VALCO MELTON D4-E Manual Download

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MM101 – D-4E HOT MELT UNIT

VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 ORCOYEN, NAVARRA

TEL: +34 948 321580 Fax: +34 948 326584 [email protected]

www.valcomelton.com

Set Language

Summary of Contents for D4-E

Page 1: ...D4 E Hot Melt Unit Manual Number MM101 Release Date 9 2009 Software Revision C018 ...

Page 2: ...etic compatibility Directive 93 68 EEC of 22 July 1993 amending Directive 73 23 EEC and Directive 89 336 EEC within the scope of the specifications indicated in the chapter describing the equipment with a B1 risk level Since it is intended to form part of a set of machines which to obtain a result are arranged and connected to perform together it cannot be operated until the set of machines has be...

Page 3: ...CT ADDRESS TELEPHONE DISTRIBUTOR CONTACT OEM ADDRESS GUARANTEE CARD APPLICATOR SERIAL NUMBER CONTROL REGISTRATION CONTROL DATE ELECTRIC CHECK CONTROL BOARD CHECK TEMPERATURE CONTROL CHECK 150 180 C HYDRAULIC CHECK 100 bar PNEUMATIC CHECK ...

Page 4: ...cation 13 Mounting Footprint 14 Routing Low Voltage Leads 15 Connecting the Electrical Power 15 Connecting the Hoses 19 Connecting the Hot Melt Hoses to the Applicators 23 Installing the Pneumatic Pressure Relief Valve Option 25 Wiring Diagram 27 Customer Connections 28 Section 5 Setup 30 Control Panel 30 Power On Off and Standby Mode 32 Navigation 33 Memory Storage 33 Editing 34 Thumbwheel vs Sin...

Page 5: ... Factory Default Settings 63 Section 6 Operation 64 Start the Unit 64 Monitoring the Unit 67 Setpoint and Actual Temperatures 67 Status LEDs 68 Clock On Off 69 Pump On Off 69 Setback On Off 70 Filling the Tank 71 Section 7 Maintenance 72 General 72 Cleaning the Exterior of the Unit 73 Changing the Adhesive 73 Flushing the System 73 Parts Replacement 75 Changing Fuses 75 Changing the Filter 78 Sect...

Page 6: ...quirement Calculation 120VAC D4 E Unit 94 System Power Requirement Calculation 240VAC D4 E Unit 95 Appendix C System Map 96 System Map 96 Main Programming Buttons Setup Button and Temperature Button 96 Temperature Button Screens 97 Setup Button Sub Menu Unlock Lock 98 Setup Button Sub Menu System 99 Setup Button Sub Menu Clock 100 Setup Button Sub Menu PID Temp 101 Setup Button Sub Menu Setback 10...

Page 7: ... information contact your ValcoMelton representative Description The D4 E hot melt unit is a low volume system designed to melt and pump thermoplastic adhesives The D4 E unit features a precision electronic temperature control a digital multi zone temperature display an electric motor driven gear pump and an adjustable pressure control Features and capabilities include o Precision electronic tempe...

Page 8: ... un insulated dangerous voltage within the product s enclosure This voltage may cause electrical shock or fire FAILURE TO OBSERVE WARNING MAY RESULT IN DEATH PERSONAL INJURY AND OR EQUIPMENT DAMAGE Warning This convention is used to alert the user to important installation operation and or maintenance information FAILURE TO OBSERVE WARNING MAY RESULT IN DEATH PERSONAL INJURY AND OR EQUIPMENT DAMAG...

Page 9: ...GE COULD OCCUR Warning Always wear insulated gloves and proper eye protection when working around hot melt equipment A protective screen around the face is also recommended OTHERWISE DEATH OR PERSONAL INJURY COULD OCCUR Warning Purge the fluid pressure from the system before disconnecting any part of the system OTHERWISE DEATH OR PERSONAL INJURY COULD OCCUR Warning People with respiratory problems...

Page 10: ...ve comes in contact with the skin do the following 1 Immediately immerse the contacted area in clean cold water 2 Cover the affected area with a clean wet compress and see a physician immediately 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 Warning Poor ventilation smoking...

