VALCO MELTON D-90 Manual Download

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D-90 Hot Melt Unit

Manual Number:

MM125

Release Date:

3/2018

Summary of Contents for D-90

Page 1: ...D 90 Hot Melt Unit D 90 Hot Melt Unit D 90 Hot Melt Unit D 90 Hot Melt Unit D 90 Hot Melt Unit Manual Number MM125 Release Date 3 2018 ...

Page 2: ...alco 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 Valco Cincinnati Limited Valco Cincinnati Limited Valco Cincinnati Limited Valco Cincinnati Limited Hortonwood 32 Telford TFI 7YN England Tel 44 1952 677911 Fax 44 1952 677945 Email sales valco co uk We...

Page 3: ...ood 32 Telford TF1 7YN England M elton S L U Pol Industrial Agustinos calle G n 34 31160 Orcoyen Navarra Spain declares that the product Product N am e D 90 Hot Melt Unit com plies with the following Council Directives Safety of M achinery 2006 42 EC Low Voltage Equipm ent 2014 35 EU EM C 2014 30 EU Reduction of Hazardous Substances RoHS 2011 65 EC and conform s to the following standards Safety E...

Page 4: ...fety Information 2 6 What to Do if Contact with Hot Adhesive Occurs 2 7 What to Do if Inhalation of Adhesive Fumes Occurs 2 7 What to Do if Adhesive Related Fire or Explosion Occurs 2 8 Hose Safety Information 2 9 Section 3 Basic Features 3 1 Overview 3 1 Main Power Disconnect 3 3 Compression Latches 3 3 Temperature Controller 3 3 Fan 3 3 Alarm Beacon 3 3 Lid 3 3 Reservoir 3 3 Casters 3 3 Grid 3 3...

Page 5: ...d Standby Mode 5 3 Display Adjustment 5 4 User Interface 5 6 Navigation 5 6 Memory Storage 5 6 Editing 5 6 Thumbwheel vs Single Digit Edit 5 7 Entering Passwords 5 8 Set Language 5 9 Set Temperature Units 5 11 Programming Temperatures 5 12 Temperature Screens 5 12 Grid Temperature 5 13 Hose Valve Temperature 5 13 System Pump Ready Temperature Offset 5 15 Ready Delay Time 5 16 Over Temperature Alar...

Page 6: ...u 5 39 Encoder Setup Menu 5 41 PID Setup Menu 5 41 PID Settings 5 41 AutoTune Feature 5 42 Initialize Screen 5 43 Restoring Factory Default Settings 5 43 Adjusting the Pressure Control Valve 5 44 Adjusting the Single Stage Relief Valve 5 44 Gramage Feature 5 45 Section 6 Operation 6 1 Unit Startup 6 1 Filling the Tank 6 3 Dispensing Adhesive 6 4 Section 7 Maintenance 7 1 General 7 1 Cleaning the E...

Page 7: ...eet Metal Assembly 10 6 Motor Pump and Manifold Assembly 10 9 D 90 Hot Melt Unit 776XX883 Parts List 10 11 Single Pump Manifold Assembly 776XX299 10 13 Dual Pump Manifold Assembly 776XX300 10 16 D 90 HMU Electrical Panel Assembly 776XX281 10 19 D90 Hot Melt Unit EQM0690 10 23 Recommended Spare Parts for EQM0690 10 29 Electrical PanelAssembly 10 30 Section 11 Warranty 11 1 Warranty Information 11 1...

Page 8: ...ic adhesives The unit features a precision electronic temperature control a digital multi zone temperature display a variable speed electric motor driven gear pump and an adjustable pressure control Features and capabilities include Precision electronic temperature control Capacity of up to four hoses and guns Positive displacement electric motor driven gear pump Adjustable pressure control Integr...

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

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

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

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

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

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

Page 15: ...e of clean cold water be provided near the hot melt work area 2 Cover the affected area with a clean wet compress and call the emergency medical response system such as 911 immediately 3 Watch for and treat the subject for signs of shock while waiting for professional help to arrive What to Do if Contact with Hot Adhesive Occurs If adhesive fumes are inhaled immediately follow these steps 1 Take t...

Page 16: ... 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 WARNING WARNING WARNING 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 following steps 1 Sound a fire ala...

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

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

Page 19: ...3 1 ValcoMelton SECTION 3 BASIC FEATURES SECTION 3 BASIC FEATURES SECTION 3 BASIC FEATURES SECTION 3 BASIC FEATURES SECTION 3 BASIC FEATURES Figure 3 1 Basic Features Overview ...

Page 20: ...3 2 ValcoMelton Section 3 Basic Features MM125 D 90 Hot Melt Unit Figure 3 2 Basic Features Overview Continued ...

Page 21: ...e serviced regularly Refer to Section 7 Maintenance Alarm Beacon The alarm beacon alerts the customer unit status dependent on different conditions The standard beacon is factory set with two lights red and blue indicating low adhesive level red and system ready blue Lid The spring loaded floating lid allows tank access It also exerts pressure against the top of the unit effectively reducing adhes...

