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VALCO MELTON D4, Manual

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VALCO MELTON D4 Manual Download Page 213

IS0344 

                                                         Anybus Installation and Setup 

 

ValcoMelton                                                                                                                                                                      5 

Modules Input Connection 

 

 

Hot Melt Unit to EthernetIP Communication Protocol 

The Melter Communication Interface Ethernet/IP module is configured to use a consistent 16 bytes of process data.  
When the Ethernet is enabled, the Melter control will initiate configuration setup with the Ethernet/IP module, and 
configure the module, using the addresses stored in the setup menus.   

When the Melter is started, the module can take up to two minutes to initialize.  This is due to the Melter configuring 
its own internal network before it starts configuring and initializing the Ethernet/IP module. 

Data is carried in specific send and receive packets, in which the PLC initiates the commands needed for the Melter 
process.  Only one command is executed at a time, and the Melter will respond with specific fault codes if the 
command cannot be executed.  For each packet, the Melter will return the Data Index and channel from the PLC 
command, to indicate proper acknowledgement. 

Data Packets used for Ethernet/IP communication 

This section describes the Process Data packets needed to operate between the Melter and PLC.  There are two 
types of packets: 

Send Packets

 that have the control information from the PLC and, 

Receive Packets

 that have the 

status information from the Melter. 

Some PLC messages may need to swap bytes in order to 
correspond with the Melter message. 

Summary of Contents for D4

Page 1: ...D4 Hot Melt Unit Manual Number MM147 Revision Date 6 2018 ...

Page 2: ...eeway Drive Suite 490 Cincinnati Ohio 45246 http www valcomelton com Part Number MM147 Written and printed in the USA Valco Cincinnati Inc 497 Circle Freeway Drive Suite 490 Cincinnati OH 45246 Tel 513 874 6550 Fax 513 874 3612 Email sales valcomelton com Web http www valcocincinnatiinc com Valco Cincinnati Limited Hortonwood 32 Telford TFI 7YN England Tel 44 1952 677911 Fax 44 1952 677945 Email s...

Page 3: ...Melt Unit complies with the following Council Directives Safety of Machinery 2006 42 EC Low Voltage Equipment 2014 35 EU EMC 2014 30 EU Reduction of Hazardous Substances RoHS 2011 65 EC and conforms to the following standards Safety EN60204 1 2006 EN13849 1 Risk ISO12100 2010 EMC Emissions EN61000 6 4 2007 EN61000 4 2 EMC Immunity EN61000 6 2 2005 EN61000 4 3 EN61000 4 4 EN61000 4 5 EN61000 4 6 EN...

Page 4: ......

Page 5: ...16 What to Do if Contact with Hot Adhesive Occurs 17 What to Do if Inhalation of Adhesive Fumes Occurs 17 What to Do if Adhesive Related Fire or Explosion Occurs 18 Hose Safety Information 19 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 Connectin...

Page 6: ...e 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...

Page 7: ...ng the Communication Protocol 86 Selecting the RTD type 87 Selecting the Number of Pumps 87 Selecting the Number of Hose Outlets 87 Selecting the Temperature Units 88 Selecting the Pattern Control 88 Finishing the Configuration 88 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 Befo...

Page 8: ...t 776xx890 117 D4 Unit Variable speed 2 exit 776xx889 before 5 18 118 D4 Unit Variable speed 4 exit 776xx890 before 5 18 119 D4 Base Unit 776xx392 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...

Page 9: ...tion 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 Eth...

Page 10: ...Table of Contents MM147 D4 Hot Melt Unit 10 Module Status LED 170 Link Activity LED 170 ...

Page 11: ... or fixed speed and an adjustable pressure control Features and capabilities include Precision electronic temperature control Capacity of up to four 4 hoses and guns Positive displacement electric motor driven gear pump Adjustable pressure control Integrated over temperature protection User selectable inputs and outputs Variable frequency drive VFD on Variable Speed Units Accepts encoder or tachom...

Page 12: ...Enable 0 None 1 Pump control included 1 handgun 2 Pump control included 2 handguns Feature 4 Motor Pump Type ST 3 18cc rev pump variseal pump HT 1 54cc rev pump variseal pump Feature 5 Not Used 00 None Feature 6 Not Used 00 None Feature 7 Pattern Control 00 None Feature 8 Level Sensors 00 None 01 Low level sensor 02 Low level sensor w beacon 03 Low level sensor w beacon alarm 04 High level sensor ...

Page 13: ...an cause puncture wounds and risk exposure to bloodborne pathogens and other debris This symbol means that Working Gloves are required This symbol means that Goggles are required This symbol indicates a Shock Hazard There is a presence of non insulated dangerous voltage within the product s enclosure This voltage may cause electrical shock or fire This symbol indicates the need to Unplug Disconnec...

Page 14: ...bligation to make certain that all personnel who will handle install maintain operate fix and work around the equipment are qualified trained and up to date with all information regarding the equipment Some examples include Make sure all personnel have the proper safety training equipment education and abilities necessary for the job function according to safety instructions and all jurisdictional...

Page 15: ...correct voltage type of current 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 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...

Page 16: ...AL INJURY COULD OCCUR WARNING Disable all triggering devices relieve all residual pressure hydraulic and air and allow adhesive to cool before attempting to disconnect guns hoses valves etc Only qualified personnel should open and service the control OTHERWISE DEATH OR PERSONAL INJURY COULD OCCUR WARNING Never point an adhesive dispensing gun valve hose air hose or anything else at yourself or ano...

Page 17: ...e to heat hot melt components or adhesive OTHERWISE DEATH PERSONAL INJURY OR DAMAGE TO EQUIPMENT COULD OCCUR What to Do if Contact with Hot Adhesive Occurs If hot adhesive comes in contact with the skin do the following WARNING Do not attempt to remove heated hot melt adhesive from the skin OTHERWISE SEVERE PERSONAL INJURY AND DEATH COULD OCCUR 1 Immediately immerse the contacted area in clean col...

Page 18: ... DAMAGE TO EQUIPMENT COULD OCCUR WARNING Exposed arcing may ignite the fume air mixture Shield all electrical equipment from melt fumes to avoid exposed arcing OTHERWISE PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR WARNING Do not use a water extinguisher to extinguish the fire OTHERWISE PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR If the hot melt adhesive ignites promptly perform the followi...

Page 19: ...ed hooks to hang hoses Do not wrap hoses over or around objects Do use a hose hanging kit P N 781xx827 Do not use the one handed one wrench technique to attach or remove hoses Do not wrench on any surface other than the large hexagon swivel nuts Do use two hands and two wrenches to tighten or loosen connections on hoses Do wrench only on large hexagon swivel nuts Do not allow hoses to rub against ...

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

Page 21: ...eries Hot Melt Systems The basic features of the D4 Hot Melt Units are similar with the exception of the tank capacity of each unit Key Features 1 Unit power switch 2 Temperature controller 3 Tank lid 4 Electrical enclosure door 5 Manifold 6 Pressure gauge 7 Pressure relief valve 8 Hose valve receptacles 9 Data plate 10 Hose ports 11 Filter ...

Page 22: ...Section 3 Basic Features MM147 D4 Hot Melt Unit 22 ...

Page 23: ...ted 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 applicators in as straight a line as possi...

Page 24: ...mage to equipment When routing low voltage leads follow these guidelines Do not route low voltage leads in the same conduit as wires carrying a high current load Do not route low voltage leads adjacent to or across wires carrying a high current load If low voltage leads must cross or run parallel to wires carrying high current keep the leads at least 6 152 mm from high current wires Do not splice ...

Page 25: ...Failure to observe could result in personal injury death or damage to equipment The D4 hot melt unit can be set up to use one of the following power sources Incoming Electrical Service Power Connector Terminals Voltage Plug Connector Label A B C D PE Part No Color Part No Color 380VAC 3 phase with Neutral 4 wire service 3 N PE AC 400 230V L1 L2 L3 N PE 029XX437 Blue 782XX262 Blue 200 to 240VAC 3 p...

Page 26: ... on the power connector 5 Remove the power connector from the 12 zone board and connect the power cable leads to the power connector terminals as shown in the chart above 6 Install the appropriate voltage selector plug into the connector marked J15 on the 12 zone board see illustration 7 Plug the power connector into the 12 zone board see illustration 8 Verify that all connectors are fully seated ...

Page 27: ...act one another Avoid positioning hoses where they can be stepped on or have a chance of being crushed or cut Avoid the use of unnecessarily long hoses where the hose is looped or curled on the floor Excess twisting of the hose can cause irreparable damage to it Maintain separation between hoses to avoid hot spots To connect the hot melt hoses to the unit follow these steps 1 Using a pair of wrenc...

Page 28: ...be used first to prevent trapped hot melt adhesive from charring in the lower portion of the manifold Fittings are available from Valco Cincinnati see Section 10 Part Number List Using two wrenches prevents the hose from twisting inside while it is being tightened 7 Connect the lead assembly s male electrical connector to the electrical receptacle located on the back panel above the fluid outlet p...

Page 29: ...plicators 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 follow these steps 1 Mount the applicator to the desired location on the parent machine Do not place applicators where t...

Page 30: ...PLY 029XX791 DC TO BOARD 029XX569 AC TO SWITCH J4 J15 J27 HOPPER FEEDER KIT 776XX305 DISPLAY CABLE BOARD TO BOARD CONNECTION PROGRAMMABLE INPUTS FEEDER SOLENIOD CABLE FEEDER SENSOR CABLE TANK RTD 029XX788 J30 BEACON KIT 782XX701 029XX551 J35 J37 MOTOR ASSEMBLY CABLE ASSEMBLY INCLUDED 110XX365 VARIABLE SPEED OR 110XX357 FIXED SPEED J37 VARIABLE SPEED ONLY 029XX792 VFD POWER CABLE GROUND TO VFD GREE...

Page 31: ...TO PWR SUPPLY I O POWER SWITCH 480XX246 148XX076 75W 24VDC POWER SUPPLY 029XX791 DC TO BOARD 029XX569 AC TO SWITCH J4 AUXILIARY I O BOARD 151XX661 J15 J27 HOPPER FEEDER KIT 776XX157 DISPLAY CABLE BOARD TO BOARD CONNECTION PROGRAMMABLE INPUTS FEEDER SOLENIOD CABLE FEEDER SENSOR CABLE TANK RTD 029XX788 J30 BEACON KIT 776XX137 029XX551 24V RELAY KIT 776XX537 24VDC SIGNAL J23 J35 J37 MOTOR ASSEMBLY CA...

Page 32: ... four opto isolated inputs that can be programmed by the user for a variety of options See the chart below There are also four dry contact user selectable outputs rated for 250V 2A each CPU Board Showing Input Output Connectors Beacon Output Connection Auxilliary I O Anybus Board Connection 4 Output Relay Contacts 4 Opto Isolated Inputs See the following page for input wiring options See the follo...

Page 33: ...NG NORMALLY OPEN NORMALLY CLOSED OUTPUT 1 N O OUTPUT 2 N O OUTPUT 3 N O OUTPUT 4 N O OUTPUT 1 N C OUTPUT 2 N C OUTPUT 3 N C OUTPUT 4 N C PLC SOURCING OUTPUT MODULE I1 I2 I3 I4 SOURCING INPUTS 24VDC 24 VDC SOURCING OUTPUT PLC SOURCING OUTPUT MODULE PLC SINKING OUTPUT MODULE I1 I2 I3 I4 SINKING INPUTS GND DC COMMON DC COMMON SINKING OUTPUT PLC SINKING OUTPUT MODULE PNP SENSOR 24VDC EXCITATION VOLTAG...

