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Valco Cincinnati LLD, Manual

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© 2011 Valco Cincinnati, Inc.

All Rights Reserved.

This manual is furnished with the Low Level Detection Alarm/AutoRefill Systems and may be used or
copied 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. The information in this manual is furnished for educational purposes only, is subject to
change without notice, and should not be construed as a commitment by Valco Cincinnati, Inc.

This manual written and designed at Valco Cincinnati, Inc., 411 Circle Freeway Drive, Cincinnati, Ohio
45246.

Part Number: MC036

Printed in the USA

To order parts, please contact your closest Valco office by mail, phone, or Email:

Valco Cincinnati, Inc.

Valco Cincinnati, Inc.

Valco Cincinnati, Inc.

Valco Cincinnati, Inc.

Valco Cincinnati, Inc.
411 Circle Freeway Drive
Cincinnati, OH 45246
TEL:

(513) 874-6550

FAX:

(513) 874-3612

Email: [email protected]
Web:

http://www.valcomelton.com

Valco Cincinnati Limited

Valco Cincinnati Limited

Valco Cincinnati Limited

Valco Cincinnati Limited

Valco Cincinnati Limited
Hortonwood 32
Telford, TFI 7YN, England
TEL:

(+44) 1952-677911

FAX:

(+44) 1952-677945

Email: [email protected]
Web:

http://www.valco.co.uk

Valco Cincinnati GmbH

Valco Cincinnati GmbH

Valco Cincinnati GmbH

Valco Cincinnati GmbH

Valco Cincinnati GmbH
Storkower Strasse 6
D-15749 Gallun, Germany
TEL:

(+49) 337 648 700

FAX:

(+49) 337 648 7070

Email: [email protected]

Melton S.L.U.

Melton S.L.U.

Melton S.L.U.

Melton S.L.U.

Melton S.L.U.
Pol. Industrial Agustinos
calle G, n. 34
31160 Orcoyen, Navarra, Spain
TEL: (34) 948-321-580
FAX: (34) 948-326-584
Web:

http://www.valcomelton.com

Summary of Contents for LLD

Page 1: ...Date Issue Date Issue Date Issue Date Issue Date 7 2011 7 2011 7 2011 7 2011 7 2011 Low Level Detection Alarm Low Level Detection Alarm Low Level Detection Alarm Low Level Detection Alarm Low Level Detection Alarm AutoRefill Systems AutoRefill Systems AutoRefill Systems AutoRefill Systems AutoRefill Systems ...

Page 2: ...contact your closest Valco office by mail phone or Email Valco Cincinnati Inc Valco Cincinnati Inc Valco Cincinnati Inc Valco Cincinnati Inc Valco Cincinnati Inc 411 Circle Freeway Drive Cincinnati OH 45246 TEL 513 874 6550 FAX 513 874 3612 Email sales valcomelton com Web http www valcomelton com Valco Cincinnati Limited Valco Cincinnati Limited Valco Cincinnati Limited Valco Cincinnati Limited Va...

Page 3: ... TF1 7YN England Melton S L U Pol Industrial Agustinos calle G n 34 31160 Orcoye Navarra Spain declares that the product Product Name Low Level Detection Alarm AutoRefill Systems complies with the following Council Directives Safety of Machinery 2006 42 EC Low Voltage Equipment 2006 95 EC EMC 2004 108 EC and conforms to the following standards Safety EN60204 1 2006 EN13849 1 Risk EN14121 1 2007 EM...

Page 4: ......

Page 5: ...on of Adhesive Fumes Occurs 2 7 What to Do if Adhesive Related Fire or Explosion Occurs 2 8 Hose Safety Information 2 9 Section 3 Installation 1 1 LLD Alarm Installation 1 1 Mounting the Control Box 1 1 Electrical Installation of the Control Box 1 1 Mechanical Installation of the Probe 1 3 Electrical Installation of the Probe 1 6 Testing the LLD Alarm System 1 7 The AutoRefill LLD Installation 1 8...

Page 6: ...Alarm Assembly Parts List 8 4 LLD Control Assembly 080xx545 8 4 Installation Kit 781xx258 8 7 Probe Assemblies 8 7 The LLD AutoRefill Assembly Parts List 8 8 LLD AutoRefill Control Assembly 098xx699 8 8 Pot Fill Kit 754xx330 8 11 Section 9 Warranty 9 1 Warranty Information 9 1 Cold Glue Equipment and Electronic Controls 9 1 Hot Melt Units Hoses Valves Guns and Related Equipment 9 1 Section 10 Serv...