Page 22: ...3 4 ValcoMelton Section 3 Basic Features MM125 D 90 Hot Melt Unit Manifold Figure 3 3 Manifold ...

Page 23: ...llows access to the level sensors if applicable gear pump and motor There are two pressure relief valves on the manifold The first valve is an adjustable pressure relief valve that can be manually adjusted to set the adhesive operating pressure The factory setting is 750 psi The second valve is a fixed pressure relief valve that limits the maximum adhesive operating pressure The factory setting is...

Page 24: ...ic Features MM125 D 90 Hot Melt Unit The dataplates provide more information regarding the system configuration Included information Part number Serial number Operating voltage Maximum current Number of phases Frequency Dataplates ...

Page 25: ... in the adhesive causes clogging of the applicator nozzles The unit should be protected from high and low ambient temperatures 10o C and 50o C as well as from rapid changes in ambient temperature The unit must be protected from condensate and water The unit must be protected from strong vibrations Avoid areas with drafts If this is not possible the guns will need protection as if the temperature f...

Page 26: ...keep the leads at least 6 152 mm from high current wires Do not splice or solder leads Trim leads to the required length Leads should be only as long as necessary for installation All wiring should be in conduits or wireways Routing Low Voltage Leads Connecting the Electrical Power Installation Kit An Installation Kit is available for this unit containing spare fuses a copy of this manual on CD an...

Page 27: ...ly should be clean and free from excess interference from other machines WARNING WARNING WARNING WARNING WARNING You MUST follow these steps to connect power to the unit or personal injury and or damage to the unit may result 1 Open the electrical cabinet 2 Route the power through either side of the cabinet Knockouts for 3 4 and 1 conduit have been provided to facilitate power cable routing and cu...

Page 28: ...le leads to the main disconnect switch as shown in sheet 1 of the Electrical Schematic Figure 4 3 Customer Connections Main Power 4 Verify that all connectors are fully seated and the terminal block screws are secure 5 Close the electrical cabinet Connecting the Electrical Power Continued ...

Page 29: ...4 5 ValcoMelton Section 4 Installation MM125 D 90 Hot Melt Unit Electrical Panel ...

Page 30: ...4 6 ValcoMelton Section 4 Installation MM125 D 90 Hot Melt Unit VFD Board Electrical Cabinet Terminal Locations Figure 4 4 Electrical Cabinet ...

Page 31: ...lt Unit VFD Board Electrical Cabinet Terminal Locations Continued Figure 4 5 Terminal Locations 1 1 1 1 1 Speed Input Board Connection Wire Number Tachometer 0 10 VDC 4010 GND 4011 Encoder V 4033 A 4032 A 4031 GND 4030 Can be 0 10 VDC or 0 2 3 VDC 2 2 2 2 2 ...

Page 32: ...rners and edges Do not bend hoses sharper than 18 460 mm radius Do not group heated hoses so that they contact 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 ho...

Page 33: ...igure 4 6 Hot Melt Hose Figure 4 7 Manifold Hose Locations 5 Attach this end of the glue hose to the fluid outlet fitting in the manifold Figure 4 7 Gun connection End of glue hose that connects to fluid fitting on applicator End of glue hose that connects to fluid fitting on unit Unit connection ...

Page 34: ...ve from charring in the lower portion of the manifold Fittings are available from Valco Melton see Section 10 Part Number List This unit comes with a 12 straight fitting unless specified otherwise in the S number The use of 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 ...

Page 35: ...Failure to observe could result in personal injury burns CAUTION CAUTION CAUTION CAUTION CAUTION Hand held applicators require a suitable hook for hanging while not in use The hook must support the weight of the applicator with the hose Failure to observe could result in damage to equipment Either hand held or fixed applicators can be used with the unit To connect the fixed applicators follow thes...

Page 36: ...t Connecting the Hot Melt Hoses to the Applicators Continued End of glue hose that connects to fluid fitting on applicator Lead assembly with female connector connects to lead assembly on applicator Figure 4 8 Hot Melt Hose Fluid inlet fitting Figure 4 9 Applicator ...

Page 37: ...4 13 ValcoMelton Section 4 Installation MM125 D 90 Hot Melt Unit Units shipped with serial number 18031219 and later Customer Connections ...

Page 38: ...GE I1 I2 I3 I4 NPN INPUTS GND DC COMMON DC COM 24VDC NPN NPN SENSOR INPUT WIRING OPTIONS OUTPUT WIRING 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...

Page 39: ...4 15 ValcoMelton Section 4 Installation MM125 D 90 Hot Melt Unit Figure 4 10 Customer Connections Units shipped with serial number 18031218 and prior ...