Page 34: ...5mA each that can be programmed by the user for a variety of options See the chart below There are also 4 dry contact user selectable outputs rated for 250V 2A each CPU Board Showing Input Output Connectors The CPU supports up to four inputs and four outputs and up to eight inputs and eight outputs with the Auxilliary I O Board The diagrams show the functions of the CPU Board Connectors and Wiring...

Page 35: ...MM147 D4 Hot Melt Unit Section 5 Setup 35 Section 5 Setup Control Panel ...

Page 36: ...GHT ARROW KEY MOVES RIGHT THRU FIELDS ON THE SCREEN 9 OK KEY ENTERS OR EXITS A SCREEN WHERE A SELECTED FIELD CAN BE EDITED 10 MINUS KEY DECREASES THE VALUE OF THE SELECTED FIELD 11 LEFT ARROW KEY MOVES LEFT THRU FIELDS ON THE SCREEN 13 SETUP MENU KEY DISPLAYS THE SETUP MENU SCREENS 14 TEMPERATURE MENU KEY DISPLAYS THE TEMPERATURE GROUP SCREENS 15 GUN LEDS ILLUMINATES GREEN WHEN THE GUN ZONE IS HEA...

Page 37: ... will illuminate green indicating that the unit is on When the Standby Button is pressed again the temperature screen will go blank the Standby LED will illuminate orange and the status bar will be active indicating the unit is in Standby Mode When the unit is in Standby Mode the internal clock is still working The clock will turn the unit off and on in the Timer Mode as usual If the Power Switch ...

Page 38: ...display This will make the characters on the display brighter and dimmer and is considered the fine adjustment 2 If this does not work or is not enough to see the display open the electrical enclosure door to view the rear of the CPU board 3 Adjust the Display Contrast Adjustment Pot on the rear of the CPU board using a small screwdriver this requires a very small slotted screwdriver 4 This is the...

Page 39: ... button s to navigate as follows Memory Storage The symbol consisting of two arrows in a circular pattern indicates that a value has been changed but the change is not yet stored in the flash memory Editing Highlighted information is editable Use the appropriate buttons depending on the navigation symbols shown to navigate through the editable highlighted information Navigation Icons ...

Page 40: ...ease 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 would be turning a hose or gun zone ON or OFF making a schedule change to turn on setback during a shift or enabling Sequential Start Use the Right Left Arrow Buttons to select the switch and then use the Plus Minus Buttons to toggle the switch ON o...

Page 41: ...words are required to prevent unauthorized access to unit programming Please see Appendix A Password Levels for more information To enter a password Unlock changes to Lock Unlocked symbol appears with Password Level Enter Password See Thumbwheel vs Single Digit Edit ...

Page 42: ...Section 5 Setup MM147 D4 Hot Melt Unit 42 Set Language Continued Next Page ...

Page 43: ...MM147 D4 Hot Melt Unit Section 5 Setup 43 Set Language Continued ...

Page 44: ...Section 5 Setup MM147 D4 Hot Melt Unit 44 Set Temperature Units ...

Page 45: ...ure Screens The tank temperature screen shows the actual tank temperature and the tank temperature setpoint For operator convenience the right side of this screen scrolls through enabled hose gun zones and displays the actual temperatures as shown Press the Temperature Button repeatedly or use the navigation keys to cycle through the temperature screens until you reach the desired screen ...

Page 46: ...Section 5 Setup MM147 D4 Hot Melt Unit 46 Tank Temperature Hose Valve Temperature Continued Next Page ...

Page 47: ...MM147 D4 Hot Melt Unit Section 5 Setup 47 Hose Valve Temperature Continued ...

Page 48: ...r 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 1 F of the setpoint The System ...

Page 49: ...r an additional period of time before the pump motor is enabled Once the zones have reached the System Ready Temperature the time 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 pump this default time of 15 minutes s...

Page 50: ...efore activating the Over Temperature Alarm If any zone goes into Over Temperature Alarm the heaters of the affected zone are automatically shut off If the Over Temperature Alarm message appears it can be cleared by pressing the OK key 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 Level 2 o...

Page 51: ...ating the 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 If the Under Temperature Alarm message appears it can be cleared by pressing the OK key 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 accesse...

Page 52: ...perature 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 or higher ...

Page 53: ...ovides a 24VDC GND connection for each beacon alarm desired This output is 24VDC 0 5A The beacon assembly is available as an option There are two versions available two light and two light with an alarm lights are blue and red If this option is ordered from the factory the beacon will be sent enabled The condition for the red light beacon 2 and the alarm are tied together Factory settings are show...

Page 54: ...Section 5 Setup MM147 D4 Hot Melt Unit 54 Beacon Alarm Setup Continued ...

Page 55: ...MM147 D4 Hot Melt Unit Section 5 Setup 55 Beacon 2 ...

Page 56: ...tem reaches temperature and the System Ready LED illuminates If the Ready Delay Time is enabled and set for a preset time 15 minutes the pump will not start and the unit will not be ready until 15 minutes AFTER the control has gotten to temperature The factory default setting is OFF This parameter can be accessed in Password Level 2 or higher ...

Page 57: ...p 57 Pressure Setup If a pump or multiple pumps are enabled Pressure Monitoring can create high or low pressure alarms Requires pressure transducer s If one pump is enabled If two pumps are enabled If three or four pumps are enabled X4 X2 ...

Page 58: ...he specific pressure monitor The sensor range calibrates the 0 10V pressure transducer analog signal input to the CPU board The high and low alarms are thresholds that trigger a message on the screen and beacon or programmable output if configured if the pressure value crosses them These alarms will NOT cause the unit to fault or stop the pump The alarms are for notification only To prevent false ...

Page 59: ...5 Setup 59 Pressure Setup Continued Example If pump 1 is enabled and pressure monitor 1 is enabled for the pump the pump screen entered by pressing the pump key will change to the following this applies to all four pumps Auto Manual ...

Page 60: ...t and the unit is ready Normal pump operation is ignored in this mode The automatic pump mode should be On Pattern control and valves are typically not used in this operating mode On delay time is set by the operator todelay pump activation x seconds after the external level input calls for glue After the delay time expires the pump will turn on and run until the external pot level triggers the le...

Page 61: ...ergized to feed glue into the tank to be melted This feature has a safety door switch that will disable the feeder if the tank door is opened The door switch internal level sensor and feeder valve need to be connected to the CPU board to operate properly The low level sensor plugs into J15 on the CPU board The Level 1 sensor needs to be enabled in the software If the Hopper Feeder and it s compone...

Page 62: ...r that shows the time remaining on the currently installed glue filter When the counter gets down to zero 0 an alarm can be sounded and the filter needs to be changed or cleaned Once the filter has been serviced the timer can be reset for a user set time of up to 2000 hours Clock and 7 Day Timer Set Day and Time ...

Page 63: ... the setback times Set the start stop and setback times for all shifts Leave the unused shifts times blank This screen states that for Shift A heaters will turn on at 7 00 AM to the setpoint temperatures set on the Temperature Screens previously shown and off at 3 00 PM with all heaters going to the setback temperatures from 11 30 AM to 12 00 PM This screen states that for Shift C nothing will be ...

Page 64: ...ng After setting all shift times previous page and programming the shifts that will be working for each day of the week this page be sure the Clock Function is On and is set properly Moving Through the Shift Time Day Screens 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 ti...

Page 65: ...e Clock Button to enable all shift settings the 7 Day Timer Do not turn off the main power to the control The clock timer will not operate if the power is off If the unit is set to Standby the clock timer will operate properly In Standby the display will show the status bar with the correct time of day ...

Page 66: ...Section 5 Setup MM147 D4 Hot Melt Unit 66 Diagnostics The Diagnostics Screen shows the current software version as well as the current temperature and status of each zone X2 ...

Page 67: ...e 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 ...

Page 68: ...ic 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 When the Automatic Setback is enabled the Auto Setback symbol will start to flash in the status bar 2 minutes prior to going into setback This will be the signal to the operator that the unit will go into setback if a...

Page 69: ...s 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 higher ...

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

Page 71: ...nd the Change History are cleared when the unit is turned off If the an alarm condition e g High Temperature Alarm lasts for a duration of 2 5 minutes the master control relay will be deactivated removing power from the heating zones and the Fault History screen will appear After correcting the cause of the fault the unit must be powered off and back on again to reset the control and reactivate th...

Page 72: ...en Input is OFF Disabled None None Hose Gun 1 On Off Enables the heaters for Hose Gun 1 Disables the heaters for Hose Gun 1 Hose Gun 2 On Off Enables the heaters for Hose Gun 2 Disables the heaters for Hose Gun 2 Hose Gun 3 On Off Enables the heaters for Hose Gun 3 Disables the heaters for Hose Gun 3 Hose Gun 4 On Off Enables the heaters for Hose Gun 4 Disables the heaters for Hose Gun 4 Hose Gun ...

Page 73: ...er Feeder runs for more than 200 seconds without satisfying Level Sensor if equipped Fault Stop The tank over temperature thermostat is open OR Any zone temperature has increased above the Maximum Temperature Setting OR The High Temperature Alarm or RTD Disconnected Alarm persists for more than 150 seconds Note Any of these conditions will cause the control to deactivate the master control relay A...

Page 74: ...the control for how many hose gun pairs are being used by the operator and if 1 or 2 tank zones will be enabled Auxiliary Zones If so equipped with the full 12 Zone Power Board there will be circuitry for Zones 15 16 These are the Auxiliary Zones and need to be enabled on this screen to read and control temperatures Details and instructions on how to set this up will be included in the documentati...

Page 75: ...in Password Level 2 or higher see Appendix A Password Levels Pump Type For pump type selection this unit will be configured for Variable Speed Gear Pump or Fixed Speed Gear Pump Variable Speed can only be chosen if the unit is equipped with a Motor Speed Board a VFD and a 3 phase motor This setting will be set at the factory before shipment Gramage Enable Gramage is ONLY enabled in coating applica...

Page 76: ...TU and Disabled If Ethernet IP is selected Mode must be set as well Mode options are Local and Remote The CPU will not allow the user to select Remote or Local if not using Ethernet IP If Ethernet IP is in use the IP Address Subnet Mask and Gateway must be configured for the customer network see Appendix E Communication Protocols CAUTION Load and balance the communication networks properly If the ...

Page 77: ...shipment Pump Configuration for Specific No Pump The Pump Heat Zone is the zone attached to the pump to heat the pump It is used to make sure the zone is enabled and heating when the pump switch is enabled Gramage should ONLY be enabled in coating applications where the user wants the unit to automatically calculate the pump speed to achieve a desired coat weight It requires the user to enter the ...

Page 78: ... Setting This setting is generally used to maintain pressure while the production line is stopped The Minimum Speed Setting determines the minimum line speed at which the pump turns at the creep speed setting The units are in either millivolts or ft min depending on the Auto Speed Input type Tach or Encoder The Maximum Pump Speed is generally set at the factory It is the motor RPM divided by the r...

