D-90 Hot Melt Unit€¦ · as an aid for installing, operating, and servicing the D-90 hot melt unit. It also contains a list of part numbers for replacement parts. If you need more

D-90 Hot Melt UnitD-90 Hot Melt UnitD-90 Hot Melt UnitD-90 Hot Melt UnitD-90 Hot Melt UnitManual Number: MM125Release Date: 1/2015

© Valco Cincinnati, Inc. All Rights Reserved

This manual is furnished with the D-90 Hot Melt Unit and may only be used in accordance with the terms ofpurchase.

No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or byany means, electronic, mechanical, recording, or otherwise, without the prior written permission of ValcoCincinnati Inc. The information in this manual is furnished for educational purposes only, is subject tochange without notice, and should not be construed as a commitment by Valco Cincinnati, Inc.

This manual written and designed at ValcoMelton, a division of Valco Cincinnati, Inc. 457 Circle FreewayDrive, Cincinnati, Ohio 45246.

Part Number: MM125

Printed in the USA

ValcoMeltonValcoMeltonValcoMeltonValcoMeltonValcoMelton457 Circle Freeway DriveCincinnati, Ohio 45246PHONE: (513) 874-5581FAX: (513) 874-8318

Declaration of ConformityDeclaration of ConformityDeclaration of ConformityDeclaration of ConformityDeclaration of Conformity(According to EN 45014)

This Declaration of Conformity has been generated electronically and is legally binding without signature

Manufacturer: Valco Melton A division of Valco Cincinnati, Incorporated 411 Circle Freeway Drive Cincinnati, OH 45246 USA

Authorized Representatives in Europe:

Valco Cincinnati, Ltd. Unit 7-8 Hortonwood 32 Telford TF1 7YN England

Melton S.L.UPol. Industrial Agustinos calle G, n. 34 31160 OrcoyeNavarra, Spain

declares that the product:

Product Name: D-90 Hot Melt Unit complies with the following Council Directives:

Safety of Machinery: 2006/42/EC

Low Voltage Equipment: 2006/95/EC

EMC: 2004/108/EC and conforms to the following standards:

Safety: EN60204-1:2006 EN13849-1

Risk: EN14121-1:2007

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 EN61000-4-8 EN61000-4-11

Place and Date: Cincinnati, Ohio USA CE Mark first fixed 2006

Signature: David H. Swedes, Director of Engineering & Manufacturing

T-1ValcoMelton

TABLE OF CONTENTSTABLE OF CONTENTSTABLE OF CONTENTSTABLE OF CONTENTSTABLE OF CONTENTS

Section 1 - Introduction.................................................. 1-1Description ................................................................................................ 1-1

Section 2 - Safety and Use ............................................. 2-1Read Thoroughly Before Handling Equipment ....................................... 2-1Symbols .................................................................................................... 2-1Owner Responsibilities ............................................................................ 2-3Limitations of Use ..................................................................................... 2-4Installation/Startup/Use Safety Information ........................................... 2-4Shut Down Safety Information ................................................................ 2-5Hot-Melt-Specific, General Safety Information ........................................ 2-6

What to Do if Contact with Hot Adhesive Occurs .......................................... 2-7What to Do if Inhalation of Adhesive Fumes Occurs .................................... 2-7What to Do if Adhesive-Related Fire or Explosion Occurs ........................... 2-8

Hose Safety Information .......................................................................... 2-9

Section 3 - Basic Features.............................................. 3-1Overview ................................................................................................... 3-1

Main Power Disconnect .................................................................................. 3-3Compression Latches ...................................................................................... 3-3Temperature Controller .................................................................................. 3-3Fan .................................................................................................................... 3-3Alarm Beacon .................................................................................................. 3-3Lid ..................................................................................................................... 3-3Reservoir .......................................................................................................... 3-3Casters .............................................................................................................. 3-3Grid ................................................................................................................... 3-3Collector ........................................................................................................... 3-3Frame ............................................................................................................... 3-3Manifold ........................................................................................................... 3-4Filter ................................................................................................................. 3-5Shut-Off Valve .................................................................................................. 3-5Hose Receptacle .............................................................................................. 3-5Level Sensor .................................................................................................... 3-5Side Panel ....................................................................................................... 3-5Pressure Relief Valves .................................................................................... 3-5Pump ................................................................................................................ 3-5Motor ................................................................................................................ 3-5Hose Support ................................................................................................... 3-5Dataplates ........................................................................................................ 3-6

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MM125 - D-90 Hot Melt Unit

Section 4 - Installation .................................................... 4-1Transport ................................................................................................... 4-1Choosing a Location ................................................................................ 4-1Installation Kit ........................................................................................... 4-2Routing Low-Voltage Leads ..................................................................... 4-2Connecting the Electrical Power .............................................................. 4-2Electrical Panel .......................................................................................... 4-5VFD Board - Electrical Cabinet/Terminal Locations ................................ 4-6Connecting the Hoses .............................................................................. 4-8Connecting the Hot Melt Hoses to the Applicators............................... 4-11Customer Connections .......................................................................... 4-13

Section 5 - Setup ............................................................. 5-1Control Panel ............................................................................................ 5-1Power On/Off and Standby Mode ............................................................ 5-3Display Adjustment ................................................................................... 5-4User Interface............................................................................................ 5-6

Navigation ........................................................................................................ 5-6Memory Storage .............................................................................................. 5-6Editing .............................................................................................................. 5-6Thumbwheel vs. Single Digit Edit .................................................................. 5-7

Entering Passwords ................................................................................. 5-8Set Language ............................................................................................ 5-9Set Temperature Units............................................................................ 5-11

Programming Temperatures ........................................................................ 5-12Temperature Screens .................................................................................... 5-12Grid Temperature .......................................................................................... 5-13Hose/Valve Temperature ............................................................................... 5-13

System/Pump Ready Temperature Offset ............................................. 5-15Ready Delay Time ................................................................................... 5-16Over Temperature Alarm ........................................................................ 5-18Under Temperature Alarm ...................................................................... 5-19Maximum Temperature........................................................................... 5-20Beacon/Alarm Setup ............................................................................... 5-21

Beacon 2 ........................................................................................................ 5-22Automatic Pump Mode ........................................................................... 5-23Level Sensor Setup ................................................................................ 5-24

Internal LevelExternal Level ......................................................................................... 5-24

Filter Change Timer ................................................................................ 5-24Clock and 7-Day Timer ........................................................................... 5-25

Set Day and Time .......................................................................................... 5-25Shift Times/Setback Times ........................................................................... 5-26Programming Shifts ...................................................................................... 5-26Moving Through the Shift Time/Day Screens ............................................. 5-28

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Diagnostics ............................................................................................. 5-30Setback.................................................................................................... 5-31

Setback Temperature .................................................................................... 5-31Automatic Setback Timeout ......................................................................... 5-32

Startup Setup .......................................................................................... 5-33Sequential Start – Hose ................................................................................ 5-33Sequential Start – Valve ............................................................................... 5-34

History ..................................................................................................... 5-35User Inputs and Outputs ........................................................................ 5-36Configuration .......................................................................................... 5-37

Number of Hose Outlets ................................................................................ 5-37Auxiliary I/O ................................................................................................... 5-37Number of Pumps .......................................................................................... 5-38Gramage Enable ........................................................................................... 5-38RTD Type Selection ....................................................................................... 5-38

Pump Setup Menu .................................................................................. 5-39Encoder Setup Menu .............................................................................. 5-41PID Setup Menu ...................................................................................... 5-41

PID Settings.................................................................................................... 5-41AutoTune Feature .......................................................................................... 5-42

Initialize Screen ....................................................................................... 5-43Restoring Factory Default Settings ....................................................... 5-43Adjusting the Pressure Control Valve ................................................... 5-44

Adjusting the Single-Stage Relief Valve ..................................................... 5-44Gramage Feature .................................................................................... 5-45

Section 6 - Operation ...................................................... 6-1Unit Startup ............................................................................................... 6-1Filling the Tank .......................................................................................... 6-3Dispensing Adhesive ................................................................................ 6-4

Section 7 - Maintenance ................................................. 7-1General ...................................................................................................... 7-1Cleaning the Exterior of the Unit ............................................................. 7-1Filter Replacement .................................................................................... 7-2Replacing the Tank Inlet Filter .................................................................. 7-3Replacing the Manifold Filter .................................................................... 7-4Changing the Adhesive ............................................................................ 7-5Flushing the System ................................................................................. 7-5Parts Replacement.................................................................................... 7-6

Changing Fuses ............................................................................................... 7-7

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Section 8 - Troubleshooting and Repair ...................... 8-1Troubleshooting ....................................................................................... 8-1Repair ........................................................................................................ 8-4

Replacing the Pump........................................................................................ 8-4Replacing the Motor ........................................................................................ 8-6Replacing the Pressure Relief Valve ............................................................. 8-7Replacing the Beacon Light Bulb .................................................................. 8-8

Section 9 - Specifications .............................................. 9-1General ...................................................................................................... 9-1Dimensions - D-90 .................................................................................... 9-2

Section 10 - Part Number List ...................................... 10-1How to Order Parts ................................................................................. 10-1D-90 Hot Melt Unit (776XX883) .............................................................. 10-2

Overall Assembly ........................................................................................... 10-2Reservoir, Collector, Grid, Frame Assembly ................................................ 10-4Sheet Metal Assembly ................................................................................... 10-6Motor, Pump and Manifold Assembly .......................................................... 10-9

D-90 Hot Melt Unit (776XX883) - Parts List ......................................... 10-11Single Pump Manifold Assembly (776XX299) ..................................... 10-13Dual Pump Manifold Assembly (776XX300) ....................................... 10-16D-90 HMU Electrical Panel Assembly (776XX281) ............................. 10-19D90 Hot Melt Unit (EQM0690) .............................................................. 10-23

Recommended Spare Parts for EQM0690.................................................. 10-29Electrical Panel Assembly .................................................................... 10-30

Section 11 - Warranty .....................................................11-1Warranty Information ............................................................................. 11-1

Cold Glue Equipment and Electronic Controls............................................ 11-1Hot Melt Units, Hoses, Valves, Guns, and Related Equipment ................... 11-1

Section 12 - Service ...................................................... 12-1

Appendix A - Password Levels ......................................A-1

Appendix B - Power Requirements ...............................B-1System Power Requirement Calculation - D-90 Units............................ B-1

1-1ValcoMelton.

SECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTION

Description

ValcoMelton, a division of Valco Cincinnati, Inc., has prepared this manualas an aid for installing, operating, and servicing the D-90 hot melt unit. It alsocontains a list of part numbers for replacement parts. If you need moreinformation, contact your ValcoMelton representative.

The D-90 hot melt unit is a high-volume system designed to melt and pumpthermoplastic adhesives. The unit features a precision electronictemperature control, a digital multi-zone temperature display, a variable-speed electric motor-driven gear pump, and an adjustable pressurecontrol.

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

• Integrated over-temperature protection

• User selectable inputs and outputs

• Variable frequency drive (VFD)

• Accepts encoder or tachometer inputs for Variable Speed Units

Other options are available. See the “Parts List” section, for additionalinformation.

See the “Schematics” section for wiring and pneumatic schematics.

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SECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USE

ReadThoroughlyBeforeHandlingEquipment

WARNING!WARNING!WARNING!WARNING!WARNING! Read and follow all safety precautions, warnings,cautions, and other recommendations in this manual.OTHERWISE, DEATH, PERSONAL INJURY OREQUIPMENT DAMAGE COULD OCCUR.

Read this entire section before handling the equipment.

SymbolsThe following symbols may be used on the equipment and/or in this manual.

This symbol represents a CautionCautionCautionCautionCaution or a WarningWarningWarningWarningWarning. Cautions drawspecial attention to anything that could damage equipment orcause the loss of data. Warnings draw special attention toanything that could injure or kill the reader. Both Cautions andWarnings are placed before the step they apply to.

This symbol represents a Hot SurfaceHot SurfaceHot SurfaceHot SurfaceHot Surface.

This symbol represents a Puncture Risk.Puncture Risk.Puncture Risk.Puncture Risk.Puncture Risk. It is usually used inregard to nozzle cleaning appliances and other sharpinstruments that can cause puncture wounds and risk exposureto bloodborne pathogens and other debris.

This symbol means that Working Gloves Working Gloves Working Gloves Working Gloves Working Gloves are required.

This symbol means that Goggles Goggles Goggles Goggles Goggles are required.

This symbol indicates a Shock HazardShock HazardShock HazardShock HazardShock Hazard. There is a presence ofnon-insulated dangerous voltage within the product’s enclosure.This voltage may cause electrical shock or fire.

Continued next page

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Section 2 - Safety Information MM125 - D-90 Hot Melt Unit

Symbols - Continued

This symbol indicates a NoteNoteNoteNoteNote. Notes point out something ofspecial interest or importance to the reader. They give tips,hints, and information in addition to what is necessary for thestep preceding it.