Page 11: ...owing steps 1 Sound a fire alarm 2 Evacuate the immediate area 3 Turn off all local electrical equipment at the source 4 Fight the fire in one of the following ways Smother the fire with a fire blanket Aim a CO2 fire extinguisher at the base of the flames Aim a dry powder fire extinguisher at the base of the flames If Adhesive fumes are inhaled immediately follow these steps 1 Take the victim away...

Page 12: ... 321580 Fax 34 948 326584 melton melton es www valcomelton com SECTION 3 BASIC FEATURES Key Features Item Name 1 Power switch 2 Control panel 3 Electrical enclosure door 4 Tank lid 5 Manifold 6 Filter 7 Pressure relief valve 8 Hose Valve electrical receptacles 9 Hose hydraulic fluid fittings 10 Data plate ...

Page 13: ...n to another it should be screwed or bolted to a suitable stable flat level surface The unit should have clearance around the outside of the case to allow air to circulate freely around it The unit should have clearance above the top of the unit so it may be filled easily without obstruction to the operator The location should be near the glue station so that the glue hoses can be routed to the ap...

Page 14: ...MM101 D 4E HOT MELT UNIT 14 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Mounting Footprint ...

Page 15: ... 6 152 mm from high current wires Do not splice or solder leads Trim leads to the required length Leads should be only as long as necessary for installation All wiring should be in conduits or wireways Warning Electrical connections should be made only by experienced service personnel Failure to observe could result in personal injury death or damage to equipment When connecting the supply of elec...

Page 16: ...iguration is located on the data plate of each unit Always check the data plate before hooking up power to the unit D4 E units are shipped from the factory with an attached power cable Units configured for 120V operation have a power cable with a molded plug that can be connected to a 120V 20 Amp receptacle Units configured for 240V operation have a power cable with flying leads that can be connec...

Page 17: ... D 4E HOT MELT UNIT 17 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com E Series 5 Zones Borrad 151xx616 120V Rev D ...

Page 18: ...1 D 4E HOT MELT UNIT 18 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com E Series 5 Zone Borrad 151xx606 240V Rev D ...

Page 19: ...o equipment Caution Electrical connections should be made only by experienced service personnel Failure to observe could result in personal injury death or damage to equipment When routing and installing heated hoses follow these guidelines Avoid creating sharp corners and edges Do not bend hoses sharper than 18 460 mm radius Do not group heated hoses so that they contact one another Avoid positio...

Page 20: ... to the unit follow these steps 1 Using a pair of wrenches one on the fluid outlet fitting and the other on the fluid cap remove the protective caps from the fluid outlet fittings 2 Ensure that the fluid outlet fitting is tight into the machine 3 Ensure that the fluid outlet ports are clean 4 Select the end of the glue hose that has the lead assembly with the male electrical connector Figure 5 1 ...

Page 21: ...Connect the lead assembly s male electrical connector to the electrical receptacle located on the back panel above the fluid outlet ports Connections are shown in Figure 5 2 The left fluid outlet port should be used first to prevent trapped hot melt adhesive from charring in the lower portion of the manifold Straight fittings are standard but other fittings are available from Valco Cincinnati see ...

Page 22: ...MM101 D 4E HOT MELT UNIT 22 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Figure 5 2 Hose Connections ...

Page 23: ...from accidental contact by the operator Failure to observe could result in personal injury burns Warning Hand held applicators require a suitable hook for hanging while not in use The hook must support the weight of the applicator with the hose Failure to observe could result in damage to equipment Either hand held or fixed applicators can be used with the unit To connect the fixed applicators fol...

Page 24: ...MM101 D 4E HOT MELT UNIT 24 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com ...

Page 25: ...the standard pressure relief valve from the manifold 6 Thread the pneumatic pressure relief valve into the manifold 7 Connect the air line fittings regulator and gauge as shown Figure 5 5 8 Reinstall the cap onto the hose outlet fitting 9 Attach the air supply to the air filter regulator and adjust the air 10 Turn on the pump and adjust the air filter regulator to obtain the desired adhesive press...

Page 26: ...comelton com Pneumatic Relief Valve Kit Optional 707xx212 Item Part Number Description Quantity 1 707xx211 Pressure Relief Valve Assy 1 2 755xx054 Air Line 1 3 797xx827 Fitting Straight JIC 1 4 594xx160 Air Filter Regulator 1 5 786xx001 Air Pressure Gauge 1 6 752xx004 Male Quick Disconnect 1 7 999XD707 002 Illustration 1 Figure 5 5 Pneumatic Relief Option ...