Page 40: ...5 1 Valco Cincinnati Inc SECTION 5 SETUP SECTION 5 SETUP SECTION 5 SETUP SECTION 5 SETUP SECTION 5 SETUP Control Panel 23 ...

Page 41: ...OK Key Enters or exits a screen where a selected field can be edited 11 Minus Key Decreases the valve of the selected field 12 Left Arrow Key Move left thru the fields on the screen 13 Pump Menu Key Displays the pump group screens 14 Setup Menu Key Displays the setup group screens 15 Temperature Menu Key Displays the temperature group screens 16 Hose LED Illuminates green when the hose zone is hea...

Page 42: ...the Standby LED 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 th...

Page 43: ...ange the contrast on the 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 ...

Page 44: ... MM125 D 90 Hot Melt Unit Display Adjustment Continued 5 Adjust the screen position by holding down the Setup key on the front panel keyboard while simultaneously pressing the left or right arrow key to move the screen left or right as needed ...

Page 45: ...ble Use the indicated 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 Highlighted information is editable Use the appropriate buttons depending on the navigation symbols shown to navigate through the editable highlighted information Editing ...

Page 46: ... Edit use the Right Left Arrow Buttons to select the digit position and the Plus Minus Arrow Buttons to increase decrease the value of the selected digit Some thumbwheel screens contain a switch that can be used to turn the selected function ON or OFF Common examples 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 Star...

Page 47: ...ti Inc Section 5 Setup MM125 D 90 Hot Melt Unit Passwords are required to prevent unauthorized access to unit programming Please see Appendix A Password Levels for more information To enter a password Entering Passwords ...

Page 48: ...5 9 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit Set Language C O N T I N U E D N E X T P A G E ...

Page 49: ...5 10 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit Set Language Continued ...

Page 50: ...5 11 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit Set Temperature Units ...

Page 51: ...gramming Temperatures 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 Temperature Screens Press the Temperature Button repeatedly or use the navigation keys to cycle through the temperature screens until you reac...

Page 52: ...5 13 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit Grid Temperature Hose Valve Temperature ...

Page 53: ...5 14 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit Hose Valve Temperature Continued ...

Page 54: ...fore 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 Ready Temperature Offset ...

Page 55: ...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 30 minutes ON at 30 minutes ON at 30 minutes ON at 30 minutes ON at 30 minutes To prolong the life of the seal in the pump thi...

Page 56: ...5 17 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit Ready Delay Time Continued ...

Page 57: ...essage appears it can be cleared by pressing the OK key If the Over Temperature Alarm condition 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 the master control re...

Page 58: ...der 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 45 F 25 C This parameter can be accessed in Passwor...

Page 59: ...t 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 390 F 199 C This parameter can be accessed in Password Level 3 or higher Maximum Temperature ...

Page 60: ...ed which is the factory default setting J30 on the CPU provides a 24VDC GND connection for each beacon alarm desired This output is rated for 24VDC 0 5A The Beacon Assembly is available as an option The Beacon Assembly features a two light alert blue and red The factory settings are shown below It is possible to change the light conditions at any time using the following procedure Password level 2...

Page 61: ...5 22 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit Beacon 2 Beacon Alarm Setup Continued ...

Page 62: ...ches 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 Automatic Pump Mode ...

Page 63: ...ter and therefore the factory default timer is OFF Filter Change Timer Level Sensor Setup Internal Level External Level There are two level control inputs that can be used with the D 90 an internal level sensor and an external level sensor These inputs can also serve as internal low and high level sensors The external level sensor is used for pot fill mode see Pot Fill Mode Section 5 The delay for...

Page 64: ...etup MM125 D 90 Hot Melt Unit The Clock sub menu is used to set the current day and time and to setup shifts with on off and setback times temperatures that are automatically run by the internal clock Clock and 7 Day Timer Set Day and Time ...

Page 65: ...hree shifts Use the Right Left Arrow Buttons to move through the times and shifts and the OK Button to get a thumbwheel to set the times and turn on the setback feature with a switch on the thumbwheel The heaters can be set with or without using the setback times Set the start stop and setback times for all shifts Leave the unused shifts times blank Programming Shifts This screen states that for S...

Page 66: ...tons cycle through the different combinations of shifts and the Left Right Arrow Buttons cycle through the days of the week This screen states that on Mondays all three shifts A B and C will be working Programming Shifts C0ntinued This screen states that on Mondays only Shift A will be working After setting all shift times previous page and programming the shifts that will be working for each day ...

Page 67: ...5 28 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit Moving Through the Shift Time Day Screens ...

Page 68: ...nued Press the 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 69: ...5 30 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit The Diagnostics Screen shows the current software version as well as the current temperature and status of each zone Diagnostics ...

Page 70: ...o 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 18 F to 342 F 10 C to 190 C The default factory setting is 90 F 50 C This parameter can be accessed in Password Level 2 or higher Setback Temperature Setback ...

Page 71: ... 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 OFF 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 an external signal...