This symbol indicates the need to Unplug/Disconnect All PowerUnplug/Disconnect All PowerUnplug/Disconnect All PowerUnplug/Disconnect All PowerUnplug/Disconnect All PowerSourcesSourcesSourcesSourcesSources and to let them de-energize before attempting any typeof work or maintenance. Remember that there can still be energyin equipment, cords, and wires even when unplugged/disconnected.

This symbol indicates the need to Lock Out All Power SourcesLock Out All Power SourcesLock Out All Power SourcesLock Out All Power SourcesLock Out All Power Sourcesand to let them de-energize before attempting any type of workor maintenance. If power is not locked out, the person workingon the equipment may be injured or killed if someoneunknowingly switches on the power to the equipment.

2-3ValcoMelton

Section 2 - Safety InformationMM125 - D-90 Hot Melt Unit

OwnerResponsibilities

The owner of the equipment is under obligation to manage all safetyinformation. Some examples include:

• Examine all safety materials and documents as well asjurisdictional laws and make certain all laws, recommendations,and other safety/hazard laws, certification requirements, training,and instructions are followed and kept current.

• Maintain all safety materials including tags, labels, documents,and MSDS information. Make certain they are distinct and can beread/understood. Replace any that are dirty, worn, or unreadable.

• Make sure all personnel who will handle, install, maintain,operate, fix, and work around the equipment have ready accessto the safety information, training, and equipment according tojurisdictional authorities.

The owner of the equipment is under obligation to make certain that allinstructions, requirements, and jurisdictional laws are met. Some examplesinclude:

• Make sure there are regular inspections of equipment and safetydevices.

• Have regular safety drills and inspections supervised by theproper authorities.

• Provide all required safety items, first aid equipment, andtraining.

The owner of the equipment is under obligation to make certain that allpersonnel who will handle, install, maintain, operate, fix, and work around theequipment are qualified, trained, and up-to-date with all information regardingthe equipment. Some examples include:

• Make sure all personnel have the proper safety training,equipment, education, and abilities necessary for the job functionaccording to safety instructions and all jurisdictional laws andregulations.

• It is strongly advised that personnel receive first-respondermedical care training in case of burns, medical emergencies, orother injuries. Training should be kept up to date.

• Make sure all personnel understand and can follow safetypolicies and procedures for the organization as well as for thespecific equipment.

• Make sure that all personnel are consistently trained, evaluated,free of alcohol and medications that may impair judgment andreflexes, and are tested for banned substances according tojurisdictional authorities.

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Limitations ofUse

Read this document and all information regarding the equipment beforehandling the equipment. The intended use of the equipment is stated inSection 1 of this manual.

Do not use this equipment for anything other than its intended use. Do notmodify, change, or alter the equipment in any way. If you are unsure of theintended use and the limitations of use for the equipment, contact your ValcoMelton Representative before handling the equipment.

Installation/Startup/UseSafetyInformation

WARNING!WARNING!WARNING!WARNING!WARNING! Only qualified personnel should install the equipment.Valco Melton strongly recommends that a Valco MeltonTechnician install all equipment. OTHERWISE, DEATH,PERSONAL INJURY, OR DAMAGE TO EQUIPMENTCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! The equipment should be installed so that it can be turnedoff at a location away away away away away from the equipment in case ofinjury, electrical problems, or malfunction. OTHERWISE,DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Properly route all electrical wires. Never tamper withequipment. Only use approved and correct voltage, typeof current, fuses, and other power supplies. Replace worncords, hoses, etc. immediately. FAILURE TO OBSERVEWARNING MAY RESULT IN DEATH, PERSONALINJURY, AND/OR EQUIPMENT DAMAGE.

WARNING!WARNING!WARNING!WARNING!WARNING! Poor ventilation, smoking, and open flames can causeoverheated hot melt to ignite. Adequate ventilation mustbe provided. Smoking should be prohibited in theimmediate vicinity of the molten adhesive. Open flamesmust be kept away from the area around molten adhesive.OTHERWISE, DEATH, PERSONAL INJURY, ORDAMAGE TO EQUIPMENT COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Never use any Valco Melton equipment in an explosiveenvironment. Explosive environments include, but are notlimited to, solvent-based cleaners or adhesives, explosivematerials, radioactive materials, etc. OTHERWISE,DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Equipment will start automatically when remotelycontrolled by triggering devices. Be sure to disable alltriggering devices, carefully release hydraulic pressure,and disconnect air pressure before servicing or workingnear guns, valves, and other triggered devices.OTHERWISE, DEATH OR PERSONAL INJURY COULDOCCUR.

Valco Melton hot melt units, cold glue units, controllers, inspection systemsand all related accessories have the following universal safety precautions(this is not intended to be an exhaustive list; follow all instructions and safetyprecautions for the specific type of equipment involved):

2-5ValcoMelton


Shut DownSafetyInformation

Valco Melton hot melt units, cold glue units, controllers, inspection systemsand all related accessories have the following universal safety precautions(this is not intended to be an exhaustive list; follow all instructions and safetyprecautions for the specific type of equipment involved):

WARNING!WARNING!WARNING!WARNING!WARNING! Purge the fluid pressure and the air pressure from thesystem before disconnecting/disabling any part of thesystem. OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Disconnect and lock out all power before maintenanceor other need to open the equipment. Only qualifiedpersonnel should open and service the control.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Equipment may still be energized even if unplugged!When making adjustments or performing checkoutprocedures, stay clear of any moving mechanical partsand do not touch exposed electrical equipment orelectrical connectors. OTHERWISE, DEATH ORPERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Disconnect/disable all mechanical and/or electricaldevices that send activation signals to the gun(s),valve(s), melter pump(s), etc. This includes patterncontrols, timers, input/output signals, etc. Only qualifiedpersonnel should open and service the control.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Disable all triggering devices, relieve all residualpressure (hydraulic and air) and allow adhesive to coolbefore attempting to disconnect guns, hoses, valves,etc. Only qualified personnel should open and servicethe control. OTHERWISE, DEATH OR PERSONALINJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Never point an adhesive dispensing gun, valve, hose, airhose, or anything else at yourself or another person.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

2-6 ValcoMelton


Hot-Melt-Specific,General SafetyInformation

WARNING!WARNING!WARNING!WARNING!WARNING! Never Never Never Never Never process any polyurethane reactive (PUR) hotmelt or solvent-based material in a Valco Melton unitunless you are certain that the unit is compatible and ismarked “PUR”! Read all instructions and MSDS sheetscarefully, following manufacturer’s instructions,especially regarding heat levels. If you have anyquestion as to the compatibility of a Valco Melton unit forPUR hot melt, call your Valco Melton Representativebefore attempting to use the unit for PUR or solvent-based materials. OTHERWISE, HAZARDOUS FUMES,EXPLOSION, DEATH, OR PERSONAL INJURYCOULD OCCUR.

Valco Melton hot melt units have the following universal safety precautions in in in in inaddition to all other universal precautions previously mentioned addition to all other universal precautions previously mentioned addition to all other universal precautions previously mentioned addition to all other universal precautions previously mentioned addition to all other universal precautions previously mentioned (this is notintended to be an exhaustive list; follow all instructions and safetyprecautions for the specific type of equipment involved):

WARNING!WARNING!WARNING!WARNING!WARNING! Keep pump cover and electrical enclosures closedexcept during setup, service, and checkout procedures.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! People with respiratory problems (e.g., asthma,bronchitis, etc.) should not work in the vicinity of moltenadhesive. RESPIRATORY PROBLEMS MAY BEAGGRAVATED BY THE FUMES. Do not wear a facemask when working around molten adhesive. THEMASK MAY TRAP THE FUMES AND DEATH ORPERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Keep hot melt hoses away from walkways and themoving parts of hot melt systems. OTHERWISE,PERSONAL INJURY OR EQUIPMENT DAMAGECOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Hot surfaces! Do not touch! Use extreme caution whenrefilling the unit by hand. OTHERWISE, PERSONALINJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Wear protective gloves and goggles at all times aroundall machinery, especially hot melt. OTHERWISE,SERIOUS PERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Never use an open flame to heat hot melt componentsor adhesive. OTHERWISE, DEATH, PERSONALINJURY, OR DAMAGE TO EQUIPMENT COULDOCCUR.

2-7ValcoMelton


If hot adhesive comes in contact with the skin, , , , , do the following:

WARNING!WARNING!WARNING!WARNING!WARNING! Do not attempt to remove heated hot melt adhesive fromthe skin. OTHERWISE, SEVERE PERSONAL INJURYAND DEATH COULD OCCUR.

1. Immediately immerse the contacted area in clean, cold water.

It is strongly recommended that asource of clean, cold water be providednear the hot melt work area.

2. Cover the affected area with a clean, wet compress and call theemergency medical response system (such as 911) immediately.

3. Watch for and treat the subject for signs of shock while waitingfor professional help to arrive.

What to Do if Contactwith Hot Adhesive

Occurs

If adhesive fumes are inhaled, immediately follow these steps:

1. Take the victim away from the immediate work area.

2. Provide victim with fresh air.

3. Call the emergency medical response system (such as 911)immediately.

What to Do ifInhalation of

Adhesive FumesOccurs

2-8 ValcoMelton


During the heating and melting process, the surface of the adhesive will beexposed to air. The mixture of polymer fumes and air can catch fire if the hotmelt is overheated.

WARNING!WARNING!WARNING!WARNING!WARNING! Poor ventilation, smoking, and open flames can causeoverheated hot melt to ignite. Adequate ventilation mustbe provided. Smoking should be prohibited in theimmediate vicinity of the molten adhesive. Open flamesmust be kept away from the area around moltenadhesive. OTHERWISE, DEATH, PERSONAL INJURY,OR DAMAGE TO EQUIPMENT COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Exposed arcing may ignite the fume/air mixture. Shieldall electrical equipment from melt fumes to avoidexposed arcing. OTHERWISE, PERSONAL INJURY OREQUIPMENT DAMAGE COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Do not use a water extinguisher to extinguish the fire!OTHERWISE, PERSONAL INJURY OR EQUIPMENTDAMAGE COULD OCCUR.

If the hot melt adhesive ignites, promptly perform the following steps:

1. Sound a fire alarm.

2. Evacuate the immediate area.

3. Turn off all local electrical equipment at the source.

4. Leave the area immediately if conditions are unsafe.

IfIfIfIfIf you feel you can fight the fire safelysafelysafelysafelysafely, do oneoneoneoneone of the following:

- Smother the fire with a fire blanket.

- Aim a CO2 fire extinguisher at the base of the flames.

- Aim a dry-powder fire extinguisher at the base of theflames.

What to Do ifAdhesive-RelatedFire or Explosion

Occurs

2-9ValcoMelton


Do notDo notDo notDo notDo not use bindings, wire ties, or unapprovedfasteners around the hoses.

DoDoDoDoDo use approved wrapping (P/N 775xx827),making sure the wrapping is slightly snug butnot tight.

Do notDo notDo notDo notDo not place hoses close together.

DoDoDoDoDo allow at least 2 inches (5.1 cm)between hoses for proper ventilation.

Do notDo notDo notDo notDo not bend hoses sharply. Do notDo notDo notDo notDo not allowkinks or indentations in the hoses.

DoDoDoDoDo use a minimum bend radius of 10inches for a 20-inch diameter coil hose.

Do notDo notDo notDo notDo not use unapproved hooks to hang hoses.Do notDo notDo notDo notDo not wrap hoses over or around objects.

DoDoDoDoDo use a hose hanging kit (P/N 781xx827).

Do notDo notDo notDo notDo not use the “one handed/one wrench”technique to attach or remove hoses. DoDoDoDoDonotnotnotnotnot wrench on any surface other than thelarge hexagon swivel nuts.

DoDoDoDoDo use two hands and two wrenches totighten or loosen connections on hoses.DoDoDoDoDo wrench only on large hexagon swivelnuts.

Hose SafetyInformation

2-10 ValcoMelton


Do notDo notDo notDo notDo not allow hoses to rub againstobjects or to come into contact withsharp edges or points.

DoDoDoDoDo wrap the hoses in approved padding(P/N 795xx549) if the hoses must beinstalled where they will come intocontact with objects.

Do notDo notDo notDo notDo not use worn, damaged, or benthoses.

Do Do Do Do Do inspect all hoses regularly fordamage and/or wear and replacedamaged or worn hoses immediately.

Hose Safety Information -Continued

3-1ValcoMelton.

SECTION 3 - BASIC FEATURESSECTION 3 - BASIC FEATURESSECTION 3 - BASIC FEATURESSECTION 3 - BASIC FEATURESSECTION 3 - BASIC FEATURES

Figure 3-1. Basic Features

Overview

3-2 ValcoMelton

Section 3 - Basic Features MM125 - D-90 Hot Melt Unit

Figure 3-2. Basic Features

Overview - Continued

3-3ValcoMelton

Section 3 - Basic FeaturesMM125 - D-90 Hot Melt Unit

Main PowerDisconnect

Controls the system main power.