Page 79: ...oard Connections If an Encoder is used for the Auto Speed Input an additional Encoder Screen Ref screen will appear between Creep Speed Setting and Max Pump Speed This screen enables setup of the relationship between the Parent Machine Speed and the Glue Pump Speed The pump speed response to the parent machine speed is linear between these points If the parent machine speed is below the Min settin...

Page 80: ...ed for the Auto Speed Input then the Encoder parameters need to be set in this menu Enter the Pulses per Revolution of the encoder and its circumference in this screen The measurement units for the encoder are selected in this screen This is only available when the encoder is used ...

Page 81: ... properly the Auto Tune function can be used to set the PID settings AutoTune Feature The Auto Tune feature will optimize the PID settings for each zone that is enabled when the Auto Tune is started The Auto Tune feature can take up to eight hours to complete and the power must not be turned off during this process It is recommended to only enable zones that need their PID values adjusted to reduc...

Page 82: ...rt up screen appears Updating 152XX746 CPU Board Software via USB Memory Stick The CPU must have bootloader 119XX301 programmed to it before it is capable of being updated with the USB stick Required Materials USB Memory Stick with desired version of software to be loaded to board software must be converted for the correct for the specific board or the update will fail 152XX746 CPU Board Old 152XX...

Page 83: ...hown below As long as there are no issues when the USB memory stick mounts the bootloader will analyze the software and begin to perform the update If the CPU board DOES already have software loaded and the version on the USB stick is the SAME the error screen will show with Error 2 as shown below If the software Has the wrong file name Was not converted or not converted successfully for the speci...

Page 84: ... in a failed programming attempt the error screen will show with Error 4 as shown below If the software is successfully updated and is starting the screen will display the following and the program will run as normal 4 Remove the USB stick 5 Cycle power The unit will force a re initialization Hot Melt CPU uTasker Bootloader 119XX301 Error Codes Error 1 USB Stick failed to mount Error 2 Software on...

Page 85: ... is configured with the correct unit settings Failure to configure the control correctly may result in damage to the equipment Adjusting the Display The display contrast can be adjusted by pressing the or buttons while holding the setup button The display position can be adjusted by pressing the left or right arrow buttons while holding the display button After adjusting the display press the righ...

Page 86: ...is by examining the part number stamped on the unit data plate and then referencing the chart below Fixed Speed Units Variable Speed Units D4 F2 D4 V2 D4 F4 D4 V4 2 After setting the unit type press the right arrow button to continue Selecting the Communication Protocol 1 Use the or buttons to select the if any communication protocols are being used in the system The allows for Modbus RTU and Ethe...

Page 87: ...than 1 pump should not be selected this will cause the system to malfunction 2 After selecting the number of pumps press the right arrow button to continue Selecting the Number of Hose Outlets 1 Use the or buttons to select the number of hose outlets equipped The number of hose outlets can be determined by examining the part number stamped on the data plate of the unit and then referencing the cha...

Page 88: ...ing the Pattern Control CAUTION Enabling the pattern control when a pattern control is not equipped will result in communication failure Only enable the pattern control when one is equipped and connected The Pattern Control is not available with the D4 Hot Melt Unit Finishing the Configuration When prompted to finish the configuration use the right arrow button to select Yes and then press the OK ...

Page 89: ...lief valve is commonly used for systems that are applying adhesive continuously laminating Adjusting the Single Stage Relief Valve 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 ...

Page 90: ...er square meter for the application Press the Pump Status Key and scroll right to get to this setting The Pump Displacement in cubic centimeters Enter the Pump Setup Menu from the Tools Key then scroll right to access this screen The Adhesive Density in grams per cubic centimeter Enter the Pump Setup Menu from the Tools Key then scroll right to access this screen If tach mode is used as the auto s...

Page 91: ...ange value 3 Press Data Ent to save new function value 4 Press DSP key to exit or arrow keys to go to the next function number Valco Setting Factory Default Function Range AI1T Voltage 5V Configuration of AI1 5V Voltage or Current L01 Drv Running NO L01 Assignment Multiple BFR 60 50 Std Motor Frequency 50HZ or 60HZ DEC 5 3 Deceleration Ramp Time 0 999 9 SEC LSP 10 0 Low Speed Frequency 0 63 2 HZ H...

Page 92: ...ypad 001 External Signal 0 10v 0 20mA 002 External Signal 4 20mA F12 005 005 Switching Frequency 001 4 kHz 002 5 kHz 003 6 kHz 004 7 2 kHz 005 8 kHz F13 00 0 00 0 Torque Boost Adjustment 00 0 10 0 F14 001 000 Stopping Method 000 Decelerate Stop 001 Free Run Stop F15 00 5 00 5 Braking Time 00 0 25 5 Seconds F16 01 5 01 5 Braking Start Frequency 01 0 10 0 Hertz F17 08 0 08 0 Braking Level 00 0 20 0 ...

Page 93: ... 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 the unit on 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 Standby Key Power On Off Switch Standb...

Page 94: ...ed zone When the zone is in warm up mode the zone LED will illuminate 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 A...

Page 95: ...t the adhesive data sheet to find the softening point temperature of the adhesive Pump Operation When the pump is enabled but waiting on the System Ready LED to illuminate green the pump symbol flashes in the status bar Pump On Off Key The Pump On Off Key is the master enable for the Pump s It can be set to come on automatically when the unit is ready see Section 5 Setup Auto Pump Enable Note that...

Page 96: ...tomatic Mode you can view the Automatic Speed Input These units will be in Volts or in ft min depending on the Auto Speed Input Type setting Tach or Encoder You can also view the Pumps RPM and enable the individual pump Clock On Off The Clock must be On Clock LED illuminated green for all of the programmed scheduled shifts to run unless the unit will be operated manually no pre programming To turn...

Page 97: ...set screens and entering values on these screens see Section 5 Setup Automatic Setback Automatic setback can be programmed through one of the remote inputs from the input screen When an input is set for Auto Setback AND the Auto Setback Timeout is enabled the control will AUTOMATICALLY go into set back if the input has not been triggered for the timeout set by the user For instance if a valve fire...

Page 98: ... to Section 5 Beacon Alarm The Beacon Alarm output connector is provided as a dedicated 24VDC 0 5A output for a visual or audio alarm This can be set up to alert the operator of one of 4 fault conditions see Section 5 Setup for description The installer can connect the lead of the alarm to Beacon 1 pin 3 and the lead to GND pin 1 of J30 on the CPU board When the Beacon Alarm screen is set up for a...

Page 99: ...intenance Section or call Valco Cincinnati 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 type of hot ...

Page 100: ...Section 6 Operation MM147 D4 Hot Melt Unit 100 ...

Page 101: ...e a seal 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 connectors External leakage indicates that service is required Shut down the system once a week and remove and clean the manifold filter Replace the filter if it cannot be thoroughly clea...

Page 102: ...e adhesive manufacturer to find out which cleaning solutions are recommended for the adhesive you are using Failure to comply could result in damage to the equipment To flush the system follow these steps 1 Place an adequate supply of either paraffin wax or suitable cleaning solution into the unit Reduce the temperature control setting to 300 F 148 C for paraffin wax Consult your supplier for prop...

Page 103: ...System Continued 10 Turn the gear pump back on and activate the applicators to purge remaining adhesive through the valve s 11 Reset the temperature control to the correct setting for the material you are using The new material can now be pumped through the system ...

Page 104: ... removing parts from the hot melt unit For drawings and a complete list of part numbers see Section 10 Part Number List Changing Fuses 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 socket on the 12 zone board see the following Figure 151xx747 240V Item Fuse Description Part Quantity 1 Fuse 2A...

Page 105: ...ray 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 Debris is collected on the inside of the filter so the filter should not be reused 4 Thread a new filter assembly into the manifold See Section 10 Part Number List for more information...

Page 106: ...Section 7 Maintenance MM147 D4 Hot Melt Unit 106 ...

Page 107: ... applicator 2d Check for blown fuse and or defective heater 2e Applicator clogged 2e Service applicator system 2f Clogged filter 2f Remove old filter and replace with new filter 2g Temperature control malfunction 2g Replace temperature control 3 Charring or gelling of adhesive in the reservoir 3a Reservoir temperature too high 3a Lower reservoir temperature in accord with adhesive manufacturer s s...

Page 108: ...emperature in accordance with adhesive manufacturer s specifications 14 5c Glue hoses not at the same temperature 15 5c Reset temperature controllers 16 5d Different pressure drop through each hose 17 5d 18 Hoses not the same length 19 Use same length hoses 20 Crimped hose s 21 Replace hose s 22 Leaking hose s 23 Replace hose s 24 5e Adhesive supply low 25 5e If sides of tank are charred drain cle...

Page 109: ...ity 8 8 lbs 4kg Melt Rate 11 1 lbs hr 5 kg hr Pump Motor driven spur gear pump Fixed or Variable Speed Pump Rate 1 59 cc rev 15 7 L hr 3 18 cc rev 31 5 L hr Viscosity Range 500 30 000 CPS Maximum Fluid Pressure 800 psi 55 bar Workplace Temperature 32 to 120o F 0 to 50o C Temperature Range 86 446o F 30 230o C Temperature Stability 1o F 0 5o C Electrical 208 240 VAC 1Ф 3Ф 380 VAC 3Ф 40 amps IP Ratin...

Page 110: ...Section 9 Specifications MM147 D4 Hot Melt Unit 110 Dimensions ...

Page 111: ...iinc com England 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 Germany Valco Cincinnati GmbH Bonnerstrasse 349 40589 Dusseldorf Benrath Germany Tel 49 211 984 798 0 Fax 49 211 984 798 20 Spain Melton S L U Pol Industrial Agustinos calle G n 34 31160 Orcoyen Navarra Spain Tel 34 948 321 580 Fax 3...

Page 112: ...Section 10 Part Number List MM147 D4 Hot Melt Unit 112 D4 Unit ...

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

Page 114: ...004 4 9 LOCK WASHER 798XX735 4 10 HUB JAW COUPLING 783XX370 1 11 HUB JAW COUPLING 783XX371 1 12 SPIDER JAW COUPLING 783XX372 1 13 SCREEN RESERVOIR 782XX297 1 14 BRACKET RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID RESERVOIR 775XX861 1 17 HANDLE PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL WARNING HOT SURFACE 781XX629 2 21 LABEL WARNING ELEC HAZARD 781XX630 2 22 NAM...

Page 115: ...ER 798XX735 4 10 HUB JAW COUPLING 783XX370 1 11 HUB JAW COUPLING 783XX371 1 12 SPIDER JAW COUPLING 783XX372 1 13 SCREEN RESERVOIR 782XX297 1 14 BRACKET RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID RESERVOIR 775XX861 1 17 HANDLE PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL WARNING HOT SURFACE 781XX629 2 21 LABEL WARNING ELEC HAZARD 781XX630 2 22 NAMEPLATE SHURE GLUE...

Page 116: ...CREEN RESERVOIR 782XX297 1 14 BRACKET RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID RESERVOIR 775XX861 1 17 HANDLE PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL WARNING HOT SURFACE 781XX629 2 21 LABEL WARNING ELEC HAZARD 781XX630 2 22 NAMEPLATE SHURE GLUE SYSTEMS 781XX566 1 23 RIVET 091XX517 2 24 INSTALLATION KIT D4 HMU 091XX734 1 25 MTR DRIVE AC VAR FREQ 1 2HP 110XX...