Page 72: ...pecified 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 Sequential Start Ho...

Page 73: ...5 34 Valco Cincinnati Inc Section 5 Setup MM125 D 90 Hot Melt Unit Sequential Start Valve ...

Page 74: ...ory and the Change History are cleared when the unit is turned off History If the an alarm condition eg 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 r...

Page 75: ... configured to control something on the hot melt control when the control receives an dry contact input For example if Input 3 is programmed for Pump On Off the pump will remain off until input 3 receives a signal for it to turn on This can be used to remotely control the glue pump See Section 4 Installation for wiring details This parameter can be accessed in Password Level 3 or higher User Input...

Page 76: ...Auxiliary I O board 151XX661 can be ordered separately as an option to allow the operator to use four more user inputs and outputs Once the board is installed the Auxiliary I O must be enabled The factory default setting is Disabled See Section 4 Installation for Auxiliary I O board connector This parameter can be accessed in Password Level 2 or higher see Appendix A Password Level When the Auxili...

Page 77: ...tomatically calculate the pump speed to achieve a desired coat weight It requires the user to enter the Pump Displacement cc Adhesive Density gram cc speed reference value if tach mode is used coating width mm and the desired coating weight gram m2 See Gramage Setup later in this section for more information Gramage Enable The RTD resistance temperature detector material type for the unit can be c...

Page 78: ...ined by the Auto Speed Input The factory default setting is 100 Continued on Next Page Continued on Next Page Continued on Next Page Continued on Next Page Continued on Next Page The Minimum Speed Setting determines the minimum line speed at which the pump turns at the creep speed setting The units are in either milli volts or ft min depending on the Auto Speed Input type Tach or Encoder The Maxim...

Page 79: ...line speed input used to adjust the pump speed See the VFD board connections below to find the input connectors for the Auto Speed Input Allowable settings and their corresponding connections are listed in the table below Pump Setup Menu Continued Setting Board Connection 0 2 8 0 10 DC COM 0 10 0 10 DC COM Encoder V A 1A B 1B DC COM ...

Page 80: ...ment units for the encoder are selected in this screen This is only available when the encoder is used Encoder Setup Menu If an Encoder is used 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 ...

Page 81: ...word Level 3 Changing out gun hose pairs or moving a gun or hose from it s original AutoTune position will require that AutoTune be run again to optimize the PID settings again PID Settings Continued The PID settings are factory set for each zone The factory PID settings complement Valco Melton s Tank Hose and Gun watt densities Tank 1 screen shown Use left right keys to access other screens CAUTI...

Page 82: ...he Setup Button and the OK Button on the keypad The buttons can be released once the start up screen appears Restoring Factory Default Settings Initialize Screen The Init or Initialize Screen is used to reset ALL of the control parameters back to the factory settings When OK is selected to Initialize ALL Data the set up wizard will take the user through the control initialization to reconfigure th...

Page 83: ...mp motor and resume operation Adjusting the Pressure Control Valve Adjusting the Single Stage Relief Valve The D 90 unit contains a single stage external manually adjustable relief valve see figure below Additionally the D 90 unit can use an optional pneumatic relief valve Uniflow 12 and Uniflow 24V contact Valco Melton for details The single stage relief valve is a simple safety device which prot...

Page 84: ...mp Displacement cc Adhesive Density gram cc speed reference valve if tach mode is used coating width mm and the desired coating weight gram m2 The Gramage Enable for the appropriate pump must be enabled in order to view these setting screens see Gramage Enable earlier in this section for more information The Pump Displacement Adhesive Density and Speed Reference must be set in the Pump Setup menu ...

Page 85: ...n 5 Setup MM125 D 90 Hot Melt Unit The Application Width and Gramage Application Weight must be set in the Pump Menu This parameter can be accessed in Password Level 1 or higher see Appendix A Password Level Gramage Feature Continued ...

Page 86: ...URY OR EQUIPMENT DAMAGE COULD OCCUR This unit should only be used by qualified personnel who understand all of the procedures and are familiar with the necessary safety measures Make sure that the person operating the machine is properly protects and that all safety instructions are followed OTHERWISE SERIOUS PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR Unit Startup 1 Turn on the unit by turnin...

Page 87: ...eratures of all of the connected heating zones collector grid manifold filter block hose etc See Section 5 Setup for details on how to adjust the temperature values 2 Wait for the system to heat up and for the system ready LED to illuminate WARNING WARNING WARNING WARNING WARNING Hot surfaces Do not touch unless necessary Use caution while performing the operation procedures in the following secti...

Page 88: ...oader attach the fill hose to the tank inlet at the back of the unit 3 An optional tank inlet filter and hose support are available to prevent tank contamination and to prevent damage caused by excessive hose bending see Figure 6 3 The optional capacitive level sensors are recommended when filling the tank with a drum unloader The high level sensor will prevent the adhesive from feeding from the d...