Page 27: ...MM101 D 4E HOT MELT UNIT 27 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Wiring Diagram ...

Page 28: ...able inputs rated for 24V 15mA and one dry contact user selectable output rated for 250V 5A Inputs and outputs can be programmed for the following functions see Section Setup Peripherals for programming instructions Input 1 Input 2 Output 2 Disabled Disabled Disabled Setback Setback System Ready Auto Setback Auto Setback Ready Pump On Heater On Off Heater On Off Alarm Pump On Off Pump On Off A 24V...

Page 29: ...MM101 D 4E HOT MELT UNIT 29 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com PLC sensor wiring ...

Page 30: ...MM101 D 4E HOT MELT UNIT 30 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com SECTION 5 SETUP Control Panel ...

Page 31: ...ield 9 OK Button Enters or exits a screen subscreen where a selected field can be edited 10 Right Arrow Button Moves right through editable fields in the selected menu group 11 Minus Button Decreases the value of the selected editable field 12 Left Arrow Button Moves left through editable fields in the selected menu group 13 Display Screen Displays the menu and event screens 14 Setup Button Displa...

Page 32: ... will illuminate green indicating that the unit is on When the Standby Button is pressed again the display screen will go blank and the Standby LED will illuminate orange indicating the unit is in Standby Mode Power On Off Switch D4 E Unit Standby LE Standby Button Display Button D4 E Unit Control Panel When the unit is in Standby Mode the internal clock is still working The clock will turn the un...

Page 33: ...symbols on the bottom of the display screen indicate that 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 Navigation Symbols Change made but not yet stored in flash memory Navigation Memory Storage ...

Page 34: ...ring up a thumbwheel for more detailed editing Editable highlighted information Single Digit Editing Thumbwheel Editing 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 Some thumbwheel screens contain a switch that can be used to turn the selected function ON or OFF Common examples...

Page 35: ...ARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Passwords are required to prevent unauthorized access to unit programming Please see Appendix A Password Levels for more information To enter a password Press the powr button to turn the unit on Entering Passwords ...

Page 36: ...MM101 D 4E HOT MELT UNIT 36 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Set Language ...

Page 37: ...MM101 D 4E HOT MELT UNIT 37 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com ...

Page 38: ...MM101 D 4E HOT MELT UNIT 38 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Set Temperature Units ...

Page 39: ...ature Button if the Temperature LED is not illuminated green to show the first temperature screen The tank temperature screen shows the actual tank temperature and the tank temperature setpoint For operator convenience the right side of this screen alternately displays the first hose and valve temperatures and the second hose and valve temperatures Press the Temperature Button repeatedly or use th...

Page 40: ...MM101 D 4E HOT MELT UNIT 40 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Tank Temperature ...

Page 41: ...MM101 D 4E HOT MELT UNIT 41 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Hose Valve Temperature ...

Page 42: ...MM101 D 4E HOT MELT UNIT 42 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com ...

Page 43: ...otor This prevents the pump motor from being activated before the adhesive in the pump has softened Consult the adhesive data sheet to find the softening point temperature The System Ready Temperature Offset must be set to at least 5 F 3 C If it is set too close to the setpoint for example 1 F the pump motor will stop during momentary drops in temperature of any zone until the zone is again within...

Page 44: ...This feature allows the adhesive in the system to heat for an additional period of time before the pump motor is enabled Once the zones have reached the System Ready remaining before the system is ready is displayed on the status bar at the bottom of the screen The ready delay range is 1 minute to 120 minutes The default factory setting is ON at 15 minutes To prolong the life of the seal in the pu...

Page 45: ...alarm tolerance is the number of degrees that any zone can heat above its temperature setpoint before triggering an over temperature alarm If any zone goes into Over Temperature Alarm the heaters of the affected zone are automatically shut off The over temperature alarm tolerance range is 9 F to 108 F 5 C to 60 C The factory default setting is 45 F 25 C This parameter can be accessed in Password L...

Page 46: ...is the number of degrees that any zone can cool below its temperature setpoint before triggering an under temperature alarm If any zone goes into Under Temperature Alarm the heaters of the affected zone will remain on to compensate for the drop in temperature The under temperature alarm tolerance range is 9 F to 108 F 5 C to 60 C The factory default setting is 27 F 15 C This parameter can be acces...

