D4 Hot Melt Unit...Tel: +49 211 984 798-0 Fax: +49 211 984 798-20 Melton S.L.U. Pol. Industrial...

D4 Hot Melt Unit Manual Number: MM147

Revision Date: 6/2018

© Valco Melton All Rights Reserved

This manual is provided with the D4 Hot Melt Unit and may be used only in accordance with the terms of purchase. No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Valco Cincinnati, Inc. The information in this manual is furnished for educational purposes only, is subject to change without notice, and should not be construed as a commitment by Valco Cincinnati, Inc. This manual written and designed at Valco Melton, 497 Circle Freeway Drive, Suite 490, Cincinnati, Ohio 45246. http://www.valcomelton.com Part Number: MM147 Written and printed in the USA.

Valco Cincinnati, Inc. 497 Circle Freeway Drive Suite 490 Cincinnati, OH 45246 Tel: (513) 874-6550 Fax: (513) 874-3612 Email: [email protected] Web: http://www.valcocincinnatiinc.com

Valco Cincinnati Limited Hortonwood 32 Telford, TFI 7YN, England Tel: (+44) 1952-677911 Fax: (+44) 1952-677945 Email: [email protected] Web: http://www.valco.co.uk

Valco Cincinnati GmbH Bonnerstrasse 349 40589 Dusseldorf-Benrath, Germany Tel: +49 211 984 798-0 Fax: +49 211 984 798-20 Melton S.L.U. Pol. Industrial Agustinos calle G, n. 34 31160 Orcoyen, Navarra, Spain Tel: (34) 948-321-580 Fax: (34) 948-326-584 Valco Melton France Technoparc des Hautes Faventines 32 Rue Jean Bertin 26000 Valence Tel: +33 (0)4 75 78 13 73 Fax: +33 (0)4 75 55 74 20

Declaration of Conformity (According to EN 45014)

The following declaration is issued under the sole responsibility of the manufacturer:

Manufacturer: Valco Melton A division of Valco Cincinnati, Inc. 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.U. Pol. Industrial Agustinos calle G, n. 34 31160 Orcoyen Navarra, Spain

declares that the product:

Product Name: D4 Hot Melt Unit complies with the following Council Directives:

Safety of Machinery: 2006/42/EC

Low Voltage Equipment: 2014/35/EU

EMC: 2014/30/EU

Reduction of Hazardous Substances (RoHS) 2011/65/EC and conforms to the following standards:

Safety: EN60204-1:2006 EN13849-1

Risk: ISO12100:2010

EMC Emissions: EN61000-6-4:2007 EN61000-4-2

EMC Immunity: EN61000-6-2:2005 EN61000-4-3 EN61000-4-4 EN61000-4-5 EN61000-4-6 EN61000-4-8 EN61000-4-11

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

Signature: Cincinnati, OH USA David H. Swedes, Vice President of Engineering & Manufacturing

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

MM147 - D4 Hot Melt Unit Table of Contents

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Table of Contents

Table of Contents ................................................................................................ 5

Section 1 - Introduction ....................................................................................... 11

Description ............................................................................................................................................................... 11

Nameplate ................................................................................................................................................................ 11

S Number Configuration .......................................................................................................................................... 12

Section 2 - Safety and Use ................................................................................... 13

Read Thoroughly Before Handling Equipment ....................................................................................................... 13

Symbols ................................................................................................................................................................... 13

Owner Responsibilities ............................................................................................................................................ 14

Limitations of Use .................................................................................................................................................... 14

Installation/Startup/Use Safety Information............................................................................................................. 15

Shut Down Safety Information ................................................................................................................................ 16

Hot-Melt-Specific, General Safety Information ....................................................................................................... 16 What to Do if Contact with Hot Adhesive Occurs ................................................................................... 17 What to Do if Inhalation of Adhesive Fumes Occurs .............................................................................. 17 What to Do if Adhesive-Related Fire or Explosion Occurs ..................................................................... 18

Hose Safety Information .......................................................................................................................................... 19

Section 3 - Basic Features ................................................................................... 21

Key Features ............................................................................................................................................................ 21

Section 4 - Installation ......................................................................................... 23

Choosing a Location ................................................................................................................................................ 23 Mounting Footprint .................................................................................................................................. 24

Installation Kit ........................................................................................................................................................... 24

Routing Low-Voltage Leads .................................................................................................................................... 24

Connecting the Electrical Power ............................................................................................................................. 25

Connecting the Hoses ............................................................................................................................................. 27

Connecting the Hot Melt Hoses to the Applicators ................................................................................................. 29

Wiring Diagram ........................................................................................................................................................ 30

Wiring Diagram - Before 5/18 .................................................................................................................................. 31

Input/Output Connections ........................................................................................................................................ 32

Input/Output Connections - Before 5/18 ................................................................................................................. 34

Section 5 - Setup ................................................................................................. 35

Control Panel ........................................................................................................................................................... 35

Table of Contents MM147 - D4 Hot Melt Unit

6

Power On/Off and Standby Mode ........................................................................................................................... 37

Display Contrast Adjustment ................................................................................................................................... 38

User Interface........................................................................................................................................................... 39 Navigation ............................................................................................................................................... 39 Memory Storage ..................................................................................................................................... 39 Thumbwheel vs. Single Digit Edit ........................................................................................................... 40

Entering Passwords ................................................................................................................................................. 41

Set Language ........................................................................................................................................................... 42

Set Temperature Units ............................................................................................................................................ 44 Programming Temperatures ................................................................................................................... 45 Tank Temperature .................................................................................................................................. 46 Hose/Valve Temperature ........................................................................................................................ 46

System/Pump Ready Temperature Offset ............................................................................................................. 48

Ready Delay Time ................................................................................................................................................... 49

Over Temperature Alarm ......................................................................................................................................... 50

Under Temperature Alarm ....................................................................................................................................... 51

Maximum Temperature ........................................................................................................................................... 52

Beacon/Alarm Setup ................................................................................................................................................ 53 Beacon 2 ................................................................................................................................................. 55

Automatic Pump Mode ............................................................................................................................................ 56

Pressure Setup ........................................................................................................................................................ 57

Pot Fill Mode ............................................................................................................................................................ 60

Level Sensor Setup ................................................................................................................................................. 61 Hopper Feeder - Low Level Detection .................................................................................................... 61

Door Switch ..................................................................................................................................61 Feeder Valve Operation ..............................................................................................................61

Filter Change Timer ................................................................................................................................................. 62

Clock and 7-Day Timer ............................................................................................................................................ 62 Programming Shifts ................................................................................................................................ 63

Diagnostics ............................................................................................................................................................... 66

Setback .................................................................................................................................................................... 67 Setback Temperature ............................................................................................................................. 67 Automatic Setback Timeout .................................................................................................................... 68

Startup Setup ........................................................................................................................................................... 69 Sequential Start - Hose .......................................................................................................................... 69

History ...................................................................................................................................................................... 71

User Inputs and Outputs .......................................................................................................................................... 72

Configuration ............................................................................................................................................................ 74 Zone Configuration ................................................................................................................................. 74 Auxiliary Zones ....................................................................................................................................... 74 Auxiliary I/O ............................................................................................................................................ 75 Pump Type ............................................................................................................................................. 75 Gramage Enable .................................................................................................................................... 75 Config Comm Menu ................................................................................................................................ 76


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Pump Configuration ................................................................................................................................ 77 Number of Pumps ........................................................................................................................ 77 Pump Configuration for Specific No. Pump ................................................................................ 77

Pump Setup Menu .................................................................................................................................. 78

Encoder Setup Menu ............................................................................................................................................... 80

PID Setup Menu ...................................................................................................................................................... 81 PID Settings ............................................................................................................................................ 81 AutoTune Feature ................................................................................................................................... 81

Memory Menu .......................................................................................................................................................... 82

Restoring Factory Default Settings ......................................................................................................................... 82

Updating 152XX746 CPU Board Software via USB Memory Stick ....................................................................... 82 Required Materials .................................................................................................................................. 82 Procedure ................................................................................................................................................ 82 Hot Melt CPU uTasker Bootloader (119XX301) Error Codes ................................................................. 84

Initialization Instructions ........................................................................................................................................... 85 Navigating the Setup Wizard .................................................................................................................. 85 Adjusting the Display............................................................................................................................... 85 Selecting the Language .......................................................................................................................... 85 Configuring the Unit Type ....................................................................................................................... 86 Selecting the Communication Protocol ................................................................................................... 86 Selecting the RTD type ........................................................................................................................... 87 Selecting the Number of Pumps ............................................................................................................. 87 Selecting the Number of Hose Outlets.................................................................................................... 87 Selecting the Temperature Units ............................................................................................................ 88 Selecting the Pattern Control .................................................................................................................. 88 Finishing the Configuration ..................................................................................................................... 88

Adjusting the Pressure Control Valve ..................................................................................................................... 89 Adjusting the Single-Stage Relief Valve ................................................................................................. 89

Gramage Feature .................................................................................................................................................... 90

D Series Variable Frequency Drive Configuration (If Equipped) ........................................................................... 91 Before 5/18 .............................................................................................................................................. 92

Section 6 - Operation ........................................................................................... 93

Start the Unit ............................................................................................................................................................ 93

Temperature ............................................................................................................................................................ 94 Setpoint and Actual Temperature ........................................................................................................... 94 Temperature Status LEDs ...................................................................................................................... 94

Pump Operation ....................................................................................................................................................... 95 Pump On/Off Key .................................................................................................................................... 95 Pump Status Key .................................................................................................................................... 95

Fixed Speed Unit ......................................................................................................................... 95 Variable Speed Unit ..................................................................................................................... 96

Clock On/Off ............................................................................................................................................................. 96

Setback .................................................................................................................................................................... 97 Automatic Setback .................................................................................................................................. 97

Pot Fill - External Low Level Detection ................................................................................................................... 98

Hopper Feeder - Internal Low Level Detection ....................................................................................................... 98

Beacon Alarm .......................................................................................................................................................... 98


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External Input ........................................................................................................................................................... 98

Filling the Tank ......................................................................................................................................................... 99

Section 7 - Maintenance ...................................................................................... 101

General..................................................................................................................................................................... 101

Cleaning the Exterior of the Unit ............................................................................................................................. 101

Changing the Adhesive ........................................................................................................................................... 102

Flushing the System ................................................................................................................................................ 102

Parts Replacement .................................................................................................................................................. 104 Changing Fuses ..................................................................................................................................... 104 Changing the Filter ................................................................................................................................. 105

Section 8 - Troubleshooting and Repair ............................................................... 107

Section 9 - Specifications .................................................................................... 109

General..................................................................................................................................................................... 109

Dimensions .............................................................................................................................................................. 110

Section 10 - Part Number List .............................................................................. 111

How to Order Parts .................................................................................................................................................. 111

D4 Unit ..................................................................................................................................................................... 112 D4 Unit, Fixed speed, 2 exit (776xx887) ................................................................................................ 114 D4 Unit, Fixed speed, 4 exit (776xx888) ................................................................................................ 115 D4 Unit, Variable speed, 2 exit (776xx889) ............................................................................................ 116 D4 Unit, Variable speed, 4 exit (776xx890) ............................................................................................ 117 D4 Unit, Variable speed, 2 exit (776xx889) - before 5/18 ...................................................................... 118 D4 Unit, Variable speed, 4 exit (776xx890) - before 5/18 ...................................................................... 119

D4 Base Unit (776xx392) ........................................................................................................................................ 120 D4 Base Unit (776xx392) - before 5/18 .................................................................................................. 123

Installation Kit (091xx734) ....................................................................................................................................... 125

Option Kits ................................................................................................................................................................ 126 AutoFeed ................................................................................................................................................ 126

Vacuum Feeder Assembly - 776xx305 .......................................................................................126 Pump Control .......................................................................................................................................... 128

Cable Assembly Handgun Pump Control (029xx552) ................................................................128 Pump Kit, Standard Width (561xx216) ........................................................................................129 Pump Kit, Half Width (561xx220) ................................................................................................129

Internal Level Sensors ............................................................................................................................ 130 Internal Low-Level Sensor Kit (776xx892) ..................................................................................130

External Pot Fill ...................................................................................................................................... 131 External Pot Fill Kit (776xx757) ...................................................................................................131

Alarm Beacon ......................................................................................................................................... 133 Alarm Beacon Assembly, 24V (782xx701) .................................................................................133 Alarm Beacon Replacement Bulb ...............................................................................................134 Siren Element Kit (776xx762) ......................................................................................................134

Pressure Relief ....................................................................................................................................... 135 Pneumatic Pressure Relief Kit (707xx212) .................................................................................135 Relief Valve Assembly (594xx189) ..............................................................................................136

Pressure Monitoring ............................................................................................................................... 137


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Pressure Switch Kit, 50-130 PSI (481xx050) .............................................................................. 137 Pressure Switch Kit, 160-400 PSI (481xx051) ............................................................................ 138 Pressure Switch Kit, 275-850 PSI (481xx052) ............................................................................ 138 Heavy Duty Pressure Gauge (786xx129) ................................................................................... 138 Pressure Transducer Assembly (521xx019)............................................................................... 139

Auxiliary I/O ............................................................................................................................................. 140 Optional I/O HMU PCB Assembly (098xx134) ........................................................................... 140 Ethernet IP Kit (098xx133) .......................................................................................................... 140 24V VDC Relay Kit (776xx537) ................................................................................................... 140

Section 11 - Warranty .......................................................................................... 141

Warranty Information ............................................................................................................................................... 141 Cold Glue Equipment and Electronic Controls ....................................................................................... 141 Hot Melt Units, Hoses, Valves, Guns, and Related Equipment .............................................................. 141

Section 12 - Service ............................................................................................. 143

Appendix A - Password Levels ............................................................................. 145

Appendix B - Power Requirements ....................................................................... 147

System Power Requirement Calculation - D Series Units ..................................................................................... 147

Appendix C - Instruction Sheets for Option Kits .................................................... 149

Appendix D - Micro SD Backup & Restore ............................................................ 151

Functions .................................................................................................................................................................. 151

Error Codes .............................................................................................................................................................. 152

Appendix E - Communication Protocols-Modbus .................................................. 153

Communication Specifications ................................................................................................................................ 153

Hardware Considerations ........................................................................................................................................ 153

Parameter List .......................................................................................................................................................... 154

Appendix F - Communication Protocols-Ethernet IP ............................................. 163

Hot Melt Unit to EthernetIP Communication Protocol ............................................................................................ 163

Data Packets used for Ethernet/IP communication ................................................................................................ 163 Send Packet (PLC) Frame ...................................................................................................................... 163 Bit Definitions for Control Byte 0 ............................................................................................................. 164 Command Byte 1 .................................................................................................................................... 164 Data Index Byte 2 .................................................................................................................................... 165 Channel Byte 3 ........................................................................................................................................ 165 Data Value Byte 4 and 5 ......................................................................................................................... 166 Pump1 speed%...Pump4 speed% Byte 6 - 13 ........................................................................................ 166 Receive Packet (Melter) Frame .............................................................................................................. 166 Data Index Byte 2 .................................................................................................................................... 167 Channel Byte 3 ........................................................................................................................................ 167 Channel Read Data Bytes 4 and 5 ......................................................................................................... 167 Channel Read Data + Bytes 6 - 15 ......................................................................................................... 167

Current Alarm Types................................................................................................................................................ 168 Error Codes ............................................................................................................................................. 169

Examples ..................................................................................................................................... 169 Status Indicators ..................................................................................................................................... 170

Network Status LED .................................................................................................................... 170


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Module Status LED ......................................................................................................................170 Link/Activity LED ..........................................................................................................................170

MM147 - D4 Hot Melt Unit Section 1 - Introduction

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Section 1 - Introduction ValcoMelton, a division of Valco Cincinnati, Inc., has prepared this manual as an aid for installing, operating, and servicing the D4 hot melt unit. It also contains a list of part numbers for replacement parts. If you need more information, contact your ValcoMelton representative.

Description The D4 hot melt unit is a medium-volume system designed to melt and pump thermoplastic adhesives. The D4 unit features a precision electronic temperature control, a digital multi-zone temperature display, an electric motor-driven gear pump (variable or fixed speed), and an adjustable pressure control.

Features and capabilities include:

• Precision electronic temperature control

• Capacity of up to four (4) hoses and guns

• Positive displacement electric motor-driven gear pump

• Adjustable pressure control

• Integrated over-temperature protection

• User selectable inputs and outputs

• Variable frequency drive (VFD) on Variable Speed Units

• Accepts encoder or tachometer inputs for Variable Speed Units

Nameplate The nameplate on the side of the unit identifies the unit as well as key information. This information includes the part number, serial number, operating voltage, maximum current, number of phases and the frequency. The part number, operating voltage and maximum current will vary depending on the platen type and operating voltage.

Figure 1-1. Nameplate Information

Section 1 - Introduction MM147 - D4 Hot Melt Unit

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S Number Configuration The S number is used to configure the D4 hot melt unit to meet specific customer needs. All options are add-ons to the base unit assembly and as a result, most of the options can be field installed. All units ordered using the S number configuration will have a final selection number engraved on the nameplate.