Page 89: ...essing the Pump On Off Key This may occur automatically if the Automatic Pump Enable setting is turned on Refer to Section 5 Setup for details The pump will operate only when the following conditions are met All of the heating zones are at the setpoint temperature The Pump clearance delay time has passed The pump enable jumper or customer input is connected properly The pump is set to Manual or Au...

Page 90: ...eal and other connectors External leakage indicates that service is required Periodically clean the exterior of the D 90 hot melt unit Inspect the exterior of the unit for any noticeable damage that may cause a system malfunction General SECTION 7 MAINTENANCE SECTION 7 MAINTENANCE SECTION 7 MAINTENANCE SECTION 7 MAINTENANCE SECTION 7 MAINTENANCE Cleaning the Exterior of the Unit To clean the exter...

Page 91: ...7 2 Valco Melton Section 7 Maintenance MM125 D 90 Hot Melt Unit Filter Replacement See Figure 7 2 See Figure 7 3 ...

Page 92: ...clean filter back into the block 7 Tighten the filter cap Figure 7 2 Replacing the Tank Inlet Filter Replacing the Tank Inlet Filter The optional tanlk inlet filter should be cleaned or replaced periodically to prevent adhesive flow restriction due to debris buildup Clean or replace the filter as follows 1 Turn the Drum Unloader pump OFF CAUTION CAUTION CAUTION CAUTION CAUTION Make sure the the ta...

Page 93: ... 4 wrench to loosen the filter cap rotating it slowly counter clockwise 3 Use a rag or towel to remove debris buildup on the filter screen or replace the screen as follows WARNING WARNING WARNING WARNING WARNING Wear heat resistant gloves and safety glasses when performing this procedure a Remove the screw at the bottom b Pull the screen out 4 Check the condition of the filter assembly O rings Rep...

Page 94: ... prolonged period Changing the Adhesive Flushing the System Use a purge recommended by the adhesive manufacturer CAUTION CAUTION CAUTION CAUTION CAUTION If a cleaning solution is to be flushed through the hot melt system it must be compatible with silicone Viton Teflon carbon graphite brass steel and aluminum Consult the adhesive manufacturer to find out which cleaning solutions are recommended fo...

Page 95: ...tting for the material you are using The new material can now be pumped through the system Parts Replacement Flushing the System Continued 5 Manually activate the applicators to relieve any system pressure buildup if the system is hot if applicable 6 Disconnect glue hoses from applicators unit and collect purged material with an appropriate container 7 Turn off the heating zone for the applicators...

Page 96: ...085xx271 4 3 Fuse 20A Class G 085xx273 4 4 Fuse 8A 5 x 20 mm 085xx272 4 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 If the blown fuse is on the 12 zone board see Figure 7 4 If not see Section 10 Part Number List Changing Fuses Figure 7 4 Main Board Power Fuses ...

Page 97: ...tion Machine does not power up Main power to the unit is not connected Connect the main power to the unit according to the wiring schematic Unit is switched off Turn on the unit using the main disconnect Insufficient amount of voltage being applied to the unit supply Verify the incoming voltage matches what is indicated on the nameplate 10 Unit is not enabled Castings have overheated The thermosta...

Page 98: ...control Fuming or smoking of adhesive Operating temperature exceed adhesive s recommended temperature Keep setpoint temperature within recommended range Consider another adhesive Uneven flowof adhesive to applicators Adhesive viscosity is too high Castings and or manifold temperature too low Raise castings and or manifold temperatures in accordance with adhesive manufacturer s specifications Wrong...

Page 99: ...dhesive manufacturer s specifications Wrong adhesive See adhesive manufacturer s recommendations Adhesive temperature is too low Raise the Castings manifold hoses and applicators temperatures in accordance with adhesive manufacturer s specifications Adhesive is old Change adhesive Bead with fine threads Adhesive temperature is too low Raise the Castings manifold hoses and applicators temperatures ...

Page 100: ...de disk from the coupling should come off Set it aside while replacing the pump 5 Relieve the glue pressure in the system if any exists 6 Remove the 4 M8 screws holding the pump to the manifold WARNING WARNING WARNING WARNING WARNING Wear heat resistant gloves and safety glasses Even when the adhesive flow has been shut off residual adhesive will drip from the manifold Wear gloves and use a rag or...

Page 101: ...8 5 Valco Cincinnati Inc Section 8 Troubleshooting and Repair MM125 D 90 Hot Melt Unit Replacing the Pump Continued Figure 8 1 Replacing the Pump ...

Page 102: ...e motor through the electrical cabinet bottom compartment 6 Remove the M6 screws holding the motor to the bracket 7 Remove the set screws from the motor coupling 8 Attach the new motor using the four 4 M6 screws that were removed in step 6 9 Re insert the set screw on the motor coupling 10 Reattach the motor bracket to the frame using the M10 Screws 11 Open the electrical box on the new motor 12 R...