Page 47: ...0 Fax 34 948 326584 melton melton es www valcomelton com 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 This parameter can be accessed in Password Level 3 Maximum Temperature ...

Page 48: ...will automatically start when the system reaches temperature and the System Ready LED illuminates When the Automatic Pump Mode is off the pump can be turned on and off by pressing the Pump On Off Button The System Ready LED must be illuminated for the pump to operate The factory default setting is OFF This parameter can be accessed in Password Level 2 or higher see Appendix A Password Levels Autom...

Page 49: ... by a given temperature differential to allow the hot melt to remain soft but not molten during periods of inactivity The setback temperature differential is relative to the temperature setpoint of each zone The setback temperature differential range is 45 F to 342 F 25 C to 190 C The default factory setting is 90 F 50 C This parameter can be accessed in Password Level 2 or higher see Appendix A P...

Page 50: ...hin the automatic setback timeout period the unit will automatically go into setback The Automatic Setback Timeout feature is used only in conjunction with the Automatic Setback External Input It is not used in manual or scheduled setback modes The automatic setback timeout range is 1 minute to 120 minutes The default factory setting is 30 minutes This parameter can be accessed in Password Level 2...

Page 51: ...er 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 The sequential start range is 0 F to 450 F 0 C to 250 C The default factory setting is OFF This parameter can be accessed in Password Level 2 or hig...

Page 52: ...MM101 D 4E HOT MELT UNIT 52 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Sequential Start Valve ...

Page 53: ...k Auto Setback Ready Pump On Heater On Off Heater On Off Alarm Pump On Off Pump On Off Peripherals are user selectable inputs and outputs that can be triggered by a remote signal Inputs include pump enable heater enable and setback Outputs include alarms and system ready signal See Customer Connections in Section 4 Installation for a detailed description of these features This parameter can be acc...

Page 54: ...48 321580 Fax 34 948 326584 melton melton es www valcomelton com 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 History ...

Page 55: ...Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com The Diagnostics Screen shows the current software version as well as the current temperature and status of each zone Diagnostics ...

Page 56: ...AVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 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 by the internal clock Clock and 7 Day Timer Set Day and Time ...

Page 57: ...MM101 D 4E HOT MELT UNIT 57 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com ...

Page 58: ...OYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 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 Shift Time Setback Times ...

Page 59: ... set the times and turn on the setback feature with a switch on the thumbwheel The heaters can be set with or without using the setback times Set the start stop and setback times for all shifts Leave unused shifts times blank Setback Start Stop Times for the shift shown above Heaters Start Stop Times for the shift shown above Shift A B or C This screen states that for Shift A heaters will turn on ...

Page 60: ... different combinations of shifts and the Left Right Arrow Buttons cycle through the days of the week Shifts that will work on the above day of the week A B C A B B C OFF etc Day Monday through Sunday 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 After setting all shift times previous page and programmi...

Page 61: ...melton es www valcomelton com Continue to use the Right Left Up Down and OK Buttons to set all shift times and what shifts work on each day Turn the Clock On and your unit is set to work with your shift times and days Clock Button Press the Clock Button to enable all shift setting the 7 Day Timer Moving Through the Shift Time Day Screens ...

Page 62: ...pressure The single stage relief valve is commonly used for systems that are applying adhesive continuously laminating To adjust the single stage relief valve follow these steps Caution Do not overtighten adjusting screw Failure to comply could result in damage to the equipment 1 Turn off pump motor 2 Loosen the locknut on the pressure relief valve 3 Turn adjustment screw clockwise to increase pre...

Page 63: ... factory default settings follow these steps Caution Restoring the factory default settings will permanently erase changes made to any parameter or setting 1 Switch off power to the unit 2 Power the unit back up while pressing and holding the Setup Button and the OK Button on the keypad The buttons can be released once the start up screen appears Restoring Factory Default Settings ...

Page 64: ...s Section and operate the D4 E unit OTHERWISE DAMAGE TO EQUIPMENT AND PERSONAL INJURY COULD OCCUR To start the unit do the following 1 Toggle the Power On Off Switch to the On position to power up the system Power On Off Switch The Standby LED will illuminate green when the power to the unit is on If the Standby LED illuminates orange the unit is in Standby Mode Press the Standby Button to turn th...

