOFF; HEX, M-F 091XX706 HEX NUT-M4, SS 798XX299 *SWITCH, DISCONNECT, FUSIBLE...
  • Page 138 Section 10 - Part Number List MM125 - D-90 Hot Melt Unit ITEM DESCRIPTION PART # Electrical Panel Assembly - Continued SPACER, SCREW, & WASHER 091XX351 JUMPER, 2 POLE 091XX426 DUCT COVER,30001400 067XX018 LUG, 215390 091XX026 SHCS M8 X 12 SS...

  • Page 139: Section 11 - Warranty

    SECTION 11 - WARRANTY SECTION 11 - WARRANTY SECTION 11 - WARRANTY SECTION 11 - WARRANTY SECTION 11 - WARRANTY Valco Cincinnati, Inc. warrants its equipment worldwide against defects in Warranty material and workmanship as outlined in this section. Liability of the company is limited to repair of the product, or replacement of Information any part shown to be defective, and does not extend to defects caused by accidents, misuse, abuse, neglect, tampering or deterioration by corrosion.

  • Page 140: Section 12 - Service

    SECTION 12 - SERVICE SECTION 12 - SERVICE SECTION 12 - SERVICE 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.

  • Page 141: Appendix A - Password Levels

    APPENDIX A - PASSWORD LEVELS APPENDIX A - PASSWORD LEVELS APPENDIX A - PASSWORD LEVELS 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’.
  • Page 142 Appendix A - Password Levels MM125 - D-90 Hot Melt Unit Setting Level 0 as Default - Continued ValcoMelton...

  • Page 143: Appendix B - Power Requirements

    The wattage for any hose/gun pair · The total wattage for all hoses and guns Perform the system power requirement calculation for the D-90 unit as follows, referring to Table 1, below: Table 1. Maximum Allowable Wattage for the D-90 Series Unit Table 1.

  • Page 144: System Power Requirement Calculation - D-90 Units

    Appendix B - Power Requirements MM125 - D-90 Hot Melt Unit Add the power requirements of hose #6 and gun #6. Compare System Power Requirement this value to the maximum wattage given in Line 6 of Table 1. Calculation - D-90 Units - Continued Add the power requirements of all hoses and all guns.

  • Page 145: Appendix C - Schematics

    APPENDIX C - SCHEMATICS APPENDIX C - SCHEMATICS APPENDIX C - SCHEMATICS APPENDIX C - SCHEMATICS APPENDIX C - SCHEMATICS ValcoMelton.
  • Page 146 Appendix C - Schematics MM125 - D-90 Hot Melt Unit 029XX435 240V 3Ø ValcoMelton...
  • Page 147 MM125 - D-90 Hot Melt Unit Appendix C - Schematics 029X X435 240V 3Ø ValcoMelton...
  • Page 148 Appendix C - Schematics MM125 - D-90 Hot Melt Unit ValcoMelton...
  • Page 149 MM125 - D-90 Hot Melt Unit Appendix C - Schematics ValcoMelton...
  • Page 150 Appendix C - Schematics MM125 - D-90 Hot Melt Unit ValcoMelton...

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