WARNING!WARNING!WARNING!WARNING!WARNING! If the main power is switched “off,” anything from themain disconnect to the incoming power is still energized.

Compression LatchesThe compression latches hold the electrical cabinet and side panels closed.They can be opened for installation, maintenance or repair. Only qualifiedpersonnel should be authorized to access the enclosure.

TemperatureController

The temperature controller is used to monitor and adjust the system’sdifferent heating zones. It is also used to control the pump and motor.

FanThe Cooling Fan and Exhaust Grill provide air circulation and cooling to theelectrical enclosure. It must be serviced regularly. Refer to Section 7 -Maintenance.

Alarm BeaconThe alarm beacon alerts the customer unit status, dependent on differentconditions. The standard beacon is factory set with two lights (red and blue),indicating low adhesive level (red), and system ready (blue).

LidThe spring-loaded, floating lid allows tank access. It also exerts pressureagainst the top of the unit, effectively reducing adhesive fumes.

ReservoirThe unit reservoir stores adhesive prior to dispensing. Optional low-and-high-level sensors, and an optional filter block for the reservoir fill hose, areavailable.

CastersCasters allow easier unit movement. Optional feet with limited movement arealso available.

GridCast-in heaters provide on-demand heat to melt adhesive while minimizingchar.

CollectorThe collector traps adhesive melted by the grid and feeds the manifold. Thecollector also has cast-in heaters for added melting capabilities.

FrameThe welded-steel frame supports the entire unit.

3-4 ValcoMelton


Manifold

Figure 3-3. Manifold

3-5ValcoMelton

Section 3 - Basic FeaturesMM125 - D-90 Hot Melt Unit

FilterThe filter reduces the chance of pressurized adhesive becomingcontaminated. Clean or replace the filter periodically (see Maintenancesection).

Shut-Off ValveThis valve shuts off adhesive to the manifold for maintenance/partsreplacement. Turn the valve 1/4 turn CW to close; CCW to open (see Figure 3-3).

Hose ReceptacleThe hose receptacle receives the hose electrical connections.

Receptacles shown are Harting latching connectors, but Nordson-compatiblereceptacles are also available.

Level SensorThe optional level sensors available are high-temperature Rechnercapacitive sensors. These level sensors accurately detect adhesive level,and send a signal to the drum unloader (if applicable) in order to fill the unitautomatically.

Side PanelThe side panel allows access to the grid, collector and manifold heaters,RTDs and thermostats. It also allows access to the level sensors (ifapplicable), gear pump and motor.

There are two pressure relief valves on the manifold. The first valve is anadjustable pressure relief valve that can be manually adjusted to set theadhesive operating pressure. The factory setting is 750 psi. The secondvalve is a fixed pressure relief valve that limits the maximum adhesiveoperating pressure. The factory setting is 1000 psi. Some units may have thevalves switched.

The physical location of these pressurerelief valves may be reversed in someunits.

WARNING!WARNING!WARNING!WARNING!WARNING! Do not adjust the fixed pressure relief valve. Thisprotects the system from excessive pressure buildup.OTHERWISE, SERIOUS PERSONAL INJURY OREQUIPMENT DAMAGE COULD OCCUR.

Pressure ReliefValves

PumpTransfers the molten material from the drum to hoses or guns as required bythe application.

MotorAC gear motor that is controlled by a variable frequency drive.

Hose SupportThe hose support is used to prevent the fill hose from the drum unloader frombending excessively. See Section 2 – Safety and Use for more detailsconcerning hose safety.

3-6 ValcoMelton


The dataplates provide more information regarding the system configuration.

Included information:

• Part number• Serial number• Operating voltage• Maximum current• Number of phases• Frequency

Dataplates

4-1ValcoMelton.

SECTION 4 - INSTALLATIONSECTION 4 - INSTALLATIONSECTION 4 - INSTALLATIONSECTION 4 - INSTALLATIONSECTION 4 - INSTALLATION

The D-90 hot melt unit is assembled at the factory. However, the power andthe glue hoses must be connected by the customer. This section containsinstructions for making the necessary connections.

While choosing a location for the unit, keep in mind that:

• Service personnel will need access to the front and sides of theunit for electrical service. See Section 9 - Specifications, for theworking profile.

• The operator needs easy access to the front of the unit.

• If using casters, make sure the locks in the casters are engaged.

• The unit should have clearance around the outside of the case toallow air to circulate freely around it.

• The location should be near the glue station so that the gluehoses can be routed to the applicators in as straight a line aspossible.

• The location for the unit should be clean. Contaminants in theadhesive causes clogging of the applicator nozzles.

• The unit should be protected from high and low ambienttemperatures (<-10oC and >50oC), as well as from rapid changesin 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 needprotection, as if the temperature falls rapidly, they may notoperate properly.

Choosing aLocation

TransportThe equipment is supplied on a pallet.

Approximate dimensions:Approximate dimensions:Approximate dimensions:Approximate dimensions:Approximate dimensions: 53”H x 30”W x 41”DApproximate weight:Approximate weight:Approximate weight:Approximate weight:Approximate weight: 1050 lbs. (maximum weight for the D-90 with all of theoptions installed, coupled with the weight of the crate)

Remove the top and front covers to unpack.

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Unpack carefully to prevent damage to the machine.Inspect the equipment for damage caused duringtransport.The unit may be shipped with the cable trackdisconnected. The track must be reconnected prior tooperation.

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Section 4 - Installation MM125 - D-90 Hot Melt Unit

WARNING!WARNING!WARNING!WARNING!WARNING! Electrical connections should be made only byexperienced service personnel! Failure to observecould result in personal injury, death, or damage toequipment.

When connecting the supply of electrical power, follow these guidelines:

• Connect the unit to a “clean” supply of electrical power. Use adedicated circuit if possible.

WARNING!WARNING!WARNING!WARNING!WARNING! Failure to observe could result in personal injury, death,or damage to equipment.

When routing low-voltage leads, follow these guidelines:

• Do not route low-voltage leads in the same conduit as wirescarrying a high-current load.

• Do not route low-voltage leads adjacent to, or across wirescarrying a high-current load. If low-voltage leads must cross orrun parallel to wires carrying high current, keep the leads at least6" (152 mm) from high-current wires.

• Do not splice or solder leads.

• Trim leads to the required length. Leads should be only as longas necessary for installation.

• All wiring should be in conduits or wireways.

Routing Low-Voltage Leads

Connectingthe ElectricalPower

Installation KitAn Installation Kit is available for this unit, containing spare fuses, a copy of thismanual on CD and warranty information. For details, see Section 10 - Parts List.

WARNING!WARNING!WARNING!WARNING!WARNING! Only experienced service personnel should connectpower to the unit! Failure to observe could result inpersonal injury, death, or damage to equipment.

The use of an earth-leakage or ground-fault powerbreaker is recommended with this unit. This unit must beearthed or grounded. Failure to observe could result inpersonal injury, death, or damage to equipment.

WARNING!WARNING!WARNING!WARNING!WARNING! The external power source must be turned off beforeconnecting power to the unit! Failure to observe couldresult in personal injury, death, or damage to equipment.

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Section 4 - InstallationMM125 - D-90 Hot Melt Unit

Connecting the Electrical Power -Continued

The D-90 hot melt unit can be set up to use 380, 400, 440, 480, 575 and 595VAC.All types are three phase and 50/60 Hz. Refer to sheet 1 of the ElectricalSchematic for the transformer wiring diagram.

The system should be connected via a suitable type of flexible conduit from asupply isolator and ground-fault power breaker. The supply should be cleanand free from excess interference from other machines.

WARNING!WARNING!WARNING!WARNING!WARNING! You MUST follow these steps to connect power to theunit, or personal injury and/or damage to the unit mayresult.

1. Open the electrical cabinet.

2. Route the power through either side of the cabinet. Knockouts (for3/4” and 1” conduit) have been provided to facilitate power cablerouting and customer connections into the unit. The power cablemust meet the minimum voltage and current requirements. Referto Figure 4-2.

Figure 4-2. Power Cable Routing

PowerEntry 2

Power Entry 1 3/4” ConduitKnockout

1” ConduitKnockout

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3. Connect the power cable leads to the main disconnect switch asshown 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 blockscrews are secure.

5. Close the electrical cabinet.

Connecting the Electrical Power -Continued

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Electrical Panel

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VFD Board - Electrical Cabinet/Terminal Locations

Figure 4-4. Electrical Cabinet

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VFD Board - ElectricalCabinet/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

0-10 VDC

GND

V+

A

/ AB

/ B

GND

“ 2 ”“ 2 ”“ 2 ”“ 2 ”“ 2 ”

Analog LineSpeed Input

Encoder LineSpeed Input

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WARNING!WARNING!WARNING!WARNING!WARNING! Never disconnect the hot melt hoses from a running unit.Hot melt is under high pressure. Turn off the pump, shutoff power to the unit, and actuate the gun to relieveresidual pressure before removing the hose. Failure toobserve could result in personal injury, death, ordamage to equipment.

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Do not operate the unit with the fluid outlet ports open tothe air. Failure to observe could result in personal injury,death, or damage to equipment.

When routing and installing heated hoses, follow these guidelines:

• Avoid creating sharp corners and edges.

• Do not bend hoses sharper than 18" (460 mm) radius.

• Do not group heated hoses so that they contact one another.

• Avoid positioning hoses where they can be stepped on or have achance of being crushed or cut.

• Avoid the use of unnecessarily long hoses where the hose islooped or curled on the floor. Excess twisting of the hose cancause 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 wrenches, one on the fluid outlet fitting and theother on the fluid cap, remove the protective caps from the fluidoutlet fittings.

2. Ensure that the fluid outlet fitting is tight into the machine.

3. Ensure that the fluid outlet ports are clean.

4. Select the end of the glue hose that has the lead assembly withthe male electrical connector (Figure 6).

Connectingthe Hoses

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Connecting the Hoses - Continued

Figure 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 themanifold (Figure 4-7).

Gun connection

End of glue hose that connectsto fluid fitting on applicator

End of glue hose that connects to fluidfitting on unit

Unit connection

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Connecting the Hoses -Continued

6. Using two wrenches, one on the fluid outlet fitting and the otheron the hose swivel nut, connect hose ‘one’ to fluid outlet port‘one’ of the machine.

The Hose #1 fluid outlet port shouldbe used first to prevent trapped hotmelt adhesive from charring in thelower portion of the manifold.

Fittings are available from ValcoMelton (see Section 10—Part-Number List). This unit comes witha #12 straight fitting, unlessspecified otherwise in the S-number.

The use of two wrenches preventsthe hose from twisting inside whileit is being tightened.

7. Connect the lead assembly’s male electrical connector to theelectrical receptacle located on the back panel above thefluid outlet ports.

Fuses for the receptacles arelocated in the installation kitprovided with the unit.

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WARNING!WARNING!WARNING!WARNING!WARNING! If hand-held applicators are used, care should betaken to ensure safe operation. Heat protectivegloves should be worn. Hot melt is under highpressure at the nozzle tip of the applicator. Failure toobserve could result in personal injury (burns).

WARNING!WARNING!WARNING!WARNING!WARNING! If hand-held applicators are used, operators shouldnot work facing each other. Failure to observe couldresult in personal injury (burns).

If fixed applicators are used, they should beprotected from accidental contact by the operator.Failure to observe could result in personal injury(burns).

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Hand-held applicators require a suitable hook forhanging while not in use. The hook must support theweight of the applicator with the hose. Failure toobserve 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 parentmachine.

Do not place applicators where theambient temperature is low orwhere there is a draft.

2. Connect the end of the hot melt hose (Figure 4-8) to the fluidinlet fitting on the applicator (Figure 4-9).

3. Connect the hot melt hose lead assembly’s female connectorto the lead assembly on the applicator.

Connectingthe Hot MeltHoses to theApplicators

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Connecting the Hot MeltHoses to the Applicators -Continued

End of glue hose that connects tofluid fitting on applicator

Lead assembly with femaleconnector (connects to lead

assembly on applicator)

Figure 4-8. Hot Melt Hose

Fluid inlet fitting

Figure 4-9. Applicator

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CustomerConnections

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5-1Valco Cincinnati, Inc.

SECTION 5 – SETUPSECTION 5 – SETUPSECTION 5 – SETUPSECTION 5 – SETUPSECTION 5 – SETUP

Control Panel

23

5-2 Valco Cincinnati, Inc.

Section 5 – Setup MM125 - D-90 Hot Melt Unit

Control Panel, Continued

ITEM NAME DESCRIPTION 1 System/Ready LED Illuminates green when the unit reaches ready temperature 2 Warning LED Illuminates red when the unit enters an alarm condition

3 Setback ON/OFF Key Put unit into and out of setback mode. This reduces the temperature to keep the adhesive soft but not molten during downtime. Yellow LED indicates that the setback mode is initialized.