Page 65: ...4 948 326584 melton melton es www valcomelton com Once the unit has completed its start up sequence it will turn on the heaters in the tank and all active hoses and guns The heater s corresponding Zone LED will illuminate green when the heater is on Reservoir Tank Zone LED Hose 1 Hose 2 Zone LEDs Gun 1 Gun 2 Zone LEDs ...

Page 66: ...f Button to turn the pump on the Pump On Off LED illuminates green and turn the pump off the Pump On Off LED does not illuminate The pump can be set to come on automatically when the unit is ready see Section 5 Setup Programming Temperatures Note that all temperatures must reach the system ready temperature and the Ready LED must be illuminated green for the pump to operate When the pump is enable...

Page 67: ...lton melton es www valcomelton com 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 1 Gun 1 temperatures and the Hose 2 Gun 2 temperatures Monitoring the unit Setpoint and Actual Temperatures ...

Page 68: ...minate green and stay on continuously Once the zone reaches its setpoint temperature the LED will blink on and off indicating that the heaters are switching on and off to maintain the setpoint temperature If the LED illuminates red it indicates a fault for that zone The status bar will provide a more detailed explanation of the fault Also if the fault triggers a temperature alarm the Temperature A...

Page 69: ...hifts to run unless the unit will be operated manually no pre programming To turn the clock on or off press the Clock On Off Button When the clock is on the Clock LED illuminates green See Section 5 Setup for detailed information on setting the clock The pump can be set to come on automatically when the unit is ready see Programming Temperatures Section 5 Setup The pump mode must beset to Automati...

Page 70: ...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 If however an unscheduled break occurs the Setback Button can be pressed Setback LED illuminated yellow to put the unit into setback manually To exit setback mode press the Setback Button again LED not ...

Page 71: ...ructions in the Maintenance Section or call ValcoMelton for full instructions OTHERWISE DAMAGE TO EQUIPMENT COULD OCCUR To fill the tank do the following Warning Use caution when opening the tank lid and filling the tank Wear gloves and eye protection Burns and splashing of molten adhesive may occur DEATH OR PERSONAL INJURY COULD OCCUR FROM BURNS 1 Open the tank lid 2 Fill the tank with the proper...

Page 72: ...ls of the tank Keep the tank lid closed Any contamination in the tank will increase the chance of poor performance Moisture dirt and charred adhesive are the major causes of clogged nozzles Remove adhesive spills immediately Use a putty knife while the material is still soft While the unit is still hot but not operating use cheesecloth to remove material leaking from the pump seal and other connec...

Page 73: ...s always consult adhesive suppliers to check compatibility between adhesives Failure to comply could result in damage to the equipment To change the adhesive follow these steps 1 If the old adhesive and the new adhesive are compatible pump enough of the new adhesive through the system to ensure that all of the old adhesive has been cleared out generally 3 to 5 lbs or 1 1 to 1 9 kg 2 If the two mat...

Page 74: ...ng 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 2 Make sure that the pump is turned off 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 appropriat...

Page 75: ...ear insulated gloves and eye protection when disconnecting hoses Failure to observe could result in personal injury death or damage to equipment Occasionally parts may need to be repaired or replaced The following paragraphs contain instructions for removing parts from the hot melt unit For drawings and a complete list of part numbers see Section 10 Part Number List In the event that a fuse must b...

Page 76: ...RA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 151xx616 120V Item Fuse Description Part Number Quantity 1 Fuse 1A 5 x 20 mm 085xx239 2 2 Fuse 3 15A 5 x 20 mm 085xx208 2 3 Fuse 15A 5 x 20 mm 085xx254 2 4 Fuse 10A 5 x 20 mm 085xx224 4 Front of the unit 151xx616 Rev D ...

Page 77: ...EN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com 151xx606 240V Item Fuse Description Part Number Quantity 1 Fuse 500mA 5 x 20 mm 085xx219 2 2 Fuse 1 6A 5 x 20 mm 085xx209 2 3 Fuse 6 3A 5 x 20 mm 085xx221 2 4 Fuse 5A 5 x 20 mm 085xx206 4 151xx606 Rev D ...