Page 117: ...X297 1 14 BRACKET RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID RESERVOIR 775XX861 1 17 HANDLE PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL WARNING HOT SURFACE 781XX629 2 21 LABEL WARNING ELEC HAZARD 781XX630 2 22 NAMEPLATE SHURE GLUE SYSTEMS 781XX566 1 23 RIVET BLIND 091XX517 2 24 INSTALLATION KIT D4 HMU 091XX734 1 25 MTR DRIVE AC VAR FREQ 1 2HP 110XX425 1 26 PCB A...

Page 118: ... 1 13 SCREEN RESERVOIR 782XX297 1 14 BRACKET RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID RESERVOIR 775XX861 1 17 HANDLE PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL WARNING HOT SURFACE 781XX629 2 21 LABEL WARNING ELEC HAZARD 781XX630 2 22 NAMEPLATE SHURE GLUE SYSTEMS 781XX566 1 23 RIVET 091XX517 2 24 INSTALLATION KIT D4 HMU 091XX734 1 25 MTR DRIVE AC VAR FREQ 1 2H...

Page 119: ...IR 782XX297 1 14 BRACKET RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID RESERVOIR 775XX861 1 17 HANDLE PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL WARNING HOT SURFACE 781XX629 2 21 LABEL WARNING ELEC HAZARD 781XX630 2 22 NAMEPLATE SHURE GLUE SYSTEMS 781XX566 1 23 RIVET BLIND 091XX517 2 24 INSTALLATION KIT D4 HMU 091XX734 1 25 MTR DRIVE AC VAR FREQ 1 2HP 110XX310 1 2...

Page 120: ...Section 10 Part Number List MM147 D4 Hot Melt Unit 120 D4 Base Unit 776xx392 ...

Page 121: ...ESERVOIR 782XX098 1 18 CORD GRIP 066XX244 1 19 LABEL GROUND SYMBOL 781XX110 1 20 MANIFOLD D4 HOT MELT UNIT 776XX317 1 21 HEX PLUG 799XX127 10 22 PLUG PIPE SOCKET 799XX548 2 23 SOCKET HEAD PIPE PLUG 797XX042 3 24 FILTER ASSY 593XX461 1 25 VALVE PRESSURE RELIEF 707XX222 1 26 PRESS GAUGE 786XX122 1 27 O RING 745XX021 1 28 SCREW 884XX002 4 29 WASHER 784XX476 4 30 PANEL HOSE RECEPTACLE D4 776XX319 1 31...

Page 122: ...8 1 48 OVERLAY ASSY HM CTRL D SERIE 137XX029 1 49 LATCH SPRING CAM 781XX892 2 50 SWITCH ROCKER 480XX246 1 51 NUT FLANGE 784XX677 7 52 CABLE TIE 067XX154 6 53 CASE D4 776XX886 1 54 ELECTRICAL CONNECTIONS STICKER 917XX811 1 55 SCREW 784XX491 4 56 LANYARD 781XX890 2 57 SCREW 798XX188 4 58 WIRE TERMINAL 075XX332 3 59 CABLE ASSY 029XX569 1 60 CABLE ASSY 029XX608 1 61 PLUG HOLLOW HEX 1 2 BSPP 799XX875 1...

Page 123: ...RESERVOIR 782XX098 1 18 CORD GRIP 066XX138 2 19 LABEL GROUND SYMBOL 781XX110 1 20 MANIFOLD D4 HOT MELT UNIT 776XX317 1 21 HEX PLUG 799XX127 10 22 PLUG PIPE SOCKET 799XX548 2 23 SOCKET HEAD PIPE PLUG 797XX042 3 24 FILTER ASSY 593XX461 1 25 VALVE PRESSURE RELIEF 707XX222 1 26 PRESS GAUGE 786XX122 1 27 O RING 745XX021 1 28 SCREW 884XX002 4 29 WASHER 784XX476 4 30 PANEL HOSE RECEPTACLE D4 776XX319 1 3...

Page 124: ...PANEL OPERATOR D4 776XX318 1 48 OVERLAY ASSY HM CTRL D SERIE 137XX017 1 49 LATCH SPRING CAM 781XX892 2 50 SWITCH ROCKER 480XX246 1 51 NUT FLANGE 784XX677 7 52 CABLE TIE 067XX154 6 53 CASE D4 776XX886 1 54 ELECTRICAL CONNECTIONS STICKER 917XX811 1 55 SCREW 784XX491 4 56 LANYARD 781XX890 2 57 SCREW 798XX188 4 58 WIRE TERMINAL 075XX332 3 59 CABLE ASSY 029XX569 1 60 CABLE ASSY 029XX608 1 99 ELECTRICAL...

Page 125: ...t 125 Installation Kit 091xx734 ITEM DESCRIPTION PART NO QTY 1 FUSE 085XX220 2 2 FUSE 085XX271 2 3 FUSE 085XX289 2 4 FUSE TIME LAG 085XX272 2 5 D4 HOT MELT UNIT MANUAL CD MM147 CD 1 6 BOX TRAY 730XX015 1 7 WARRANTY CARD VALCOMELTON LOGO 999XA774 157 1 ...

Page 126: ...ly two of the following sensors may be selected Autofeed Internal Low Level External Pot Fill AutoFeed Vacuum Feeder Assembly 776xx305 Refer also to Appendix C Instruction Sheets for Option Kits IS0231 DETAIL A DETAIL B 14 4 6 5 7 8 9 17 SEE DETAIL B PORT 1 PORT 3 PORT 2 10 18 19 20 SEE DETAIL A 12 15 21 38 16 37 40 23 ...

Page 127: ...NNECT 752XX004 1 15 MALE CONNECTOR STRAIGHT 799XX662 1 16 EXHAUST MUFFLER 411XX601 1 17 SCREW 784XX050 2 18 SCREW 784XX496 4 19 MAGNET 783XX310 2 20 SCREW 884XX276 2 21 NUT ACORN 884XX280 2 22 LEVEL SENSOR ASSY 098XX110 1 23 CABLE CLAMP 066XX220 1 24 BUSHING SQUARE 066XX221 2 25 ASSEMBLY FEEDER TUBE K051701002 1 26 CABLE ASSY REED SENSOR 029XX583 1 27 JUMPER CABLE ASSY 029XX584 1 30 CABLE TIE 0 14...

Page 128: ... also to Appendix C Instruction Sheets for Option Kits IS0161 ITEM DESCRIPTION PART NO QTY 1 SLEEVING 755XX077 40 2 CONN SHELL 061XX033 1 3 SOCKET 061XX448 2 5 FERRULE 075XX302 8 6 WIRE PTFE 540XX162 3 5 7 WIRE PTFE 540XX159 3 5 8 WIRE PTFE 540XX164 0 333 9 INSTRUCTION SHEET PUMP CNTROL IS0161 1 10 CABLE TIE 067XX154 1 ...

Page 129: ... TAG PUMP INFORMATION 782XX085 1 5 SCREW 784XX341 4 6 INFORMATION SHEET PUMPS 998IS696 1 7 D S SERIES PUMP CHANGE PROCEDURE IS0212 1 Pump Kit Half Width 561xx220 Refer also to Appendix C Instruction Sheets for Option Kits IS0212 ITEM DESCRIPTION PART NO QTY 1 GEAR PUMP HALF WIDTH 561XX330 1 2 SCREW 798XX171 4 3 O RING 745XX035 2 4 TAG PUMP INFORMATION 782XX085 1 5 SCREW 784XX340 4 6 INFORMATION SH...

Page 130: ...SCRIPTION PART NO QTY 1 AMPLIFIER LEVEL SENSOR 098XX106 1 2 LEVEL SENSOR HIGH TEMPERATURE 098XX107 1 3 SCREW 784XX359 2 4 CONNECTOR 070XX662 1 5 CONTACT 061XX424 3 6 WIRE PTFE 540XX061 2 167 7 WIRE TERMINAL 075XX179 1 8 WIRE TERMINAL 075XX393 1 9 NYLON WIRE LABELS 075XX359 1 10 IS INTERNAL LEVEL SENSOR IS0232 1 11 LOCK WASHER 784XX352 1 12 HEX NUT 784XX349 1 13 SILICONE RTV ALUM 710XX211 1 ...

Page 131: ...ernal Pot Fill External Pot Fill Kit 776xx757 Refer also to Appendix C Instruction Sheets for Option Kits IS0234 4 PLCS 2 PLCS 2 PLCS 4 PLCS 4 PLCS 3 PLCS DETAIL A TERMINAL STRIP PIN LOCATION SCALE 2 1 WIRE LENGTHS TO BE 0 50 12 7 MM UNLESS OTHERWISE SPECIFIED ...

Page 132: ...X679 SLEEVING FIBERGLASS 3 8 BLAK 60 12 066XX138 CORD GRIP BLACK PG 13 5 1 13 061XX211 CONNECTOR M12 5PIN MALE 1 14 075XX387 CONNECTOR 4 PIN TERMINAL 1 15 884XX269 SHCS M2 5 X 12 SS 2 16 075XX303 FERRULE INS 20AWG WHITE 8MM 4 17 075XX301 FERRULE INS 24AWG LT BLU 8MM 4 18 030XX596 CABLE ASSY M12 FEM 10M 1 19 070XX662 CONNECTOR 3 POS 3A 098 XA 1 20 061XX424 CONTACT FEM SOCKET 3A XA 3 21 583XX286 SEN...

Page 133: ...MM147 D4 Hot Melt Unit Section 10 Part Number List 133 Alarm Beacon Alarm Beacon Assembly 24V 782xx701 Refer also to Appendix C Instruction Sheets for Option Kits IS0233 0 5 4 3 2 1 ...

Page 134: ...E 540XX035 8 5 6 WIRE 540XX034 3 7 FERRULE 075XX303 8 8 BULB 105XX050 2 9 BEACON LIGHT ELEMENT BLUE 105XX051 1 10 BEACON LIGHT ELEMENT RED 105XX053 1 11 SCREW 784XX313 2 12 NUT 798XX488 2 Alarm Beacon Replacement Bulb PART NO DESCRIPTION 105XX050 24V 5W Siren Element Kit 776xx762 Refer also to Appendix C Instruction Sheets for Option Kits IS0233 ITEM PART NO DESCRIPTION QTY 1 105XX054 BEACON SIREN...

Page 135: ...it 707xx212 4 6 5 3 2 1 ITEM PART NO DESCRIPTION QTY 1 707XX897 VALVE ASSY PRESSURE RELIEF 1 2 755XX054 AIR LINE 203051 1 3 797XX827 MALE CONNECTOR 94929026 1 4 594XX160 FILTER REGULATOR AIR 5 125PSI 1 5 786XX001 GAUGE 960LP 1 6 752XX004 MALE QUICK DISCONNECT 1 7 999XD707 002 ILLUSTRATION DRAWING 1 ...