Selection Number – D10/D16 Hot Melt Unit Unit Code Code Description Code Description

D4 Base unit prefix Feature 1 Unit Type

F2 Fixed speed, 2 exit V2 Variable speed, 2 exit F4 Fixed speed, 4 exit V4 Variable speed, 4 exit

Feature 2 Alternate Lid 0 None 1 Auto feed included

Feature 3 Pump Enable

0 None 1 Pump control included 1 handgun 2 Pump control included 2 handguns

Feature 4 Motor/Pump Type ST 3.18cc/rev pump, variseal pump HT 1.54cc/rev pump, variseal pump

Feature 5 Not Used 00 None

Feature 6 Not Used 00 None

Feature 7 Pattern Control 00 None

Feature 8 Level Sensors

00 None 01 Low level sensor 02 Low level sensor w/beacon 03 Low level sensor w/beacon & alarm 04 High level sensor 10 External pot fill 11 External pot fill w/beacon 12 External pot fill w/beacon & alarm 13 Beacon 14 Beacon & alarm

Feature 9 Pressure Relief

00 Manual relief PR Pneumatic Relief UR Uniflow Relief

Feature 10 Pressure

Monitoring

00 None P1 Pressure switch 50-130psi P2 Pressure switch 160-400psi P3 Pressure switch 275-850psi P4 Heavy duty pressure gauge T1 Pressure transducer

Feature 11 Auxiliary I/O

Board

0 None Y Auxiliary I/O board included 4 Ethernet IP included

MM147 - D4 Hot Melt Unit Section 2 - Safety and Use

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Section 2 - Safety and Use Read Thoroughly Before Handling Equipment

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

Read this entire section before handling the equipment.

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

This symbol represents a Caution or a Warning. Cautions draw special attention to anything that could damage equipment or cause the loss of data. Warnings draw special attention to anything that could injure or kill the reader. Both Cautions and Warnings are placed before the step they apply to.

This symbol represents a Hot Surface.

This symbol represents a Puncture Risk. It is usually used in regard to nozzle cleaning appliances and other sharp instruments that can cause puncture wounds and risk exposure to bloodborne pathogens and other debris.

This symbol means that Working Gloves are required.

This symbol means that Goggles are required.

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

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

This symbol indicates the need to Lock Out All Power Sources and to let them de-energize before attempting any type of work or maintenance. If power is not locked out, the person working on the equipment may be injured or killed if someone unknowingly switches on the power to the equipment.

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

Section 2 - Safety and Use MM147 - D4 Hot Melt Unit

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Owner Responsibilities The owner of the equipment is under obligation to manage all safety information. Some examples include:

• Examine all safety materials and documents as well as jurisdictional 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 be read/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 access to the safety information, training, and equipment according to jurisdictional authorities.

The owner of the equipment is under obligation to make certain that all instructions, requirements, and jurisdictional laws are met. Some examples include:

• Make sure there are regular inspections of equipment and safety devices.

• Have regular safety drills and inspections supervised by the proper authorities.

• Provide all required safety items, first aid equipment, and training.

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

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

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

• Make sure all personnel understand and can follow safety policies and procedures for the organization as well as for the specific equipment.

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

Limitations of Use Read this document and all information regarding the equipment before handling the equipment. The intended use of the equipment is stated in Section 1 of this manual.

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


15

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

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

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

WARNING! Properly route all electrical wires. Never tamper with equipment. Only use approved and correct voltage, type of current, fuses, and other power supplies. Replace worn cords, hoses, etc. immediately. FAILURE TO OBSERVE WARNING MAY RESULT IN DEATH, PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE.

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

WARNING! Never use any Valco Melton equipment in an explosive environment. Explosive environments include, but are not limited to, solvent-based cleaners or adhesives, explosive materials, radioactive materials, etc. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING! Equipment will start automatically when remotely controlled by triggering devices. Be sure to disable all triggering devices, carefully release hydraulic pressure, and disconnect air pressure before servicing or working near guns, valves, and other triggered devices. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.


16

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

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

WARNING! Disconnect and lock out all power before maintenance or other need to open the equipment. Only qualified personnel should open and service the control. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING! Equipment may still be energized even if unplugged! When making adjustments or performing checkout procedures, stay clear of any moving mechanical parts and do not touch exposed electrical equipment or electrical connectors. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING! Disconnect/disable all mechanical and/or electrical devices that send activation signals to the gun(s), valve(s), melter pump(s), etc. This includes pattern controls, timers, input/output signals, etc. Only qualified personnel should open and service the control. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING! Disable all triggering devices, relieve all residual pressure (hydraulic and air) and allow adhesive to cool before attempting to disconnect guns, hoses, valves, etc. Only qualified personnel should open and service the control. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

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

Hot-Melt-Specific, General Safety Information Valco Melton hot melt units have the following universal safety precautions in addition to all other universal precautions previously mentioned (this is not intended to be an exhaustive list; follow all instructions and safety precautions for the specific type of equipment involved):

WARNING! Never process any polyurethane reactive (PUR) hot melt or solvent-based material in a Valco Melton unit unless you are certain that the unit is compatible and is marked “PUR”! Read all instructions and MSDS sheets carefully, following manufacturer’s instructions, especially regarding heat levels. If you have any question as to the compatibility of a Valco Melton unit for PUR hot melt, call your Valco Melton Representative before attempting to use the unit for PUR or solvent-based materials. OTHERWISE, HAZARDOUS FUMES, EXPLOSION, DEATH, OR PERSONAL INJURY COULD OCCUR.

WARNING! Keep pump cover and electrical enclosures closed except during setup, service, and checkout procedures. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.


17

WARNING! People with respiratory problems (e.g., asthma, bronchitis, etc.) should not work in the vicinity of molten adhesive. RESPIRATORY PROBLEMS MAY BE AGGRAVATED BY THE FUMES. Do not wear a face mask when working around molten adhesive. THE MASK MAY TRAP THE FUMES AND DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING! Keep hot melt hoses away from walkways and the moving parts of hot melt systems. OTHERWISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR.

WARNING! Hot surfaces! Do not touch! Use extreme caution when refilling the unit by hand. OTHERWISE, PERSONAL INJURY COULD OCCUR.

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

WARNING! Never use an open flame to heat hot melt components or adhesive. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR.

What to Do if Contact with Hot Adhesive Occurs

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

WARNING! Do not attempt to remove heated hot melt adhesive from the skin. OTHERWISE, SEVERE PERSONAL INJURY AND DEATH COULD OCCUR.

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

It is strongly recommended that a source of clean, cold water be provided near the hot melt work area.

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

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

What to Do if Inhalation of Adhesive Fumes 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.


18

What to Do if Adhesive-Related Fire or Explosion Occurs

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

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

WARNING! Exposed arcing may ignite the fume/air mixture. Shield all electrical equipment from melt fumes to avoid exposed arcing. OTHERWISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR.

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

If the hot melt adhesive ignites, promptly perform the 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.

If you feel you can fight the fire safely, do one 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 the flames.


19

Hose Safety Information

DO NOT DO Do not use bindings, wire ties, or unapproved fasteners around the hoses.

Do use approved wrapping (P/N 775xx827), making sure the wrapping is slightly snug but not tight.

Do not place hoses close together.

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

Do not bend hoses sharply. Do not allow kinks or indentations in the hoses.

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

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

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

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

Do use two hands and two wrenches to tighten or loosen connections on hoses. Do wrench only on large hexagon swivel nuts.

Do not allow hoses to rub against objects or to come into contact with sharp edges or points.

Do wrap the hoses in approved padding (P/N 795xx549) if the hoses must be installed where they will come into contact with objects.

Do not use worn, damaged, or bent hoses.

Do inspect all hoses regularly for damage and/or wear and replace damaged or worn hoses immediately.


20

MM147 - D4 Hot Melt Unit Section 3 - Basic Features

21

Section 3 - Basic Features Key Features This section describes the basic features of the D-Series Hot Melt Systems. The basic features of the D4 Hot Melt Units are similar, with the exception of the tank capacity of each unit.

Key Features1 Unit power switch

2 Temperature controller

3 Tank lid

4 Electrical enclosure door

5 Manifold

6 Pressure gauge

7 Pressure relief valve

8 Hose/valve receptacles

9 Data plate

10 Hose ports

11 Filter

Section 3 - Basic Features MM147 - D4 Hot Melt Unit

22

MM147 - D4 Hot Melt Unit Section 4 - Installation

23

Section 4 - Installation Choosing a Location The D4 hot melt unit is assembled at the factory. However, the power and the glue hoses must be connected by the customer. This section contains instructions for making the necessary connections.

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

• Service personnel will need access to the left and right sides of the unit for electrical service, and the back of the unit for changing the glue hoses and filter.

• The operator needs easy access to the front operator panel.

• If the unit will not be moved from one location to another, it should be screwed or bolted to a suitable stable, flat, level surface.

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

• The unit should have clearance above the top of the unit so it may be filled easily without obstruction to the operator.

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

• The location for the unit should be clean. Dirt in the glue tank causes clogging of the applicator nozzles.

• The unit should be protected from high and low ambient temperatures, as well as from rapid changes in ambient temperature.

• The unit must be protected from condensate and water.

• The unit must be protected from strong vibrations.

• The tank lid must be able to open fully back so there is no danger of it falling onto operator’s hands while filling.

Section 4 - Installation MM147 - D4 Hot Melt Unit

24

Mounting Footprint

Installation Kit An Installation Kit (091xx734) is available for this unit, containing spare fuses, a copy of this manual on CD and warranty information. For details, see Section 10 - Parts List.

Routing Low-Voltage Leads 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 wires carrying a high-current load.

• Do not route low-voltage leads adjacent to, or across wires carrying a high-current load. If low-voltage leads must cross or run parallel to wires carrying high current, keep the leads at least 6" (152 mm) from high-current wires.

• Do not splice or solder leads.

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

• All wiring should be in conduits or wireways.


25

Connecting the Electrical Power WARNING! Electrical connections should be made only by experienced service personnel! Failure to

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

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

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

If a dedicated circuit is not available, do not connect the unit to a circuit that supplies high-amperage equipment—use another circuit such as a lighting circuit. Otherwise, equipment may not function properly.

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

WARNING! Only experienced service personnel should connect power to the unit! Failure to observe could result in personal injury, death, or damage to equipment. The use of an earth-leakage or ground-fault power breaker is recommended with this unit. This unit must be earthed or grounded. Failure to observe could result in personal injury, death, or damage to equipment.

The D4 hot melt unit can be set up to use one of the following power sources:

Incoming Electrical Service Power Connector

Terminals Voltage Plug Connector Label

A B C D PE Part No. / Color Part No. / Color

380VAC 3-phase with Neutral (4 wire service)

3/N/PE AC 400/230V L1 L2 L3 N PE 029XX437

Blue 782XX262

Blue

200 to 240VAC 3-phase w/o Neutral (3 wire service)

3/PE AC 200-240V L1 L2 X L3 PE 029XX435

Black 782XX260

Black

200 to 240VAC 1-phase w/o Neutral (2 wire service)

1/PE AC 200-240V L1 X X L2 PE 029XX436

White 782XX261

White

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

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

1. Open the electrical enclosure door.

2. Route the power cable through the cable clamp in the chassis of the unit. The power cable must meet the minimum requirements given in the chart above.

3. Referring to the chart above, locate the appropriate voltage selector plug and power connector label corresponding to the incoming electrical service.


26

Connecting the Electrical Power - Continued

4. Attach the appropriate power connector label to the power connector on the 12 zone board (see illustration).

029XX435 Selector Plug Matching Black Label

WARNING! The label must be correctly oriented on the power connector.

5. Remove the power connector from the 12 zone board and connect the power cable leads to the power connector terminals as shown in the chart above.

6. Install the appropriate voltage selector plug into the connector marked J15 on the 12 zone board (see illustration).

7. Plug the power connector into the 12 zone board (see illustration).

8. Verify that all connectors are fully seated and the power connector terminal screws are secure.

9. Close the electrical enclosure door.


27

Connecting the Hoses WARNING! Never disconnect the hot melt hoses from a running unit. Hot melt is under high pressure.

Turn off the pump, shut off power to the unit, and actuate the gun to relieve residual pressure before removing the hose. Failure to observe could result in personal injury, death, or damage to equipment.

CAUTION! Do not operate the unit with the fluid outlet ports open to the 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 a chance of being crushed or cut.

• Avoid the use of unnecessarily long hoses where the hose is looped or curled on the floor. Excess twisting of the hose can cause irreparable damage to it.

• Maintain separation between hoses to avoid hot spots.

To connect the hot melt hoses to the unit, follow these steps:

1. Using a pair of wrenches, one on the fluid outlet fitting and the other on the fluid cap, remove the protective caps from the fluid outlet fittings.

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

3. Ensure that the fluid outlet ports are clean.

4. Select the end of the glue hose that has the lead assembly with the male electrical connector (Figure 4-1).

Figure 4-1. Hot Melt Hose

End of glue hose that connects to fluid fitting on applicator

Unit connection

Gun connection

End of glue hose that connectsto fluid fitting on unit


28

Connecting the Hoses - Continued

5. Attach this end of the glue hose to the fluid outlet fitting in the manifold (Figure 4-2).

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

The left fluid outlet port should be used first to prevent trapped hot melt adhesive from charring in the lower portion of the manifold.

Fittings are available from Valco Cincinnati (see Section 10 - Part-Number List).

Using two wrenches prevents the hose from twisting inside while it is being tightened.

7. Connect the lead assembly’s male electrical connector to the electrical receptacle located on the back panel above the fluid outlet ports. Connections are shown in Figure 4-2.

Fuses for the receptacles are located in the installation kit provided with the unit.

Figure 4-2. Hose Connections


29

Connecting the Hot Melt Hoses to the Applicators WARNING! If hand-held applicators are used, care should be taken to ensure safe operation. Heat

protective gloves should be worn. Hot melt is under high pressure at the nozzle tip of the applicator. Failure to observe could result in personal injury (burns).

WARNING! If hand-held applicators are used, operators should not work facing each other. Failure to observe could result in personal injury (burns). If fixed applicators are used, they should be protected from accidental contact by the operator. Failure to observe could result in personal injury (burns).

CAUTION! Hand-held applicators require a suitable hook for hanging while not in use. The hook must support the weight of the applicator with the hose. Failure to observe could result in damage to equipment.

Either hand-held or fixed applicators can be used with the unit.

To connect the fixed applicators, follow these steps:

1. Mount the applicator to the desired location on the parent machine.

Do not place applicators where the ambient temperature is low or where there is a draft.

2. Connect the end of the hot melt hose (Figure 4-3) to the fluid inlet fitting on the applicator (Figure 4-4).

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

Figure 4-3. Hot Melt Hose

Figure 4-4. Applicator

Fluid inlet fitting

Lead assembly with female connector (connects to lead assembly on applicator)

End of glue hose that connects to fluid fitting on applicator


30

Wiring Diagram

O'TEMP SENSOR

TA

NK

D C B AG

ND

TANK HEATER

PR

OG

RAM

MAB

LEO

UTP

UTS

POW

ER IN

PUT

240V

AC

, 1 P

HA

SE

240V

AC

, 3 P

HA

SE

400/

380,

3 P

HA

SE

40A

MA

X.

SE

E C

HA

RT

FOR

CO

NN

EC

TIO

NS

HO

SE

/GU

N 1

029XX789

029XX548

J3

3J

30

J6

J3

2

J3

1

J8 J

27

029XX790

TO

GR

OU

ND

ST

UD

J3

4

J1

1

CO

MM

UN

ICA

TIO

N C

AB

LE

15

1X

X7

47

- 1

2 Z

ON

E B

OA

RD

(Ni1

20)

CP

U B

OA

RD

15

1X

X7

46

OV

ER

LA

Y/C

PU

BO

AR

D A

SS

Y1

37

XX

02

9

02

9X

X5

46

21

OK

43 65

1

B

2

A

J1

4

HO

SE

/GU

N 2

J2

8

J2

50

29

XX

546

HO

SE

/GU

N 3

J1

6

J1

70

29

XX

546

HO

SE

/GU

N 4

J1

1

J1

20

29

XX

546

SW TO PWR SUPPLY

I O

PO

WE

R S

WIT

CH

48

0X

X2

46

14

8X

X0

76

- 7

5W

24V

DC

PO

WE

R S

UP

PL

Y

02

9X

X7

91D

C T

O B

OA

RD

02

9X

X5

69

AC

TO

SW

ITC

H

J4

J1

5J

27

HO

PP

ER

FE

ED

ER

KIT

77

6X

X3

05

DISPLAY CABLE

BOARD TO BOARDCONNECTION P

RO

GR

AMM

ABLE

INP

UTS

FE

ED

ER

SO

LE

NIO

D C

AB

LE

FE

ED

ER

SE

NS

OR

CA

BL

E

TANK RTD

029XX788

J3

0

BE

AC

ON

KIT

78

2X

X7

01

02

9X

X5

51

J3

5J

37

MO

TO

R A

SS

EM

BL

Y(C

AB

LE

AS

SE

MB

LY

INC

LU

DE

D)

11

0X

X3

65

- V

AR

IAB

LE

SP

EE

D-O

R-

11

0X

X3

57

- F

IXE

D S

PE

ED

J3

7 (VARIABLE SPEED ONLY)

02

9X

X7

92

VF

D P

OW

ER

CA

BL

EGR

OU

ND

TO

VF

D G

RE

EN

MO

UN

TIN

G S

CR

EW

L1

- B

LK

L2

- B

LK

T2

- B

LK

T3

- R

ED

T1

- W

HT

VA

RIA

BL

E S

PE

ED

ON

LY

GR

OU

ND

TO

VF

D G

RE

EN

MO

UN

TIN

G S

CR

EW

VF

D B

OA

RD

15

1X

X7

01

VF

D1

10

XX

42

5

J3

029XX856

VFD SIGNAL CABLE

R1

C -

BL

UL

I1 -

OR

G+

24

- R

ED

AI1

- B

LK

CO

M -

WH

T

J1

R1

B -

YE

L

J7

J7

L0

- - G

RY

L0

+ -

BR

N

1

GN

D

VF

D C

OM

M C

AB

LE

02

9X

X8

57

AU

XIL

IAR

Y I/

O B

OA

RD

09

8X

X1

34

KIT

09

8X

X1

33-O

R-

ET

HE

RN

ET

IP K

IT

LE

VE

L 1

SE

NS

OR

KIT

(L

OW

)7

76

XX

89

2

FE

ED

ER

SE

NS

OR

-OR

-L

EV

EL

1 S

EN

SO

RT

O J

15


31

Wiring Diagram - Before 5/18

O'TEMP SENSOR

TA

NK

D C B AG

ND

TANK HEATER

PR

OG

RA

MM

ABL

EO

UTP

UTS

POW

ER IN

PUT

240V

AC

, 1 P

HA

SE

240V

AC

, 3 P

HA

SE

400/

380,

3 P

HA

SE

40A

MA

X.