4 Display Screen Displays the menu and event screens

5 Clock ON/OFF Key Turns the clock function on and off. Green LED indicates the clock is active.

6 Pump ON/OFF Key Turns the pump on and off. Green LED indicates the pump is active.

7 Standby ON/OFF Key Puts the unit in and out of standby. Green LED indicates the unit is on and an orange LED indicates the unit is in standby.

8 Plus Key Increases the valve of the selected field 9 Right Arrow Key Move right thru the fields on the screen

10 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 heating and red when the zone is in alarm.

17 Gun LED Illuminates green when the gun zone is heating and red when the zone is in alarm.

18 Tank LED Illuminates green when the collector zone is heating and red when the zone is in alarm.

19 Grid LED Illuminates green when the grid zone is heating and red when the zone is in alarm.

20 Pump Manifold LED Illuminates green when the manifold zone is heating and red when the zone is in alarm.

21 Internal Low Level LED Always on unless low level occurs on the internal level control input 22 External Low Level LED Always on unless low level occurs on the external level control input

23 Tank Inlet Filter Illuminates green when the tank inlet filter block (optional) zone is heating, and red when the zone is in alarm.


Section 5 – SetupMM125 - D-90 Hot Melt Unit

Power On/Offand StandbyMode

The Power Disconnect Switch is located on the front of the electrical cabinet(see picture below). The Power Disconnect Switch controls the power to thesystem.

The Standby Button controls the power to the Heater circuits. Press theStandby Button once. The display screen will come on and the Standby LEDwill illuminate green, indicating that the unit is on. When the Standby Button ispressed again, the temperature screen will go blank, the Standby LED willilluminate orange and the status bar will be active, indicating the unit is inStandby Mode.

When the unit is in Standby Mode, theinternal clock is still working. The clockwill turn the unit off and on in the TimerMode, as usual. If the Power Switch isturned off, however, the internal clockwill NOT automatically turn the unit onand off; the internal clock has no powerwhen the system is off.

Power Disconnect Switch



DisplayAdjustment

The display contrast is adjusted for optimal viewing at the factory. If thedisplay is not visible when the Temperature Controller powers up, thecontrast may need to be adjusted.

Follow the procedure below to adjust the contrast:

1. While holding down the ‘SETUP’ key on the front panel keyboard,simultaneously press the “+” and “-” keys to change the contraston the display. This will make the characters on the displaybrighter and dimmer, and is considered the fine adjustment.

2. If this does not work, or is not enough to see the display, openthe electrical enclosure door to view the rear of the CPU board.

3. Adjust the Display Contrast Adjustment Pot on the rear of theCPU board using a small screwdriver. (this requires a very smallslotted screwdriver)

4. This is the course adjustment and small incremental turns of thispot will make drastic changes in the brightness of the display.

Contrast Adjustment – Coarse Adjustment

Contrast AdjustmentPot, Coarse Tune



Display Adjustment - Continued5. Adjust the screen position by holding down the “Setup” key on the front panelkeyboard, while simultaneously pressing the left or right arrow key, to move thescreen left or right, as needed.



User Interface

NavigationNavigation symbols on the bottom of the display screen indicate thatadditional menus are available. Use the indicated button(s) to navigate asfollows:

Memory StorageThe symbol consisting of two arrows in a circular pattern indicates that avalue has been changed but the change is not yet stored in the flash memory.

Highlighted information is editable. Use the appropriate buttons (dependingon the navigation symbols shown) to navigate through the editable(highlighted) information

Editing



When editable information is numerical, the information may be edited withthe Plus/Minus Buttons for single digit editing, or the OK Button may bepressed to bring up a thumbwheel for more detailed editing.

Thumbwheel vs.Single Digit Edit

In Thumbwheel Edit, use the Right/LeftArrow Buttons to select the digitposition, and the Plus/Minus ArrowButtons to increase/decrease the valueof the selected digit.

Some thumbwheel screens contain aswitch that can be used to turn theselected function ON or OFF. Commonexamples would be turning a hose orgun zone ON or OFF, making aschedule change to turn on setbackduring a shift, or enabling SequentialStart. Use the Right/Left Arrow Buttonsto select the switch, then use the Plus/Minus Buttons to toggle the switch ONor OFF.



Passwords are required to prevent unauthorized access to unit programming.Please see Appendix A - Password Levels for more information. To enter apassword:

EnteringPasswords



Set Language

C O N T I N U E D N E X T P A G E



Set Language - Continued



SetTemperatureUnits



GridGridGridGridGrid

Actual GridActual GridActual GridActual GridActual Grid

Press the Temperature Button (if the Temperature LED is not illuminatedgreen) to show the first temperature screen.Programming

Temperatures

The tank temperature screen shows the actual tank temperature and the tanktemperature setpoint. For operator convenience, the right side of this screenscrolls through enabled hose / gun zones and displays the actualtemperatures as shown.

Temperature Screens

Press the Temperature Button repeatedly (or use the navigation keys) tocycle through the temperature screens until you reach the desired screen.

CollectorCollectorCollectorCollectorCollector



Grid Temperature

Hose/ValveTemperature



Hose/Valve TemperatureContinued



The System Ready Temperature is relative to the temperature setpoint ofeach zone. The system is ready (and the System Ready LED illuminatesgreen) when all zones reach their respective temperature setpoints minus theSystem Ready Temperature Offset.

The system ready signal enables the pump motor. This prevents the pumpmotor 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). Ifit is set too close to the setpoint (for example, -1°F), the pump motor will stopduring momentary drops in temperature of any zone until the zone is againwithin 1°F of the setpoint.

The System Ready Temperature Offset parameter range is 0°F to 36°F (0°Cto 20°C) and the default factory setting is 5°F (3°C).

This parameter can be accessed in Password Level 2 or higher (seeAppendix A - Password Levels).

System/PumpReadyTemperatureOffset



Ready DelayTime

When the Ready Delay Time is used, the System Ready LED will illuminate apreset time after all of the zones reach their respective temperature setpointsminus the System Ready Temperature Offset. This feature allows theadhesive in the system to heat for an additional period of time before thepump motor is enabled.

Once the zones have reached the System Ready Temperature, the timeremaining before the system is ready is displayed on the status bar at thebottom of the screen.

The ready delay range is 1 minute to 120 minutes. The default factory settingis ON at 30 minutesON at 30 minutesON at 30 minutesON at 30 minutesON at 30 minutes.

To prolong the life of the seal in the pump, this default time of 15 minutesshould not be reduced.


C O N T I N U E D N E X T P A G E



Ready Delay Time-Continued



The Over Temperature Alarm setting pertains to all active zones.

The number entered on this screen, is the amount of degrees ABOVE eachzone’s set temperature that a zone can heat to before activating the OverTemperature Alarm.

If any zone goes into Over Temperature Alarm, the heaters of the affectedzone are automatically shut off. If the Over Temperature Alarm messageappears, it can be cleared by pressing the ‘OK’ key.

If the Over Temperature Alarmcondition lasts for a duration of 2.5minutes, the master control relay will bedeactivated removing power from theheating zones, and the Fault Historyscreen will appear. After correcting thecause of the fault, the unit must bepowered off and back on again to resetthe control and reactivate the mastercontrol relay.

The over temperature alarm tolerance range is 9°F to 108°F (5°C to 60°C).The factory default setting is 27°F (15°C).


OverTemperatureAlarm



The Under Temperature Alarm setting pertains to all active zones.

The number entered on this screen, is the amount of degrees BELOW eachzone’s set temperature that a zone can cool to before activating the UnderTemperature Alarm.

If any zone goes into Under Temperature Alarm, the heaters of the affectedzone will remain on to compensate for the drop in temperature. If the UnderTemperature 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).


UnderTemperatureAlarm



The Maximum Temperature setting is the maximum value for the setpoint ofany 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 .

MaximumTemperature



Beacon/AlarmSetup The Beacon/Alarm Setup allows a specific Beacon, designated by number, to

be set to indicate one of six conditions:

• Pump On• Ready• Alarm (Zone Faults)• Low Level• Setback On• Feeder Alarm (Not applicable for this unit)

The alarm may also be set to “Disabled,” 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 Assemblyfeatures 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 followingprocedure. Password level 2 or higher is required (see Appendix A -Password Levels).

Light Color Condition Blue System Ready Red Low Level

Continued on Next Page



Beacon 2

Beacon/Alarm Setup - Continued



When the Automatic Pump Mode is on, the pump will automatically startwhen the system reaches temperature and the System Ready LEDilluminates.

If the Ready Delay Time is enabled and set for a preset time (15 minutes), thepump will not start and the unit will not be ready until 15 minutes AFTER thecontrol has gotten to temperature.

The factory default setting is OFF.

This parameter can be accessed in Password Level 2 or higher.

AutomaticPump Mode



The Filter Change Timer Screen is a count down timer that shows the timeremaining on the currently installed glue filter. When the counter gets down tozero (0), an alarm can be sounded and the filter needs to be changed orcleaned. Once the filter has been serviced, the timer can be reset for a userset time of up to 2000 hours.

The D-90 does not have a filter and, therefore, the factory default timer is OFF.

Filter ChangeTimer

Level SensorSetup

Internal LevelExternal Level

There are two level-control inputs that can be used with the D-90, an internallevel sensor and an external level sensor. These inputs can also serve asinternal low and high level sensors. The external level sensor is used for potfill mode (see Pot Fill Mode – Section 5). The delay for these sensors toactivate can be set in this screen. These inputs can be enabled, and the timedelay set, on the screen shown below. They can be tied into a programmableoutput (see “User Inputs and Outputs,” later in this section).



The Clock sub menu is used to set the current day and time and to setupshifts with on, off, and setback times/temperatures that are automatically runby the internal clock.

Clock and 7-Day Timer

Set Day and Time



Shift Times/SetbackTimes

Three shifts can be programmed into the unit. Start shift, end shift, andsetback times can be pre-programmed for each shift to reduce downtime.Make certain all desired temperatures are set first (see ProgrammingTemperatures, this section).

First program the time the heaters will be on, off, and in setback for each ofthe three shifts. Use the Right/Left Arrow Buttons to move through the timesand shifts and the OK Button to get a thumbwheel to set the times and turn onthe setback feature with a “switch” on the thumbwheel. (The heaters can beset 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 Shift A, heaters will turn on at 7:00 AM to thesetpoint temperatures (set on the Temperature Screens, previously shown)and off at 3:00 PM, with all heaters going to the setback temperatures from11:30 AM to 12:00 PM.



This screen states that for Shift C, nothing will be on, since there is no Shift Cworking.

After setting all shift times, program the shifts that will be enabled for eachday of the week. The Up/Down Arrow Buttons cycle through the differentcombinations of shifts, and the Left/Right Arrow Buttons cycle through thedays of the week.

This screen states that on Mondays all three shifts (A, B, and C) will beworking.

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 thatwill be working for each day of the week (this page), be sure the ClockFunction is On and is set properly.



Moving Through theShift Time/Day

Screens



Moving Through the Shift Time/Day Screens - Continued

Press the Clock Button to enable all shift settings (the 7-Day Timer)

Do not turn off the main power to thecontrol. The clock/timer will not operateif 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 withthe correct time of day.



The Diagnostics Screen shows the current software version as well as thecurrent temperature and status of each zone.Diagnostics



The setback feature is used to reduce the temperatures of all zones by agiven temperature differential to allow the hot melt to remain soft but notmolten during periods of inactivity.

The setback temperature differential is relative to the temperature setpoint ofeach 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).


Setback Temperature

Setback



If the Automatic Setback Timeout input is enabled and the unit does not seean external input within the automatic setback timeout period, the unit willautomatically go into setback.

The Automatic Setback Timeout feature is used only in conjunction with theAutomatic Setback External Input. It is not used in manual or scheduledsetback modes.

The automatic setback timeout range is 1 minute to 120 minutes. The defaultfactory setting is “OFF.”

When the Automatic Setback is enabled, the Auto Setback symbol will start toflash in the status bar 2 minutes prior to going into setback. This will be thesignal to the operator that the unit will go into setback if an external signal isnot applied to the control that resets this feature.


Automatic SetbackTimeout



The Sequential Start function allows the hoses and the valves (guns) to beginheating after the upper platen (referred to as the Tank, below) reaches aspecified temperature offset below the setpoint temperature. This feature isused to reduce adhesive degradation caused from heating adhesive in thehoses and valves for long periods while waiting for the tank to reachtemperature.

The sequential start range is 0°F to 450°F (0°C to 250°C). The default factorysetting is OFF.


Sequential Start –Hose

Startup Setup



Sequential Start –Valve



The Fault History Screen keeps a log of all faults that occur with any zone.

The Change History Screen keeps a log of all parameter and setting changes.

The Fault History and the Change History are cleared when the unit is turnedoff.

History

If the an alarm condition (eg HighTemperature Alarm) lasts for a durationof 2.5 minutes, the master control relaywill be deactivated removing powerfrom the heating zones, and the FaultHistory screen will appear. Aftercorrecting the cause of the fault, theunit must be powered off and back onagain to reset the control and reactivatethe master control relay.