Page 103: ...Set the pressure relief valve to the desired adhesive operating pressure See Section 5 Setup Adjusting the Pressure Control Valve Replacing the Pressure Relief Valve 1 Turn on the unit and allow it to reach the operating temperature 2 Relieve any pressure in the system 3 Remove the pressure relief valve from the manifold The physical location of these pressure relief valves may be reversed in some...

Page 104: ...unit and disconnect the power 2 Twist the beacon that needs to be replaced counter clockwise and remove 3 Twist the light bulb inside of the beacon case clockwise a quarter turn and discard the bulb 4 Attach the new light bulb by reversing step 3 5 Replace the beacon by aligning the white lines and twisting it clockwise until it locks ...

Page 105: ...mm Width 30inches 762mm Depth 41inches 1041 mm Tank Capacity 90kg 200lb Drop In Grid Standard Melt Rate 100 kg hr 220lb hr Gear Pump 0 7 lb hr 0 3kg hr 41 lb hr 19 kg hr 1 4 lb hr 0 6kg hr 85 lb hr 39 kg hr 3lb hr 1 3kg hr 170lb hr 77 kg hr 6lb hr 2 5kg hr 334lb hr 152kg hr Gear Pump Control A C with line tracking feature for variable speeds Number of Pumps 1 2 Number of Hoses Guns 1 6 Hose Fittin...

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

Page 107: ...Valco Cincinnati Limited Valco Cincinnati Limited Valco Cincinnati Limited Hortonwood 32 Telford TFI 7YN England Tel 44 1952 677911 Fax 44 1952 677945 Email sales valco co uk Web http www valco co uk Valco Cincinnati GmbH Valco Cincinnati GmbH Valco Cincinnati GmbH Valco Cincinnati GmbH Valco Cincinnati GmbH Bonnerstrasse 349 40589 Dusseldorf Benrath Germany Tel 49 211 984 798 0 Fax 49 211 984 798...

Page 108: ...10 2 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit D 90 Hot Melt Unit 776XX883 Overall Assembly 776XX883 01 dwg ...

Page 109: ...10 3 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit Overall Assembly Continued 776XX883 01 dwg ...

Page 110: ...10 4 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit Reservoir Collector Grid Frame Assembly 776XX883 02 ...

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

Page 112: ...10 6 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit Sheet Metal Assembly 776XX883 03 ...

Page 113: ...10 7 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit 776XX883 03 Sheet Metal Assembly Continued ...

Page 114: ...10 8 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit 776XX883 03 Sheet Metal Assembly Continued ...

Page 115: ...lcoMelton MM125 D 90 Hot Melt Unit 776XX883 04 Motor Pump and Manifold Assembly A further breakdown of the Single Pump Manifold Assembly is shown on Page 10 13 A further breakdown of the Dual Pump Manifold Assembly is shown on Page 10 16 ...

Page 116: ...10 10 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit 776XX882 04 Motor Pump and Manifold Assembly Continued ...

Page 117: ...84XX015 6 21 SCREW 784XX569 6 22 LEVEL SENSOR HIGH TEMPERATURE 098XX107 2 23 SLEEVING FIBERGLASS 755XX087 24 100 PLATE SEALING 782XX513 1 112 O RING 745XX005 1 114 SCREW 784XX411 4 200 GASKET TOP 776XX275 1 201 COVER TOP 776XX278 1 202 SCREW 784XX367 31 203 HINGE LID RIGHT 776XX260 1 204 HINGE LID LEFT 776XX259 1 205 LOCK WASHER 784XX375 4 206 SCREW 884XX353 2 207 FLAT WASHER 784XX183 2 208 WASHER...

Page 118: ...37XX028 1 417 FRAME OVERLAY 776XX266 1 418 HEX NUT 798XX299 6 419 NUT 793XX491 6 420 ALARM BEACON ASSY 105XX339 1 421 FAN KIT 087XX014 1 422 EXHAUST GRILL 087XX016 2 423 EXHAUST GRILL 087XX013 1 424 SWITCH HANDLE DISCONNECT RED 485XX122 1 425 ELECTRICAL PANEL ASSY 776XX281 1 426 TRANSFORMER 550XX153 1 427 SCREW 784XX362 4 428 NAMEPLATE SHURE GLUE SYSTEMS 781XX566 1 429 RIVET BLIND 091XX517 6 430 P...

Page 119: ...10 13 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit Single Pump Manifold Assembly 776XX299 776XX299 01 dwg ...

Page 120: ...10 14 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit Single Pump Manifold Assembly 776XX299 Continued 776XX299 02 dwg ...