Page 78: ...rotection when disconnecting hoses Trapped air pockets may cause adhesive spray and result in personal injury burns or death 1 Make sure that the pump is turned off 2 Manually activate the applicators to relieve any system pressure 3 Unscrew the filter assembly from the manifold and discard 4 Thread a new filter assembly into the manifold See Section 10 Part Number List for more information The ne...

Page 79: ...applicator 2e Applicator clogged 2f Clogged filter 2g Temperature control malfunction 2a Check temperature setting is correct Ensure that reservoir heater has power Check fuses 2b Check for system ready condition Check for blown fuse 2c Replace hose 2d Check for blown fuse and or defective heater 2e Service applicator system 2f Remove old filter and replace with new filter 2g Replace temperature c...

Page 80: ...ve 5b Adhesive overheated 5c Glue hoses not at the same temperature 5d Different pressure drop through each hose Hoses not the same length Crimped hose s Leaking hose s 5e Adhesive supply low 5f Manifold partially clogged 5g Nozzles partially clogged 5a Raise reservoir temperature in accordance with adhesive manufacturer s specifications Seek adhesive manufacturer s recommendations 5b Reduce reser...

Page 81: ... lbs hr 5 kg hr Pump Rate 60 lbs hr 27 kg kr Gear Pump Control Fixed speed Pressure Relief Single stage or optional pneumatic compound relief Maximum Pressure 800 psi 55 bar Number of Hoses Guns 1 2 Temperature Control Microprocessor control and 7 day clock Voltage 120VAC or 240VAC 1PH 50 60 Hz Power Consumption 2400 W 120VAC 4200 W 240VAC Inputs 2 User Selectable Inputs Rated for 24VDC 15mA Opto ...

Page 82: ...MM101 D 4E HOT MELT UNIT 82 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Dimensions ...

Page 83: ...83 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com SECTION 10 PART NUMBER LIST 775XX850 120 VAC Model 775XX851 240 VAC Model D4 E Unit ...

Page 84: ...MM101 D 4E HOT MELT UNIT 84 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com ...

Page 85: ...90 2 13 Fuente de alimentación Power source 1 14 Tarjeta de potencia Power board Depending on model 1 Tarjeta de potencia 220VAC 220VAC Power board 151XX606 Tarjeta de potencia 115VAC 115VAC Power board 151XX616 15 Arandela M4x48mm M H Standoff M4x48mm M F 091XX601 8 16 Distancial Ø6x1 4 Spacer Ø6x1 4 091XX417 4 17 Prensa PVC PG13 negro Press PVC PG13 black 2 18 Tuerca PVC PG13 negro Nut PVC PG13 ...

Page 86: ...Terminal faston M panel TE938 Terminal faston M panel 1 5 Conjunto cables Cable assembly heater pwr 029XX384 1 6 Brida sonda Probe flange 1 7 Junta torica viton 26 64x2 62 26 64x2 62 viton o ring 1 8 Arandela grover M8 inox Stainless M8 grover washer 4 9 Arandela dentada M3 M3 washer 2 10 Tornillo allen M3x6 inox Stainless M3x6 allen screw 2 11 Tornillo allen M4x10 inox Stainless M4x10 allen screw...

Page 87: ... 8 X 1 2 LG JIC CAP 3 8I X 1 2 LG STEEL 795XX508 2 7 Tapon 9 16 con junta Plug 9 16 with seal 5 8 Racor recto 9 16 M M junta viton 9 16 M M straight bushing 2 9 Arandela grover 8 inox Stainless 8 grover washer 4 10 Junta torica viton 17x2 62 17x2 62 viton o ring 2 11 Tapon 1 4 GAS NPT 1 4 GAS NPT plug 1 12 Tornillo hexagonal M8x90 M8x90 hexagonal screw 4 Nº Descripción Description Ref Qty 1 Soport...

Page 88: ... eléctrico Sticker electric risks 1 4 Reten SOUTHCO SOUTHCO detent 2 5 Conjunto pantalla tarjeta de control Overlay assembly 137XX010 1 6 Conjunto interruptor Cable assembly power switch 029XX379 1 7 Tuerca hexagonal M3 inox Stainless M3 hexagonal nut 2 8 Tuerca hexagonal M4 inox Stainless M4 hexagonal nut 6 9 Arandela dentada M3 inox Stainless M3 washer 1 10 Arandela dentada M4 inox Stainless M4 ...