There are 4 individual outputs that can be configured to control remotedevices as set up by the user. An output relay will turn on when theconditions of the selected feature are met. For example, if Output #1 isprogrammed for “System Ready”, the output relay will energize when thecontrol reaches temperature and is ready to glue. See the chart below foruser selectable output features.

There are also 4 individual inputs that can be configured to control somethingon the hot melt control when the control receives an dry contact input. Forexample, if Input #3 is programmed for “Pump On/Off”, the pump will remainoff until input #3 receives a signal for it to turn on. This can be used toremotely control the glue pump.

See Section 4 - Installation for wiring details.


User Inputsand Outputs

Input and Output Functions Inputs 1-4 Outputs 1-4 Disabled Disabled

Hose and Gun #1 thru #6 On/Off Setback On All Heaters On/Off Alarm

Pump On/Off Ready & Pump On Auto Setback System Ready

Setback Power On External Level Internal Level

The same procedure can be used to change the Outputs.



Configuration The Configuration Menu contains screens that allow the user to setup globalparameters for the hot melt control. These configurations are shown below.

The number of hoses is used to set the control for how many hose/gun pairsare being used by the operator. This setting would be set at the factory beforeshipment.

Number of HoseOutlets

An Auxiliary I/O board (151XX661) can be ordered separately as an option toallow the operator to use four more user inputs and outputs. Once the boardis installed, the Auxiliary I/O must be enabled. The factory default setting is“Disabled”. See Section 4 – Installation for Auxiliary I/O board connector. Thisparameter can be accessed in Password Level 2 or higher (see Appendix APassword Level).

When the Auxiliary I/O is set to “Enabled”, the additional programmableinputs and outputs (5-8) will be activated.

When the Auxiliary I/O is set to “Disabled”, the additional programmableinputs and outputs (5-8) will be deactivated.

Auxiliary I/O



The total number of pumps for the unit can be configured in this screen. Forthis unit, the number is one. This setting will be set at the factory beforeshipment.

Number of Pumps

Gramage should ONLY be enabled in coating applications where the userwants the unit to automatically calculate the pump speed, to achieve adesired 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 GramageSetup later in this section for more information.

Gramage Enable

The RTD (resistance temperature detector) material type for the unit can beconfigured in this screen. For this unit, the RTD type is Ni120. This setting willbe set at the factory before shipment.

RTD Type Selection



The Creep Speed Setting is the speed that the pump will run when the AutoSpeed Input is below the Minimum Speed Setting. This setting is generallyused to maintain pressure while the production line is stopped.

Pump SetupMenu

The Speed Gain value is adjustable from 0-200%. It scales the pump speedwhen using Automatic Pump Mode, when the pump speed is determined bythe Auto Speed Input. The factory default setting is 100%.

Continued on Next PageContinued on Next PageContinued on Next PageContinued on Next PageContinued on Next Page

The Minimum Speed Setting determines the minimum line speed at which thepump 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 Maximum Pump Speed is generally set at the factory. It is the motorRPM divided by the reducer size (or pump speed when the motor runs at100%). It is used to calculate and display the actual speed of the pump onthe Pump Status Screens.



VFD Board Connections

The Auto Speed Input setting is the type of line speed input used to adjust thepump speed. See the VFD board connections (below) to find the inputconnectors for the Auto Speed Input. Allowable settings and theircorresponding 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.



PID SetupMenu

PID Settings

The measurement units for the encoder are selected in this screen. This isonly available when the encoder is used.

EncoderSetup Menu

If an Encoder is used for the Auto Speed Input, then the Encoder parametersneed to be set in this menu. Enter the Pulses per Revolution of the encoderand its circumference in this screen.



AutoTune FeatureThe Auto Tune feature will optimize the PID settings for each zone that isenabled when the Auto Tune is started. The Auto Tune feature can take up toeight hours to complete and the power must not be turned off during thisprocess. It is recommended to only enable zones that need their PID valuesadjusted to reduce the time taken for tuning.

The AutoTune Feature is located in the PID Screen and can ONLY beaccomplished under the password Level 3!

Changing out gun/hose pairs or movinga gun or hose from it’s originalAutoTune position, will require thatAutoTune be run again to optimize thePID settings again.

PID Settings - Continued The PID settings are factory set for each zone. The factory PID settingscomplement Valco Melton’s Tank, Hose, and Gun watt densities (Tank 1screen shown. Use left/right keys to access other screens).

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Changing these settings is not recommended. Changesshould be made only by authorized ValcoMeltonpersonnel.

In the case where a special temperature zone is used (example: coatinghead) and its temperature does not regulate properly, the Auto Tune functioncan be used to set the PID settings.



To restore the factory default settings, follow these steps:

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Restoring the factory default settings will permanentlyerase changes made to any parameter or setting!

1. Switch off power to the unit.

2. Power the unit back up while pressing and holding the SetupButton and the OK Button on the keypad. The buttons can bereleased once the start-up screen appears.

RestoringFactoryDefaultSettings

InitializeScreen

The Init or Initialize Screen is used to reset ALL of the control parametersback to the factory settings. When “OK” is selected to Initialize ALL Data, theset up wizard will take the user through the control initialization to reconfigurethe hot melt control as if it were a brand new installation. From this point, theuser will be able to select number of hose / gun pairs, piston or gear pump,etc.



To adjust the single-stage relief valve, follow these steps:

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Do not overtighten adjusting screw. Otherwise,equipment damage could occur.

1. Turn the pump motor off.

2. Loosen the locknut on the pressure relief valve.


3. Turn adjustment screw clockwise to increase pressure,counterclockwise to decrease pressure.

4. Tighten the locknut on the pressure relief valve.

5. Turn on pump motor and resume operation.

Adjusting thePressureControl Valve

Adjusting the Single-Stage Relief Valve

The D-90 unit contains a single-stage, external, manually adjustable reliefvalve (see figure below). Additionally, the D-90 unit can use an optionalpneumatic relief valve, Uniflow 12 and Uniflow 24V (contact Valco Melton fordetails).

The single-stage relief valve is a simple safety device which protects thesystem from excessive pressure. The single-stage relief valve is commonlyused for systems that are applying adhesive continuously (laminating).

WARNING!WARNING!WARNING!WARNING!WARNING! Do not adjust the fixed pressure relief valve. Thisprotects the system from excessive pressure buildup.Otherwise, serious personal injury or equipment damagecould occur.



GramageFeature

The Gramage Feature should ONLY be enabled in coating applicationswhere the user wants the unit automatically calculate the pump speed toachieve a desired coat weight. It requires the user to enter the PumpDisplacement (cc), Adhesive Density (gram/cc), speed reference valve if tachmode is used, coating width (mm) and the desired coating weight (gram/m2).The “Gramage Enable” for the appropriate pump must be enabled in order toview these setting screens, see Gramage Enable earlier in this section formore information.

The Pump Displacement, Adhesive Density and Speed Reference must beset in the “Pump Setup” menu. This parameter can be accessed in PasswordLevel 2 or higher (see Appendix A Password Level).



The Application Width and Gramage (Application Weight) must be set in the“Pump Menu”. This parameter can be accessed in Password Level 1 orhigher (see Appendix A Password Level).

Gramage Feature - Continued

6-1ValcoMelton.

SECTION 6 - OPERATIONSECTION 6 - OPERATIONSECTION 6 - OPERATIONSECTION 6 - OPERATIONSECTION 6 - OPERATION

WARNING!WARNING!WARNING!WARNING!WARNING! It is recommended that Section 5 – Setup is read,understood and followed before attempting to read thissection and operate the unit. OTHERWISE, SERIOUSPERSONAL INJURY OR EQUIPMENT DAMAGECOULD OCCUR.

This unit should only be used by qualified personnelwho understand all of the procedures and are familiarwith the necessary safety measures. Make sure that theperson operating the machine is properly protects andthat all safety instructions are followed. OTHERWISE,SERIOUS PERSONAL INJURY OR EQUIPMENTDAMAGE COULD OCCUR

Unit Startup1. Turn on the unit by turning the power disconnect switch to the

“ON” position.

Figure 6-1. Main Power Disconnect Switch

Power Disconnect Switch

ON

OFF

6-2 ValcoMelton

Section 6 - Operation MM125 - D-90 Hot Melt Unit

Unit Startup - Continued 1. If the power disconnect switch is on but there is nothing on thedisplay, the unit is in Standby mode. Push the Standby key onthe control and ensure the LED changes from orange to green.

Figure 6-2. Temperature Controller Important Operation Keys

1. Set the temperatures 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 toilluminate.

WARNING!WARNING!WARNING!WARNING!WARNING! Hot surfaces! Do not touch unless necessary! Usecaution while performing the operation procedures in thefollowing sections. Wear protective gloves and gogglesat all times. OTHERWISE, SERIOUS PERSONALINJURY OR EQUIPMENT DAMAGE COULD OCCUR.

Collector

Grid

Filter Block

6-3ValcoMelton

Section 6 - OperationMM125 - D-90 Hot Melt Unit

1. If filling the Reservoir manually (using bricks, pillows or pellets),open the lid and fill the Reservoir to the desired level.

WARNING!WARNING!WARNING!WARNING!WARNING! Do not overfill the tank! Allow the adhesive to melt, andcheck the adhesive level before adding more adhesive.

Filling theTank

2. If filling automatically with a drum unloader, attach the fill hose tothe tank inlet at the back of the unit.

3. An optional tank inlet filter and hose support are available toprevent tank contamination, and to prevent damage caused byexcessive hose bending (see Figure 6-3).

The optional capacitive level sensorsare recommended when filling thetank with a drum unloader. The high-level sensor will prevent the adhesivefrom feeding from the drum unloaderwhen the level is high.

Figure 6-3. Filling the Tank

Fill Hose Fitting

Access to the tank inlet filter byraising the lid (if applicable)

Insert hose through springsupport (if applicable)

6-4 ValcoMelton

Section 6 - Operation MM125 - D-90 Hot Melt Unit

WARNING!WARNING!WARNING!WARNING!WARNING! Make sure all heating zones are at the correcttemperature. The Pump Ready light should be on.

Make sure all hoses and fittings/connections aresecured properly to prevent adhesive leaks.

1. Turn the pump on by pressing the Pump On/Off Key.

This may occur automatically if theAutomatic Pump Enable setting isturned on. Refer to Section 5 - Setupfor 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 connectedproperly

• The pump is set to Manual or Automatic, as needed

2. Adjust the motor speed if necessary (refer to Section 5 - Setup fordetails).

DispensingAdhesive

7-1Valco Melton

This section contains guidelines and procedures for maintaining the D-90 hotmelt unit. Your hot melt system will run longer and more consistently if apreventative maintenance program is used. Daily attention to themaintenance of your system is recommended.

ValcoMelton recommends the following general maintenance procedures:

• Remove adhesive spills immediately. (Use a putty knife whilethe material is still soft.)

• While the unit is still hot, but not operatingbut not operatingbut not operatingbut not operatingbut not operating, use cheesecloth toremove material leaking from the pump seal and otherconnectors. 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 thatmay cause a system malfunction.

General

SECTION 7 – MAINTENANCESECTION 7 – MAINTENANCESECTION 7 – MAINTENANCESECTION 7 – MAINTENANCESECTION 7 – MAINTENANCE

Cleaning theExterior of theUnit

To clean the exterior of the D-90 hot melt unit, follow these steps:

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Never hose or steam-clean the unit. If the surroundingarea is cleaned in this manner, protect the unit bycovering it with plastic or other waterproof material.Failure to comply could result in damage to theequipment

1. Turn off the main power.

2. Using a damp cloth, clean the cabinet with a mild soap-and-watersolution.

7-2 Valco Melton

Section 7 – Maintenance MM125 - D-90 Hot Melt Unit

FilterReplacement

See Figure 7-2

See Figure 7-3

7-3Valco Melton

Section 7 – MaintenanceMM125 - D-90 Hot Melt Unit

4. 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 whenperforming this procedure.

a. Remove the screw at the bottom.

b. Pull the screen out.

5. Check the condition of the filter assembly O-rings. Replace themif necessary (refer to Section 10 - Part Numbers List).

6. Insert the clean filter back into the block.

7. Tighten the filter cap.

Figure 7-2. Replacing the Tank Inlet Filter

Replacing theTank InletFilter

The optional tanlk inlet filter should be cleaned or replaced periodically toprevent 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 tank inlet filter block is up totemperature. Removing the filter while the filter block iscold could result in damage to seals and the filterscreen.

2. Open the lid to access the filter cap.

3. Use a 3/4” wrench to loosen the filter cap, rotating it, slowly,counter-clockwise.

7-4 Valco Melton


1. Turn off the D-90 pumps.

WARNING!WARNING!WARNING!WARNING!WARNING! Make sure pressure gauge reads 0 psi.0 psi.0 psi.0 psi.0 psi.

Make sure the manifold is up to temperature.