Page 121: ... SCREW 798XX590 1 11 O RING 745XX360 1 12 O RING 745XX361 1 13 O RING 745XX328 1 14 FILTER SCREEN 778XX356 1 15 VALVE PRESSURE RELIEF 707XX222 1 16 VALVE PRESSURE RELIEF 707XX654 1 17 PRESS GAUGE 1000 PSI KG 786XX122 1 18 VALVE SHUT OFF 776XX248 1 19 O RING 745XX108 1 20 RING RETAINING INTERNAL 783XX346 1 21 HX PLUG 799XX146 7 22 HEX PLUG W O RING 799XX329 3 23 HOLLOW HX PLUG 799XX234 2 24 CABLE A...

Page 122: ...10 16 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit Dual Pump Manifold Assembly 776XX300 776XX300 01 dwg ...

Page 123: ...10 17 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit Dual Pump Manifold Assembly 776XX300 Continued 776XX300 02 dwg ...

Page 124: ... SCREW 798XX590 2 11 O RING 745XX360 2 12 O RING 745XX361 2 13 O RING 745XX328 2 14 FILTER SCREEN 778XX356 2 15 VALVE PRESSURE RELIEF 707XX222 2 16 VALVE PRESSURE RELIEF 707XX654 2 17 PRESS GAUGE 1000 PSI KG 786XX122 2 18 VALVE SHUT OFF 776XX248 2 19 O RING 745XX108 2 20 RING RETAINING INTERNAL 783XX346 2 21 HX PLUG 799XX146 8 22 HEX PLUG W O RING 799XX329 6 23 HOLLOW HX PLUG 799XX234 6 24 CABLE A...

Page 125: ...10 19 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit D 90 HMU Electrical Panel Assembly 776XX281 ...

Page 126: ...10 20 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit D 90 HMU Electrical Panel Assembly 776XX281 Continued ...

Page 127: ...X106 2 27 SCREW 884XX085 8 28 TERMINAL BLOCK 075XX275 47 29 TERM BLOCK 075XX298 6 30 NUT HEX 798XX679 4 31 OBSOLETE USE 798XX764 798XX755 4 32 DIN MOUNTING RAIL 091XX277 55 33 SCREW 784XX374 32 34 ELEC ELEMENTARY 999XD776 19 1 35 FUSE 085XX281 3 36 FUSE 085XX280 3 37 FUSE 085XX199 3 38 FUSE 085XX093 3 39 FUSE 085XX154 3 40 FUSE 085XX261 2 41 CIRCUIT BRAKER EARTH LEAKAGE 056XX123 1 42 FUSE HOLDER 0...

Page 128: ... PART QTY 60 SCREW 784XX604 1 61 LABEL GROUND SYMBOL 781XX110 1 62 COVER RELAY 160XX150 4 63 SHAFT EXTENSION 485XX123 1 64 CONTACTOR 160XX293 1 65 FUSE 085XX151 3 66 CABLE ASSY AUX1 OUT TO SSR 029XX624 1 67 CABLE ASSY AUX2 OUT TO SSR 029XX625 1 68 CABLE ASSY MCR 029XX626 1 Item 10 is an un programmed VFD A pre programmed VFD is available 110xx416 ...

Page 129: ...10 23 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit D90 Hot Melt Unit EQM0690 EQM0690 01 dwg ...

Page 130: ...10 24 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit D90 Hot Melt Unit EQM0690 Continued EQM0690 02 dwg ...

Page 131: ...10 25 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit D90 Hot Melt Unit EQM0690 Continued EQM0690 03 dwg ...

Page 132: ...10 26 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit D90 Hot Melt Unit EQM0690 Continued EQM0690 04 dwg ...

Page 133: ...PERATURE 098XX107 1 23 SLEEVING FIBERGLASS 4 BLACK 755XX087 24 24 AMPLIFIER LEVEL SENSOR PNP 098XX106 1 25 WIRE TERMINAL RING 10 075XX200 12 100 PLATE SEALING 782XX513 1 112 O RING 745XX005 1 114 HHCS M8 X 30 ZINC 784XX411 4 200 GASKET TOP 776XX275 1 201 COVER TOP 776XX278 1 202 BHCS M6 X 16 SS 784XX367 31 203 HINGE LID RIGHT 776XX260 1 204 HINGE LID LEFT 776XX259 1 205 LOCK WASHER M6 STL 784XX375...

Page 134: ...3 10 415 SLW M10 SS 784XX569 10 417 PLATE COVER EQM0700 1 419 NUT M6 793XX491 6 420 ALARM BEACON ASSY 105XX339 1 421 FAN KIT 4 IN 230VAC 087XX014 2 422 EXHAUST GRILL 087XX016 4 423 EXHAUST GRILL 4 IN 087XX013 2 424 SWITCH HANDLE DISCONNECT RED 485XX122 1 425 ELECTRICAL PANEL ASSY D90 EQM0694 1 426 TRANSFORMER 14KVA 3PH 220V 550XX153 1 427 HHCS M8 X 20 SS 784XX362 4 428 NAMEPLATE SHURE GLUE SYSTEMS...