SEE

CH

AR

T FO

RC

ON

NE

CTI

ON

S

HO

SE

/GU

N 1

029XX789

029XX548

J33

J30

J6

J32

J31

J8 J27

029XX790

TO

GR

OU

ND

ST

UD

J34

J11

CO

MM

UN

ICA

TIO

N C

AB

LE

15

1X

X7

47

- 1

2 Z

ON

E B

OA

RD

(N

i12

0)

CP

U B

OA

RD

15

1X

X6

50

OV

ER

LA

Y/C

PU

BO

AR

D A

SS

Y1

37

XX

01

7

02

9X

X5

46

21

OK

43 65

1

B

2

A

J14

HO

SE

/GU

N 2

J28

J25

02

9X

X5

46

HO

SE

/GU

N 3

J16

J17

02

9X

X5

46

HO

SE

/GU

N 4

J11

J12

02

9X

X5

46

SW TO PWR SUPPLY

I O

PO

WE

R S

WIT

CH

48

0X

X2

46

14

8X

X0

76

- 7

5W

2

4V

DC

PO

WE

R S

UP

PL

Y

02

9X

X7

91

DC

TO

BO

AR

D

02

9X

X5

69

AC

TO

SW

ITC

H

J4A

UX

ILIA

RY

I/O

BO

AR

D1

51

XX

66

1

J15

J27

HO

PP

ER

FE

ED

ER

KIT

776

XX

157

DISPLAY CABLE

BOARD TO BOARDCONNECTION P

RO

GR

AMM

AB

LEIN

PU

TS

FE

ED

ER

SO

LEN

IOD

CA

BL

E

FE

ED

ER

SE

NS

OR

CA

BLE

TANK RTD

029XX788

J30

BE

AC

ON

KIT

77

6X

X13

7

02

9X

X5

51

24

V R

EL

AY

KIT

77

6X

X5

37

24

VD

C S

IGN

AL

J2

3

J35

J37

MO

TO

R A

SS

EM

BL

Y(C

AB

LE

AS

SE

MB

LY

INC

LU

DE

D)

11

0X

X3

65

- V

AR

IAB

LE

SP

EE

D-O

R-

11

0X

X3

57

- F

IXE

D S

PE

ED

VF

D1

10

XX

31

0

J37 (VARIABLE SPEED ONLY)

029XX793

VFD SIGNAL CABLE

2 -

BL

U3

- O

RG

5 -

RE

D9

- B

LK1

0 -

WH

T

02

9X

X7

92

VF

D P

OW

ER

CA

BL

EGR

OU

ND

TO

VF

D G

RE

EN

MO

UN

TIN

G S

CR

EW

L1

- B

LK

L2

- B

LK

T2

- B

LKT

3 -

RE

D

T1

- W

HT

VA

RIA

BL

E S

PE

ED

ON

LY

GR

OU

ND

TO

VF

D G

RE

EN

MO

UN

TIN

G S

CR

EW

1 -

YE

L

VF

D B

OA

RD

15

1X

X6

82

J3

J5


32

Input/Output Connections The Input/Output connection interface is on the J-23 & J-24 terminals, on the bottom of the CPU Board. The CPU Board is located directly behind the Keypad. There are four opto-isolated inputs that can be programmed by the user for a variety of options. See the chart below. There are also four, dry-contact, user-selectable outputs rated for 250V @ 2A each.

CPU Board Showing Input & Output Connectors

Beacon Output Connection

Auxilliary I/O / AnybusBoard Connection

4 Output Relay Contacts

4 Opto Isolated Inputs

See the following page for input wiring options.

See the following page for output wiring options.


33

Input/Output Connections - Continued

INDIVIDUAL DRY CONTACTS

INPUT 1: DRY CONTACT BETWEEN I1 - GNDINPUT 2: DRY CONTACT BETWEEN I2 - GNDINPUT 3: DRY CONTACT BETWEEN I3 - GNDINPUT 4: DRY CONTACT BETWEEN I4 - GND

DRY CONTACTS WITH COMMON

INPUT 1: DRY CONTACT BETWEEN I1 - GNDINPUT 2: DRY CONTACT BETWEEN I2 - GNDINPUT 3: DRY CONTACT BETWEEN I3 - GNDINPUT 4: DRY CONTACT BETWEEN I4 - GND

NPN SENSOR

+: 24VDC EXCITATION VOLTAGEI1, I2, I3, I4: NPN INPUTSGND: DC COMMON

DC COM

+24VDC

NPN

NPN SENSOR

INPUT WIRING OPTIONS OUTPUT WIRING

NORMALLY OPEN NORMALLY CLOSED

OUTPUT 1N.O.

OUTPUT 2N.O.

OUTPUT 3N.O.

OUTPUT 4N.O.

OUTPUT 1N.C.

OUTPUT 2N.C.

OUTPUT 3N.C.

OUTPUT 4N.C.

PLC SOURCING OUTPUT MODULE

I1, I2, I3, I4: SOURCING INPUTS+: 24VDC

+24 VDC

SOURCING OUTPUT

PLC SOURCINGOUTPUT MODULE

PLC SINKING OUTPUT MODULE

I1, I2, I3, I4: SINKING INPUTSGND: DC COMMON

DC COMMON

SINKING OUTPUT

PLC SINKINGOUTPUT MODULE

PNP SENSOR

+: 24VDC EXCITATION VOLTAGEI1, I2, I3, I4: PNP INPUTSGND: DC COMMON

DC COM

+24VDC

PNP

PNP SENSOR

The CPU supports up to four inputs and four outputs, and up to eight inputs and eight outputs with the Auxilliary I/O Board.

The diagrams show the functions of the CPU Board Connectors and Wiring Connections. Further descriptions of these functions can be found in Section 6 - Operation.


34

Input/Output Connections - Before 5/18 The Input/Output connection interface is on the J-23 & J-24 terminals, on the bottom of the CPU Board. The CPU Board is located directly behind the Keypad.

There are 4 opto isolated inputs rated for +24VDC @ 15mA each, that can be programmed by the user for a variety of options. See the chart below.

There are also, 4 dry contact user selectable outputs rated for 250V @ 2A each.

CPU Board Showing Input & Output Connectors

The CPU supports up to four inputs and four outputs, and up to eight inputs and eight outputs with the Auxilliary I/O Board.

The diagrams show the functions of the CPU Board Connectors and Wiring Connections. Further descriptions of these functions can be found in Section 6 - Operation.

MM147 - D4 Hot Melt Unit Section 5 - Setup

35

Section 5 - Setup Control Panel

Section 5 - Setup MM147 - D4 Hot Melt Unit

36

Control Panel, Continued

ITEM NAME DESCRIPTION

1 SYSTEM READY LED ILLUMINATES GREEN WHEN THE SYSTEM REACHES READY TEMPERATURE

2 WARNING LED ILLUMINATES RED WHEN THE UNIT ENTERS AN ALARM CONDITION

3 SETBACK ON/OFF KEY

PUTS THE 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 STANDBY KEY PUTS THE UNIT IN AND OUT OF STANDBY. GREEN LED INDICATES UNIT IS ON, ORANGE LED INDICATES UNIT IS IN STANDBY.

7 PLUS KEY INCREASES THE VALUE OF THE SELECTED FIELD

8 RIGHT ARROW KEY MOVES RIGHT THRU FIELDS ON THE SCREEN

9 OK KEY ENTERS OR EXITS A SCREEN WHERE A SELECTED FIELD CAN BE EDITED.

10 MINUS KEY DECREASES THE VALUE OF THE SELECTED FIELD

11 LEFT ARROW KEY MOVES LEFT THRU FIELDS ON THE SCREEN

13 SETUP MENU KEY DISPLAYS THE SETUP MENU SCREENS

14 TEMPERATURE MENU KEY DISPLAYS THE TEMPERATURE GROUP SCREENS

15 GUN LEDS ILLUMINATES GREEN WHEN THE GUN ZONE IS HEATING AND RED WHEN THE ZONE IS IN ALARM.

16 HOSE LEDS ILLUMINATES GREEN WHEN THE HOSE ZONE IS HEATING AND RED WHEN THE ZONE IS IN ALARM.

17 TANK LED ILLUMINATES GREEN WHEN THE TANK ZONE IS HEATING AND RED WHEN THE ZONE IS IN ALARM.

18 PUMP ON/OFF KEY TURNS THE PUMP ON AND OFF. GREEN LED INDICATES PUMP IS ACTIVE.

19 PUMP MENU KEY DISPLAYS THE PUMP GROUP SCREENS

20 ABOVE OR BELOW MINIMUM SPEED LEDs

APPLICABLE LIGHT ILLUMINATES WHEN SPEED IS ABOVE OR BELOW MINIMUM SETTING.

21 LEVEL CONTROL LEDs ALWAYS ON UNLESS LOW LEVEL OCCURS ON THE INTERNAL OR EXTERNAL LEVEL CONTROL INPUTS.


37

Power On/Off and Standby Mode The Power On/Off Switch is located on the front of the unit (see picture below). The Power Switch controls the power to the system.

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

When the unit is in Standby Mode, the internal clock is still working. The clock will turn the unit off and on in the Timer Mode, as usual. If the Power Switch is turned off, however, the internal clock will NOT automatically turn the unit on and off; the internal clock has no power when the system is off.


38

Display Contrast Adjustment The display contrast is adjusted for optimal viewing at the factory. If the display is not visible when the Hot Melt Controller powers up, the contrast 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 contrast on the display. This will make the characters on the display brighter and dimmer, and is considered the fine adjustment.

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

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

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

Contrast Adjustment - Fine Adjust

Contrast Adjustment - Coarse Adjustment

Contrast Adjustment Pot, Coarse Tune


39

User Interface Navigation

Navigation symbols on the bottom of the display screen indicate that additional menus are available. Use the indicated button(s) to navigate as follows:

Memory Storage

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

Editing

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

Navigation Icons


40

Thumbwheel vs. Single Digit Edit

In Thumbwheel Edit, use the Right/Left Arrow Buttons to select the digit position, and the Plus/Minus Arrow Buttons to increase/decrease the value of the selected digit. Some thumbwheel screens contain a switch that can be used to turn the selected function ON or OFF. Common examples would be turning a hose or gun zone ON or OFF, making a schedule change to turn on setback during a shift, or enabling Sequential Start. Use the Right/Left Arrow Buttons to select the switch, and then use the Plus/Minus Buttons to toggle the switch ON or OFF.


41

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

Unlock changes to Lock Unlocked symbol appears with Password Level

Enter Password (See Thumbwheel vs. Single Digit Edit)


42

Set Language

Continued Next Page


43

Set Language - Continued


44

Set Temperature Units


45

Programming Temperatures

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

Temperature Screens

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

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


46

Tank Temperature

Hose/Valve Temperature

Continued Next Page


47

Hose/Valve Temperature - Continued


48

System/Pump Ready Temperature Offset The System Ready Temperature is relative to the temperature setpoint of each zone. The system is ready (and the System Ready LED illuminates green) when all zones reach their respective temperature setpoints minus the System Ready Temperature Offset.

The system ready signal enables the pump motor. This prevents the pump motor from being activated before the adhesive in the pump has softened.

Consult the adhesive data sheet to find the softening point temperature.

The System Ready Temperature Offset must be set to at least -5°F (-3°C). If it is set too close to the setpoint (for example, -1°F), the pump motor will stop during momentary drops in temperature of any zone until the zone is again within 1°F of the setpoint.

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

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


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Ready Delay Time When the Ready Delay Time is used, the System Ready LED will illuminate a preset time after all of the zones reach their respective temperature setpoints minus the System Ready Temperature Offset. This feature allows the adhesive in the system to heat for an additional period of time before the pump motor is enabled.

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

The ready delay range is 1 minute to 120 minutes. The default factory setting is ON at 15 minutes.

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



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Over Temperature Alarm The Over Temperature Alarm setting pertains to all active zones.

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

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

The over temperature alarm tolerance range is 9°F to 108°F (5°C to 60°C). The factory default setting is 45°F (25°C).


Body Text


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Under Temperature Alarm The Under Temperature Alarm setting pertains to all active zones.

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

If any zone goes into Under Temperature Alarm, the heaters of the affected zone will remain on to compensate for the drop in temperature. If the Under Temperature Alarm message appears, it can be cleared by pressing the ‘OK’ key.

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



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Maximum Temperature The Maximum Temperature setting is the maximum value for the setpoint of any zone.

The maximum temperature range is 32°F to 446°F (0°C to 230°C).

The factory default setting is 446°F (230°C).

This parameter can be accessed in Password Level 3 or higher.


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Beacon/Alarm Setup The Beacon/Alarm Setup allows a specific Beacon, designated by number, to be set to indicate one of several conditions:

• Ready & Level

• Pump On

• Power On

• Ready

• Alarm/Level

• Level 1

• Level 2

• Setback On

• Fault/Stop

• Pressure Alarm

The alarm may also be set to “Disabled,” which is the factory default setting.

J30, on the New CPU, provides a +24VDC - GND connection for each beacon/alarm desired. This output is +24VDC, 0.5A.

The beacon assembly is available as an option.

There are two versions available: two-light, and two-light with an alarm (lights are blue and red).

If this option is ordered from the factory, the beacon will be sent enabled. The condition for the red light (beacon #2) and the alarm are tied together. Factory settings are shown below.

Beacon Element Condition

Blue Light System Ready

Red Light Fault

Alarm Fault



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Beacon/Alarm Setup - Continued


55

Beacon 2


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Automatic Pump Mode When the Automatic Pump Mode is on, the pump will automatically start when the system reaches temperature and the System Ready LED illuminates.

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

The factory default setting is OFF.



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Pressure Setup If a pump, or multiple pumps, are enabled, Pressure Monitoring can create high or low pressure alarms (Requires pressure transducer[s])

If one pump is enabled:

If two pumps are enabled:

If three or four pumps are enabled:

X4

X2


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Pressure Setup - Continued Pressure-measurement units of can be either bar or PSI (whichever is selected, the CPU will convert every pressure to a related value)

Each pressure-monitoring input (1-4) has a user-configuration page:

The 1, 2, 3, or 4, above, only shows if the corresponding pump is enabled. Within these screens, the user is able to enable or disable the specific pressure monitor. The sensor range calibrates the 0-10V pressure transducer analog signal, input to the CPU board. The high and low alarms are thresholds that trigger a message on the screen (and beacon or programmable output, if configured), if the pressure value crosses them.

These alarms will NOT cause the unit to fault or stop the pump. The alarms are for notification only.

To prevent false alarms while the pressure is building, or during another circumstance, there are two delay settings:

• one that is common to all low pressure alarms and,

• one that is common to all high pressure alarms.


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Pressure Setup - Continued Example: If pump 1 is enabled and pressure monitor 1 is enabled for the pump, the pump screen (entered by pressing the pump key) will change to the following (this applies to all four pumps):

Auto: Manual:


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Pot Fill Mode In this mode of operation, melted glue is pumped into an external pot when the external lever control falls below a set level. The external level control is wired to the external level input on the CPU, J6.

In this mode, the pump turns on ONLY when it receives a signal from the external level input, and the unit is ready. Normal pump operation is ignored in this mode. The automatic pump mode should be ‘On.’ Pattern control and valves are typically not used in this operating mode.

On-delay time is set by the operator todelay pump activation ‘x’ seconds after the external level input calls for glue.

After the delay time expires, the pump will turn on and run until the external pot level triggers the level sensor that the pot is full, and the pump then turns off.



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Level Sensor Setup

Level 1 and 2

There are two level controls typically used with the D-Series Units. The Level 1 sensor can be used inside the tank of the unit to trigger an auto-fill device (see hopper feeder below), or an alarm state. The Level 2 sensor is used for pot fill mode (see Pot Fill Mode - Section 5). The delay for these sensors to activate can be set in this screen.

Hopper Feeder - Low Level Detection

The Hopper Feeder option is used to refill the hot melt control’s tank with fresh adhesive when the tank level drops below the set level sensor. This eliminates the need for the operator to manually open the tank lid and add adhesive to the tank.

The internal low level sensor is mounted in the hot melt tank lid so that when the adhesive drops below the sensor, a feeder valve is energized to feed glue into the tank to be melted. This feature has a safety door switch that will disable the feeder if the tank door is opened. The door switch, internal level sensor and feeder valve need to be connected to the CPU board, to operate properly.