Page 136: ...RESSURE RELIEF 1 2 797XX079 HEX NIPPLE M M 1 8 1 3 411XX118 VALVE ASSY 3 WAY W M12 24V 1 4 799XX582 CONNECTOR MALE 8MM X 1 8 NPT 2 5 755XX575 TUBING NYLON 8MM O D 360 6 797XX395 FITTING MALE 5 16I X 1 4NPT 4 7 797XX019 STREET TEE F F M 1 4 1 8 594XX033 FILTER REGULATOR ASSY 1 9 582XX300 BRACKET REGULATOR 1 10 594XX004 AIR REGULATOR M750LPG 1 11 580XX861 BRACKET 1 12 999XD774 197 ILLUST DWG UNIFLOW...

Page 137: ...DESCRIPTION QTY 1 485XX105 SWITCH PRESSURE 1 2 792XX340 FITTING ADAPTER 1 3 797XX073 REDUCER M M 1 2 X 1 4 1 4 IS0213 IS UE PRESSURE SWITCHES 1 5 075XX304 FERRULE INS 18AWG RED 8MM 4 6 755XX087 SLEEVING FIBERGLASS 4 BLACK 69 5 7 067XX154 TY RAP 14 X 5 5 L HIGH TEM 4 8 067XX002 HARNESS ANCHOR 75 INCH 2 9 075XX179 WIRE TERMINAL RING 1 10 784XX352 LOCK WASHER M5 1 11 784XX349 HEX NUT M5 0 8 ZINC 1 ...

Page 138: ...IRE TERMINAL RING 1 10 784XX352 LOCK WASHER M5 1 11 784XX349 HEX NUT M5 0 8 ZINC 1 Pressure Switch Kit 275 850 PSI 481xx052 Refer also to Appendix C Instruction Sheets for Option Kits IS0213 ITEM PART NO DESCRIPTION QTY 1 485XX106 SWITCH PRESSURE 1 2 792XX340 FITTING ADAPTER 1 3 797XX073 REDUCER M M 1 2 X 1 4 1 4 IS0213 IS UE PRESSURE SWITCHES 1 5 075XX304 FERRULE INS 18AWG RED 8MM 4 6 755XX087 SL...

Page 139: ... Instruction Sheets for Option Kits IS0377 ITEM DESCRIPTION PART NO QTY 1 TRANSDUCER PRESSURE 520XX031 1 2 WIRE 540XX160 4 583 3 WIRE 540XX166 4 583 4 WIRE 540XX164 4 583 5 SLEEVING 755XX087 52 5 6 CONNECTOR 070XX662 1 7 CONTACT 061XX424 3 8 FERRULE 075XX302 3 9 CABLE TIE 067XX154 2 10 IS PRESSURE TRANSDUCER IS0377 1 ...

Page 140: ...33 Refer also to Appendix C Instruction Sheets for Option Kits IS0344 ITEM PART NO DESCRIPTION QTY 1 151XX724 PCB ASSY ANYBUS EXPANDED I O 1 2 098XX123 MODULE ANYBUS ETHERNET IP 1 3 091XX644 SPACER PCB 14MM SNAP IN 1 4 091XX563 STANDOFF 6MM HEX 2 5 784XX541 SCREW 2 6 029XX787 CABLE RIBBON 30P 2MM 1 7 IS0344 IS ANYBUS INSTALLATION 1 8 MM139CD CD MM139 MANUAL 1 24V VDC Relay Kit 776xx537 Refer also ...

Page 141: ...f 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 ex works Telford U K If the inspection of the equipment does not disclose any defect of workmanship or material ...

Page 142: ...Section 11 Warranty MM147 D4 Hot Melt Unit 142 ...

Page 143: ...ed 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 installation or operatio...

Page 144: ...Section 12 Service MM147 D4 Hot Melt Unit 144 ...

Page 145: ... 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 groups Level 3 Supervisor PIN Code 6550 Can access all Level 1 and 2 features Can access Maximum Temperature parameter in System Setup menu Can access Peripherals Inputs Outputs and Temperature Control PID menu gr...

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

Page 147: ...l for hose gun 2 pair 1800 3 Total for hose gun 3 pair 1400 4 Total for hose gun 4 pair 1400 5 Total for all hoses and guns 8400 1 Add the power requirements of hose 1 and gun 1 Compare this value to the maximum wattage given in Line 1 of Table 1 2 Add the power requirements of hose 2 and gun 2 Compare this value to the maximum wattage given in Line 2 of Table 1 3 Add the power requirements of hos...

Page 148: ...Appendix B Power Requirements MM147 D4 Hot Melt Unit 148 ...

Page 149: ...eature Description Option Kit Instruction Sheet 1 N A 2 Autofeed 776XX305 IS0231 3 Pump Control 029XX552 IS0161 4 Pump Type 561XX216 IS0212 561XX220 5 N A 6 N A 7 N A 8 Internal Level Sensors 776XX892 IS0232 External Pot Fill 776xx757 IS0234 Alarm Beacon 782XX701 IS0233 776XX762 9 Pressure Relief 707XX212 999XD707 002 594XX189 999XD774 197 10 Pressure Monitoring 481XX050 IS0213 481XX051 481XX052 5...

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

Page 151: ...stalled FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN A PERSONAL INJURY DEATH OR DAMAGE TO EQUIPMENT WARNING WARNING WARNING WARNING WARNING The equipment may still be energized even after the circuit breaker or main power switch is off All equipment must be properly grounded and fused in accordance with rate current consumption refer to the equipment identification plate Gauge and insulati...

Page 152: ...our 4 M5 flange nuts from the bottom corners of the case 6 Remove any other connections that are holding the case to the chassis 7 Remove the case 8 Carefully remove the three 3 circular knockouts from the top of the case 9 Carefully remove the circular knockout on the center bulkhead in the case ...

Page 153: ... two 2 M4 socket head cap screws 13 Attach the terminal ring from the amplifier box to the grounding stud on the top of the case 14 Route the sensor through the knockout in the center bulkhead and then through the knockout on the top of the case 15 Install the reed sensors into the appropriate knockout on the top of the case The reed sensor number is indicated by a label on one of the lead wires T...

Page 154: ...tangular connector from the top of the air valve 19 Remove wiring insert using a small flat head screwdriver 20 Route the cable assembly through the bottom of the connector 21 Attach the three 3 ferrules to the connector by following the labels on the wire ends 22 Replace the wiring insert back into the connector Make sure the fiberglass sleeving is held by the strain relief in the bottom of the c...

Page 155: ...Installation Continued 24 Using the two 2 ty raps included in the kit attach the cable to the case walls This will ensure that the tank does not crush the wires when the case is reinstalled 24 Attach the terminal strip to the side of the case using two 2 M3 x 16 socket head cap screws ...

Page 156: ... lid bracket to the unit using three 3 M6 button head cap screws 31 Attach the new lid with vacuum feeder to the bracket 32 Reattach the rectangular connector to the air valve 33 Remove the yellow cap from the end of the feeder tube 34 Attach the hose to the feeder inlet using a Phillips head screwdriver to tighten the hose clamp 25 Attach the three 3 flying leads from the amplifier box to the ter...

Page 157: ...h the flying terminal ring from the cable assembly to one of the grounding studs on the base of the chassis 35 Attach the 10 mm tubing to the push in 90 swivel fitting on the air valve 36 Slide the level probe through the cable clamp on the top of the lid Use a Phillips head screwdriver to tighten the probe to the clamp The top of the sensor should be about 25 above the top of the clamp 37 Connect...

Page 158: ...et the tank fill with adhesive 46 If the vacuum feeder does not turn on check that the feeder LED is on If the feeder LED is not on check that the jumper cable and level sensor cable are in the correct locations If the feeder LED is on the height of the reed sensors needs to be readjusted 47 Once the vacuum feeder has stopped open the lid and make sure the unit is filled and the adhesive level is ...

Page 159: ...adhesive is not at the appropriate level repeat step 50 CAUTION CAUTION CAUTION CAUTION CAUTION Check the adhesive level periodically to confirm the sensor is working properly 53 Reinsert the protective screw into the amplifier box 54 Close the front operator panel To adjust the sensor delay time CAUTION CAUTION CAUTION CAUTION CAUTION The adhesive pile will be uneven measure from the top of the p...

Page 160: ...nal ON Delay based on the desired sensor and adjust the time for your application The default time for the sensor is 5 seconds 55 Access the setting screen by pressing 56 Unlock the control by using the level 3 password 6550 57 Access the setting screen by pressing again 58 Access the System screen ...

Page 161: ...sembly has a flange mounted connector route the cable assembly along the inside of the unit as shown Input 1 Input 2 Input 3 Input 4 Pin 2 I1 Orange Pin 5 I2 Orange Pin 8 I3 Orange Pin 11 I4 Orange Pin 3 GND Yellow Pin 6 GND Yellow Pin 9 GND Yellow Pin 12 GND Yellow Cable Connections 5 Choose which of the four inputs that you want to connect to Then connect the Yellow and Orange wires from the Cab...

Page 162: ... Scroll to whichever Input that you have the Handgun Switch Cable connected to 5 Choose the function that you want the Handgun Switch to control using the up and down arrow keys a Pump On Off will activate the pump when the handgun trigger is pulled b Auto Setback resets the Auto Setback Timer when the trigger is pulled If Auto Setback is enabled see manual when the Auto Setback Timer expires the ...

Page 163: ...nd wait for all zones to reach temperature and for the System Ready light to come on 4 Enable the Pump by pressing the Pump On Off Key on the Keypad 5 Pull the handgun trigger to activate the pump Testing is successful when the pump is enabled during the time the trigger is held Testing To tell if the pump is enabled when the trigger is held listen for the sound of the pump activating Also if ther...

Page 164: ...he unit 4 Choose whether you want to connect to Input 1 or Input 2 Then connect the Yellow and Orange wires from the cable and jumper wire to the Customer connector J6 as follows Input 1 Input 2 Pin 2 24 Orange Pin 2 24 Orange Pin 3 GND Blue Jumper Wire Pin 3 GND Blue Jumper Wire Pin 4 IN1 Blue Jumper Wire Pin 6 IN2 Blue Jumper Wire Pin 5 IN1 Yellow Pin 7 IN2 Yellow If you use two handguns and wan...

Page 165: ... the Setup Button and unlock the system using password 6550 3 Once the system is unlocked scroll right to PERIPH press OK Key 4 Scroll to the Input that you have the Handgun Switch Cable connected to Input Setup 5 Choose the function that you want the Handgun Switch to control using the up and down arrow keys a Pump On Off will activate the pump when the handgun trigger is pulled b Auto Setback re...

Page 166: ... wait for all zones to reach temperature and for the System Ready light to come on 4 Enable the Pump by pressing the Pump On Off Key on the Keypad 5 Pull the handgun trigger to activate the pump Testing is successful when the pump is enabled during the time the trigger is held Testing To tell if the pump is enabled when the trigger is held listen for the sound of the pump activating Also if there ...

Page 167: ...elow 3 From underneath unit run the flying lead end of the Handgun Switch Cable assembly through an available cord grip into the electronics cabinet of the unit 4 Connect the Yellow and Orange wires from the included cable assembly to the customer connector J13 on the Power Board as follows On J13 Customer Connector Pin 5 Remove Box GND Orange Pin 6 Remote Box Sig Yellow If you use two handguns an...