Page 7: ...Warning level The warning level is indicated by a flashing light that alerts the operator that the glue level is low Low level for non pressurized drums and vats only Low level for non pressurized drums and vats only Low level for non pressurized drums and vats only Low level for non pressurized drums and vats only Low level for non pressurized drums and vats only The low level is indicated by an ...

Page 8: ...1 2 ValcoMelton Section 1 Introduction MC036 Low Level Detection Alarm AutoRefill Systems ...

Page 9: ...rnings draw special attention to anything that could injure or kill the reader Both Cautions and Warnings are placed before the step they apply to This symbol represents a Hot Surface Hot Surface Hot Surface Hot Surface Hot Surface This symbol represents a Puncture Risk Puncture Risk Puncture Risk Puncture Risk Puncture Risk It is usually used in regard to nozzle cleaning appliances and other shar...

Page 10: ...connect All Power Unplug Disconnect All Power Sources Sources Sources Sources Sources and to let them de energize before attempting any type of work or maintenance Remember that there can still be energy in equipment cords and wires even when unplugged disconnected This symbol indicates the need to Lock Out All Power Sources Lock Out All Power Sources Lock Out All Power Sources Lock Out All Power ...

Page 11: ...e sure there are regular inspections of equipment and safety devices Have regular safety drills and inspections supervised by the proper authorities Provide all required safety items first aid equipment and training The owner of the equipment is under obligation to make certain that all personnel who will handle install maintain operate fix and work around the equipment are qualified trained and u...

Page 12: ...urrent fuses and other power supplies Replace worn cords hoses etc immediately FAILURE TO OBSERVE WARNING MAY RESULT IN DEATH PERSONAL INJURY AND OR EQUIPMENT DAMAGE Warning Warning Warning Warning Warning Poor ventilation smoking and open flames can cause overheated hot melt to ignite Adequate ventilation must be provided Smoking should be prohibited in the immediate vicinity of the molten adhesi...

Page 13: ...nt may still be energized even if unplugged When making adjustments or performing checkout procedures stay clear of any moving mechanical parts and do not touch exposed electrical equipment or electrical connectors OTHERWISE DEATH OR PERSONAL INJURY COULD OCCUR Warning Warning Warning Warning Warning Disconnect disable all mechanical and or electrical devices that send activation signals to the gu...

Page 14: ...s previously mentioned this is not intended to be an exhaustive list follow all instructions and safety precautions for the specific type of equipment involved Warning Warning Warning Warning Warning Keep pump cover and electrical enclosures closed except during setup service and checkout procedures OTHERWISE DEATH OR PERSONAL INJURY COULD OCCUR Warning Warning Warning Warning Warning People with ...

Page 15: ... that a source of clean cold water be provided near the hot melt work area 2 Cover the affected area with a clean wet compress and call the emergency medical response system such as 911 immediately 3 Watch for and treat the subject for signs of shock while waiting for professional help to arrive What to Do if Contact with Hot Adhesive Occurs If adhesive fumes are inhaled immediately follow these s...

Page 16: ...ing 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 Warning Warning Warning Warning Warning Poor ventilation smoking and open flames can cause overheated hot melt to ignite Adequate ventilation must be provided Smoking should be prohibited in the immediate vicinity of the molten adhesive Open flames must b...

Page 17: ... not Do not Do not Do not allow kinks or indentations in the hoses Do Do Do Do Do use a minimum bend radius of 10 inches for a 20 inch diameter coil hose Do not Do not Do not Do not Do not use unapproved hooks to hang hoses Do not Do not Do not Do not Do not wrap hoses over or around objects Do Do Do Do Do use a hose hanging kit P N 781xx827 Do not Do not Do not Do not Do not use the one handed on...

Page 18: ...ontact with sharp edges or points Do Do Do Do Do wrap the hoses in approved padding P N 795xx549 if the hoses must be installed where they will come into contact with objects Do not Do not Do not Do not Do not use worn damaged or bent hoses Do Do Do Do Do inspect all hoses regularly for damage and or wear and replace damaged or worn hoses immediately Hose Safety Information Continued ...

Page 19: ...control box follow these steps 1 Using the upper and lower mounting flanges of the unit mount the control box to a stationary non vibrating support The main power supply must be 115 230 VAC 50 60 Hz 2 1 A The 115 230 power requirement is field switchable The power module accepts a standard IEC line cord supplied To connect the line cord follow these steps 1 Attach the line cord clamp to the bottom...