The low level sensor plugs into J15 on the CPU board. The Level 1 sensor needs to be enabled in the software. If the Hopper Feeder and it’s components are connected as described above, the valve will energize when the door switch is closed and the sensor calls for glue.

Door Switch

The tank lid door switch will be wired to J14 on the CPU. The switch must be in the closed position for the feeder valve to energize and add adhesive to the tank. When the tank lid is opened, the feeder valve will turn off.

Feeder Valve Operation

The feeder valve is a dedicated +24VDC @ 0.5A output that will energize when the internal low level sensor calls for glue and the door switch is closed. This is J17 on the CPU board; pin 1 is +24V, pin 2 is ground.

Internal Level Control Feeder Valve Connector


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Filter Change Timer The Filter Change Timer Screen is a countdown timer that shows the time remaining on the currently installed glue filter. When the counter gets down to zero (0), an alarm can be sounded and the filter needs to be changed or cleaned. Once the filter has been serviced, the timer can be reset for a user set time of up to 2000 hours.

Clock and 7-Day Timer

Set Day and Time


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Shift Times/Setback Times

Programming Shifts

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

First program the time the heaters will be on, off, and in setback for each of the three shifts. Use the Right/Left Arrow Buttons to move through the times and shifts and the OK Button to get a thumbwheel to set the times and turn on the setback feature with a “switch” on the thumbwheel. (The heaters can be set with or without using the setback times.)

Set the start, stop, and setback times for all shifts. Leave the unused shifts/times blank (— —).

This screen states that for Shift A, heaters will turn on at 7:00 AM to the setpoint temperatures (set on the Temperature Screens, previously shown) and off at 3:00 PM, with all heaters going to the setback temperatures from 11:30 AM to 12:00 PM.

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

After setting all shift times, program the shifts that will be enabled for each day of the week. The Up/Down Arrow Buttons cycle through the different combinations of shifts, and the Left/Right Arrow Buttons cycle through the days of the week.

From this screen, use the Up/Down Buttons and the Right/Left Buttons to go through and adjust the shifts and setback times as desired. See the next page for an in-depth review.


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Programming Shifts - Continued

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

This screen states that on Mondays only Shift A will be working.

After setting all shift times (previous page) and programming the shifts that will be working for each day of the week (this page), be sure the Clock Function is On and is set properly.

Moving Through the Shift Time/Day Screens

Continue to use the Right/Left, Up/Down, and OK Buttons to set all shift times and what shifts work on each day. Turn the Clock On and your unit is set to work with your shift times and days.


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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 the control. The clock/timer will not operate if the power is off.

If the unit is set to ‘Standby’, the clock/timer will operate properly. In Standby, the display will show the status bar with the correct time of day.


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

X2


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Setback Setback Temperature

The setback feature is used to reduce the temperatures of all zones by a given temperature differential to allow the hot melt to remain soft but not molten during periods of inactivity.

The setback temperature differential is relative to the temperature setpoint of each zone.

The setback temperature differential range is 45°F to 342°F (25°C to 190°C). The default factory setting is 90°F (50°C).



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Automatic Setback Timeout

If the Automatic Setback Timeout input is enabled and the unit does not see an external input within the automatic setback timeout period, the unit will automatically go into setback.

The Automatic Setback Timeout feature is used only in conjunction with the Automatic Setback External Input. It is not used in manual or scheduled setback modes.

The automatic setback timeout range is 1 minute to 120 minutes. The default factory setting is 30 minutes.

When the Automatic Setback is enabled, the Auto Setback symbol will start to flash in the status bar 2 minutes prior to going into setback. This will be the signal to the operator that the unit will go into setback if an external signal is not applied to the control that resets this feature.



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Startup Setup Sequential Start - Hose

The Sequential Start function allows the hoses and the valves (guns) to begin heating after the tank reaches a specified temperature offset below the setpoint temperature. This feature is used to reduce adhesive degradation caused from heating adhesive in the hoses and valves for long periods while waiting for the tank to reach temperature.

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



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Sequential Start - Valve


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

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

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

If the an alarm condition (e.g. High Temperature Alarm) lasts for a duration of 2.5 minutes, the master control relay will be deactivated removing power from the heating zones, and the Fault History screen will appear. After correcting the cause of the fault, the unit must be powered off and back on again to reset the control and reactivate the master control relay.


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

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

See “Connections” in Section 4 - Installation for a detailed description of these features.


Inputs 1-4 Result when Input is ON Result when Input is OFF Disabled None None Hose & Gun #1 On/Off Enables the heaters for Hose & Gun #1 Disables the heaters for Hose & Gun #1 Hose & Gun #2 On/Off Enables the heaters for Hose & Gun #2 Disables the heaters for Hose & Gun #2 Hose & Gun #3 On/Off Enables the heaters for Hose & Gun #3 Disables the heaters for Hose & Gun #3 Hose & Gun #4 On/Off Enables the heaters for Hose & Gun #4 Disables the heaters for Hose & Gun #4 Hose & Gun #5 On/Off Enables the heaters for Hose & Gun #5 Disables the heaters for Hose & Gun #5 Hose & Gun #6 On/Off Enables the heaters for Hose & Gun #6 Disables the heaters for Hose & Gun #6 All Heaters On/Off Enables the heaters for all zones Disables the heaters for all zones Pump On/Off Enables the pump (pump must also be

enabled using the Pump On/Off key, or by setting Automatic Pump Mode to ON)

Disables the pump

Auto Setback/Standby Resets the Auto Setback/Standby Timeout timer

Allows the unit to enter Setback/Standby mode if Timeout timer is exceeded

Setback Puts the control into Setback mode Takes the control out of Setback mode Control Power Off Puts the control in Standby mode Takes the control out of Standby mode Melter On/Off Enables the tank heaters Disables the tank heaters


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User Inputs and Outputs - Continued

Outputs 1-4 Conditions to Turn Output ON Disabled None Setback On Control is in Setback mode Alarm High Temperature Alarm OR,

Low Temperature Alarm OR, RTD Disconnected Alarm OR, Drive Fault (if equipped) OR, Filter Alarm (if equipped) OR, Communication Fault

System Ready & Pump On All zones have reached their respective temperature setpoints minus the System Ready Temperature Offset, the Ready Delay Time has elapsed AND the pump is ON.

System Ready All zones have reached their respective temperature setpoints minus the System Ready Temperature Offset AND the Ready Delay Time has elapsed.

Power On Control power is ON Level 2 Material is below the Level 2 Sensor (if equipped) Level 1 Material is below the Level 1 Sensor (if equipped) OR,

Hopper Feeder runs for more than 200 seconds without satisfying Level Sensor (if equipped)

Fault/Stop The tank over-temperature thermostat is open OR, Any zone temperature has increased above the Maximum Temperature Setting OR, The High Temperature Alarm or RTD Disconnected Alarm persists for more than 150 seconds Note: Any of these conditions will cause the control to deactivate the master control relay

Alarm/Level High Temp Alarm OR, Low Temp Alarm OR, RTD Disconnected Alarm OR, Drive Fault (if equipped) OR, Filter Alarm (if equipped) OR, Communication Fault OR, Material is below the Low Level Sensor (if equipped) OR, Hopper Feeder runs for more than 200 seconds without satisfying Level Sensor (if equipped)

Ready & Level All zones have reached their respective temperature setpoints minus the System Ready Temperature Offset, the Ready Delay Time has elapsed AND the material is below the level 1 sensor.

Pressure Alarm The pump is ON, the pressure alarm delay has elapsed AND material pressure is outside of the setpoint range.


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Configuration The Configuration Menu of screens allows the user to set up global parameters for the hot melt control. These configurations are shown below.

Zone Configuration

The Zone Configuration is used to set the control for how many hose/gun pairs are being used by the operator and if 1 or 2 tank zones will be enabled.

Auxiliary Zones

If so equipped with the full 12 Zone Power Board, there will be circuitry for Zones 15 &16. These are the Auxiliary Zones and need to be enabled on this screen to read and control temperatures. Details and instructions on how to set this up will be included in the documentation with the Hot Melt Control.

X5

Zone Configuration Menu


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Auxiliary I/O

When the Auxiliary I/O is set to “Enabled,” auxiliary I/O devices will be activated.

When the Auxiliary I/O is set to “Disabled,” auxiliary I/O devices will be deactivated.

The factory default setting is “Disabled.”

An Auxiliary I/O Board (098xx134) can be ordered separately as an option to allow the operator four more user inputs and four more outputs. Once the board is installed, the Auxiliary I/O must be enabled.

See Installation, 4-19 for Auxiliary I/ O Board Connector, J4.

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

Pump Type

For pump type selection, this unit will be configured for Variable Speed Gear Pump or Fixed Speed Gear Pump. Variable Speed can only be chosen if the unit is equipped with a Motor Speed Board, a VFD, and a 3 phase motor. This setting will be set at the factory before shipment.

Gramage Enable

Gramage is ONLY enabled in coating applications where the user wants the unit automatically calculate the pump speed to achieve a desired coat weight. It requires the user to enter the Pump Displacement (cc), Adhesive Density (gram/cc), speed reference values if tach mode is used, coating width (mm), and the desired coating weight (gram/square meter). See Gramage Setup, in this section, for more information.


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Config Comm Menu

Comm Menu, located in the Config Menu, allows the user to select Modbus RTU, Ethernet IP, or to disable remote communication. Level 3 is required for all of these settings.

5. Select Comm to access the Remote Communication screen.

Protocol options are Ethernet IP, Modbus RTU, and Disabled. If Ethernet IP is selected, Mode must be set as well. Mode options are Local and Remote. The CPU will not allow the user to select Remote or Local, if not using Ethernet IP. If Ethernet IP is in use, the IP Address, Subnet Mask, and Gateway must be configured for the customer network: (see Appendix E - Communication Protocols)

CAUTION! Load and balance the communication networks properly. If the CPU is the end node in the communication daisy-chain, for each of those protocols, enable the SDO Comm and Modbus RTU resistors.


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Config Comm Menu - Continued

6. If Modbus RTU is in use, set the Slave ID and Baud Rate for the CPU.

Reference Manual MM139 for more information on configuring Remote Communications

Pump Configuration

Number of Pumps

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

Pump Configuration for Specific No. Pump

The Pump Heat Zone is the zone attached to the pump to heat the pump. It is used to make sure the zone is enabled and heating when the pump switch is enabled.

Gramage should ONLY be enabled in coating applications where the user wants the unit to automatically calculate the pump speed, to achieve a desired coat weight. It requires the user to enter the Pump Displacement (cc),

Adhesive Density (gram/cc), speed reference value if tach mode is used, coating width (mm) and the desired coating weight (gram/m2). See Gramage Feature later in this section for more information.


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Pump Setup Menu

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

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

The Minimum Speed Setting determines the minimum line speed at which the pump turns at the creep speed setting. The units are in either millivolts or ft./min depending on the Auto Speed Input type (Tach or Encoder).

The Maximum Pump Speed is generally set at the factory. It is the motor RPM divided by the reducer size (or pump speed when the motor runs at 100%). It is used to calculate and display the actual speed of the pump on the Pump Status Screens.

Continued on Next Page


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Pump Setup Menu - Continued

The Auto Speed Input setting is the type of line speed input used to adjust the pump speed. See the VFD board connections (below) to find the input connectors for the Auto Speed Input. Allowable settings and their corresponding connections are shown below.

VFD Board Connections

If an Encoder is used for the Auto Speed Input, an additional “Encoder Screen Ref.” screen will appear between “Creep Speed Setting” and “Max Pump Speed.” This screen enables setup of the relationship between the Parent Machine Speed and the Glue Pump Speed. The pump speed response to the parent machine speed is linear between these points. If the parent machine speed is below the ‘Min’ setting, then the pump will run at the Creep Speed setting.

0-10 VDC GND

Analog Line Speed Input

GND

Encoder Line Speed Input

/B B /A A V+


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Encoder Setup Menu If an Encoder is used for the Auto Speed Input, then the Encoder parameters need to be set in this menu. Enter the Pulses per Revolution of the encoder and its circumference in this screen.

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


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PID Setup Menu PID Settings

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

CAUTION! Changing these settings is not recommended. Changes should be made only by authorized ValcoMelton personnel.

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

AutoTune Feature

The Auto Tune feature will optimize the PID settings for each zone that is enabled when the Auto Tune is started. The Auto Tune feature can take up to eight hours to complete and the power must not be turned off during this process. It is recommended to only enable zones that need their PID values adjusted to reduce the time taken for tuning.

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

Changing out gun/hose pairs, or moving a gun or hose from its original AutoTune position, will require that AutoTune be run again to optimize the PID settings.

X5


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Memory Menu The Memory Menu is used to backup, restore or initialize ALL control parameters.

For more information on these functions, see Appendix D - Micro SD Backup & Restore.

Restoring Factory Default Settings To restore the factory default settings, follow these steps:

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

1. Switch off power to the unit.

a. Power the unit back up while pressing and holding the Setup Button and the OK Button on the keypad. The buttons can be released once the start-up screen appears.

Updating 152XX746 CPU Board Software via USB Memory Stick The CPU must have bootloader (119XX301) programmed to it before it is capable of being updated with the USB stick.

Required Materials

• USB Memory Stick with desired version of software to be loaded to board (software must be converted for the correct for the specific board or the update will fail)

• 152XX746 CPU Board

Old 152XX650 based CPU boards do not have this capability

Procedure

CAUTION! Before beginning, be sure that the new software to be loaded is desired and necessary as the existing software on the CPU board (if there is software already loaded) will be overwritten.

1. Turn off power to 152XX746 CPU Board, if not already off.

2. Insert the USB memory stick into the USB port (J7 – at the rear of the CPU board)

X5


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Procedure - Continued

3. Turn on power to the CPU board.

If the USB memory stick mounts successfully, the screen will display the following:

If there is a problem with the USB memory stick mounting, the screen will display the error screen with “Error 1” as shown below:

As long as there are no issues when the USB memory stick mounts, the bootloader will analyze the software and begin to perform the update.

If the CPU board DOES already have software loaded and the version on the USB stick is the SAME, the error screen will show with “Error 2” as shown below:

If the software:

• Has the wrong file name

• Was not converted, or not converted successfully for the specific board

• Is corrupted in some way

Then the error screen will show with “Error 3” as shown below:


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Procedure - Continued If the software has the correct name, has been correctly converted for loading, is not corrupted, and is not the same as the version already installed (if a software is already loaded), then the update will continue and the screen will display the following:

If there is a problem in the copying of the new software or the USB memory stick is pulled out early resulting in a failed programming attempt, the error screen will show with “Error 4” as shown below:

If the software is successfully updated and is starting, the screen will display the following and the program will run as normal:

4. Remove the USB stick.

5. Cycle power.

The unit will force a re-initialization.

Hot Melt CPU uTasker Bootloader (119XX301) Error Codes

Error 1: USB Stick failed to mount

Error 2: Software on USB Stick is the same that is loaded on CPU already

Error 3: Software on USB Stick is not valid

(Does not have correct filename, file was not converted using utility, or file is corrupted)

Error 4: Programming failed during copying


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Initialization Instructions Navigating the Setup Wizard

Upon restoring the control to factory settings, the control will launch a wizard that will guide you through a series of control configuration steps. You can navigate the wizard settings using the left and right arrow buttons, and edit the settings using the + and – buttons.

CAUTION! It is important the control is configured with the correct unit settings. Failure to configure the control correctly may result in damage to the equipment.

Adjusting the Display

The display contrast can be adjusted by pressing the + or – buttons, while holding the setup button. The display position can be adjusted by pressing the left or right arrow buttons, while holding the display button. After adjusting the display, press the right arrow button to continue.

Selecting the Language

1. Use the + and – buttons to select your language from the list of available languages.

2. After selecting a language, press the right arrow button to continue.


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Configuring the Unit Type

1. Use the + and – buttons to select the appropriate unit type. In this case, the unit type should be D Series Variable Speed or D Series Fixed Speed.

OR

Variable speed units are equipped with a variable frequency drive.

CAUTION! It is important to correctly identify if the unit has a variable or fixed-speed motor. Determine this by examining the part number stamped on the unit data plate, and then referencing the chart below.

Fixed Speed Units Variable Speed Units D4 F2… D4 V2… D4 F4… D4 V4…

2. After setting the unit type, press the right arrow button to continue.

Selecting the Communication Protocol

1. Use the + or – buttons to select the if any communication protocols are being used in the system. The

allows for Modbus RTU and Ethernet IP (if ordered as an option).

Communication Disabled Ethernet IP Enabled

D10 …00 D10 …40

D16 …00 D16 …40

2. After selecting the communication protocol, press the right arrow button to continue.


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Selecting the RTD type

1. Use the + or – buttons to select the type of RTDs used in the system. The RTD type can be Ni120 or

PT100.

All D10/D16 hot melt units use Ni120 RTDs. PT100 should not be selected, this will cause the system to malfunction.

2. After selecting the RTD type, press the right arrow button to continue.

Selecting the Number of Pumps

1. Use the + or – buttons to select the number of pumps on the hot melt unit.

All D10/D16 hot melt units use 1 pump. More than 1 pump should not be selected, this will cause the system to malfunction.