Replacing theManifold Filter

The procedure for replacing themanifold filter is similar to that ofreplacing the Inlet Filter.

2. Use a 3/4” 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 whenperforming this procedure.

a. Remove the screw at the bottom.

b. Pull the screen out.

4. Check the condition of the filter assembly O-rings. Replace themif necessary (refer to Section 10 - Part Numbers List).

5. Insert the clean filter back into the block.

6. Tighten the filter cap.

Figure 7-3. Replacing the Manifold Filter

7-5Valco Melton


CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! When changing adhesives, always consult adhesivesuppliers to check compatibility between adhesives.Failure to comply could result in damage to theequipment.

To change the adhesive, follow these steps:

1. If the old adhesive and the new adhesive are compatible, pumpenough of the new adhesive through the system to ensure that allof the old adhesive has been cleared out (generally 3 to 5 lbs. or1.1 to 1.9 kg).

2. If the two materials are not compatible, flush the system (see

“Flushing the System” below).

The system needs to be flushed:

• When changing to an adhesive that is not compatible with thepreviously used adhesive

• When the unit is not used for a prolonged period

Changing theAdhesive

Flushing theSystem

Use a purge recommended by the adhesive manufacturer.

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! If a cleaning solution is to be flushed through the hotmelt system, it must be compatible with silicone,Viton,Teflon, carbon graphite, brass, steel andaluminum. Consult the adhesive manufacturer to find outwhich cleaning solutions are recommended for theadhesive you are using. Failure to comply could result indamage to the equipment.

To flush the system without a purge system, follow these steps:

1. Fill the tank with the purge material.

2. Close the lid.

3. Set the temperature of the heating zones to the proper setting forthe purge material.

WARNING!WARNING!WARNING!WARNING!WARNING! If the system is hot, wear insulated glovesand eye protection when disconnectinghoses. Trapped air pockets may causeadhesive spray and result in personal injury(burns) or death.

4. Make sure that the pump is turned off.

7-6 Valco Melton


WARNING!WARNING!WARNING!WARNING!WARNING! If the system is hot, wear insulated glovesand eye protection when disconnectinghoses. Failure to observe could result inpersonal injury, death, or damage toequipment.

11. Turn the pump off.

12. Turn on the heating zones for the applicators.

13. Allow the applicators to reach temperature.

14. Reconnect the glue hoses to the applicators/units.

15. Turn the pump back on and activate the applicators to purgeremaining adhesive through the valve(s).

16. Reset the temperature control to the correct setting for thematerial you are using.

The new material can now be pumpedthrough the system.

PartsReplacement

Flushing the System - Continued 5. Manually activate the applicators to relieve any system pressurebuildup if the system is hot (if applicable).

6. Disconnect glue hoses from applicators/unit, and collect purgedmaterial with an appropriate container.

7. Turn off the heating zone for the applicators.

8. Allow the unit and hoses to reach temperature.

9. Turn the pump on.

10. Pump purge material through the unit and glue hoses untildischarged material is free of particles.

Occasionally, parts may need to be repaired or replaced. The followingparagraphs contain instructions for removing parts from the hot melt unit. Fordrawings and a complete list of part numbers, see Section 10 — Part NumberList.

7-7Valco Melton


2

4

1

3

151xx680 240V

Item Fuse Description Part # Quantity

1 Fuse, 2A, 5 x 20 mm 085xx220 2

2 Fuse, 6.3A, 5 x 20 mm 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 sparefuses from the included installation kit and insert the fuse in the appropriatesocket. If the blown fuse is on the 12-zone board, see Figure 7-4. If not, seeSection 10 - Part Number List.

Changing Fuses

Figure 7-4. Main Board Power Fuses

8-1ValcoMelton.

SECTION 8 - TROUBLESHOOTING AND REPAIRSECTION 8 - TROUBLESHOOTING AND REPAIRSECTION 8 - TROUBLESHOOTING AND REPAIRSECTION 8 - TROUBLESHOOTING AND REPAIRSECTION 8 - TROUBLESHOOTING AND REPAIR

TroubleshootingWARNING!WARNING!WARNING!WARNING!WARNING! Only qualified personnel who understand the processes

and is familiar with the safety measures involved shouldtroubleshoot the equipment. OTHERWISE, DEATH,PERSONAL INJURY OR DAMAGE TO THEEQUIPMENT COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Troubleshooting may require the unit to be energized.Therefore, all necessary safety precaution should betaken while working on the system. OTHERWISE,DEATH, SERVERE PERSONAL INJURY OR DAMAGETO THE EQUIPMENT COULD OCCUR.

This section includes some of the common faults that can occur with the S-drum hot melt unit. If the problem can not be solved with the information inthis manual, contact your Valco Melton representative.

Problem Possible Cause Possible Solution

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 thermostat was triggered. Allow the unit to cool down and restart.

Motor will not start

Voltage not being applied to frequency drive (VFD)

Check that the supply voltage to the VFD is 240VAC ±10%.

Voltage not being send from VFD to the motor Check the voltage to the motor.

Heating zones are over/under temperature

Wait for all heating zones to reach the set temperature.

Zone does not heat up

Zone is turned off or not set to the correct temperature

Check the temperature setting for the zone and verify that the zone is turned on.

Zone not heating Check for blown fuse. Hose/Gun connector is unplugged/connected incorrectly

Check the pins on both connectors to ensure they are in good condition.

Temperature sensor is faulty Check the resistance of the sensor. If faulty, replace sensor.


Section 8 - Troubleshooting and Repair MM125 - D-90 Hot Melt Unit

Troubleshooting - Continued


Adhesive pressure is too high Pressure relief valve set too high

Loosen the pressure relief valve adjustment screw until the desired pressure is obtained. Replace pressure relief valve.

No adhesive output

Adhesive not hot enough Check temperature setting is correct. Ensure that platen and manifold heaters have power. Check for blow fuses.

Pump not moving Check system for ready condition. Check blown fuse.

Filter Clean or replace filter. Cold glue hose or damaged hosed Replace hose.

Cold applicator Check for blown fuse and/or defective heater.

Clogged applicator Service applicator system. Temperature control malfunction Replace temperature control.

Fuming or smoking of adhesive Operating temperature exceed adhesive’s recommended temperature

Keep setpoint temperature within recommended range. Consider another adhesive.

Uneven flow of 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 adhesive See adhesive manufacturer’s recommendations.

Adhesive overheated Reduce castings and manifold temperatures in accordance with adhesive manufacturer’s specifications.

Glue hoses not at the same temperature Check temperature setting in the control.

Different pressure drop through each hose

-Hoses not the same length Use same length hoses. -Crimped hose(s) Replace hose(s). -Leaking hose(s) Replace hose(s). Adhesive supply low Change drum. Manifold partially clogged Clean and flush system.

Nozzles partially clogged Inspect system for charred adhesive and foreign matter. Clean and flush system.


Section 8 - Troubleshooting and RepairMM125 - D-90 Hot Melt Unit


Cold adhesive on product after dispensing

Adhesive temperature is too low

Raise the Castings, manifold, hoses and applicators temperatures in accordance with adhesive manufacturer’s specifications.

Nozzles are too far from gluing surface

Move the applicator closer to the gluing surface.

Too much adhesive output at the start and end of the bead

Adhesive pressure is too low Adjust the pressure by increasing the pressure relief valve.

Applicator is partially clogged Clean the applicator nozzles. Nozzles are too far from gluing surface


Nozzle outlet is too large Change to a smaller nozzle size

Bead breaks during dispersion


-Castings and manifold temperature too low

Raise Castings and manifold temperatures in accordance with adhesive manufacturer’s specifications.




Adhesive is old Change adhesive

Bead with fine threads



Adhesive is old Change adhesive Nozzles are too far from gluing surface



-Castings and manifold temperature too low

Raise Castings and manifold temperatures in accordance with adhesive manufacturer’s specifications.


Frequent nozzle obstruction Adhesive is charring

Raise the Castings, manifold, hoses and applicators temperatures in accordance with adhesive manufacturer’s specifications or change adhesive type.

Pre-existing obstructions Clean and flush system. Applicator filters are dirty Clean/replace the filters.

Troubleshooting - Continued



RepairWARNING!WARNING!WARNING!WARNING!WARNING! All of these operations should be performed with the

machine switched off at the main breaker anddisconnected from the incoming air, making sure thesystem has been duly bled and depressurized.

WARNING!WARNING!WARNING!WARNING!WARNING! Make sure the pump is up to temperature.

1. Turn the pump off.

2. Set the manifold shutoff valve to the CLOSE position. This will shutoff the adhesive flow to the manifold.

3. Loosen the (4) M10 screws on the motor bracket.

4. Slide the motor back as far as possible to gain pump access.

The slide disk from the couplingshould come off. Set it aside whilereplacing 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, residualadhesive will drip from the manifold. Wear gloves, anduse a rag or towel to clean it off.

7. Install the new pump to the manifold, in the same orientation asthe old pump. Use NEW O-rings.

8. Install the slide disk to the pump coupling, with the arrows pointingtoward the roller bearings.

9. While holding the slide disk in place, slide the gear motor towardthe pump until the motor coupling roller bearings enter the slidedisk.

10. Tighten the M10 screws on the motor bracket.

11. Set the shutoff valve to OPEN.

Replacing the Pump



Replacing the Pump - Continued

Figu

re 8

-1. R

epla

cing

the

Pum

p



Replacing the MotorIf the motor needs to be replaced, proceed as follows:

1. Turn off the unit and disconnect the power.

2. Open the electrical box on the motor.

3. Disconnect the wires inside of the motor.

4. Remove the M10 socket head cap screws, washers and nutsfrom the motor bracket.

5. Remove the motor through the electrical cabinet bottomcompartment.

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 wereremoved 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. Reconnect the wires from step #3 to the new motor according tothe wiring schematic (999XD776-18).

13. Close the electrical box on the new motor.

14. Test the motor. It should run clockwise.



Figure 8-4. Pressure Relief Valve Locations – Front of the Unit

5. Attach the new pressure relief valve to the manifold.

6. Set the pressure relief valve to the desired adhesive operatingpressure. See Section 5 - Setup, “Adjusting the Pressure ControlValve.”

Replacing thePressure 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.




Replacing the BeaconLight Bulb

1. Turn off the unit and disconnect the power.

2. Twist the beacon that needs to be replaced counter-clockwiseand remove.

3. Twist the light bulb inside of the beacon case clockwise a quarterturn 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 itclockwise until it locks.


SECTION 9 - SPECIFICATIONSSECTION 9 - SPECIFICATIONSSECTION 9 - SPECIFICATIONSSECTION 9 - SPECIFICATIONSSECTION 9 - SPECIFICATIONS

GeneralIt is the purchaser’s responsibility to ensure that all local, county, state, andnational codes, regulations, rules, and laws relating to safety and safeoperating conditions are met and followed.

# Weight (maximum) includes the unit with all options installed, coupled with the weight of the crate.

* Test run with standard adhesive at 10,000 cPs. Melt rate will vary with input voltage and adhesive.

** Pump rate based on a motor speed of 100 rpm and material with a specific gravity of 1.0.

Height 53 inches (1,346 mm)Width 30 inches (762 mm)Depth 41 inches (1041 mm)Tank Capacity 90 kg (200lb)Drop-In Grid StandardMelt Rate 100 kg/hr (220 lb/hr)

Gear Pump

0.7 lb/hr (0.3 kg/hr) - 41 lb/hr (19 kg/hr)1.4 lb/hr (0.6 kg/hr) - 85 lb/hr (39 kg/hr)3 lb/hr (1.3 kg/hr) - 170 lb/hr (77 kg/hr)6 lb/hr (2.5 kg/hr) - 334 lb/hr (152 kg/hr)

Gear Pump Control A.C. with line-tracking feature for variable speedsNumber of Pumps 1-2Number of Hoses/Guns 1-6Hose Fittings #6 (3/8"), #8 (1/2"), #12 (3/4") and #16 (1") options

Pressure Safety Relief

Manual relief with internal safety reliefPneumatic relief with manual reliefUniflow 12V with manual reliefUniflow 24V with manual relief

Temperature Control UTC-20 Microprocessor PID 16-Zone capableVoltage 380, 400, 440, 480, 575, 595 VAC, 3PH, 50/60 HzLevel Sensors Optional Low and High Level SensorsPressure Monitor OptionalApplications Profile Wrapping, Laminating, Book Binding

SPECIFICATIONS


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

10-1ValcoMelton

SECTION 10 - PART NUMBER LISTSECTION 10 - PART NUMBER LISTSECTION 10 - PART NUMBER LISTSECTION 10 - PART NUMBER LISTSECTION 10 - PART NUMBER LIST

How to OrderParts

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

Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.411 Circle Freeway DriveCincinnati, OH 45246TEL: (513) 874-6550FAX: (513) 874-3612Email: [email protected]: http://www.valcomelton.com

Valco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedHortonwood 32Telford, TFI 7YN, EnglandTEL: (+44) 1952-677911FAX: (+44) 1952-677945Email: [email protected]: http://www.valco.co.uk

Valco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHStorkower Strasse 6D-15749 Gallun, GermanyTEL: (+49) 337 648 700FAX: (+49) 337 648 7070Email: [email protected]

Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Pol. Industrial Agustinoscalle G, n. 3431160 Orcoyen, Navarra, SpainTEL: (34) 948-321-580FAX: (34) 948-326-584

Germany:

England:

USA:

Spain:

10-2

Section 10 - Part Number List

ValcoMelton


D-90 Hot Melt Unit (776XX883)

Overall Assembly

776XX883-01.dwg

10-3


ValcoMelton


Overall Assembly - Continued

776XX883-01.dwg

10-4


ValcoMelton


Reservoir, Collector, Grid, Frame Assembly

776XX883-02

10-5


ValcoMelton


776XX883-02

Reservoir, Collector, Grid, FrameAssembly - Continued

10-6


ValcoMelton


Sheet Metal Assembly

776XX883-03

10-7


ValcoMelton


776XX883-03

Sheet Metal Assembly -Continued

10-8


ValcoMelton


776XX883-03

Sheet Metal Assembly -Continued

10-9


ValcoMelton


776XX883-04

Motor, Pump andManifold Assembly

A further breakdown of the Single Pump Manifold Assemblyis shown on Page 10-13.