Page 168: ...t the hose handgun to the D10 Unit 2 Connect the 4 pin circular connector from the Handgun Switch Cable installed to the mating connector from the hose 3 Turn ON the unit and wait for all zones to reach temperature and for the System Ready light to come on 4 Enable the Pump by pressing the Manual Pump On Off on the Keypad 5 Pull the handgun trigger to activate the pump Testing is successful when t...

Page 169: ...H OR DAMAGE TO EQUIPMENT Caution Caution Caution Caution Caution The instructions and guidelines in this instruction sheet are general guidelines Always follow the manufacturer s documentation and instructions for each part of the system such as the valve the solenoid the application mechanism etc Failure TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN DAMAGE TO EQUIPMENT Before Replacing the Pump If...

Page 170: ...he D Series Unit Pump 1 Locate the unit in which the pump needs to be changed Warning Warning Warning Warning Warning Make sure that the unit is at room temperature 2 Turn the unit on its side 4 Remove motor bracket bolts 5 Slide the motor forward out of the way a The coupling will come apart easily Motor bracket bolts ...

Page 171: ...ng half from the pump 8 Remove the pump jacket if installed 9 Remove the 4 pump mounting bolts 10 Remove the pump Replacing the D Series Unit Pump Continued 6 Place the center disk aside for now Slide Motor and Bracket this way Center Disk Jacket Pump Mounting Bolts Coupling Half ...

Page 172: ... the figure below The arrows on the face should point to the bearing placement on the center disk Caution Caution Caution Caution Caution Install by cross tightening the four 4 mb x 90 socket head cap screws This will ensure the pump has a uniform seal with the manifold and will not leak Replacing the D Series Unit Pump Continued See the figure below for the correct motor bracket mounting hole D S...

Page 173: ...7945 Valco Cincinnati GmbH Storkower Strasse 6 D 15749 Gallun Germany TEL 49 33764 8700 FAX 49 33764 87070 No part of this document may be reproduced without express permission from Valco Cincinnati Inc All rights reserved Designs and other information may change without notice 2013 Valco Cincinnati Inc www valcomelton com IS0212 4 13 To Replace an S Series Unit Pump 1 Remove the right side and lo...

Page 174: ...e properly grounded and fused in accordance with rate current consumption refer to the equipment identification plate Gauge and insulation for power supply must be adequate to handle rated current consumption FAILING TO FOLLOW ALL INSTRUCTIONS COULD RESULT IN PERSONAL INJURY DEATH OR DAMAGE TO EQUIPMENT Important Information Description This instruction sheet will cover how to install an internal ...

Page 175: ...nued 6 Remove the four 4 M5 flange nuts from the bottom corners of the case 7 Remove any other connections that are holding the case to the chassis 8 Remove the case exposing the tank 9 Rotate the metal tab on the amplifier box by the Lemo connector away from the base of the amplifier box to be able to access the tab while the case is on 10 Attach the amplifier box to the appropriate mounting loca...

Page 176: ...f the tank for the desired mounting location and discard 13 Apply high temperature silicone RTV to the sensor threads 14 Thread the sensor into the tank so that the tip of the sensor is 1 5 inches from the wall of the tank 15 Feed the cable with the Lemo connector through the holes in the chassis as shown below High Internal Level Sensor Low Internal Level Sensor ...

Page 177: ...d 16 Reattach the case to the chassis by reversing steps 2 6 17 Attach the Lemo connector to the bottom of the appropriate Rechner amplifier box 18 Attach the JST connector from the assembly to the appropriate position as shown below Internal High Ext Level Internal Low Int Level ...

Page 178: ...he back hose panel CAUTION CAUTION CAUTION CAUTION CAUTION Periodically check the level of adhesive to ensure the sensor is working properly 1 Remove the protective screw on the amplifier box 2 Reconnect the power and turn on the unit 3 Fill the tank with adhesive until the adhesive level is in the center of the desired sensor 4 On the amplifier box if the sensor light is green carefully turn the ...

Page 179: ...vel is below the sensor and ensure that the sensor light changes to green CAUTION CAUTION CAUTION CAUTION CAUTION Periodically check the level of adhesive to ensure the sensor is working properly 7 Reinsert the protective screw back into the amplifier box 8 Close the front operator panel Adjusting the Sensor Time Delay 1 Go to the setting screen by pressing 2 Unlock the control by using the level ...

Page 180: ...l Sensor Instructions 5 Select Internal low or External high ON Delay based on the desired sensor and adjust the time depending on your application The default time for either sensor is 5 seconds Adjusting the Sensor Time Delay Continued ...

Page 181: ...on refer to the equipment identification plate Gauge and insulation for the power supply must be adequate to handle rated current consumption Description This instruction sheet will cover how to install an external pot fill system This system can be installed with any parent machine that has the universal temperature control Installation 1 Open the front operator panel on the parent machine To ins...

Page 182: ...If the cord grip is not going to be used proceed to step 2 of Installing to the External Pot Fill System below Installing to the External Pot Fill System below Installing to the External Pot Fill System below Installing to the External Pot Fill System below Installing to the External Pot Fill System below 5 Drill a 0 80 diameter hole in the desired location 6 File down any remaining metal chips in...

Page 183: ...ion if needed 6 Attach the hose to the fitting A 8 core hose fitting is included with the assembly Additional sizes can be purchased separately For part numbers please refer to the illustration drawing included with the assembly 7 Remove the two 2 jam nuts from the sensor 8 Insert the sensor into the mounting bracket using the two 2 jam nuts from the previous step The bottom of the sensor should b...

Page 184: ...he enclosure box 11 Mount the enclosure box to the desired location 12 Attach the female Turck connector to the enclosure box 18 Select Pot Fill Mode and press the up arrow to enable it 19 Enable the External On Delay 13 Turn the parent machine on 14 Access the setting screen by pressing 15 Unlock the control by using the level 3 password 6550 16 Return to the setting screen by pressing again 17 A...

Page 185: ...seconds 4 If the sensor light is green turn the screw on the amplifier box clockwise carefully until the light changes to orange 5 Close the lid 6 Remove some adhesive so that the adhesive level is below the sensor Make sure the sensor light changes to red and that the parent machine begins to pump adhesive 7 Verify that the pump on the parent machine turns off after the unit is filled to the desi...

Page 186: ...al ON Delay based on the desired sensor and adjust the time dependent on the application The default time for either sensor is five seconds 8 Reinsert the protective screw into the amplifier box 9 If the desired adhesive level was not reached adjust the sensor and repeat steps 18 19 of Installing to the External Pot Fill System and 1 2 of Calibrating the Sensor If the desired adhesive level was re...

Page 187: ...EQUIPMENT DAMAGE WARNING WARNING WARNING WARNING WARNING The equipment may still be energized even after the circuit breaker or main power switch is off All equipment must be properly grounded and fused in accordance with rate current consumption refer to the equipment identification plate Gauge and insulation for the power supply must be adequate to handle rated current consumption Description Th...

Page 188: ...ve the five 5 knockouts at the top of the operator panel 3 Attach the beacon assembly to the operator panel using the four 4 M5 X 8 socket head cap screws 4 Attach the female connector included in the bag to the beacon assembly 5 Attach the three 3 flying leads to the universal control as shown below Wire Locations Pin 1 Pin 2 GND White Blue Brown ...

Page 189: ...the electrical cabinet to ensure everything is connected and the power is hooked up correctly 7 Close the front operator panel Enabling the Beacon 1 Turn the unit on 2 Access the setting screen by pressing 3 Unlock the control using the level 3 password 6550 4 Return to the setting screen by pressing again 5 Access the System screen ...

Page 190: ... Element to an Existing Beacon Assembly 1 Turn the unit off 2 Remove the cap from the top of the existing beacon assembly 3 Line up the white lines on the top of the light and on the bottom of the siren 4 Twist the siren element clockwise until it locks 5 Remove the beacon assembly and verify the black jumper wire is still connected to pins 2 and 3 6 If the jumper is still connected reattach the b...

Page 191: ...E AS SHOWN ENSURE THAT EMBOSSED ARROW ON REGULATOR POINTS IN DIRECTION OF AIRFLOW DO NOT USE TEFLON TAPE ON FITTINGS THAT THREAD INTO AIR LINE USE TEFLON TAPE ON ALL OTHER CONNECTIONS 8 REINSTALL JIC CAP ONTO HOSE OUTLET FITTING 9 ATTACH AIR SUPPLY TO AIR FILTER REGULATOR AND ADJUST AIR PRESSURE TO 0 PSI 10 TURN ON PUMP AND ADJUST AIR FILTER REGULATOR TO OBTAIN DESIRED ADHESIVE PRESSURE 11 CHECK F...

Page 192: ...ED BY MANUALLY ACTIVATING THE UNIFLOW RELIEF SOLENOID VALVE PRESSURE SETTING SHOULD BE 100 150 PSI FOR HIGHER APPLICATION PRESSURE THE SETTING SHOULD NOT EXCEED 900 PSI 5 PATTERN CONTROL CABLE MAY BE PURCHASED SEPERATELY 030XX890 6 ALL CABLES AND TUBING ARE NOT DRAWN TO SCALE 999XD774 197 KJC0272 ILLUSTRATION DRAWING UNIFLOW PRESSURE RELIEF INSTALLATION 08JUL11 1 4 1 1 KJC AJK AJK SEE P L NONE REM...

Page 193: ...Y DEATH OR DAMAGE TO EQUIPMENT PRESSURE SWITCH INSTALLATION INSTRUCTIONS IS0213 1 0 1 1 1 0 1 1 1 0 1 1 1 0 1 1 1 0 1 1 Important Information Description The pressure switch has a 316 stainless steel housing and are hermetically sealed The pressure switches have a set operating range and are provided below Part Number Operating Range psi 481XX050 50 130 481XX051 160 400 481XX052 275 850 These pres...

Page 194: ...alled into the side of the manifold If the pressure switch is to be installed into the side of the manifold If the pressure switch is to be installed into the side of the manifold If the pressure switch is to be installed into the side of the manifold proceed to Installing the Pressure Switch into the Side of a proceed to Installing the Pressure Switch into the Side of a proceed to Installing the ...

Page 195: ...into the unit s universal control route the cables through either the cord grip or the slot into the electrical cabinet 3 Bundle any remaining wire 4 Open the front operator panel 5 Connect the flying leads from the pressure switch to the universal control as detailed below Wire Color Function Brown Common Red N C Blue N O Green PE 6 Connect the brown wire into GND for the desired input a If a pre...

Page 196: ...screwdriver or blade and turn clockwise to increase the set point or counter clockwise to decrease the set point Adjust the nut accordingly until the switch clicks 12 Adjust the adhesive pressure to be below and above the set point while verifying that the led on the control board for that input is turning on and off a If the switch does not turn on and off as expected repeat step 11 13 Slide the ...

Page 197: ... to Alarm Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati Ohio 45246 USA TEL 1 513 874 6550 FAX 1 513 874 3612 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 Valco Cincinnati Ltd Unit 7 8 Hortonwood 32 Telford TF1 7YN England TEL 44 1952 677911 FAX 44 1952 677945 Valco Cincinnati GmbH Storkower Strasse 6 D 1574...

Page 198: ...provided and applicable codes for the region installed FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN A PERSONAL INJURY DEATH OR EQUIPMENT DAMAGE WARNING The equipment may still be energized even after the circuit breaker or main power switch is off All equipment must be properly grounded and fused in accordance with rate current consumption refer to the equipment identification plate Gauge ...