2. After selecting the number of pumps, press the right arrow button to continue.

Selecting the Number of Hose Outlets

1. Use the + or – buttons to select the number of hose outlets equipped. The number of hose outlets can be

determined by examining the part number stamped on the data plate of the unit, and then referencing the chart below.

2 Hose Outlets 4 Hose Outlets

D4 F2… D4 F4…

D4 V2… D4 V4…

The number of hose outlets should match the number of hose connectors mounted in the back panel of the unit. D series units have 2 or 4 hose connectors.

2. After selecting the number of hose outlets, press the right arrow button to continue.


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Selecting the Temperature Units

1. Use the + or – buttons to select the desired temperature units.

2. After selecting the desired temperature units, press the right arrow button to continue.

Selecting the Pattern Control

CAUTION! Enabling the pattern control when a pattern control is not equipped will result in communication failure. Only enable the pattern control when one is equipped and connected.

The Pattern Control is not available with the D4 Hot Melt Unit.

Finishing the Configuration

When prompted to finish the configuration, use the right arrow button to select ‘Yes,’ and then press the OK button to save the configuration.


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Adjusting the Pressure Control Valve The D4 unit contains a single-stage relief valve (see figure below). Additionally, the D4 unit can use an optional pneumatic relief valve (707XX212).

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

Adjusting the Single-Stage Relief Valve

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

CAUTION! Do not overtighten adjusting screw. Failure to comply could result in damage to the equipment.

1. Turn off pump motor.

2. Loosen the locknut on the pressure relief valve.

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

4. Tighten the locknut on the pressure relief valve.

5. Turn on pump motor and resume operation.


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Gramage Feature The Gramage Feature is ONLY enabled in coating applications where the user wants the unit automatically calculate the pump speed to achieve a desired coat weight. If this feature is used then the following parameters must be set.

The width of the coating application is in millimeters. Press the Pump Status Key and scroll right to get to this setting.

The desired Application Weight (Gramage) in grams per square meter for the application. Press the Pump Status Key and scroll right to get to this setting.

The Pump Displacement in cubic centimeters. Enter the Pump Setup Menu from the Tools Key, then scroll right to access this screen.

The Adhesive Density in grams per cubic centimeter. Enter the Pump Setup Menu from the Tools Key, then scroll right to access this screen.

If tach mode is used as the auto speed input for gramage mode, then these speed reference values must be entered for the control to know how the 0-10V input translates to an actual speed in meters per minute. Enter the Pump Setup Menu from the Tools Key, then scroll right to access this screen.


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D Series Variable Frequency Drive Configuration (If Equipped) 1. Press ‘DSP’ to display ‘F’ number; use arrow keys to reach function to change.

2. Press ‘Data Ent’ to display current value, use arrow keys to change value.

3. Press ‘Data Ent’ to save new function value.

4. Press ‘DSP’ key to exit or arrow keys to go to the next function number.

Valco Setting Factory Default Function Range

AI1T Voltage 5V Configuration of AI1 5V, Voltage, or Current L01 Drv. Running NO L01 Assignment Multiple BFR 60 50 Std. Motor Frequency 50HZ or 60HZ DEC 5 3 Deceleration Ramp Time 0-999.9 SEC. LSP 10 0 Low Speed Frequency 0-63.2 HZ HSP 63.2 60 High Speed Frequency 10-72 HZ


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Before 5/18

Valco Setting Factory Default Function Range F01 03.0 05.0 Acceleration Time 00.1 – 999 Seconds F02 05.0 05.0 Deceleration Time 00.1 – 999 Seconds

F03 000 000 External Operation Mode 000: Fwd/Stop, Rev/Stop 001: Run/Stop, Fwd/Rev

F04 000 000 Direction Selection 000: Forward 001: Reverse

F05 004 004 V/F Pattern Setting

001: 50 Hz General Application 002: 50 Hz High Starting Torque 003: 50 Hz Variable Torque 004: 60 Hz General Application 005: 60 Hz High Starting Torque 006: 60 Hz Variable Torque

F06 63.2 60 Maximum Frequency 01.0 – 120 Hertz F07 10.0 00.0 Minimum Frequency 00.0 – 120 Hertz F08 10.0 10.0 Preset Speed 1 (SP1) 01.0 – 120 Hertz F09 06.0 06.0 Jog Frequency 01.0 – 10 Hertz

F10 001 000 Operation Control Method 000: Keypad 001: External Terminal

F11 001 000 Speed Control Method 000: Keypad 001: External Signal (0~10v/0~20mA) 002: External Signal (4~20mA)

F12 005 005 Switching Frequency

001: 4 kHz 002: 5 kHz 003: 6 kHz 004: 7.2 kHz 005: 8 kHz

F13 00.0 00.0 Torque Boost Adjustment 00.0 – 10.0%

F14 001 000 Stopping Method 000: Decelerate Stop 001: Free Run Stop

F15 00.5 00.5 Braking Time 00.0 – 25.5 Seconds F16 01.5 01.5 Braking Start Frequency 01.0 – 10.0 Hertz F17 08.0 08.0 Braking Level 00.0 – 20.0% F18 83 100 Current Limit 000 – 100%

F19 002 002 Input Terminal 6 Function

001: Jog 002: SP1 003: Emergency Stop 004: External Base Block 005: Reset

F20 005 005 Input Terminal 7 Function

001: Jog 002: SP1 003: Emergency Stop 004: External Base Block 005: Reset

F21 003 003 Output Terminal Function 001: Operating 002: Frequency Reached 003: Fault

F22 001 000 Reverse Enable 000: Rev Command Enabled 001: Rev Command Disabled

F23 000 000 Auto Restart Enable 000: Auto Restart Enabled 001: Auto Restart Disabled

F24 005 000 Auto Restart Times 000 – 005 Times

F25 000 000 Restore Factory Settings 010: Restore to 50 Hz Settings 020: Restore to 60 Hz Settings

MM147 - D4 Hot Melt Unit Section 6 - Operation

93

Section 6 - Operation WARNING! It is recommended that Section 5 - Setup is read, understood, and followed before attempting

to read this Section and operate the Universal Temperature Control unit. OTHERWISE, DAMAGE TO EQUIPMENT AND PERSONAL INJURY COULD OCCUR.

Start the Unit To start the unit, do the following:

1. Toggle the Power On/Off Switch to the “On” position to power up the system.

The Standby LED will illuminate green when the power to the unit is on. If the Standby LED illuminates orange, the unit is in Standby Mode. Press the Standby Button to turn the unit on.

Once the unit has completed its start-up sequence, it will turn on the heaters in the tank and all active hoses and guns. The heater’s corresponding Zone LED will illuminate green when the heater is on.

Standby Key

Power On/Off Switch

Standby Key & LED

Pump On/Off Key & LED Warning Alarm LED

System Ready LED

Hose Zone LEDs

Setback On/Off Key & LED

Display Screen

Clock On/Off Key & LED

Gun Zone LEDs

Tank Heater LED

Heater (Temperature)

Menu Key & LED

Setup Key & LED

Pump Menu Key

Navigation Keys

Section 6 - Operation MM147 - D4 Hot Melt Unit

94

Temperature The tank temperature screen will show the actual tank temperature and the tank temperature setpoint. For operator convenience, the right side of the display screen alternately displays the Hose & Gun temperatures (see Section 5 – Setup, for setting zone temperatures). Press the Heater Key (or use the Navigation Buttons) to cycle through the temperature screens until you reach the desired screen.

Setpoint and Actual Temperature

Temperature Status LEDs

The Control Panel contains LEDs that indicate the status of each heated zone. When the zone is in warm-up mode, the zone LED will illuminate green and stay on continuously. Once the zone reaches its setpoint temperature, the LED will blink on and off indicating that the heaters are switching on and off to maintain the setpoint temperature. If the LED illuminates red, it indicates a fault for that zone. The status bar will provide a more detailed explanation of the fault. Also, if the fault triggers a temperature alarm, the Temperature Alarm LED will illuminate red (see Section 5 - Setup, “Over Temperature Alarm” and “Under Temperature Alarm” for details).

Actual Temperature

Setpoint Temperature

Tank Heater LED

Hose Zone LEDs Gun Zone LEDs Heater

(Temperature) Menu Key & LED

Tank Heater LED

Hose Zone LEDs Gun Zone LEDs

System Ready LED Warning/Alarm LED


95

Temperature Status LEDs - Continued If the temperature set points are not correct or need to be adjusted, select the appropriate zone and adjust the temperature setting (see Section 5 – Setup for setting temperatures). The system is ready (and the System Ready LED illuminates green) when all zones reach their respective temperature setpoints minus the System Ready Temperature Offset.

The system ready signal enables the pump motor. This prevents the pump motor from being activated before the adhesive in the pump has softened.

Consult the adhesive data sheet to find the softening point temperature of the adhesive.

Pump Operation

When the pump is enabled but waiting on the System Ready LED to illuminate green, the pump symbol flashes in the status bar.

Pump On/Off Key

The Pump On/Off Key is the master enable for the Pump(s). It can be set to come on automatically when the unit is ready (see Section 5 - Setup, “Auto Pump Enable”). Note that all temperatures must reach the system ready temperature and the Ready LED must be illuminated green for the pump to operate.

Pump Status Key

Fixed Speed Unit

The Pump Menu Key will give you access to this screen where the Pump RPM is shown and the individual pump can be enabled.

Pump Symbol (flashes)

Pump On/Off LED

Status Bar

Pump On/Off Key

Pump Menu Key

Navigation Keys


96

Variable Speed Unit

In a Variable Speed Unit the Pump Menu Key allows you to choose the pumps operating mode, manual or automatic. You can also see the pump’s speed input value, the pump RPM, and the individual pump enable.

In Manual Mode you can change the Pump speed from 0 – 100%. You can also view the Pumps RPM and enable the individual pump.

In Automatic Mode you can view the Automatic Speed Input. These units will be in Volts or in ft/min depending on the Auto Speed Input Type setting (Tach or Encoder).

You can also view the Pumps RPM, and enable the individual pump.

Clock On/Off The Clock must be On (Clock LED illuminated green) for all of the programmed scheduled shifts to run, unless the unit will be operated manually (no pre-programming).

To turn the clock on or off, press the Clock On/Off Button. When the clock is on, the Clock LED illuminates green. See Section 5 - Setup for detailed information on setting the clock.

Clock On/Off Key & LED


97

Setback The Setback Temperatures are pre-programmed (see “Setback Temperatures”, Section 5 - Setup). When setback times are set (See “Clock - Shift Times/Setback Times,” Section 5 - Setup) and the clock is on, the unit automatically enters setback during each shift as programmed. If, however, an unscheduled break occurs, the Setback Button can be pressed (Setback LED illuminated yellow) to put the unit into setback manually. To exit setback mode, press the Setback Button again (LED not illuminated). The setback time and temperature can be set manually by using the arrow navigation keys to access the temperature and time set screens and entering values on these screens (see Section 5 - Setup).

Automatic Setback

Automatic setback can be programmed through one of the remote inputs from the input screen. When an input is set for Auto Setback, AND the Auto Setback Timeout is enabled, the control will AUTOMATICALLY go into set back if the input has not been triggered for the timeout set by the user.

For instance, if a valve fire signal is connected to Input #2, Input #2 is programmed for Auto. Setback and the Auto Setback Timeout is enabled and set for 30 minutes, the control will automatically go into set back if the valve has not been fired for 30 minutes. Each valve fire within that 30 minute time period will reset the Timeout timer to start back at 30 minutes. The setback symbol will start to flash 2 minutes prior to the control going into setback.

Setback On/Off Key & LED


98

Pot Fill - External Low Level Detection Pot Fill is used when the hot melt control is being used to heat the hot melt adhesive and remotely fill a pot. Using the Pot Fill mode, the hot melt control can precisely monitor the pot level and fill the pot on demand from the low level sensor mounted in the pot.

For setup details, refer to Section 5.

Hopper Feeder - Internal Low Level Detection The Hopper Feeder option is used to refill the hot melt control’s tank with fresh adhesive when the tank level drops below the set level sensor. This eliminates the need for the operator to manually open the tank lid and add adhesive to the tank.

For setup details, refer to Section 5.

Beacon Alarm The Beacon / Alarm output connector is provided as a dedicated +24VDC @ 0.5A output for a visual or audio alarm. This can be set up to alert the operator of one of 4 fault conditions (see Section 5 – Setup for description).

The installer can connect the “+” lead of the alarm to Beacon 1 (pin 3) and the “-” lead to GND (pin 1) of J30 on the CPU board. When the Beacon / Alarm screen is set up for an alarm condition, the +24VDC output will enable the alarm device to signal that the condition on the control has been met (eg. Low Level).

External Input The External Input can accept 230VAC, 24VAC or +24VDC to reset the Setback Timeout when the control is in Auto. Setback. This is used in special applications and the programmable inputs should be used for this feature (see Automatic Setback above). The pin out for this connector on the CPU board is critical (see Section 5 – Setup for this connector location).


99

Filling the Tank WARNING! Do not overfill the tank. The adhesive could leak out and damage equipment and cause

extensive burns to persons. DAMAGE TO EQUIPMENT AND DEATH OR PERSONAL INJURY COULD OCCUR. Always wear insulated gloves, clothing, and proper eye protection when working around hot melt equipment. A protective screen around the face is also recommended. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

CAUTION! Always use the same adhesive type in the unit. If it is necessary to change the adhesive type, completely flush the system by following all instructions in the Maintenance Section (or call Valco Cincinnati for full instructions). OTHERWISE, DAMAGE TO EQUIPMENT COULD OCCUR.

To fill the tank, do the following:

WARNING! Use caution when opening the tank lid and filling the tank. Wear gloves and eye protection. Burns and splashing of molten adhesive may occur. DEATH OR PERSONAL INJURY COULD OCCUR FROM BURNS.

1. Open the tank lid.

2. Fill the tank with the proper type of hot melt. Use a small scoop and fill the tank slowly to avoid splashing hot melt adhesive or overfilling the tank.

The tank should be kept 3/4 full at all times to avoid build-up of char on the sides of the tank.

3. Close the tank lid slowly and carefully to avoid splashing hot melt adhesive.

The tank lid should be kept closed to minimize heat loss, reduce vapors, and prevent debris from contaminating the tank and the adhesive.


100

MM147 - D4 Hot Melt Unit Section 7 - Maintenance

101

Section 7 - Maintenance This section contains guidelines and procedures for maintaining the D4 hot melt unit. Your hot melt system will run longer and more consistently if a preventative maintenance program is used. Daily attention to the maintenance of your system is recommended.

General ValcoMelton recommends the following general maintenance procedures:

• Keep the tank as full of adhesive as possible. This reduces the formation of charred adhesive on the interior side walls of the tank.

• Keep the tank lid closed. (Any contamination in the tank will increase the chance of poor performance. Moisture, dirt, and charred adhesive are the major causes of clogged nozzles.)

In order to prevent pressure buildup in the tank, the tank lid does not have a seal.

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

• While the unit is still hot, but not operating, use cheesecloth to remove material leaking from the pump seal and other connectors. External leakage indicates that service is required.

• Shut down the system once a week and remove and clean the manifold filter. Replace the filter if it cannot be thoroughly cleaned.

• Completely drain and clean the system when clogging due to charred adhesive or dirt becomes frequent.

• Periodically clean the exterior of the D4 hot melt unit.

Cleaning the Exterior of the Unit To clean the exterior of the D4 hot melt unit, follow these steps:

CAUTION! Never hose or steam-clean the unit. If the surrounding area is cleaned in this manner, protect the unit by covering it with plastic or other waterproof material. Failure to comply could result in damage to the equipment

1. Turn off the main power.

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

Section 7 - Maintenance MM147 - D4 Hot Melt Unit

102

Changing the Adhesive CAUTION! When changing adhesives, always consult adhesive suppliers to check compatibility between

adhesives. Failure to comply could result in damage to the equipment.

To change the adhesive, follow these steps:

1. If the old adhesive and the new adhesive are compatible, pump enough of the new adhesive through the system to ensure that all of the old adhesive has been cleared out (generally 3 to 5 lbs. or 1.1 to 1.9 kg).

2. If the two materials are not compatible, flush the system (see “Flushing the System” below).

Flushing the System The system needs to be flushed under the following circumstances:

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

• When loose particles of charred adhesive are causing frequent clogging of screens and nozzles

ValcoMelton recommends using paraffin wax to flush the unit.

CAUTION! If a cleaning solution is to be flushed through the hot melt system, it must be compatible with silicone, Viton,Teflon, carbon graphite, and aluminum. Consult the adhesive manufacturer to find out which cleaning solutions are recommended for the adhesive you are using. Failure to comply could result in damage to the equipment.

To flush the system, follow these steps:

1. Place an adequate supply of either paraffin wax or suitable cleaning solution into the unit.

Reduce the temperature control setting to 300°F (148°C) for paraffin wax. Consult your supplier for proper temperature setting if cleaning solution is being used.

WARNING! If the system is hot, wear insulated gloves and eye protection when disconnecting hoses. Trapped air pockets may cause adhesive spray and result in personal injury (burns) or death.

2. Make sure that the pump is turned off.

3. Manually activate the applicators to relieve any system pressure buildup if the system is hot.

4. Disconnect glue hoses from applicators and collect purged material with appropriate container.

5. Turn the D4 hot melt unit on and allow 20-30 minutes for hoses and guns to reach temperature.

6. Turn the pump on.

7. Pump 5-6 lbs. (2 kg) of material through the unit and glue hoses.

If particles are still present in the discharged material, additional material may be needed to flush the unit completely free of charred adhesive.