Page 20: ...wer from the unit 2 Remove the line cord 3 Use a small screwdriver to open the hinged door of the fuse holder 4 Remove the fuse drawer ensure that the fuses in the holder remain in place 5 The drawer is labeled 230V and 115V Rotate the drawer to the appropriate voltage 6 For line to neutral operation use the shorting clip jumper and one fuse Shorting clip must be on left side when rotated to read ...

Page 21: ...ll prove adequate in most cases However systems that require two feed pipes will not accommodate the LLD alarm system To install the low level detection probe on epoxy coated and stainless steel tanks follow these steps 1 Completely release tank pressure by either disconnecting the air hose from the input of the air regulator or adjusting the air regulator knob counterclockwise so gauge reads 0 ps...

Page 22: ...ection Probe for New Style Pressurized Tanks 1 2 x 1 4 NPT reducer bushing shown 3 8 x 1 4 NPT reducer bushing 3 gallon only 12 gallon 20 25 inches 514 4 mm 5 and 7 gallon 13 15 inches 336 6 mm 3 gallon 9 00 inches 228 6 mm 12 gallon 21 0 inches 5 gallon 17 7 inches 3 gallon 10 2 inches Pressurized Tanks Continued Figure 3 4 Manual Pressure Release Safety Valve and Pop Safety Valve ...

Page 23: ... which are the same length are the longest probes The low level and common probes should be installed approximately 1 inch above the suction tube on the pump Probes can be shortened to suit any drum To install the low level detection probe assembly on a 55 gallon drum follow these steps 1 Determine the glue level at which the alarm will be activated 2 Install the probe assembly into the inspection...

Page 24: ...PROBE IN 3 Tighten the cord grip used by the probe cable Electrical relay connections are as follows Switched 115 230VAC output Switched 115 230VAC output Switched 115 230VAC output Switched 115 230VAC output Switched 115 230VAC output This output can be used as the voltage source 115 or 230VAC depending on the alarm system s source voltage for the glue supply pump When the alarm system is activat...

Page 25: ...main power supply 5 Turn the control switch to the ON position The flashing light should flash on and off The audio alarm should also sound if the PROBE IN connector was wired for a dual sensor 6 Connect the probe to the probe cable Warning devices should turn off Testing the LLD Alarm System Internal Connections Item Description Part Number 41 Wire terminal 075xx244 43 Cable assy 030xx425 57 Beac...

Page 26: ...fully inspect the system for damage incurred during shipment If damage is discovered contact your shipper Mounting the Control Box The control box should be mounted Close to both an electrical power outlet and to the glue tank A 15 foot 5 M probe cable and 7 5 foot 2 5 M power cable are supplied with the AutoRefill LLD system To install the control box follow these steps 1 Using the upper and lowe...

Page 27: ... control box using the two screws on either side of the power module 2 Insert the line cord into the power module 3 Tighten the line cord clamp to prevent inadvertent loss of power The line cord supplied can either be directly wired to a branch circuit or with the proper plug type plugged into a 115 or 230 VAC outlet socket The wire colors of the supplied line cord are as follows Wire Type Interna...

Page 28: ...e a small screwdriver to open the hinged door of the fuse holder 4 Remove the fuse drawer ensure that the fuses in the holder remain in place 5 The drawer is labeled 230V and 115V Rotate the drawer to the appropriate voltage 6 For line to neutral operation use the shorting clip jumper and one fuse Shorting clip must be on left side when rotated to read the correct voltage For line to line operatio...

Page 29: ...n on all the parts and options available see the Parts List Section Figure 3 11 shows the wiring diagrams for the AutoRefill LLD System CAUTION CAUTION CAUTION CAUTION CAUTION The low level detection probe with automatic refill feature can only be used on non pressurized 55 gallon drums Mechanical Installation of the Probe non pressurized tanks Figure 3 10 AutoRefill LLD System Setup Example ...

Page 30: ...11 Wiring Diagram for External and Internal Connections AutoRefill LLD System 098xx699 Please see the Part Number List Section for more details Item Description Part Number 16 Terminal crimp 075xx239 25 Beacon red low profile 105xx036 38 Wire PVC brown 540xx035 41 Wire terminal 075xx244 43 Cable assy 030xx425 52 LED assy power on off 107xx022 ...

Page 31: ...s for the traditional LLD Alarm Stainless steel 3 gallon tank assembly Top view of stainless steel 3 5 and 10 gallon tank assembly Top view of OVS stainless steel 3 gallon tank assembly Epoxy coated 5 gallon tank assembly Top view of Epoxy coated 5 gallon tank assembly Top view of OVS stainless steel 5 gallon tank assembly Top view of OVS stainless steel 10 gallon tank assembly Epoxy coated 7 and ...

