VALCO MELTON D4 Manuals

Manuals and User Guides for VALCO MELTON D4. We have 1 VALCO MELTON D4 manual available for free PDF download: Manual

VALCO MELTON D4 Manual

VALCO MELTON D4 Manual (253 pages)

Hot Melt Unit

Brand: VALCO MELTON | Category: Melting Machines | Size: 7 MB

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
Section 3 - Basic Features
21
- Key Features
  21
Section 4 - Installation
23
- Choosing a Location
  23
  - Mounting Footprint
    24
- Installation Kit
  24
- Routing Low-Voltage Leads
  24
- Connecting the Electrical Power
  25
- Connecting the Hoses
  27
- Connecting the Hot Melt Hoses to the Applicators
  29
- Wiring Diagram
  30
- Wiring Diagram - before 5/18
  31
- Input/Output Connections
  32
- Input/Output Connections - before 5/18
  34
Section 5 - Setup
35
- Control Panel
  35
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
42
Set Temperature Units
44
- Programming Temperatures
  45
- Tank Temperature
  46
- Hose/Valve Temperature
  46
System/Pump Ready Temperature Offset
48
Ready Delay Time
49
Over Temperature Alarm
50
Under Temperature Alarm
51
Maximum Temperature
52
Beacon/Alarm Setup
53
- Beacon 2
  55
Automatic Pump Mode
56
Pressure Setup
57
Pot Fill Mode
60
Level Sensor Setup
61
- Hopper Feeder - Low Level Detection
  61
  - Door Switch
    61
  - Feeder Valve Operation
    61
Filter Change Timer
62
Clock and 7-Day Timer
62
- Programming Shifts
  63
Diagnostics
66
Setback
67
- Setback Temperature
  67
- Automatic Setback Timeout
  68
Startup Setup
69
- Sequential Start - Hose
  69
History
71
User Inputs and Outputs
72
Configuration
74
- Zone Configuration
  74
- Auxiliary Zones
  74
- Auxiliary I/O
  75
- Pump Type
  75
- Gramage Enable
  75
- Config Comm Menu
  76
  - 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
    81
  - Autotune Feature
    81
- Memory Menu
  82
- Restoring Factory Default Settings
  82
- Updating 152XX746 CPU Board Software Via USB Memory Stick
  82
- Initialization Instructions
  85
- Adjusting the Pressure Control Valve
  89
  - Adjusting the Single-Stage Relief Valve
    89
- Gramage Feature
  90
- D Series Variable Frequency Drive Configuration (if Equipped)
  91
  - Before 5/18
    92
Section 6 - Operation
93
- Start the Unit
  93
- Temperature
  94
  - Setpoint and Actual Temperature
    94
  - Temperature Status Leds
    94
- Pump Operation
  95
  - Pump On/Off Key
    95
  - Pump Status Key
    95
    
    Fixed Speed Unit
    95
    
    Variable Speed Unit
    96
- Clock On/Off
  96
- Setback
  97
  - Automatic Setback
    97
- Pot Fill - External Low Level Detection
  98
- Hopper Feeder - Internal Low Level Detection
  98
- Beacon Alarm
  98
- External Input
  98
- Filling the Tank
  99
Section 7 - Maintenance
101
- General
  101
- Cleaning the Exterior of the Unit
  101
- Changing the Adhesive
  102
- Flushing the System
  102
- Parts Replacement
  104
  - Changing Fuses
    104
  - Changing the Filter
    105
Section 8 - Troubleshooting and Repair
107
Section 9 - Specifications
109
- General
  109
- Dimensions
  110
Section 10 - Part Number List
111
- How to Order Parts
  111
- D4 Unit
  112
- D4 Base Unit (776Xx392)
  120
  - D4 Base Unit (776Xx392) - before 5/18
    123
- Installation Kit (091Xx734)
  125
- Option Kits
  126
  - Autofeed
    126
    
    Vacuum Feeder Assembly - 776Xx305
    126
  - Pump Control
    128
    
    Cable Assembly Handgun Pump Control (029Xx552)
    128
    
    Pump Kit, Standard Width (561Xx216)
    129
    
    Pump Kit, Half Width (561Xx220)
    129
  - Internal Level Sensors
    130
    
    Internal Low-Level Sensor Kit (776Xx892)
    130
  - External Pot Fill
    131
    
    External Pot Fill Kit (776Xx757)
    131
  - Alarm Beacon
    133
    
    Alarm Beacon Assembly, 24V (782Xx701)
    133
    
    Alarm Beacon Replacement Bulb
    134
    
    Siren Element Kit (776Xx762)
    134
  - Pressure Relief
    135
    
    Pneumatic Pressure Relief Kit (707Xx212)
    135
    
    Relief Valve Assembly (594Xx189)
    136
  - Pressure Monitoring
    137
    
    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)
    139
  - Auxiliary I/O
    140
    
    Optional I/O HMU PCB Assembly (098Xx134)
    140
    
    Ethernet IP Kit (098Xx133)
    140
    
    VDC Relay Kit (776Xx537)
    140
Section 11 - Warranty
141
- Warranty Information
  141
  - Cold Glue Equipment and Electronic Controls
    141
  - Hot Melt Units, Hoses, Valves, Guns, and Related Equipment
    141
Section 12 - Service
143
Appendix A - Password Levels
145
Appendix B - Power Requirements
147
- System Power Requirement Calculation - D Series Units
  147
Appendix C - Instruction Sheets for Option Kits
149
Appendix D - Micro SD Backup & Restore
151
- Functions
  151
- Error Codes
  152
Appendix E - Communication Protocols-Modbus
153
- Communication Specifications
  153
- Hardware Considerations
  153
- Parameter List
  154
Appendix F - Communication Protocols-Ethernet IP
163
- Hot Melt Unit to Ethernetip Communication Protocol
  163
- Data Packets Used for Ethernet/Ip Communication
  163
  - Send Packet (PLC) Frame
    163
  - Bit Definitions for Control Byte 0
    164
  - Command Byte 1
    164
  - Data Index Byte 2
    165
  - Channel Byte 3
    165
  - Data Value Byte 4 and 5
    166
  - Pump1 Speed
    166
  - Receive Packet (Melter) Frame
    166
  - Data Index Byte 2
    167
  - Channel Byte 3
    167
  - Channel Read Data Bytes 4 and 5
    167
  - Channel Read Data + Bytes 6 - 15
    167
- Current Alarm Types
  168
  - Error Codes
    169
    
    Examples
    169
  - Status Indicators
    170
    
    Network Status LED
    170

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