8. Turn the pump off.

9. Reconnect the glue hoses to the applicators.


103

Flushing the System - Continued

10. Turn the gear pump back on and activate the applicators to purge remaining adhesive through the valve(s).

11. Reset the temperature control to the correct setting for the material you are using.

The new material can now be pumped through the system.


104

Parts Replacement WARNING! If the system is hot, wear insulated gloves and eye protection when disconnecting hoses.

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

Occasionally, parts may need to be repaired or replaced. The following paragraphs contain instructions for removing parts from the hot melt unit. For drawings and a complete list of part numbers, see Section 10 - Part Number List.

Changing Fuses

In the event that a fuse must be replaced, simply remove one of the spare fuses from the included installation kit and insert the fuse in the appropriate socket on the 12-zone board (see the following Figure).

151xx747 240V

Item Fuse Description Part # Quantity

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

2 Fuse, 6.3A, 5 x 20 mm 085xx271 4

3 Fuse, 8A, Class G 085xx289 4

4 Fuse, 8A, 5 x 20 mm 085xx272 4

5 Fuse, 6.3A, 5 x 20 mm 085xx221 2


105

Changing the Filter

WARNING! If the system is hot, wear insulated gloves and eye protection when disconnecting hoses. Trapped air pockets may cause adhesive spray and result in personal injury (burns) or death.

1. Make sure that the pump is turned off.

2. Manually activate the applicators to relieve any system pressure.

3. Unscrew the filter assembly from the manifold and discard.

Debris is collected on the inside of the filter, so the filter should not be reused.

4. Thread a new filter assembly into the manifold. See Section 10 - Part Number List for more information.

Filter


106

MM147 - D4 Hot Melt Unit Section 8 - Troubleshooting and Repair

107

Section 8 - Troubleshooting and Repair Problem Possible Cause Possible Solution

1. Material in reservoir will not melt

1a. Temperature control malfunction or adjustment

1a. Check indicator lights. Reset adjustments.

1b. Loose, broken or shorted connectors (heater, wiring harness)

1b. Tighten loose connectors. Repair broken connectors or shorted connectors.

1c. Circuit breaker tripped 1c. Check fuses. Replace if necessary.

2. No adhesive output

2a. Adhesive not hot enough 2a. Check temperature setting is correct. Ensure that reservoir heater has power. Check fuses.

2b. Pump not moving 2b. Check for system ready condition. Check for blown fuse.

2c. Cold glue hose or damaged hose

2c. Replace hose.

2d. Cold applicator 2d. Check for blown fuse and/or defective heater.

2e. Applicator clogged 2e. Service applicator system.

2f. Clogged filter 2f. Remove old filter and replace with new filter.

2g. Temperature control malfunction

2g. Replace temperature control.

3. Charring or gelling of adhesive in the reservoir

3a. Reservoir temperature too high

3a. Lower reservoir temperature in accord with adhesive manufacturer’s specifications.

3b. Surface oxidation of the adhesive in the reservoir

3b. Keep reservoir closed.

3c. Poor adhesive heat stability 3c. Change adhesive. If not possible, hold the reservoir temperature at a minimum.

3d. Low reservoir level 3d. Keep reservoir full.

3e. Temperature control malfunction

3e. Replace temperature control.

4. Fuming or smoking of adhesive in the reservoir

4a. Operating temperature exceeds adhesives’ recommended temperature

4a. Keep setpoint within recommended range. Keep reservoir covered. Consider another adhesive. Keep reservoir covered.

Section 8 - Troubleshooting and Repair MM147 - D4 Hot Melt Unit

108

Problem Possible Cause Possible Solution

5. 5. Uneven flow of adhesive to applicators

6. 5a. Material viscosity too high 7. 5a.

8. -Reservoir temperature too low 9. -Raise reservoir temperature in accordance with adhesive manufacturer’s specifications.

10. -Wrong adhesive 11. -Seek adhesive manufacturer's recommendations.

12. 5b. Adhesive overheated 13. 5b. Reduce reservoir temperature in accordance with adhesive manufacturer’s specifications.

14. 5c. Glue hoses not at the same temperature

15. 5c. Reset temperature controllers.

16. 5d. Different pressure drop through each hose

17. 5d.

18. -Hoses not the same length 19. -Use same length hoses.

20. -Crimped hose(s) 21. -Replace hose(s)

22. -Leaking hose(s) 23. -Replace hose(s)

24. 5e. Adhesive supply low 25. 5e. If sides of tank are charred, drain, clean, flush, and refill system.

26. 5f. Manifold partially clogged 27. 5f. Drain, clean, flush and refill.

28. 5g. Nozzles partially clogged 29. 5g. Inspect system for charred adhesive and foreign matter. Drain, clean, flush and refill system.

MM147 - D4 Hot Melt Unit Section 9 - Specifications

109

Section 9 - Specifications General It is the purchaser’s responsibility to ensure that all local, county, state, and national codes, regulations, rules, and laws relating to safety and safe operating conditions are met and followed.

Specifications Gun Attachments 2 or 4

Tank Capacity 8.8 lbs. (4kg)

Melt Rate* 11.1 lbs/hr (5 kg/hr)

Pump Motor-driven spur gear pump/Fixed or Variable Speed

Pump Rate 1.59 cc/rev (15.7 L/hr) 3.18 cc/rev (31.5 L/hr)

Viscosity Range 500 – 30,000 CPS

Maximum Fluid Pressure 800 psi (55 bar)

Workplace Temperature 32 to 120oF (0 to 50oC)

Temperature Range 86 - 446oF (30 - 230oC)

Temperature Stability 1oF (0.5oC)

Electrical 208 – 240 VAC 1Ф/3Ф, 380 VAC 3Ф, 40 amps

IP Rating IP 54

Width (W) 12.3 in (311 mm)

Height (H) 16.8 in (427 mm)

Depth (D) 23.9 in (607 mm)

* Test run with standard packaging grade adhesive.

Section 9 - Specifications MM147 - D4 Hot Melt Unit

110

Dimensions

MM147 - D4 Hot Melt Unit Section 10 - Part Number List

111

Section 10 - Part Number List How to Order Parts To order parts, please contact your closest Valco office by mail, phone, or Email:

USA Valco Cincinnati, Inc. 497 Circle Freeway Drive Suite 490 Cincinnati, OH 45246 Tel: (513) 874-6550 Fax: (513) 874-3612 Email: [email protected] Web: http://www.valcocincinnatiinc.com England Valco Cincinnati Limited Hortonwood 32 Telford, TFI 7YN, England Tel: (+44) 1952-677911 Fax: (+44) 1952-677945 Email: [email protected] Web: http://www.valco.co.uk Germany Valco Cincinnati GmbH Bonnerstrasse 349 40589 Dusseldorf-Benrath, Germany Tel: +49 211 984 798-0 Fax: +49 211 984 798-20 Spain Melton S.L.U. Pol. Industrial Agustinos calle G, n. 34 31160 Orcoyen, Navarra, Spain Tel: (34) 948-321-580 Fax: (34) 948-326-584 France Valco Melton France Technoparc des Hautes Faventines 32 Rue Jean Bertin 26000 Valence Tel: +33 (0)4 75 78 13 73 Fax: +33 (0)4 75 55 74 20

Section 10 - Part Number List MM147 - D4 Hot Melt Unit

112

D4 Unit


113

D4 Unit - Continued


114

D4 Unit - Continued

D4 Unit, Fixed speed, 2 exit (776xx887)

ITEM DESCRIPTION PART NO. QTY. 1 BASE UNIT ASSY, D4 776XX392 1 2 BRACKET MOTOR 776XX313 1 3 BRACKET MOUNTING LEFT 776XX314 1 4 BRACKET MOUNTING RIGHT 776XX315 1 5 SCREW 884XX223 8 6 FLAT WASHER 798XX302 8 7 GEARMOTOR ASSY 110XX357 1 8 SCREW 884XX004 4 9 LOCK WASHER 798XX735 4

10 HUB JAW COUPLING 783XX370 1 11 HUB JAW COUPLING 783XX371 1 12 SPIDER JAW COUPLING 783XX372 1 13 SCREEN, RESERVOIR 782XX297 1 14 BRACKET,RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID,RESERVOIR 775XX861 1 17 HANDLE, PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL,WARNING-HOT SURFACE 781XX629 2 21 LABEL, WARNING-ELEC.HAZARD 781XX630 2 22 NAMEPLATE, SHURE-GLUE SYSTEMS 781XX566 1 23 RIVET 091XX517 2 24 INSTALLATION KIT, D4 HMU 091XX734 1 98 SKID WOOD - HMU 730XX020 1 99 BOX OUTER SHIPPER 023XX108 1


115

D4 Unit - Continued

D4 Unit, Fixed speed, 4 exit (776xx888)

ITEM DESCRIPTION PART NO. QTY. 1 BASE UNIT ASSY, D4 776XX392 1 2 BRACKET MOTOR 776XX313 1 3 BRACKET MOUNTING LEFT 776XX314 1 4 BRACKET MOUNTING RIGHT 776XX315 1 5 SCREW 884XX223 8 6 FLAT WASHER 798XX302 8 7 GEARMOTOR ASSY 110XX357 1 8 SCREW 884XX004 4 9 LOCK WASHER 798XX735 4

10 HUB JAW COUPLING 783XX370 1 11 HUB JAW COUPLING 783XX371 1 12 SPIDER JAW COUPLING 783XX372 1 13 SCREEN, RESERVOIR 782XX297 1 14 BRACKET,RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID,RESERVOIR 775XX861 1 17 HANDLE, PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL,WARNING-HOT SURFACE 781XX629 2 21 LABEL, WARNING-ELEC.HAZARD 781XX630 2 22 NAMEPLATE, SHURE-GLUE SYSTEMS 781XX566 1 23 RIVET 091XX517 2 24 INSTALLATION KIT, D4 HMU 091XX734 1 25 UPGRADE KIT 4 EXITS 776XX140 1 98 SKID WOOD - HMU 730XX020 1 99 BOX OUTER SHIPPER 023XX108 1


116

D4 Unit - Continued

D4 Unit, Variable speed, 2 exit (776xx889)

ITEM DESCRIPTION PART NO. QTY. 1 BASE UNIT ASSY, D4 776XX392 1 2 BRACKET MOTOR 776XX313 1 3 BRACKET MOUNTING LEFT 776XX314 1 4 BRACKET MOUNTING RIGHT 776XX315 1 5 SCREW 884XX223 8 6 FLAT WASHER 798XX302 8 7 GEARMOTOR 110XX365 1 8 SCREW 884XX004 4 9 LOCK WASHER 798XX735 4

10 HUB JAW COUPLING 783XX370 1 11 HUB JAW COUPLING 783XX371 1 12 SPIDER JAW COUPLING 783XX372 1 13 SCREEN, RESERVOIR 782XX297 1 14 BRACKET,RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID,RESERVOIR 775XX861 1 17 HANDLE, PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL,WARNING-HOT SURFACE 781XX629 2 21 LABEL, WARNING-ELEC.HAZARD 781XX630 2 22 NAMEPLATE, SHURE-GLUE SYSTEMS 781XX566 1 23 RIVET 091XX517 2 24 INSTALLATION KIT, D4 HMU 091XX734 1 25 MTR DRIVE, AC VAR FREQ, 1/2HP 110XX425 1 26 PCB ASSY VFD D-SERIES HMU 151XX701 1 27 CABLE ASSY; VFD SIGNAL 029XX856 1 28 CABLE ASSY; VFD POWER 029XX792 1 29 SCREW 798XX188 2 30 STANDOFF 091XX666 4 31 SCREW 784XX112 4 34 CABLE ASSY, VFD POWER AND COMM 029XX857 1 98 SKID WOOD - HMU 730XX020 1 99 BOX OUTER SHIPPER 023XX108 1


117

D4 Unit - Continued

D4 Unit, Variable speed, 4 exit (776xx890)


10 HUB JAW COUPLING 783XX370 1 11 HUB JAW COUPLING 783XX371 1 12 SPIDER JAW COUPLING 783XX372 1 13 SCREEN, RESERVOIR 782XX297 1 14 BRACKET,RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID,RESERVOIR 775XX861 1 17 HANDLE, PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL,WARNING-HOT SURFACE 781XX629 2 21 LABEL, WARNING-ELEC.HAZARD 781XX630 2 22 NAMEPLATE, SHURE-GLUE SYSTEMS 781XX566 1 23 RIVET, BLIND 091XX517 2 24 INSTALLATION KIT, D4 HMU 091XX734 1 25 MTR DRIVE, AC VAR FREQ, 1/2HP 110XX425 1 26 PCB ASSY VFD D-SERIES HMU 151XX701 1 27 CABLE ASSY; VFD SIGNAL 029XX856 1 28 CABLE ASSY; VFD POWER 029XX792 1 29 SCREW 798XX188 2 30 STANDOFF 091XX666 4 31 SCREW 784XX112 4 32 UPGRADE KIT 4 EXITS 776XX140 1 34 CABLE ASSY, VFD POWER AND COMM 029XX857 1 98 SKID WOOD - HMU 730XX020 1 99 BOX OUTER SHIPPER 023XX108 1


118

D4 Unit - Continued

D4 Unit, Variable speed, 2 exit (776xx889) - before 5/18


10 HUB JAW COUPLING 783XX370 1 11 HUB JAW COUPLING 783XX371 1 12 SPIDER JAW COUPLING 783XX372 1 13 SCREEN, RESERVOIR 782XX297 1 14 BRACKET,RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID,RESERVOIR 775XX861 1 17 HANDLE, PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL,WARNING-HOT SURFACE 781XX629 2 21 LABEL, WARNING-ELEC.HAZARD 781XX630 2 22 NAMEPLATE, SHURE-GLUE SYSTEMS 781XX566 1 23 RIVET 091XX517 2 24 INSTALLATION KIT, D4 HMU 091XX734 1 25 MTR DRIVE, AC VAR FREQ, 1/2HP 110XX310 1 26 PCB ASSY VFD D-SERIES HMU 151XX682 1 27 CABLE ASSY; VFD SIGNAL 029XX793 1 28 CABLE ASSY; VFD POWER 029XX792 1 29 SCREW 798XX046 3 30 STANDOFF 091XX666 2 31 SCREW 784XX112 2 33 VFD PARAMETERS, D SERIES 999XB776-31 1 98 SKID WOOD - HMU 730XX020 1 99 BOX OUTER SHIPPER 023XX108 1


119

D4 Unit - Continued

D4 Unit, Variable speed, 4 exit (776xx890) - before 5/18


10 HUB JAW COUPLING 783XX370 1 11 HUB JAW COUPLING 783XX371 1 12 SPIDER JAW COUPLING 783XX372 1 13 SCREEN, RESERVOIR 782XX297 1 14 BRACKET,RESERVOIR LID 775XX862 1 15 SCREW 784XX491 3 16 LID,RESERVOIR 775XX861 1 17 HANDLE, PULL 104XX135 1 18 SCREW 784XX300 2 19 FLAT WASHER 784XX568 2 20 LABEL,WARNING-HOT SURFACE 781XX629 2 21 LABEL, WARNING-ELEC.HAZARD 781XX630 2 22 NAMEPLATE, SHURE-GLUE SYSTEMS 781XX566 1 23 RIVET, BLIND 091XX517 2 24 INSTALLATION KIT, D4 HMU 091XX734 1 25 MTR DRIVE, AC VAR FREQ, 1/2HP 110XX310 1 26 PCB ASSY VFD D-SERIES HMU 151XX682 1 27 CABLE ASSY; VFD SIGNAL 029XX793 1 28 CABLE ASSY; VFD POWER 029XX792 1 29 SCREW 798XX046 3 30 STANDOFF 091XX666 2 31 SCREW 784XX112 2 32 UPGRADE KIT 4 EXITS 776XX140 1 33 VFD PARAMETERS, D SERIES 999XB776-31 1 98 SKID WOOD - HMU 730XX020 1 99 BOX OUTER SHIPPER 023XX108 1


120

D4 Base Unit (776xx392)


121

D4 Base Unit (776xx392) - Continued

ITEM DESCRIPTION PART NO. QTY. 1 CHASSIS 775XX858 1 2 STANDOFF 775XX857 4 3 RESERVOIR KIT 916XX808 1 4 WASHER 798XX593 4 5 NUT 798XX301 4 6 CABLE ASSY, RESERVOIR RTD 029XX788 1 7 SUPPORTING FLANGE 914XX169 1 8 SCREW 784XX423 2 9 CABLE ASSY, RESERVOIR HEATER 029XX789 1

10 CABLE ASSY, THERMOSTAT 029XX548 1 11 SCREW 784XX049 2 12 SCREW 784XX992 1 13 LOCK WASHER 798XX776 4 14 WIRE TERMINAL 075XX205 1 15 WIRE PTFE 540XX149 6 16 NOMEX 794XX327 0.15 17 GASKET,RESERVOIR 782XX098 1 18 CORD GRIP 066XX244 1 19 LABEL, GROUND SYMBOL 781XX110 1 20 MANIFOLD, D4 HOT MELT UNIT 776XX317 1 21 HEX PLUG 799XX127 10 22 PLUG,PIPE,SOCKET 799XX548 2 23 SOCKET HEAD PIPE PLUG 797XX042 3 24 FILTER ASSY 593XX461 1 25 VALVE, PRESSURE RELIEF 707XX222 1 26 PRESS. GAUGE 786XX122 1 27 O-RING 745XX021 1 28 SCREW 884XX002 4 29 WASHER 784XX476 4 30 PANEL HOSE RECEPTACLE D4 776XX319 1 31 CABLE ASSY, HOSE/GUN 029XX546 2 32 WASHER 798XX772 8 33 NUT 798XX489 12 34 TERMINAL,TAB 091XX609 3 35 LOCK WASHER 784XX352 6 36 NUT 784XX349 4 37 WIRE TERMINAL, RING 075XX179 5 38 POWER SUPPLY 148XX076 1 39 SCREW 784XX112 2 40 CABLE ASSY, POWER SWITCH 029XX790 1 41 CABLE ASSY, DC SUPPLY 029XX791 1 42 STANDOFF 091XX601 7 43 STANDOFF 091XX735 7