Page 32: ...nd Probe Installation MC036 Low Level Detection Alarm AutoRefill Systems Figure 4 2 Top View of Stainless Steel 3 5 and 10 Tank Assembly Figure 4 3 Top View of OVS Stainless Steel 3 Gallon Tank Assembly LLD Alarm Assembly Drawings Continued ...

Page 33: ...ted 5 Gallon Tank Assembly Glue filter assembly screen and O ring Male quick disconnect Feed pipe Tank lid Tank lid gasket Gauge Female quick disconnect Air regulator assembly Pop relief valve Air hose Hold down clamp assembly Tank body Figure 4 5 Top View of Epoxy Coated 5 Gallon Tank Assembly LLD Alarm Assembly Drawings Continued ...

Page 34: ...d Probe Installation MC036 Low Level Detection Alarm AutoRefill Systems LLD Alarm Assembly Drawings Continued Figure 4 7 Top View of OVS Stainless Steel 10 Gallon Tank Assembly Figure 4 6 Top View of Stainless Steel OVS 5 Gallon Tank Assembly ...

Page 35: ...arm AutoRefill Systems LLD Alarm Assembly Drawings Continued Figure 4 8 7 and 12 Gallon Epoxy Coated Tank Assembly Female quick disconnect Glue filter assembly Male quick disconnect Feed pipe Gauge Air regulator assembly Tank lid assembly Tank lid safety valve Pop relief valve Air hose Tank ...

Page 36: ...ill System Assembly Drawings The LLD AutoRefill System can only be used in a non pressurized drum The following is one example of a layout for the AutoRefill System Valco Cincinnati Inc can work with you to develop a layout that fits your unique needs Figure 4 9 Non Pressurized 55 Gallon Drum with the LLD AutoRefill System ...

Page 37: ...a preventative maintenance program is used General Maintenance Valco recommends the following general maintenance Keep the control box door closed except when working on the control circuitry This will prevent dust and dirt from entering the unit Occasionally wipe the surface of the control box using a clean cloth dampened with a mild soap and water solution To prevent glue buildup remove the prob...

Page 38: ...5 2 ValcoMelton Section 5 Maintenance MC036 Low Level Detection Alarm AutoRefill Systems ...

Page 39: ...o weve r the p ower lig ht is on indic atin g tha t the re is pow er to the unit 2a Th ere is a problem w ith th e probe 2b Th ere is a problem w ith th e PC board 2 a D isco nnect the prob e If the syste m o pera tes it m eans the prob e is not a llowing th e circuit to to be b roken T herefore the p roblem is in th e probe Rep lace the p robe If the syste m d oes not o perate th e pro be m a y b...

Page 40: ...6 2 ValcoMelton Section 6 Troubleshooting MC036 Low Level Detection Alarm AutoRefill Systems ...

Page 41: ...D Alarm System Width 7 Height 14 5 Depth 5 5 LLD probe inputs Warning level activates flashing light and relays Low limit level activates audio alarm LLD Alarm system outputs Switched 115 230VAC 1 0 5A 50 60Hz switched off when warning level or lower is reached Dry contacts form C 1 N O I N C 230VAC 1A maximum LLD AutoRefill System Width 7 Height 14 5 Depth 5 5 LLD probe inputs Low limit level act...

Page 42: ...7 2 ValcoMelton Section 7 Specifications MC036 Low Level Detection Alarm AutoRefill Systems ...

Page 43: ...www valcomelton com Valco Cincinnati Limited Valco Cincinnati Limited Valco Cincinnati Limited Valco Cincinnati Limited Valco Cincinnati Limited Hortonwood 32 Telford TFI 7YN England TEL 44 1952 677911 FAX 44 1952 677945 Email sales valco co uk Web http www valco co uk Valco Cincinnati GmbH Valco Cincinnati GmbH Valco Cincinnati GmbH Valco Cincinnati GmbH Valco Cincinnati GmbH Storkower Strasse 6 ...

Page 44: ...8 2 Valco Cincinnati Inc Section 8 Part Number List MC036 Low Level Detection Alarm AutoRefill Systems Example Auto Pot Fill System Layout 080xx377 999XD080 96 ...