Page 89: ...oporte tapa deposito Bracket reservoir lid 775XX862 1 4 Pegatina riesgo temperaturas Sticker temperatura risks 1 5 Asa grande negra Black handle 1 6 Tornillo cabeza redonda M6x10 BHCS M6x10 LG S S 784XX491 3 7 Tornillo allen M5x16 inox Stainless M5x16 allen screw 2 8 Arandela plana M6 M6 washer 2 9 Tuerca hexagonal M3 inox Stainless M3 hexagonal nut 2 10 Arandela dentada M3 M3 washer 1 11 Terminal...

Page 90: ...5 1 2 Conjunto conector pistola manguera Hot melt gun hose cable assy 029XX383 1 3 Conjunto conector pistola manguera 2 Hot melt gun hose 2 cable assy 1 4 Arandela dentada M3 Me washer 9 5 Tuerca hexagonal M3 inox Stainless M3 exagonal nut 10 6 Terminal faston M panel TE938 Terminal faston M panel TE938 1 7 Pegatina riesgo de temperatura Sticker temperature risks 1 8 Pegatina riesgo electrico Stic...

Page 91: ...e time of purchase will be warranted as described above for a period of ninety 90 days from the date of shipment by ValcoMelton Components purchased by ValcoMelton from others for inclusion in its products are warranted only to the extent of the original manufacturer s warranty In no event shall ValcoMelton be liable for indirect or consequential damages arising out of the use of ValcoMelton produ...

Page 92: ...charges for a service call will be quoted at that time Any part that fails during the warranty period shall be returned prepaid to ValcoMelton Inc by the customer for disposition If an equipment problem is the result of customer abuse improper installation or operation all travel time labor parts and expenses will be charged to the customer If the responsibility for a problem cannot be absolutely ...

Page 93: ...r the different levels and describes the difference between them Level 1 Operator no password required Can view most information with only basic editing available Can adjust temperature setpoints Can turn zones on and off Level 2 Advanced Operator PIN Code 1234 Can access all Level 1 features Can access most system setup parameters Can access all Clock Setback Startup History and Diagnostics menu ...

Page 94: ...ower requirement calculation for the 120 VAC unit as follows 1 The power requirement of any hose or gun is listed on the data tag of the component List the power requirement of each component and compare these values to the maximum wattage for any one hose or gun given in Line 1 of Table B 1 2 Add the power requirements of hose 1 and gun 1 Compare this value to the maximum wattage for any hose gun...

Page 95: ...pare this value to the maximum wattage for any hose gun pair given in Line 2 of Table B 2 3 Add the power requirements of all hoses and all guns Compare this value to the maximum wattage for all hoses and guns given in Line 3 of Table B 2 4 If any of the power requirements calculated in steps 1 3 exceed any of the maximum allowable wattages given in Table B 2 then the hose length or the gun config...

Page 96: ... 96 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com APPENDIX C SYSTEM MAP System Map Main Programming Buttons Setup Button Temperature ...

Page 97: ...RRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Access to some screen menus and programmability depend on password levels See Appendix A Password Levels for details Tank Temperature Hose 1 Valve 1 Temperatures Hose 2 Valve 2 Temperatures Temperature Buttons Screen ...

Page 98: ... L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Menus available depend on password levels See Appendix A Password Levels Unlock Lock Setup Button Sub Menu Unlock Lock ...

Page 99: ...M101 D 4E HOT MELT UNIT 99 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Setup Button Sub Menu System System ...

Page 100: ...MM101 D 4E HOT MELT UNIT 100 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Clock Setup Button Sub Menu Clock ...

Page 101: ...1 D 4E HOT MELT UNIT 101 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Setup Buttons Sub Menu PID Temp PID Temp ...

Page 102: ...NIT 102 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com Setup Button Sub Menu Setback Setback Setup Button Sub Menu Startup Startup ...

Page 103: ...MM101 D 4E HOT MELT UNIT 103 VALCO MELTON S L U Pol Ind Agustinos C G 34 3116 0 ORCOYEN NAVARRA TEL 34 948 321580 Fax 34 948 326584 melton melton es www valcomelton com ...

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