122

D4 Base Unit (776xx392) - Continued

ITEM DESCRIPTION PART NO. QTY. 44 PCB ASSY, 12 ZONE GEAR PUMP 151XX747 1 45 WIRE TERMINAL, RING 075XX070 1 46 NUT 798XX488 13 47 PANEL OPERATOR D4 776XX318 1 48 OVERLAY ASSY, HM CTRL, D-SERIE 137XX029 1 49 LATCH,SPRING CAM 781XX892 2 50 SWITCH, ROCKER 480XX246 1 51 NUT FLANGE 784XX677 7 52 CABLE TIE 067XX154 6 53 CASE D4 776XX886 1 54 ELECTRICAL CONNECTIONS STICKER 917XX811 1 55 SCREW 784XX491 4 56 LANYARD 781XX890 2 57 SCREW 798XX188 4 58 WIRE TERMINAL 075XX332 3 59 CABLE ASSY 029XX569 1 60 CABLE ASSY 029XX608 1 61 PLUG HOLLOW HEX 1/2 BSPP 799XX875 1 99 ELECTRICAL ELEMENTARY 999XD776-48 1


123

D4 Base Unit (776xx392) - before 5/18

ITEM DESCRIPTION PART NO. QTY. 1 CHASSIS 775XX858 1 2 STANDOFF 775XX857 4 3 RESERVOIR KIT 916XX808 1 4 WASHER 798XX593 4 5 NUT 798XX301 4 6 CABLE ASSY, RESERVOIR RTD 029XX788 1 7 SUPPORTING FLANGE 914XX169 1 8 SCREW 784XX423 2 9 CABLE ASSY, RESERVOIR HEATER 029XX789 1

10 CABLE ASSY, THERMOSTAT 029XX548 1 11 SCREW 784XX049 2 12 SCREW 784XX992 1 13 LOCK WASHER 798XX776 4 14 WIRE TERMINAL 075XX205 1 15 WIRE PTFE 540XX149 6 16 NOMEX 794XX327 0.15 17 GASKET,RESERVOIR 782XX098 1 18 CORD GRIP 066XX138 2 19 LABEL, GROUND SYMBOL 781XX110 1 20 MANIFOLD, D4 HOT MELT UNIT 776XX317 1 21 HEX PLUG 799XX127 10 22 PLUG,PIPE,SOCKET 799XX548 2 23 SOCKET HEAD PIPE PLUG 797XX042 3 24 FILTER ASSY 593XX461 1 25 VALVE, PRESSURE RELIEF 707XX222 1 26 PRESS. GAUGE 786XX122 1 27 O-RING 745XX021 1 28 SCREW 884XX002 4 29 WASHER 784XX476 4 30 PANEL HOSE RECEPTACLE D4 776XX319 1 31 CABLE ASSY, HOSE/GUN 029XX546 2 32 WASHER 798XX772 8 33 NUT 798XX489 12 34 TERMINAL,TAB 091XX609 3 35 LOCK WASHER 784XX352 6 36 NUT 784XX349 4 37 WIRE TERMINAL, RING 075XX179 5 38 POWER SUPPLY 148XX076 1 39 SCREW 784XX112 2 40 CABLE ASSY, POWER SWITCH 029XX790 1 41 CABLE ASSY, DC SUPPLY 029XX791 1 42 STANDOFF 091XX601 7 43 STANDOFF 091XX735 7


124

D4 Base Unit (776xx392) - before 5/18 - Continued

ITEM DESCRIPTION PART NO. QTY. 44 PCB ASSY, 12 ZONE GEAR PUMP 151XX747 1 45 WIRE TERMINAL, RING 075XX070 1 46 NUT 798XX488 13 47 PANEL OPERATOR D4 776XX318 1 48 OVERLAY ASSY, HM CTRL, D-SERIE 137XX017 1 49 LATCH,SPRING CAM 781XX892 2 50 SWITCH, ROCKER 480XX246 1 51 NUT FLANGE 784XX677 7 52 CABLE TIE 067XX154 6 53 CASE D4 776XX886 1 54 ELECTRICAL CONNECTIONS STICKER 917XX811 1 55 SCREW 784XX491 4 56 LANYARD 781XX890 2 57 SCREW 798XX188 4 58 WIRE TERMINAL 075XX332 3 59 CABLE ASSY 029XX569 1 60 CABLE ASSY 029XX608 1 99 ELECTRICAL ELEMENTARY 999XD776-32 1


125

Installation Kit (091xx734) ITEM DESCRIPTION PART NO. QTY.

1 FUSE 085XX220 2

2 FUSE 085XX271 2

3 FUSE 085XX289 2

4 FUSE; TIME LAG 085XX272 2

5 D4 HOT MELT UNIT MANUAL - CD MM147-CD 1

6 BOX,TRAY 730XX015 1

7 WARRANTY CARD; VALCOMELTON LOGO 999XA774-157 1


126

Option Kits The D4 can support a maximum of two level sensors; only two of the following sensors may be selected:

• Autofeed

• Internal Low-Level

• External Pot Fill

AutoFeed

Vacuum Feeder Assembly - 776xx305

Refer also to Appendix C - Instruction Sheets for Option Kits: IS0231

DETAIL 'A'

DETAIL 'B'

14

46

5

7

8

9

17 SEE DETAIL "B"

PORT 1

PORT 3

PORT 2

10

18

19

20

SEE DETAIL "A"

12

15

21

38

16

37

40

23


127

Vacuum Feeder Assembly - 776xx305 - Continued

ITEM DESCRIPTION PART NO. QTY. 1 LID, RESERVOIR 776XX041 1 2 BRACKET,RESERVOIR, D4-E 776XX042 1 3 SCREW 784XX491 3 4 FEEDER TUBE D050170100 1 5 FEEDER TUBE ADAPTER 776XX102 1 6 SCREW 784XX008 2 7 VALVE MOUNTING BRACKET 776XX160 1 8 SCREW 784XX374 4 9 VACUUM FEEDING FILTER 910XX465 1

10 3-WAY SOLENOID 411XX863 1 12 CONTROL, FLOW 707XX574 1 14 MALE QUICK DISCONNECT 752XX004 1 15 MALE CONNECTOR,STRAIGHT 799XX662 1 16 EXHAUST MUFFLER 411XX601 1 17 SCREW 784XX050 2 18 SCREW 784XX496 4 19 MAGNET 783XX310 2 20 SCREW 884XX276 2 21 NUT ACORN 884XX280 2 22 LEVEL SENSOR ASSY 098XX110 1 23 CABLE CLAMP 066XX220 1 24 BUSHING, SQUARE 066XX221 2 25 ASSEMBLY,FEEDER TUBE K051701002 1 26 CABLE ASSY, REED SENSOR 029XX583 1 27 JUMPER CABLE ASSY 029XX584 1 30 CABLE TIE 0.14 X 6.1 BLK 067XX154 2 34 CONNECTOR; 4 PIN TERMINAL 075XX392 1 35 SCREW 784XX598 2 36 IS; VACUUM FEEDER IS0231 1 37 LABEL,WARNING-HOT SURFACE 781XX629 1 38 CABLE CLAMP 066XX075 1 39 SCREW 784XX359 2 40 NUT,LOCK,STEEL 799XX574 2 99 IS; VACUUM FEEDER IS0231 1


128

Pump Control

Cable Assembly Handgun Pump Control (029xx552)


ITEM DESCRIPTION PART NO. QTY. 1 SLEEVING 755XX077 40 2 CONN,SHELL 061XX033 1 3 SOCKET 061XX448 2 5 FERRULE 075XX302 8 6 WIRE PTFE 540XX162 3.5 7 WIRE PTFE 540XX159 3.5 8 WIRE PTFE 540XX164 0.333 9 INSTRUCTION SHEET,PUMP CNTROL IS0161 1

10 CABLE TIE 067XX154 1


129

Pump Kit, Standard Width (561xx216)


ITEM DESCRIPTION PART NO. QTY. 1 GEAR PUMP, STANDARD WIDTH 561XX308 1 2 SCREW 798XX173 4 3 O-RING 745XX035 2 4 TAG,PUMP INFORMATION 782XX085 1 5 SCREW 784XX341 4 6 INFORMATION SHEET, PUMPS 998IS696 1 7 D & S SERIES PUMP CHANGE PROCEDURE IS0212 1

Pump Kit, Half Width (561xx220)


ITEM DESCRIPTION PART NO. QTY. 1 GEAR PUMP, HALF WIDTH 561XX330 1 2 SCREW 798XX171 4 3 O-RING 745XX035 2 4 TAG,PUMP INFORMATION 782XX085 1 5 SCREW 784XX340 4 6 INFORMATION SHEET, PUMPS 998IS696 1 7 D & S SERIES PUMP CHANGE PROCEDURE IS0212 1


130

Internal Level Sensors

Internal Low-Level Sensor Kit (776xx892)


ITEM DESCRIPTION PART NO. QTY. 1 AMPLIFIER, LEVEL SENSOR 098XX106 1 2 LEVEL SENSOR, HIGH TEMPERATURE 098XX107 1 3 SCREW 784XX359 2 4 CONNECTOR 070XX662 1 5 CONTACT 061XX424 3 6 WIRE PTFE 540XX061 2.167 7 WIRE TERMINAL 075XX179 1 8 WIRE TERMINAL 075XX393 1 9 NYLON WIRE LABELS 075XX359 1

10 IS: INTERNAL LEVEL SENSOR IS0232 1 11 LOCK WASHER 784XX352 1 12 HEX NUT 784XX349 1 13 SILICONE, RTV ALUM 710XX211 1


131

External Pot Fill

External Pot Fill Kit (776xx757)


4 P

LCS

2 P

LCS

2 P

LCS

4 P

LCS

4 P

LCS

3 P

LCS

DET

AIL

"A"

TER

MIN

AL

STR

IPP

IN L

OC

ATI

ON

SCA

LE 2

:1

WIR

E L

EN

GTH

S T

O B

E ±

0.50

[12

.7 M

M]

UN

LES

S O

THE

RW

ISE

SPEC

IFIE

D.


132

External Pot Fill Kit (776xx757) - Continued

ITEM PART NO. DESCRIPTION QTY. 1 026XX317 ENCLOSURE, MODIFICATION 1 2 026XX318 MOUNTING PLATE, INTERNAL 1 3 784XX945 SHCS,M3 X 5MM LONG,S.S. 4 4 098XX106 AMPLIFIER, LEVEL SENSOR, PNP 1 5 798XX188 SHCS - M4 X 8MM, S.S. 2 6 784XX435 FLAT WASHER M4 SS 2 7 098XX107 LEVEL SENSOR, HIGH TEMPERATURE 1 8 540XX061 WIRE PTFE 18 AWG GRN/YEL 6.5 9 075XX393 WIRE TERMINAL; RECP, .110, INS 1 10 075XX179 WIRE TERMINAL; RING 1 11 755XX679 SLEEVING; FIBERGLASS 3/8 BLAK 60 12 066XX138 CORD GRIP; BLACK PG 13.5 1 13 061XX211 CONNECTOR,M12,5PIN, MALE 1 14 075XX387 CONNECTOR; 4 PIN TERMINAL 1 15 884XX269 SHCS M2.5 X 12 SS 2 16 075XX303 FERRULE;INS,20AWG,WHITE,8MM 4 17 075XX301 FERRULE;INS,24AWG,LT-BLU,8MM 4 18 030XX596 CABLE ASSY; M12 FEM., 10M 1 19 070XX662 CONNECTOR, 3 POS 3A, .098" XA 1 20 061XX424 CONTACT, FEM. SOCKET, 3A XA 3 21 583XX286 SENSOR MOUNTING PLATE 1 22 799XX368 ELBOW-90; 1/2JIC X 3/4NPT-M 1 23 066XX155 CORD GRIP 1 24 067XX154 TY-RAP .14" X 5.5"L,HIGH TEM 2 25 067XX002 HARNESS ANCHOR .75 INCH 2 26 999XA583-13 FITTING SELECTION GUIDE 1 27 IS0234 IS; EXTERNAL POT FILL 1 28 784XX352 LOCK WASHER M5 1 29 784XX349 HEX NUT M5 0,8 ZINC 1


133

Alarm Beacon

Alarm Beacon Assembly, 24V (782xx701)


0

54

3

21


134

Alarm Beacon Assembly, 24V (782xx701) - Continued

ITEM DESCRIPTION PART NO. QTY. 1 BEACON, COVER & BASE 105XX055 1 2 SLEEVING, FIBERGLASS 755XX087 5.5 3 WIRE 540XX043 8.5 4 WIRE 540XX040 8.5 5 WIRE 540XX035 8.5 6 WIRE 540XX034 3 7 FERRULE 075XX303 8 8 BULB 105XX050 2 9 BEACON, LIGHT ELEMENT, BLUE 105XX051 1

10 BEACON, LIGHT ELEMENT, RED 105XX053 1 11 SCREW 784XX313 2 12 NUT 798XX488 2

Alarm Beacon Replacement Bulb

PART NO. DESCRIPTION 105XX050 24V, 5W

Siren Element Kit (776xx762)


ITEM PART NO. DESCRIPTION QTY. 1 105XX054 BEACON, SIREN ELEMENT 1 2 IS0233 IS; ALARM BEACON ASSY 1


135

Pressure Relief

Pneumatic Pressure Relief Kit (707xx212)

4

6

5

3

2

1

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


136

Relief Valve Assembly (594xx189)

Refer also to Appendix C - Instruction Sheets for Option Kits: 999XD774-197

Unit Description Part # QTY 1 707XX897 VALVE ASSY,PRESSURE RELIEF 1 2 797XX079 HEX NIPPLE M-M 1/8 1 3 411XX118 VALVE ASSY, 3-WAY W/M12 24V 1 4 799XX582 CONNECTOR,MALE: 8MM X 1/8 NPT 2 5 755XX575 TUBING,NYLON,8MM O.D. 360 6 797XX395 FITTING, MALE: 5/16I X 1/4NPT 4 7 797XX019 STREET TEE F-F-M 1/4 1 8 594XX033 FILTER REGULATOR ASSY. 1 9 582XX300 BRACKET-REGULATOR 1 10 594XX004 AIR REGULATOR M750LPG 1 11 580XX861 BRACKET 1 12 999XD774-197 ILLUST. DWG.: UNIFLOW REL. VA 1


137

Pressure Monitoring

Pressure Switch Kit, 50-130 PSI (481xx050)


ITEM PART NO. DESCRIPTION QTY. 1 485XX105 SWITCH; PRESSURE 1 2 792XX340 FITTING ADAPTER 1 3 797XX073 REDUCER M-M 1/2 X 1/4 1 4 IS0213 IS, UE PRESSURE SWITCHES 1 5 075XX304 FERRULE;INS,18AWG,RED,8MM 4 6 755XX087 SLEEVING;FIBERGLASS,#4,BLACK 69.5 7 067XX154 TY-RAP .14" X 5.5"L,HIGH TEM 4 8 067XX002 HARNESS ANCHOR .75 INCH 2 9 075XX179 WIRE TERMINAL; RING 1 10 784XX352 LOCK WASHER M5 1 11 784XX349 HEX NUT M5 0,8 ZINC 1


138







Heavy Duty Pressure Gauge (786xx129)

ITEM PART NO. DESCRIPTION QTY. 1 786XX129 PRESSURE GAUGE 1


139

Pressure Transducer Assembly (521xx019)


ITEM DESCRIPTION PART NO. QTY. 1 TRANSDUCER PRESSURE 520XX031 1 2 WIRE 540XX160 4.583 3 WIRE 540XX166 4.583 4 WIRE 540XX164 4.583 5 SLEEVING 755XX087 52.5 6 CONNECTOR 070XX662 1 7 CONTACT 061XX424 3 8 FERRULE 075XX302 3 9 CABLE TIE 067XX154 2

10 IS, PRESSURE TRANSDUCER IS0377 1


140

Auxiliary I/O

Optional I/O HMU PCB Assembly (098xx134)


ITEM PART NO. DESCRIPTION QTY. 1 151XX724 PCB ASSY ANYBUS EXPANDED-I/O 1 3 091XX644 SPACER, PCB 14MM SNAP IN 1 4 091XX563 STANDOFF,6MM HEX 2 5 784XX541 SCREW 2 7 IS0343 IS, ADDITIONAL I/O BOARD 1

Ethernet IP Kit (098xx133)


ITEM PART NO. DESCRIPTION QTY. 1 151XX724 PCB ASSY ANYBUS EXPANDED-I/O 1 2 098XX123 MODULE, ANYBUS, ETHERNET/IP 1 3 091XX644 SPACER, PCB 14MM SNAP IN 1 4 091XX563 STANDOFF,6MM HEX 2 5 784XX541 SCREW 2 6 029XX787 CABLE RIBBON 30P 2MM 1 7 IS0344 IS, ANYBUS INSTALLATION 1 8 MM139CD CD, MM139 MANUAL 1

24V VDC Relay Kit (776xx537)


ITEM PART NO. DESCRIPTION QTY. 1 160XX292 RELAY 1 2 400XX028 SOCKET, RELAY 1 3 030XX722 CABLE 2.5 4 075XX302 FERRULE 4 5 784XX184 SCREW 1

MM147 - D4 Hot Melt Unit Section 11 - Warranty

141

Section 11 - Warranty Warranty Information Valco Cincinnati, Inc. warrants its equipment worldwide against defects in material and workmanship as outlined in this section.