Page 135: ...SI 786XX122 5 DOUBLE WIDTH PUMP VARISEAL 561XX218 6 PUMP ORINGS 745XX035 7 COUPLING ASSY 783XX322 8 3 8 HP 10 1 REDUCER EQM0691 9 NC HOSE RECEPTACLE ASSY 029XX719 10 CPU OVERLAY ASSEMBLY UTC 20 137XX028 11 12 ZONE POWER BOARD 151XX680 12 VFD 1 2 HP POWER FLEX EQM0699 13 4 ZONE BOARD 151XX684 14 MOTOR CONTROL BOARD 151XX701 15 PRESSURE SWITCH 160 400 PSI 485XX107 16 CABLE ASSY REMOTE DISPLAY KJC139...

Page 136: ...10 30 Section 10 Part Number List ValcoMelton MM125 D 90 Hot Melt Unit Electrical Panel Assembly EQM0694 dwg ...

Page 137: ...X701 2 24 CABLE ASSY AC POWER TO 4 ZONE 029XX710 1 25 CABLE ASSY UTC POWER COMM 029XX712 1 26 CABLE ASSY HEATER CONDUCTORS TAJ0534 2 27 CABLE ASSY RTD SIGNALS TAJ0535 2 28 TERMINAL BLOCK 075XX275 72 29 TERM BLOCK 50A GRAY 075XX298 7 30 NUT HEX 3 8 16 SS 798XX679 4 31 FLAT WASHER 3 8 SS 798XX764 4 32 DIN MOUNTING RAIL 091XX277 55 33 BHCS M5 X 10 SS 784XX374 33 35 FUSE 50A 600VAC 085XX281 3 36 FUSE ...

Page 138: ...123 1 64 CONTACTOR 3P 32A AC COIL 160XX293 1 65 FUSE 3 AMP 085XX151 3 66 CABLE ASSY AUX1 OUT TO SSR 029XX624 1 67 CABLE ASSY AUX2 OUT TO SSR 029XX625 1 68 CABLE ASSY MCR 029XX626 1 73 ELECTRICAL ELEMENTARY 3 PUMP TAJ0598 1 74 CABLE ASSY COMMUNICATION TAJ0606 1 75 CABLE ASSY UTC POWER COM TAJ0602 1 76 WIRE PTFE 10 AWG BLK 540XX132 150 77 WIRE PTFE 12 AWG BLK 540XX137 50 78 WIRE PTFE 22 AWG BLU C501...

Page 139: ...urer s warranty In no event shall Valco Cincinnati Inc be liable for indirect or consequential damages arising out of the use of Valco Cincinnati products This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to Valco Cincinnati Inc for examination and verification If claimed defect is verified repairs or replacements will be made F O B Cincinnati Ohio U S A...

Page 140: ...ervice call will be quoted at that time Any part that fails during the warranty period shall be returned prepaid to Valco Cincinnati Inc by the customer for disposition Upon request ValcoMelton personnel are available to repair or replace such parts at the customer s facility Charges for this service include travel time and expenses If an equipment problem is the result of customer abuse improper ...

Page 141: ...d Operator Level 2 Advanced Operator PIN Code 1234 PIN Code 1234 PIN Code 1234 PIN Code 1234 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 Level 3 Supervisor Level 3 Supervisor Level 3 Supervisor Level 3 Supervisor PIN Code 6550 PIN Code 6550 PIN Code 6550 PIN Code 65...

Page 142: ...A 2 ValcoMelton Appendix A Password Levels MM125 D 90 Hot Melt Unit Setting Level 0 as Default Continued ...

Page 143: ...o Table 1 below 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 hose 3 and gun 3 Compare this value to the maximum wattage given in Line 3 of Table 1 4 Add the power requirements o...

Page 144: ...ompare this value to the maximum wattage for all hoses and guns given in Line 7 of Table 1 8 If any of the power requirements calculated in steps 1 7 exceed any of the maximum allowable wattages given in Table 1 the hose length or gun configuration must be changed to reduce all power requirements to below maximum allowable wattages If each of the power requirements calculated in steps 1 7 is below...

Page 145: ...C 1 ValcoMelton APPENDIX C SCHEMATICS APPENDIX C SCHEMATICS APPENDIX C SCHEMATICS APPENDIX C SCHEMATICS APPENDIX C SCHEMATICS ...

Page 146: ...C 2 ValcoMelton Appendix C Schematics MM125 D 90 Hot Melt Unit 240V 3Ø 029XX435 ...

Page 147: ...C 3 ValcoMelton Appendix C Schematics MM125 D 90 Hot Melt Unit 240V 3Ø 029XX435 ...

Page 148: ...C 4 ValcoMelton Appendix C Schematics MM125 D 90 Hot Melt Unit ...

Page 149: ...C 5 ValcoMelton Appendix C Schematics MM125 D 90 Hot Melt Unit ...

Page 150: ...C 6 ValcoMelton Appendix C Schematics MM125 D 90 Hot Melt Unit ...

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