Page 199: ...gauge port Ensure the plug is wrapped with Teflon tape 3 Install the pressure transducer into the open port on the manifold Orient the electrical connector as shown by loosening the adjustment nut and rotating the connector Once the desired orientation is achieved tighten the adjustment nut Do not over rotate the electrical connector as it may over strain the internal wire and break the connection...

Page 200: ... 4 Route the cable along the side of the unit and through the support bracket on the chassis 5 Route the cable into the electrical cabinet through the D shaped hole on the chassis 6 Secure the cable using ty raps and connect it to J5 on the temperature control board 152XX746 ...

Page 201: ...utton 2 Press the OK button and unlock the control using the level 3 password 6550 3 Access the Pressure screen by pressing the button three times followed by the OK button 4 Press the right arrow button and select the desired unit of measure using the or arrow buttons Pressure Units of Measure Bar PSI ...

Page 202: ...fault alarms if desired 6 Press the right arrow button to get to the next screen and enable the pressure monitoring by pressing the button 7 Press the right arrow and set the sensor range based on the table below P N S Number Code Sensor Range KJC3344 D10 D16 T1 100 bar 1450 psi 8 Press the right arrow twice and set the desired high pressure alarm ...

Page 203: ... Incorporated 411 Circle Freeway Drive Cincinnati Ohio 45246 USA TEL 1 513 874 6550 FAX 1 513 874 3612 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 Valco Cincinnati Ltd Unit 7 8 Hortonwood 32 Telford TF1 7YN England TEL 44 1952 677911 FAX 44 1952 677945 Valco Cincinnati GmbH Bonnerstrasse 349 40589 Dusseldorf Benrath Germany T...

Page 204: ...ING All equipment is to be installed and all connections made only by qualified personnel Components and accessories are to be installed in accordance with the instructions provided and applicable codes for the region installed FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN A PERSONAL INJURY DEATH OR EQUIPMENT DAMAGE WARNING WARNING WARNING WARNING WARNING The equipment may still be energize...

Page 205: ...oard is receiving power by checking that the 24V led is on 5 Access the setting screen by pressing ITEM NO DESCRIPTION PART NO QTY 1 PCB ASSEMBLY ANYBUS I O EXTEND BJK0347 1 3 SPACER PCB 14MM LONG SNAP IN NYLON 091XX644 1 4 STANDOFF 6MM HEX M3 X 0 5 THREAD 091XX563 2 5 SCREW BUTTON HEAD CAP M3 X 6 784XX541 2 Installation 1 Attach the auxiliary I O board to the universal control as shown below ...

Page 206: ...y I O and press the up arrow to enable it 10 Return to the setting screen by pressing again 6 Unlock the control using the level 3 password 6550 7 Return to the setting screen by pressing again 8 Access the Configuration screen 11 Select input or output depending on your application ...

Page 207: ... any of the inputs or outputs select the desired function Use the diagram below to hook up an input or output 4 Opto Isolated Inputs See the table on the following page for input wiring options See the table on the following page for output wiring options 4 Output Relay Contacts ...

Page 208: ...5 Valco Melton IS0343 Anybus Installation Installation Continued ...

Page 209: ... Remote mode The PLC acts as the master in a master slave system The user can read and write all parameters that are available through the interface In this mode many parameters cannot be changed from the Hot Melt Unit display because they are set from the Melter Communication Interface 2 Local mode The PLC is serves only as an observer of the Melter and can only read but not change system paramet...

Page 210: ...or the new address to take effect The default network settings are shown below The network settings should be changed to match your network Remote Communication The interface can be enabled by changing the Protocol from Disabled to Ethernet IP The operation mode should also have Local selected as shown below Network Settings The network settings should be configured for your network The default se...

Page 211: ...S0344 Anybus Installation and Setup ValcoMelton 3 RSLogix 5000 Setup 1 In communication tree choose New Module under the Ethernet port 2 Select Generic Ethernet Module from the list of available modules ...

Page 212: ...p the Comm Format and Connection parameters as shown 4 Set the module to the appropriate IP address The new modules Output connection will be Send Packet as described in Data Packets used for Ethernet IP communication below and the new module Input connection will be Receive Packet Modules Output Connection ...

Page 213: ... initializing the Ethernet IP module Data is carried in specific send and receive packets in which the PLC initiates the commands needed for the Melter process Only one command is executed at a time and the Melter will respond with specific fault codes if the command cannot be executed For each packet the Melter will return the Data Index and channel from the PLC command to indicate proper acknowl...

Page 214: ...t 2 Pump 1 ON OFF Bit 3 Pump 2 ON OFF Bit 4 Pump 3 ON OFF Bit 5 Pump 4 ON OFF Bit 6 Temperature Setback ON OFF Bit 7 Auto Pump Enable ON OFF Command Byte 1 This command byte tells the Melter what to do with the Data Index and Channel bytes The following command codes in hex are defined Command Description 0x01 Control Byte Only 0x03 Read 0x06 Write If the Melter is put into local mode the Write Co...

Page 215: ... RW 0 1 Activate Hose Gun Zone Pair 115 0 19 RW 40 230 C Zone Temperature Set Point 120 0 19 RO 40 230 C Zone Current Temperature 128 RW 5 190 C Standby Temperature 135 RW 0 1440 min AutoSetback Time 136 RW 0 1440 min AutoStandby Time 142 RW 5 60 C UnderTemp Fault Offset 152 RW 5 60 C OverTemp Fault Offset 160 RW 1 180 min Exit Standby Time 170 0 3 RW 0 2 Pump Auto Mode Input Speed Type 0 0 10V 1 ...

Page 216: ...nitions for Status Bytes 0 and 1 These are the response bytes sent back from the Melter at every message Bit 0 Melter Ready for Operation 1 Ready 0 Not Ready Bit 1 Ready Delay Enabled 1 Enabled 0 OFF Bit 2 System is in Alarm State 1 Alarm 0 No Alarm Bit 3 System is in Fault State 1 Fault 0 No Fault Bit 4 Melter is Shutdown 1 Shutdown 0 Not Shutdown Bit 5 Melter in Warmup State 1 Warmup active 0 Wa...

Page 217: ... A read request to Data Index 182 Pump Speed channel 0 Channel Read Data Bytes 4 and 5 returns Pump1 speed Channel Read Data 1 Bytes 6 and 7 returns Pump2 speed Channel Read Data 2 Bytes 8 and 9 returns Pump3 speed Channel Read Data 3 Bytes 10 and 11 returns Pump4 speed Current Alarm Types When Reading the Current Alarm Type Data Index 23 a specific code is returned on Read Data Byte 4 5 For Zone ...

Page 218: ...temperature setpoint Control 0x01 Heater enable only Command Write 0x06 Data Index 115 0x73 Setpoint Channel 0 Data 70 degrees 0x46 PLC Æ CPU 0x01 0x06 0x73 0x00 0x46 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 CPU Æ PLC 0x00 0x01 0x73 0x00 0x46 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 2 Read current zone 1 temperature Control 0x01 Heater enable only Command Read 0x03 Data...

Page 219: ...ASHING GREEN ONLINE WITHOUT CONNECTIONS ESTABLISHED RED FATAL ERROR FLASHING RED CONNECTION TIMED OUT Module Status LED LED State Description OFF NO POWER GREEN CONTROLLED BY A SCANNER IN RUN STATE FLASHING GREEN NOT CONFIGURED OR SCANNER IN IDLE STATE RED MAJOR FAULT FLASHING RED RECOVERABLE FAULT Link Activity LED LED State Description OFF NO LINK NO ACTIVITY GREEN LINK 100Mbit s FLASHING GREEN ...

Page 220: ...and all connections are to be made only by qualified personnel Components and accessories are to be installed in accordance with the instructions provided and applicable codes for the region installed FAILURE TO FOLLOW THESE INSTRUCTIONS COULD RESULT IN A PERSONAL INJURY DEATH OR DAMAGE TO EQUIPMENT WARNING WARNING WARNING WARNING WARNING The equipment may still be energized even after the circuit...

Page 221: ...d to the next section To install the 5 6 zone power board do the following 2 Open the front operator panel 3 Remove the 5 6 zone board from the static bag 4 Connect the green Phoenix connector on the 5 6 zone board to the main power board 5 Fix the board to the electrical panel using two 2 M4 X 6 pan head machine screws 6 Connect the 5 6 zone power cable to both of the boards ...

Page 222: ...right side of the tank The connector with the flange should be in the back of the unit 9 Remove the knockout on the back hose panel for the appropriate slot if necessary 10 Attach the flanged connector to the inside of the hose panel using four 4 M3 lock washers and four 4 M3 hex nuts into the appropriate numbered slot 11 Attach the flying connectors in the operator panel to the appropriate positi...

Page 223: ...emblies 13 Close the back hose panel 14 Check the electrical cabinet to ensure everything is connected and the power is hooked up correctly 15 Close the front operator panel 16 Turn on the unit 17 Go to the setting screen by pressing 18 Unlock the control by using the level 3 password 6550 19 Go to the setting screen by pressing again 20 Go the Config screen ...

Page 224: ...lowing To test the new hoses and zones do the following To test the new hoses and zones do the following To test the new hoses and zones do the following To test the new hoses and zones do the following 22 Attach the new hose s to the manifold and back hose panel 23 Turn on the new hose and gun and set to the desired temperature 24 Verify that the hose and gun heat up and maintain temperature ...

Page 225: ...cable codes for the region installed Failure to follow these instructions could result in personal injury death or damage to equipment CAUTION The instructions and guidelines in this instruction sheet are general guidelines Always follow the manufacturer s documentation and instructions for each part of the system such as the valve the solenoid the application mechanism etc Failure to follow these...

Page 226: ...ZINC 12 798XX735 4 000 EA SPLIT LOCK WASHER 1 4 ZINC 90 782XX596 1 000 EA FEELER GAUGE 040 91 782XX427 1 000 EA ANTI SEIZE LUBRICANT 98 998IS796 1 000 EA ILLUSTRATION DRAWING 99 IS0299 1 000 EA INSTRUCTION SHEET Before Starting This Procedure Before starting this procedure the unit should be heated to operating temperature the tank completely emptied and the unit disconnected from power WARNING Fa...

Page 227: ... 3 Installing the Coupling 1 With the tank completely empty and the unit disconnected from power gently lay the unit on its side 2 Using a pair of wire snips cut the tie wrap securing the motor cable to the chassis as shown in the figure below ...

Page 228: ...afts may need to be rotated manually in order to access the set screws Remove the coupling hubs from the motor shaft and the pump shaft and set them aside CAUTION The set screw used in the coupling hubs may require a 3 32 or 2 5mm hex key depending on the date of manufacture Be sure the hex key fits snugly before attempting to loosen the set screw otherwise damage to the set screw may result WARNI...

Page 229: ...et remove the 4 1 4 28 hex head cap screws securing the motor to the motor bracket Remove the motor bracket and set it aside 7 Using a ratchet and 13mm socket remove ONLY the 2 M8 hex head cap screws and washers that secure the pump to the manifold as shown in the figure below ...