A further breakdown of the Dual Pump Manifold Assemblyis shown on Page 10-16.

10-10


ValcoMelton


776XX882-04

Motor, Pump and ManifoldAssembly - Continued

10-11


ValcoMelton


D-90 Hot MeltUnit(776XX883) -Parts List

ITEM DESCRIPTION PART # QTY 1 FRAME 776XX274 1 2 CASTER-ALTERATION 794XX886 4 3 NUT,FLANGE 798XX699 4 4 INSULATION PAD 782XX509 6 5 COLLECTOR 776XX273 1 6 CABLE ASSY, COLLECTOR RTD 029XX708 1 7 PLATE, DIVERTER 776XX276 1 8 O-RING 745XX362 2 9 GRID, TEFLON COATED 778XX436 1 10 CABLE ASSY, GRID RTD 029XX707 1 11 CABLE ASSY, OVER TEMP T'STAT 029XX704 1 12 CERAMIC TERMINAL COVER, TOP 794XX391 12 13 CERAMIC TERMINAL COVER, BOTTOM 794XX392 12 14 RESERVOIR, TEFLON COATED 776XX277 1 15 BLANKET 782XX524 1 16 FLAT WASHER 784XX443 18 17 BELLEVILLE SPRING 793XX414 48 18 SCREW 784XX454 6 19 SCREW 884XX356 6 20 HEX NUT 784XX015 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, BELLVILLE 884XX347 2 209 NUT HEX 884XX354 2 210 LID, OUTER 776XX279 1 211 LID, FLOATING 776XX280 1 212 STANDOFF 091XX705 4 213 SPRING COMPRESSION 783XX347 4 214 WASHER FLAT 884XX352 4 215 HANDLE, PULL 104XX135 2 216 SCREW 784XX442 4 217 SCREW 784XX374 4 300 MANIFOLD ASSEMBLY, SINGLE PUMP 776XX299 1 320 GEAR PUMP, QUAD WIDTH 561XX219 1 321 SCREW 884XX357 4 322 O-RING 745XX035 2 323 COUPLING ASSY 783XX348 1 324 MOTOR 1HP 15.95:1 REDUCER 110XX383 1 325 BRACKET, MOTOR 776XX255 1 326 SCREW 798XX645 4 327 SCREW 784XX059 4

10-12


ValcoMelton


D-90 Hot Melt Unit (776XX883) -Parts List - Continued

ITEM DESCRIPTION PART # QTY 328 CORD GRIP 066XX191 1 329 SETTINGS, VFD PARAMETERS 999XB776-20 1 330 CABLE ASSY, VFD-MTR D90/D180 029XX720 1 400 PANEL, BACK; D180 776XX251 1 401 NUT,HEX 798XX362 8 402 LOCK WASHER 784XX663 8 403 PLATE ADAPTER 776XX249 2 404 HARTING RECEPTACLE ASSEMBLY 029XX697 4 410 ENCLOSURE, ELECTRICAL 026XX363 1 411 SCREW 784XX337 6 412 WEATHER STRIP 795XX660 144 413 LATCH, COMPRESSION 091XX702 6 414 FLAT WASHER 784XX443 10 415 SCREW 784XX569 10 416 OVERLAY ASSEMBLY 137XX020 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 PANEL, SIDE, WHITE 776XX282 2 431 HANDLE 104XX127 2 432 TERMINAL 091XX609 4 433 HEX NUT 784XX401 4 434 LABEL, THE CURVE, BLUE 782XX458 1 435 LABEL, "M" AND "D90", BLUE 782XX515 1 436 LABEL, VALCOMELTON, BLUE 782XX460 3 437 LABEL,WARNING-HOT SURFACE 781XX629 4 438 LABEL, WARNING-ELEC.HAZARD 781XX630 3 439 LABEL, "1-6", BLACK 782XX518 1 440 RESISTOR 240XX006 3 441 PLATE,MANIFOLD COVER 769XX910 1 442 PLATE MODIFICATION 999XA769-18 1

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Single PumpManifoldAssembly(776XX299)

776X

X29

9-01

.dw

g.

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Single Pump Manifold Assembly(776XX299) - Continued

776XX299-02.dwg.

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Item Description Part Number Qty 1 MANIFOLD, SINGLE PUMP 776XX254 1 2 O` RING 745XX002 1 3 SCREW 884XX348 4 4 BLOCK, FILTER 776XX253 1 5 O-RING 745XX385 1 6 SCREW 884XX272 4 7 CAP,FILTER,MNFD ASSY. 775XX298 1 8 FILTER RETAINER 778XX361 1 9 FILTER SUPPORT 778XX362 1

10 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 ASSY; MANIFOLD HEATER 029XX701 1 25 CABLE ASSY, MANIFOLD RTD 029XX705 1 26 SCREW 784XX374 2

Single Pump Manifold Assembly(776XX299) - Continued

10-16


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Dual PumpManifoldAssembly(776XX300)

776X

X30

0-01

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g.

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Dual Pump Manifold Assembly(776XX300) - Continued

776XX300-02.dwg.

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Item Description Part Number Qty 1 MANIFOLD, DUAL PUMP 776XX295 1 2 O` RING 745XX002 1 3 SCREW 884XX348 4 4 BLOCK, FILTER 776XX253 2 5 O-RING 745XX385 2 6 SCREW 884XX272 8 7 CAP,FILTER,MNFD ASSY. 775XX298 2 8 FILTER RETAINER 778XX361 2 9 FILTER SUPPORT 778XX362 2

10 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 ASSY, MANIFOLD HEATER 029XX724 2 25 CABLE ASSY, MANIFOLD RTD 029XX705 1 26 SCREW 784XX374 3

Dual Pump Manifold Assembly(776XX300) - Continued

10-19


ValcoMelton


D-90 HMU Electrical Panel Assembly (776XX281)

10-20


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D-90 HMU Electrical PanelAssembly (776XX281) -Continued

10-21


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ITEM DESCRIPTION PART # QTY 1 PANEL, ELECTRICAL 776XX257 1 3 PCB ASSY 151XX680 1 4 STANDOFF 091XX706 14 5 HEX NUT 798XX299 7 6 SWITCH, DISCONNECT, FUSIBLE 485XX121 1 7 SCREW 784XX091 4 8 CONTACTOR 160XX290 1 9 SCREW 784XX051 2

10 VAR FREQUENCY DRIVE 110XX359 1 11 SCREW 784XX410 4 12 HEATSINK 100XX001 4 13 RELAY 160XX204 4 14 CONTACTOR 160XX291 1 16 POWER SUPPLY 148XX050 1 17 FUSE HOLDER 086XX086 1 18 DUCT 067XX017 152 20 STANDOFF 091XX704 8 21 NUT HEX 784XX990 4 22 FUSE HOLDER 086XX085 4 23 PCB ASSY 151XX701 1 26 AMPLIFIER, LEVEL SENSOR, PNP 098XX106 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 086XX084 1 43 TERM BLOCK 075XX299 6 44 CABLE ASSY 029XX712 1 46 CABLE ASSY 029XX710 1 47 CABLE ASSY 029XX709 1 48 CABLE ASSY 029XX698 1 49 CABLE ASSY 029XX699 1 50 LEVEL SENSOR KIT, INTERNAL 029XX703 1 51 LEVEL SENSOR KIT, INTERNAL 029XX702 1 52 END STOP, TERMINAL 075XX273 10 53 END SECTION, TERMINAL 075XX274 3 54 CIRCUIT SEPARATOR 075XX300 3 55 JUMPER BAR 091XX350 1 56 SPACER, SCREW, & WASHER 091XX351 6 57 JUMPER, 2 POLE 091XX426 3 58 DUCT COVER 067XX018 152 59 LUG 091XX026 1

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ValcoMelton



ITEM ITEM DESCRIPTION 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

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ValcoMelton


D90 Hot MeltUnit(EQM0690)

EQM0690-01.dwg

10-24


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D90 Hot Melt Unit (EQM0690) -Continued

EQM0690-02.dwg

10-25


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EQM0690-03.dwg

10-26


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EQM0690-04.dwg

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ITEM DESCRIPTION PART # QTY 1 FRAME EQM0684 1 2 CASTER-ALTERATION 794XX886 4 3 NUT,FLANGE 1/2-13 798XX699 4 4 INSULATION PAD 782XX509 6 5 COLLECTOR MODIFICATION EQM0680 1 7 PLATE, DIVERTER 776XX276 1 8 O-RING 745XX362 2 9 GRID, TEFLON COATED 778XX436 1

10 CABLE ASSY, GRID RTD 029XX707 2 11 CABLE ASSY, OVER TEMP T'STAT 029XX704 1 12 CERAMIC TERMINAL COVER, TOP 794XX391 12 13 CERAMIC TERMINAL COVER, BOTTOM 794XX392 12 14 RESERVOIR, TEFLON COATED 776XX277 1 15 BLANKET 782XX524 1 16 FLAT WASHER M10 SS 784XX443 18 17 BELLEVILLE SPRING 793XX414 48 18 HHCS M10 X 100 ZINC 784XX454 6 19 HHCS M10 X 130 ZINC 884XX356 6 20 HEX NUT M10 X 1,5 SS 784XX015 6 21 SLW M10 SS 784XX569 6 22 LEVEL SENSOR, HIGH TEMPERATURE 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 4 206 SCREW SHOULDER 6MM DIA X 8MM 884XX353 2 207 FLAT WASHER M6 SS 784XX183 2 208 WASHER, BELLVILLE, M6 884XX347 2 209 NUT HEX NYLON M5 SS 884XX354 2 210 EXT VACUUM FEEDER ASSY 776XX615 1 300 MANIFOLD DISTRIBUTION BLOCK EQM0679 1 301 O-RING 745XX506 2 302 SHCS M10 X 55 SS 784XX402 6 303 HEX PLUG, 9/16-18 W/O-RING 799XX329 1 304 HX. PLUG 799XX146 2 305 MANIFOLD ASSEMBLY, SINGLE PUMP EQM0695 3 306 SHCS M10 X 140 SS 884XX348 12 307 LOCK WASHER 1/4 ZINC 798XX735 12 308 VARIABLE FREQUENCY DRIVE EQM0699 3 309 SHCS M5 X 16 SS 784XX410 12 310 BRACKET; VFD MOUNTING EQM0692 1 311 SHCS M8 X 16 SS 784XX275 4

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ValcoMelton



ITEM DESCRIPTION PART # QTY 320 GEAR PUMP, DOUBLE WIDTH 561XX218 3 321 SHCS M8 X 100 BLACK 784XX381 12 322 O-RING 745XX035 6 323 COUPLING ASSY HEAVY DUTY 783XX322 3 324 MOTOR; INLINE EQM0691 3 325 BRACKET; MOTOR EQM0686 3 326 HHCS 1/4-28 X 3/4 ZINC 884XX004 12 327 HHCS M10 X 30 SS 784XX059 12 328 CORD GRIP 066XX203 3 329 SETTINGS, VFD PARAMETERS 999XB776-20 1 400 PANEL; BACK EQM0687 1 401 NUT HEX M8 SS 798XX362 8 402 LOCK WASHER SS 8MM 784XX663 16 403 PLATE ADAPTER 776XX285 2 404 RECEPTACLE ASSY 029XX719 4 410 ENCLOSURE; ELECTRICAL EQM0689 1 411 HHCS M10 X 25 784XX337 6 412 WEATHER STRIP 795XX660 144 413 LATCH, COMPRESSION 091XX702 6 414 FLAT WASHER M10 SS 784XX443 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 781XX566 1 429 RIVET, BLIND, 1/8 DIA X 1/4 LG 091XX517 4 430 PANEL, SIDE 776XX294 2 431 *HANDLE 104XX127 2 432 *TERMINAL,TAB,.250",STUD MNT 091XX609 4 433 HEX NUT M5 SS 784XX401 4 434 LABEL, CURVE, WHITE 782XX454 1 435 LABEL, "M" AND "D90", WHITE 782XX514 1 436 LABEL, VALCOMELTON, WHITE 782XX457 3 437 LABEL,WARNING-HOT SURFACE 781XX629 3 438 LABEL, WARNING-ELEC.HAZARD 781XX630 3 439 LABEL, "1-6", BLACK 782XX518 1 440 RESISTOR, 60 OHM, 50W, 1% 240XX006 3 443 CABLE ASSY, REMOTE CPU TAJ0605 1 444 *WASHER-LOCK,SPLIT,M3 784XX976 4 445 NUT HEX M3 SS 784XX990 4 446 SHAFT GUIDE, DISCONNECT 104XX177 1