Page 45: ... 2 Sensor 485xx090 1 3 Cable assembly 030xx604 1 6 Mounting bracket for scanner 581xx126 1 7 Clamp assembly 578xx526 1 8 L bar 578xx539 1 9 Mounting base 578xx527 1 10 Tool 578xx505 1 12 Air filter regulator 594xx082 1 13 Pot fill kit 754xx330 1 14 Valve cable 030xx882 1 16 Gauge 786xx001 1 17 Bushing M F 797xx045 1 Example Auto Pot Fill System Layout 080xx377 Continued ...

Page 46: ...8 4 Valco Cincinnati Inc Section 8 Part Number List MC036 Low Level Detection Alarm AutoRefill Systems LLD Control Assembly 080xx545 The LLD Alarm Assembly Parts List ...

Page 47: ...8 5 Valco Cincinnati Inc Section 8 Part Number List MC036 Low Level Detection Alarm AutoRefill Systems LLD Control Assembly 080xx545 Continued ...

Page 48: ...16 Terminal crimp 075xx239 2 22 PCB assy LLD w relay 151xx411 1 26 Adapter 795xx480 1 27 Screw 798xx295 2 29 Screw 798xx466 4 31 Hex nut 798xx687 2 33 Lock washer 798xx733 6 37 Hole plug 794xx038 1 38 Wire PVC brown 540xx035 22 39 Wire PVC white 540xx043 22 40 Wire PVC green yellow 540xx039 6 41 Wire terminal 075xx244 1 42 Power entry module 086xx055 1 43 Cable assy 030xx425 1 49 Screw 798xx442 2 ...

Page 49: ...Cord grip 066xx003 1 Dust seal 066xx006 1 Probe Assemblies Description Part Number Quantity Probe assembly for 3 5 7 and 12 gallon epoxy coated tank 080xx525 1 Probe assembly for 3 gallon stainless steel tank 080xx523 1 Probe assembly for 5 gallon stainless steel tank 080xx524 1 Probe assembly for 10 gallon stainless steel tank 080xx525 1 Probe assembly for 55 gallon drum 080xx018 1 Probe assembly...

Page 50: ...8 8 Valco Cincinnati Inc Section 8 Part Number List MC036 Low Level Detection Alarm AutoRefill Systems The LLD AutoRefill Assembly Parts List LLD AutoRefill Control Assembly 098xx699 ...

Page 51: ...8 9 Valco Cincinnati Inc Section 8 Part Number List MC036 Low Level Detection Alarm AutoRefill Systems LLD AutoRefill Control Assembly 098xx699 Continued ...

Page 52: ...7xx007 5 11 Fuse 1 AMP SLO BLO 085xx001 1 13 Latch 091xx011 1 14 Rivet 091xx030 2 16 Terminal crimp 075xx239 2 22 PCB assy LLD w relay 151xx597 1 25 Beacon red low profile 105xx036 1 29 Screw 798xx466 4 31 Hex nut 798xx687 2 33 Lock washer 798xx733 6 36 Wire PVC blue 540xx040 3 37 Hole plug 794xx038 1 38 Wire PVC brown 540xx035 22 41 Wire terminal 075xx244 1 42 Power entry module 086xx055 1 43 Cab...

Page 53: ...8 11 Valco Cincinnati Inc Section 8 Part Number List MC036 Low Level Detection Alarm AutoRefill Systems Pot Fill Kit 754xx330 ...

Page 54: ... 2 4 Swivel fitting female 750xx001 3 5 Male swivel 750xx009 3 6 Swivel fitting plug 750xx005 2 7 Flat washer 798xx768 2 8 Air tubing and fitting 753xx701 1 10 Swivel fitting female 750xx015 1 12 Mounting block 580xx606 1 13 Thumb screw 798xx864 1 18 Male branch tee 797xx027 1 20 Adapter m f 797xx961 1 21 Swivel fitting NPT 799xx104 2 22 Hose 755xx234 10 23 Elbow 797xx905 1 24 Valve assy 3 way 411...

Page 55: ...r s warranty In no event shall Valco Cincinnati Inc be liable for indirect or consequential damages arising out of the use of Valco Cincinnati products This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to Valco Cincinnati Inc for examination and verification If claimed defect is verified repairs or replacements will be made F O B Cincinnati Ohio U S A or...

Page 56: ......

Page 57: ...ervice call will be quoted at that time Any part that fails during the warranty period shall be returned prepaid to Valco Cincinnati Inc by the customer for disposition Upon request ValcoMelton personnel are available to repair or replace such parts at the customer s facility Charges for this service include travel time and expenses If an equipment problem is the result of customer abuse improper ...

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