Page 230: ...mates with the hub on the pump There will be a small gap of approximately 1 16 between the bracket and pump to minimize heat transfer 9 Using a square ensure that the motor bracket is perpendicular to the chassis before tightening the 2 M8 hex head cap screws 10 Using a ratchet drive extension 13mm socket and torque wrench tighten the 2 hex head cap screws to 20 ft lbs 27 1 N m evenly in increment...

Page 231: ...site side of the new motor bracket 12 Place the new bore jaw coupling 783XX370 on the pump shaft Use the 040 feeler gauge provided 782XX596 to position the hub on the pump shaft 040 from the motor bracket see figure below Using a 1 8 tee handle hex key tighten the set screw in the jaw coupling hub on the pump shaft 13 Position the spider 783XX372 in the hub on the pump shaft as shown ...

Page 232: ...en use a torque wrench to tighten each screw to 106 in lbs 12 N m 17 Manually rotate the motor shaft as needed in order to align the jaws of both couplings with the spider 18 Slide the jaw coupling hub on the motor shaft toward the pump engaging the spider Verify that the hub slides freely when engaging the spider With the jaw coupling hub on the motor shaft just touching the spider tighten the se...

Page 233: ...he pump and check the unit for vibration If no abnormal conditions are observed the unit is ready to be put back in service Valco Cincinnati Inc www valcomelton com IS0299 1 16 No part of this document may be reproduced without express permission from Valco Cincinnati Inc All rights reserved Designs and other information may change without notice Valco Cincinnati Incorporated 411 Circle Freeway Dr...

Page 234: ...lues to the CPU overwriting all parameter settings prior to running Restore If the function fails an error code will be displayed that is explained at the end of this doc Init Level 4 Permission Required Same function as previous sets all parameters back to default and opens the Config wizard Backups from any 152XX746 board will be able to be loaded onto any other 152XX746 board However because th...

Page 235: ...card failed to unmount Code 4 CPU failed to open the backup file Code 5 CPU failed to close the backup file Code 6 CPU failed to write information to the backup file during backup creation Code 7 CPU failed to read information from the backup file during restore Code 8 Backup file is invalid Upon creation a checksum is calculated and saved at the beginning of the file A file should only be invalid...

Page 236: ...menu 5 Only two Modbus functions are configured in the CPU 0x03 Read Multiple Holding Registers 0x10 Write Multiple Holding Registers 6 Errors Returned Modbus Exception Code 0x01 Illegal function 0x03 and 0x10 are the only supported functions Modbus Exception Code 0x02 Illegal data address if any address is out of range 7 All current temperatures have a 25 ºC offset added to them before being sent...

Page 237: ...int All Temperatures in ºC M1 prog 0x0101 W R Hose 1 Temperature Setpoint All Temperatures in ºC P1 prog 0x0102 W R Gun 1 Temperature Setpoint All Temperatures in ºC M2 prog 0x0103 W R Hose 2 Temperature Setpoint All Temperatures in ºC P2 prog 0x0104 W R Gun 2 Temperature Setpoint All Temperatures in ºC M3 prog 0x0105 W R Hose 3 Temperature Setpoint All Temperatures in ºC P3 prog 0x0106 W R Gun 3 ...

Page 238: ...tation of channel 5 Not Used by Valco CPU P16 0x011D W R Habilitation of channel 6 Not Used by Valco CPU P17 0x011E W R Number of terminal Not Used by Valco CPU P18 0x011F W R Spare Not Used by Valco CPU P19 0x0120 W R Spare Not Used by Valco CPU P20 0x0121 W R Spare Not Used by Valco CPU P21 0x0122 W R Spare Not Used by Valco CPU P22 0x0123 W R Spare Not Used by Valco CPU P23 0x0124 W R Spare Not...

Page 239: ...our ON 1 Not Used by Valco CPU MC1 0x0141 W R Wednesday Minute ON 1 Not Used by Valco CPU TC1 0x0142 W R Wednesday Type ON 1 Not Used by Valco CPU HD1 0x0143 W R Wednesday Hour OFF 1 Not Used by Valco CPU MD1 0x0144 W R Wednesday Minute OFF 1 Not Used by Valco CPU TD1 0x0145 W R Wednesday Type OFF 1 Not Used by Valco CPU HC2 0x0146 W R Wednesday Hour ON 2 Not Used by Valco CPU MC2 0x0147 W R Wedne...

Page 240: ...Friday Type OFF 2 Not Used by Valco CPU HC1 0x0164 W R Saturday Hour ON 1 Not Used by Valco CPU MC1 0x0165 W R Saturday Minute ON 1 Not Used by Valco CPU TC1 0x0166 W R Saturday Type ON 1 Not Used by Valco CPU HD1 0x0167 W R Saturday Hour OFF 1 Not Used by Valco CPU MD1 0x0168 W R Saturday Minute OFF 1 Not Used by Valco CPU TD1 0x0169 W R Saturday Type OFF 1 Not Used by Valco CPU HC2 0x016A W R Sa...

Page 241: ...88 R Gun 2 Temperature All Temperatures in ºC w 25 ºC offset added M3 actual 0x0189 R Hose 3 Temperature All Temperatures in ºC w 25 ºC offset added P3 actual 0x018A R Gun 3 Temperature All Temperatures in ºC w 25 ºC offset added M4 actual 0x018B R Hose 4 Temperature All Temperatures in ºC w 25 ºC offset added P4 actual 0x018C R Gun 4 Temperature All Temperatures in ºC w 25 ºC offset added M5 actu...

Page 242: ...Shift A Standby Start Time 0x01A3 W R Shift A Standby End Time 0x01A4 W R Shift A Standby Enable 0x01A5 W R Shift A Setback Start Time 0x01A6 W R Shift A Setback End Time 0x01A7 W R Shift A Setback Enable 0x01A8 W R Shift B Standby Start Time 0x01A9 W R Shift B Standby End Time 0x01AA W R Shift B Standby Enable 0x01AB W R Shift B Setback Start Time 0x01AC W R Shift B Setback End Time 0x01AD W R Sh...

Page 243: ... 1 Low Alarm PSI 0x01C5 W R Pressure Monitor 1 High Alarm PSI 0x01C6 R Pressure Monitor 1 Value PSI 0x01C7 W R Pressure Monitor 2 Enable Disable 0x01C9 W R Pressure Monitor 2 Low Alarm PSI 0x01CA W R Pressure Monitor 2 High Alarm PSI 0x01CB R Pressure Monitor 2 Value PSI 0x01CC W R Pressure Monitor 3 Enable Disable 0x01CD W R Pressure Monitor 3 Max Value PSI 0x01CE W R Pressure Monitor 3 Low Alarm...

Page 244: ...e 0x01E2 W R Zone 12 Enable Disable 0x01E3 W R Zone 13 Enable Disable 0x01E4 W R Zone 14 Enable Disable 0x01E5 W R Zone 15 Enable Disable 0x01E6 W R Zone 16 Enable Disable 0x01E7 W R Zone 17 Enable Disable 0x01E8 W R Zone 18 Enable Disable 0x01E9 W R Zone 19 Enable Disable 0x01EA W R Zone 20 Enable Disable 0x01EB W R Hose Gun 1 Enable Disable 0x01EC W R Hose Gun 2 Enable Disable 0x01ED W R Hose Gu...

Page 245: ...Appendix E Communication Protocols Modus MM147 D4 Hot Melt Unit 162 ...

Page 246: ...ve packets in which the PLC initiates the commands needed for the Melter process Only one command is executed at a time and the Melter will respond with specific fault codes if the command cannot be executed For each packet the Melter will return the Data Index and channel from the PLC command to indicate proper acknowledgement Data Packets used for Ethernet IP communication This section describes...

Page 247: ...of 1 and OFF has a value of 0 Bit 0 Control Power ON OFF Bit 1 Master Pump Enable ON OFF Bit 2 Pump 1 ON OFF Bit 3 Pump 2 ON OFF Bit 4 Pump 3 ON OFF Bit 5 Pump 4 ON OFF Bit 6 Temperature Setback ON OFF Bit 7 Auto Pump Enable ON OFF Command Byte 1 This command byte tells the Melter what to do with the Data Index and Channel bytes The following command codes in hex are defined Command Description 0x...

Page 248: ...urrent Temperature 128 RW 5 190 C Standby Temperature 135 RW 0 1440 min AutoSetback Time 136 RW 0 1440 min AutoStandby Time 142 RW 5 60 C UnderTemp Fault Offset 152 RW 5 60 C OverTemp Fault Offset 160 RW 1 180 min Exit Standby Time 170 0 3 RW 0 2 Pump Auto Mode Input Speed Type 0 0 10V 1 0 2 8V 2 Encoder 171 0 3 RW 0 9999 m min Pump Minimum Speed Encoder 172 0 3 RW 0 9999 RPM Pump Creep Speed 173 ...

Page 249: ...Melter Ready for Operation 1 Ready 0 Not Ready Bit 1 Ready Delay Enabled 1 Enabled 0 OFF Bit 2 System is in Alarm State 1 Alarm 0 No Alarm Bit 3 System is in Fault State 1 Fault 0 No Fault Bit 4 Melter is Shutdown 1 Shutdown 0 Not Shutdown Bit 5 Melter in Warmup State 1 Warmup active 0 Warmup not active Bit 6 Melter in Setback 1 Setback active 0 Setback not active Bit 7 Pump 1 Active 1 On 0 OFF Bi...

Page 250: ...his is the value returned during a read command for the Data Index and Channel requested Channel Read Data Bytes 6 15 When a read command is requested for a parameter with multiple zones the next channel value will also return to the PLC unless the requested channel is already the maximum channel For example A read request to Data Index 182 Pump Speed channel 0 Channel Read Data Bytes 4 and 5 retu...

Page 251: ... is returned in Byte 4 Numbers shown in Hex Byte 4 Description 0x00 No Alarm 0x01 0x14 Zone Error 0x15 System Error Zone Error 0x01 0x14 Byte 5 Description 0x00 No Alarm Fault 0x01 RTD Fault 0x02 Low Temperature Fault 0x03 High Temperature Fault System Error 0x15 Byte 5 Description 0x00 No Alarm Fault 0x02 System Fault 0x03 Filter Alarm 0x04 Pump 1 Fault 0x05 Pump 2 Fault 0x06 Pump 3 Fault 0x07 Pu...

Page 252: ...the zone 1 temperature setpoint Control 0x01 Heater enable only Command Write 0x06 Data Index 115 0x73 Setpoint Channel 0 Data 70 degrees 0x46 PLC Æ CPU 0x01 0x06 0x73 0x00 0x46 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 CPU Æ PLC 0x00 0x01 0x73 0x00 0x46 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 0x00 2 Read current zone 1 temperature Control 0x01 Heater enable only Command Rea...

Page 253: ...ESTABLISHED FLASHING GREEN ONLINE WITHOUT CONNECTIONS ESTABLISHED RED FATAL ERROR FLASHING RED CONNECTION TIMED OUT Module Status LED LED State Description OFF NO POWER GREEN CONTROLLED BY A SCANNER IN RUN STATE FLASHING GREEN NOT CONFIGURED OR SCANNER IN IDLE STATE RED MAJOR FAULT FLASHING RED RECOVERABLE FAULT Link Activity LED LED State Description OFF NO LINK NO ACTIVITY GREEN LINK 100Mbit s F...

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