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ValcoMelton


Recommended SpareParts for EQM0690

ITEM DESCRIPTION PART # 1 RECHNER LEVEL SENSORS 098XX107 2 MECHANICAL PRESSURE RELIEF 707XX222 3 PNEUMATIC RELIEF VALVE ASSY DJD3453 4 PRESSURE GAUGE 0-1000PSI 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 OVERLAY ASSEMBLY, UTC 20 137XX020 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 KJC1393 17 STRAIGHT FITTING #8 HOSE 799XX242 18 JIC CAP #8 HOSE 795XX392 1 RECHNER LEVEL SENSORS 098XX107 2 MECHANICAL PRESSURE RELIEF 707XX222 3 PNEUMATIC RELIEF VALVE ASSY DJD3453 4 PRESSURE GAUGE 0-1000PSI 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 OVERLAY ASSEMBLY, UTC 20 137XX020 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 KJC1393 17 STRAIGHT FITTING #8 HOSE 799XX242 18 JIC CAP #8 HOSE 795XX392

10-30


ValcoMelton


Electrical Panel Assembly

EQM0694.dwg

10-31


ValcoMelton


ITEM DESCRIPTION PART # QTY 1 PANEL; ELECTRICAL EQM0693 1 3 PCB ASSY, 12 ZONE GEAR NI-120 151XX680 1 4 STANDOFF; HEX, M-F 091XX706 14 5 HEX NUT-M4, SS 798XX299 7 6 *SWITCH, DISCONNECT, FUSIBLE 485XX121 1 7 SHCS M6 X 16 SS 784XX091 4 8 CONTACTOR; 50A, AC1, 3 POLE 160XX290 1 9 SHCS M4 X 12 SS 784XX051 2

12 HEATSINK; SSR, 2 C/W, DIN MT. 100XX001 4 13 *RELAY; SOLID STATE, 600VAC 160XX204 4 14 CONTACTOR; 25A, AC1, 3 POLE 160XX291 1 16 POWER SUPPLY,24VDC 5A 148XX050 1 17 FUSE HOLDER, 2 P 600V TYPE CC 086XX086 3 18 DUCT,30000403 067XX017 152 19 PCB,ASSY,STAND ALONE 4 ZONE 151XX684 1 20 STANDOFF 091XX704 16 21 NUT HEX M3 SS 784XX990 12 22 FUSE HOLDER, 3 P 600V TYPE CC 086XX085 4 23 PCB, ASSY, DUAL VFD +/-15 151XX701 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; 40A, CLASS J, FAST 085XX280 3 37 FUSE, 30A, 600V, TIME DELAY 085XX199 3 38 FUSE,20 AMP 085XX093 3 39 FUSE, 15 AMP 085XX154 3 40 FUSE, 10A 600V, TIME DELAY 085XX266 6 41 CIRCUIT BRAKER; EARTH LEAKAGE 056XX123 1 42 FUSE HOLDER, 3 P 600V TYPE J 086XX084 1 43 TERM BLOCK, GNC, 50A, YEL/GRN 075XX299 6 45 CABLE ASSY, DC SUPPLY TO 12Z 029XX711 1 47 CABLE ASSY, DC POWER 029XX709 1 48 CABLE ASSY; VFD SIGNAL 029XX698 3 52 END STOP, TERMINAL 075XX273 12 53 END SECTION, TERMINAL 075XX274 4 54 *CIRCUIT SEPARATOR 075XX300 4 55 *JUMPER BAR 091XX350 2

Electrical Panel Assembly -Continued

10-32


ValcoMelton


ITEM DESCRIPTION PART # QTY 56 SPACER, SCREW, & WASHER 091XX351 13 57 JUMPER, 2 POLE 091XX426 2 58 DUCT COVER,30001400 067XX018 152 59 LUG, 215390 091XX026 1 60 SHCS M8 X 12 SS 784XX604 1 61 LABEL, GROUND SYMBOL 781XX110 1 62 *COVER, RELAY 160XX150 4 63 SHAFT EXTENSION, 12" 485XX123 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 C501166 540XX164 100 79 *WIRE PTFE 22 AWG YEL C501094 540XX159 1 80 *WIRE PTFE 22 AWG BLK C501092 540XX166 30

Electrical Panel Assembly -Continued

11-1ValcoMelton

SECTION 11 - WARRANTYSECTION 11 - WARRANTYSECTION 11 - WARRANTYSECTION 11 - WARRANTYSECTION 11 - WARRANTY

Cold Glue Equipmentand Electronic

Controls

WarrantyInformation

Hot Melt Units,Hoses, Valves, Guns,

and RelatedEquipment

Valco Cincinnati, Inc. warrants its equipment worldwide against defects inmaterial and workmanship as outlined in this section.

Liability of the company is limited to repair of the product, or replacement ofany part shown to be defective, and does not extend to defects caused byaccidents, misuse, abuse, neglect, tampering or deterioration by corrosion.This warranty does not cover those items determined by Valco Cincinnati,Inc. to be normal wear items such as seals, O-rings, diaphragms, springs,etc.

Reconditioned equipment, unless specified otherwise at the time of purchase,will be warranted as described above for a period of ninety (90) days from thedate of shipment by Valco Cincinnati.

Components purchased by Valco Cincinnati, Inc. from others for inclusion inits products are warranted only to the extent of the original manufacturer’swarranty. In no event shall Valco Cincinnati, Inc. be liable for indirect orconsequential damages arising out of the use of Valco Cincinnati products.

This warranty is conditioned upon the prepaid return of the equipmentclaimed to be defective to Valco Cincinnati, Inc. for examination andverification. If claimed defect is verified, repairs or replacements will be madeF.O.B. Cincinnati, Ohio, U.S.A. or ex-works Telford, U.K. If the inspection ofthe equipment does notnotnotnotnot disclose any defect of workmanship or material, anynecessary repairs will be made at a reasonable charge and returntransportation will be charged.

This is the only authorized Valco Cincinnati, Inc. warranty and is in lieu of allother expressed or implied warranties, representations or any otherobligations on the part of Valco Cincinnati, Inc.

The warranty for cold glue equipment and electronic controls for a period ofone (1) year from the date of shipment by Valco Cincinnati, Inc.

All hot melt components except cast-in heating elements are warranted for aperiod of six (6) months from the date of shipment by Valco Cincinnati. Cast-in heaters carry an additional, pro-rated warranty not to exceed three (3)years from the date of shipment by ValcoMelton, a Valco Cincinnati, Inc.company.

12-1ValcoMelton

SECTION 12 - SERVICESECTION 12 - SERVICESECTION 12 - SERVICESECTION 12 - SERVICESECTION 12 - SERVICE

If a problem with your system persists, contact a ValcoMelton TechnicalSupport representative. If your need is urgent, we encourage you to contactour corporate office in Cincinnati, Ohio, U.S.A. at (513) 874-6550. If theproblem cannot be resolved, Valco Cincinnati, Inc. will promptly arrange tohave a technical representative visit your facility. Any charges for a servicecall will be quoted at that time. Any part that fails during the warranty periodshall be returned prepaid to Valco Cincinnati, Inc. by the customer fordisposition.

Upon request, ValcoMelton personnelare available to repair or replace suchparts at the customer’s facility. Chargesfor this service include travel time andexpenses.

If an equipment problem is the result of customer abuse, improper installationor operation, all travel time, labor, parts, and expenses will be charged to thecustomer.

If the responsibility for a problem cannot be absolutely determined, thecustomer will be charged for travel time and expenses only. No charge will bemade for parts and labor.

A-1ValcoMelton.

APPENDIX A - PASSWORD LEVELSAPPENDIX A - PASSWORD LEVELSAPPENDIX A - PASSWORD LEVELSAPPENDIX A - PASSWORD LEVELSAPPENDIX A - PASSWORD LEVELS

The Unit has multiple security levels to protect important information againstunauthorized access. The levels are enabled with different PIN codes whenentering the ‘Setup menu’. The following list includes the PIN codes for thedifferent levels and describes the difference between them.

Level 1- OperatorLevel 1- OperatorLevel 1- OperatorLevel 1- OperatorLevel 1- Operator (no password required - default level) (no password required - default level) (no password required - default level) (no password required - default level) (no password required - default level)

• Can view most information with only basic editing available

• Can adjust temperature setpoints

• Can turn zones on and off

Level 2 - Advanced OperatorLevel 2 - Advanced OperatorLevel 2 - Advanced OperatorLevel 2 - Advanced OperatorLevel 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 Diagnosticsmenu 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: 6550) (PIN Code: 6550)

• Can access all Level 1 and 2 features

• Can access Maximum Temperature parameter in System Setupmenu

• Can access Peripherals (Inputs/Outputs) and TemperatureControl (PID) menu groups

Level 0 - ProtectedLevel 0 - ProtectedLevel 0 - ProtectedLevel 0 - ProtectedLevel 0 - Protected (no password required) (no password required) (no password required) (no password required) (no password required)

Level 0 is an alternate default level that locks out ALL edits, for applicationswhere the plant wishes to prevent any and all changes, including temperaturechanges.

The Password Pin input function is still accessible.

To set the unit to Level 0 as the default level (from Level 2 or higher):

C o n t i n u e d N e x t P a g e

A-2 ValcoMelton

Appendix A - Password Levels MM125 - D-90 Hot Melt Unit

Setting Level 0 as Default -Continued

B-1ValcoMelton.

APPENDIX B - POWER REQUIREMENTSAPPENDIX B - POWER REQUIREMENTSAPPENDIX B - POWER REQUIREMENTSAPPENDIX B - POWER REQUIREMENTSAPPENDIX B - POWER REQUIREMENTS

System PowerRequirementCalculation -D-90 Units

WARNING!WARNING!WARNING!WARNING!WARNING! Calculate all power requirements, as stated below,before hooking up power. OTHERWISE, DEATH ORSEVERE INJURY AND DAMAGE TO EQUIPMENTAND/OR THE CIRCUIT COULD OCCUR.

For incoming power requirements, see Section 4 -Installation.

Power requirements for the D-90 System (unit, hosesand guns) must be calculated before hooking up power,to verify that the hoses and guns do not exceed thepower rating for the unit. Personnel injury, as well asserious equipment damage, can result from overloadingthe system.

This calculation will depend on the following two factors:

· The wattage for any hose/gun pair· The total wattage for all hoses and guns

Perform the system power requirement calculation for the D-90 unit as follows,referring to Table 1, below:

1. Add the power requirements of hose #1 and gun #1. Comparethis value to the maximum wattage given in Line 1 of Table 1.





Table 1. Maximum Allowable Wattage for the D-90 Series UnitTable 1. Maximum Allowable Wattage for the D-90 Series UnitTable 1. Maximum Allowable Wattage for the D-90 Series UnitTable 1. Maximum Allowable Wattage for the D-90 Series UnitTable 1. Maximum Allowable Wattage for the D-90 Series Unit

Line Description Maximum Wattage (W)

1 Total for hose/gun 1 pair 2300 2 Total for hose/gun 2 pair 2300 3 Total for hose/gun 3 pair 1400 4 Total for hose/gun 4 pair 1400 5 Total for hose/gun 5 pair 1400 6 Total for hose/gun 6 pair 1400 7 Total for all hoses and guns 8600

B-2 ValcoMelton

Appendix B - Power Requirements MM125 - D-90 Hot Melt Unit

System Power RequirementCalculation - D-90 Units -Continued


7. Add the power requirements of all hoses and all guns. Comparethis value to the maximum wattage for all hoses and guns givenin Line 7 of Table 1.

8. If any of the power requirements calculated in steps 1-7 exceedany of the maximum allowable wattages given in Table 1, thehose length or gun configuration must be changed, to reduce allpower requirements to below maximum-allowable wattages.If each of the power requirements calculated in steps 1-7 isbelow the maximum allowable wattages given in Table 1, thesystem power requirement is within allowable limits.

Documents

D-90 Hot Melt Unit€¦ · as an aid for installing, operating, and servicing the D-90 hot melt unit. It also contains a list of part numbers for replacement parts. If you need more