Liability of the company is limited to repair of the product, or replacement of any part shown to be defective, and does not extend to defects caused by accidents, 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 the date of shipment by Valco Cincinnati.

Components purchased by Valco Cincinnati, Inc. from others for inclusion in its products are warranted only to the extent of the original manufacturer’s warranty. In no event shall Valco Cincinnati, Inc. be liable for indirect or consequential damages arising out of the use of Valco Cincinnati products.

This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to Valco Cincinnati, Inc. for examination and verification. If claimed defect is verified, repairs or replacements will be made F.O.B. Cincinnati, Ohio, U.S.A. or ex-works Telford, U.K. If the inspection of the equipment does not disclose any defect of workmanship or material, any necessary repairs will be made at a reasonable charge and return transportation will be charged.

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

Cold Glue Equipment and Electronic Controls

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

Hot Melt Units, Hoses, Valves, Guns, and Related Equipment

All hot melt components except cast-in heating elements are warranted for a period 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.

Section 11 - Warranty MM147 - D4 Hot Melt Unit

142

MM147 - D4 Hot Melt Unit Section 12 - Service

143

Section 12 - Service If a problem with your system persists, contact a ValcoMelton Technical Support representative. If your need is urgent, we encourage you to contact our corporate office in Cincinnati, Ohio, U.S.A. at (513) 874-6550. If the problem cannot be resolved, Valco Cincinnati, Inc. will promptly arrange to have a technical representative visit your facility. Any charges for a service call will be quoted at that time. Any part that fails during the warranty period shall be returned prepaid to Valco Cincinnati, Inc. by the customer for disposition.

Upon request, ValcoMelton personnel are available to repair or replace such parts at the customer’s facility. Charges for this service include travel time and expenses.

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

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

Section 12 - Service MM147 - D4 Hot Melt Unit

144

MM147 - D4 Hot Melt Unit Appendix A - Password Levels

145

Appendix A - Password Levels The Unit has multiple security levels to protect important information against unauthorized access. The levels are enabled with different PIN codes when entering the ‘Setup menu’. The following list includes the PIN codes for the different levels and describes the difference between them.

Level 1- Operator (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 Operator (PIN Code: 1234)

• Can access all Level 1 features

• Can access most system setup parameters

• Can access all Clock, Setback, Startup, History, and Diagnostics menu groups

Level 3 - Supervisor (PIN Code: 6550)

• Can access all Level 1 and 2 features

• Can access Maximum Temperature parameter in System Setup menu

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

Level 0 - Protected (no password required) Level 0 is an alternate default level that locks out ALL edits, for applications where the plant wishes to prevent any and all changes, including temperature changes.

The Password Pin input function is still accessible.

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

Appendix A - Password Levels MM147 - D4 Hot Melt Unit

146

Setting Level 0 as Default - Continued

MM147 - D4 Hot Melt Unit Appendix B - Power Requirements

147

Appendix B - Power Requirements System Power Requirement Calculation - D Series Units

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

Power requirements for the D4 System (unit, hoses and guns) must be calculated before hooking up power, to verify that the hoses and guns do not exceed the power rating for the D Series unit. Personnel injury, as well as serious equipment damage, can result from overloading the 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 Series unit as follows, referring to Table 1, below:

Table 1. Maximum Allowable Wattage for the D Series Unit

Line Description Maximum Wattage (W)

1 Total for hose/gun 1 pair 1800 2 Total for hose/gun 2 pair 1800 3 Total for hose/gun 3 pair 1400 4 Total for hose/gun 4 pair 1400 5 Total for all hoses and guns 8400

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




5. Add the power requirements of all hoses and all guns. Compare this value to the maximum wattage for all hoses and guns given in Line 5 of Table 1.

6. If any of the power requirements calculated in steps 1-5 exceed any of the maximum allowable wattages given in Table 1, the hose length or gun configuration must be changed, to reduce all power requirements to below maximum-allowable wattages. If each of the power requirements calculated in steps 1-5 is below the maximum allowable wattages given in Table 1, the system power requirement is within allowable limits.

Appendix B - Power Requirements MM147 - D4 Hot Melt Unit

148

MM147 - D4 Hot Melt Unit Appendix C - Instruction Sheets for Option Kits

149

Appendix C - Instruction Sheets for Option Kits The attached Instruction Sheets apply to the Option Kits listed in the table below.

Some of the Instruction Sheets associated with this system also contain information for other systems. When using any of these Instruction Sheets, refer only to the sections that apply to your system and disregard those that do not apply.

Option Kits for D4 Feature # Description Option Kit Instruction Sheet

1 N/A 2 Autofeed 776XX305 IS0231 3 Pump Control 029XX552 IS0161

4 Pump Type 561XX216 IS0212 561XX220 5 N/A 6 N/A 7 N/A

8

Internal Level Sensors 776XX892 IS0232 External Pot Fill 776xx757 IS0234

Alarm/Beacon 782XX701 IS0233 776XX762

9 Pressure Relief 707XX212 999XD707-002 594XX189 999XD774-197

10 Pressure Monitoring

481XX050 IS0213 481XX051

481XX052 521XX019 IS0377 786XX129

11 Aux. I/O 098XX134 IS0343 098XX133 IS0344

12 N/A

Zone Upgrade Kits Part Number Description Instruction Sheet

776XX140 2-4 IS0227

Additional Upgrade Kits Part Number Description Instruction Sheet

776XX490 Jaw Coupling Upgrade Kit IS0299

Appendix C - Instruction Sheets for Option Kits MM147 - D4 Hot Melt Unit

150

1Valco Melton

VACUUM FEEDER ASSEMBLY INSTRUCTIONS

IS02314 / 1 34 / 1 34 / 1 34 / 1 34 / 1 3

ImportantInformation

WARNING!WARNING!WARNING!WARNING!WARNING! Read and follow all instructions, warnings, tags, andlabels before operating the equipment. Only qualifiedpersonnel should perform this procedure. USE OF THISEQUIPMENT IN A MANNER OTHER THANDESCRIBED IN THIS INSTRUCTION SHEET, ANDFAILING TO FOLLOW ALL INSTRUCTIONS, COULDRESULT IN PERSONAL INJURY, DEATH, ORDAMAGE TO EQUIPMENT.

All equipment is to be installed and all connectionsmade only by qualified personnel. Components andaccessories are to be installed in accordance with theinstructions provided and the applicable codes for theregion installed. FAILURE TO FOLLOW THESEINSTRUCTIONS COULD RESULT IN A PERSONALINJURY, DEATH, OR DAMAGE TO EQUIPMENT.

WARNING!WARNING!WARNING!WARNING!WARNING! The equipment may still be energized even after thecircuit breaker or main power switch is off.

All equipment must be properly grounded and fused inaccordance with rate current consumption (refer to theequipment identification plate)

Gauge and insulation for the power supply must beadequate to handle rated current consumption.

Description This installation sheet covers how to install a vacuum feeding system onto aD10 hot melt unit with a universal temperature control.

InstallationTo install a vacuum feed system:

1. Disconnect the power.

2. Open the back hose and front operator panels.

3. Remove the two (2) M4 x 12 socket head cap screws holding thelanyards to the top of the case.

4. Remove the quick-disconnect ground wire from the top of thecase.

2 Valco Melton

IS0231 Vacuum Feeder Assembly Instructions

Installation - Continued

5. Remove the four (4) M5 flange nuts from the bottom corners of thecase.

6. Remove any other connections that are holding the case to thechassis.

7. Remove the case.

8. Carefully remove the three (3) circular knockouts from the top ofthe case.

9. Carefully remove the circular knockout on the center bulkhead inthe case.

3Valco Melton

IS0231Vacuum Feeder Assembly Instructions

Installation - Continued 10. File down any sharp metal edges that occur as a result ofremoving the knockouts.

11. Turn the case on its side.

12. Install the level sensor amplifier box to the center bulkhead, usingthe two (2) M4 socket head cap screws.

13. Attach the terminal ring from the amplifier box to the groundingstud on the top of the case.

14. Route the sensor through the knockout in the center bulkhead,and then through the knockout on the top of the case.

15. Install the reed sensors into the appropriate knockout on the topof the case. The reed sensor number is indicated by a label onone of the lead wires. The top of the sensors need to be .218" -.060" +.100" from the top of the case.

4 Valco Melton



16. Route the side of the cable assembly with the terminal ringthrough the center bulkhead.

17. Route the other end of the cable assembly through the openknockout on the top of the case.

18. Remove the rectangular connector from the top of the air valve.

19. Remove wiring insert, using a small, flat-head screwdriver.

20. Route the cable assembly through the bottom of the connector.

21. Attach the three (3) ferrules to the connector by following thelabels on the wire ends.

22. Replace the wiring insert back into the connector. Make sure thefiberglass sleeving is held by the strain relief in the bottom of theconnector.

23. Route the cable assembly through the cable clamp on the backof the valve.

5Valco Melton


Route Cablethrough Clamp

Installation - Continued 24. Using the two (2) ty-raps included in the kit, attach the cable to thecase walls. This will ensure that the tank does not crush the wireswhen the case is reinstalled.

24. Attach the terminal strip to the side of the case using two (2) M3 x16 socket-head cap screws.

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27. Replace the case carefully, being sure NOT to crush any of thewires.

28. Reattach the case to the chassis by reversing steps 2-6. Do notclose the front operator panel.

29. Remove the current lid and bracket from the unit.

30. Attach the new lid bracket to the unit using three (3) M6 button-head cap screws.

31. Attach the new lid-with-vacuum-feeder to the bracket.

32. Reattach the rectangular connector to the air valve.

33. Remove the yellow cap from the end of the feeder tube.

34. Attach the hose to the feeder inlet, using a Phillips-headscrewdriver to tighten the hose clamp.

25. Attach the three (3) flying leads from the amplifier box to theterminal block.

26. Attach the three (3) flying leads from the included cable assemblyto the other side of the terminal block.

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38. Install the red jumper cable to the door switch location on thetemperature control board.

39. Connect the flying leads, with the white ferrules, to the feederlocation on the temperature control board.

40. Attach the flying terminal ring from the cable assembly to one ofthe grounding studs on the base of the chassis.

35. Attach the 10 mm tubing to the push-in 90° swivel fitting on the airvalve.

36. Slide the level probe through the cable clamp on the top of the lid.Use a Phillips-head screwdriver to tighten the probe to the clamp.The top of the sensor should be about .25" above the top of theclamp.

37. Connect the three (3) pin, white JST connector from the amplifierbox to the temperature control board.

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42. Repeat step 41, except for the knockout on the top of the case.

To calibrate the sensor:

43. Reconnect the power and turn the unit on.

44. Connect air to the air valve, using the quick-disconnect provided.

45. Activate the vacuum feeder by closing the lid and adjusting thepressure gauge on the vacuum feeder lid. Let the tank fill withadhesive.

46. If the vacuum feeder does not turn on, check that the feeder LEDis on. If the feeder LED is not on, check that the jumper cable andlevel sensor cable are in the correct locations. If the feeder LEDis on, the height of the reed sensors needs to be readjusted.

47. Once the vacuum feeder has stopped, open the lid, and makesure the unit is filled and the adhesive level is about 1.5"±0.25"from the top of the tank.

41. Snap one of the black plastic clips around the level sensor wireand the cable assembly, and insert the clip into the knockout onthe center bulkhead.

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c. If the adhesive is at the appropriate level and thelight is red carefully turn the screw clockwise until thelight changes to intermittent red-yellow.

d. After 3 seconds it should change to green.

e. If the adhesive is at the appropriate level and thelight is green, turn the screw, carefully, counterclockwise until the light changes to intermittent red-yellow.

f. After 3 seconds it should change back to green.

51. Remove half of the adhesive and close the lid. Be sure that thelight on the amplifier box turns red.

52. Allow the unit to refill. Make sure the light is green and theadhesive is at the appropriate level.

a. If the adhesive is not at the appropriate level, repeatstep 50.

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Check the adhesive level periodically to confirm thesensor is working properly.

53. Reinsert the protective screw into the amplifier box.

54. Close the front operator panel.

To adjust the sensor delay time:

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! The adhesive pile will be uneven; measure from the topof the pile to the top of the tank.

48. If the unit does not fill to the appropriate level, check to ensure thetop of the level probe is 0.25" above the clamp. If the unit does fillto the appropriate level, proceed to step 49.

49. Remove the protective screw on the amplifier box.

50. Adjust the sensor calibration, using a small, flat-head screwdriverto adjust the calibration screw on the amplifier box.

a. Turn the screw counter clockwise to raise theadhesive level.

b. Turn the screw clockwise to lower the adhesive level.

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59. Select Internal ON Delay, based on the desired sensor, andadjust the time for your application. The default time for thesensor is 5 seconds.

55. Access the setting screen by pressing .

56. Unlock the control by using the level 3 password: “6550”.

57. Access the setting screen by pressing again.

58. Access the “System” screen.

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HANDGUN SWITCH KIT INSTALLATION AND OPERATIONHANDGUN SWITCH KIT INSTALLATION AND OPERATIONHANDGUN SWITCH KIT INSTALLATION AND OPERATIONHANDGUN SWITCH KIT INSTALLATION AND OPERATIONHANDGUN SWITCH KIT INSTALLATION AND OPERATION

IS01617 / 1 27 / 1 27 / 1 27 / 1 27 / 1 2

Hot Melt Unit with Universal Control

1. Turn off power to unit and open lid to electronics cabinet.

2. Locate Control Board (151xx650) on the back of the Keypad. See figure below.

3. Run flying lead end of the included Handgun Switch Cable Assembly up to the Control Board. Ifyour Handgun Switch Cable Assembly has a flange mounted connector, install it in place of theknockouts provided in the back panel of the unit. Use hardware provided with kit.

4. If the cable assembly has a flange-mounted connector, route the cable assembly along the inside ofthe unit, as shown.

Input 1 Input 2 Input 3 Input 4 Pin 2 (I1): Orange Pin 5 (I2): Orange Pin 8 (I3): Orange Pin 11 (I4): Orange Pin 3 (GND): Yellow Pin 6 (GND): Yellow Pin 9 (GND): Yellow Pin 12 (GND): Yellow

Cable Connections

5. Choose which of the four inputs that you want to connect to. Then connect the Yellow and Orangewires from the Cable Assembly to the programmable inputs connector J23 on the Control Board asfollows.

If you use two Handguns and want both to activate an input, install the yellow and orange wires from eachcable in parallel.If you want to use one Handgun Switch for two different functions (ie Pump On/Off and Auto Setback), thenconnect to one of the inputs as shown in step 4; then run a jumper wire from where the Orange wire is landedto the other input you want to use (I1-Pin 2, I2-Pin 5, I3-Pin 8, or I4-Pin 11).

6. Discard the jumper wires included with the kit..

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IS0161 Handgun Switch Kit Installation and Operation

Input Setup

1. Connect the power and turn the unit ON.

2. Press the Setup Button and unlock the system using password “6550.”

3. Once the system is unlocked, press the Setup Button again and scroll right to “INPUT,” press OKKey.

4. Scroll to whichever Input that you have the Handgun Switch Cable connected to.

5. Choose the function that you want the Handgun Switch to control using the up and down arrowkeys.

a. ‘Pump On/Off’ will activate the pump when the handgun trigger is pulled.

b. ‘Auto Setback’ resets the Auto Setback Timer when the trigger is pulled. If Auto Setback isenabled (see manual), when the Auto Setback Timer expires, the unit goes into setback due toinactivity.

6. Setup is complete.

Cable Connections - Continued

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IS0161Handgun Switch Kit Installation and Operation

1. Connect the hose/handgun to the Hot Melt Unit.

2. Connect the 4-pin circular connector from the Handgun Switch Cable installed, to the matingconnector from the hose.

3. Turn ON the unit and wait for all zones to reach temperature and for the System Ready light tocome on.

4. Enable the Pump by pressing the Pump On/Off Key on the Keypad.

5. Pull the handgun trigger to activate the pump. Testing is successful when the pump is enabledduring the time the trigger is held.

Testing

To tell if the pump is enabled when thetrigger is held, listen for the sound ofthe pump activating. Also, if there isglue in the system, the handgun willdispense glue.

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D4-E Unit with Old Control (Serial # prior to 1002-035)

Cable Connections


2. Locate Power Board (151xx606/151xx616), mounted in the base of the cabinet.

3. From underneath the D4-E unit, run the flying lead end of the Handgun Switch Cable assemblythrough an available cord grip into the electronics cabinet of the unit.

4. Choose whether you want to connect to Input 1 or Input 2. Then connect the Yellow and Orangewires from the cable and jumper wire to the Customer connector J6 as follows.

Input 1 Input 2

Pin 2 (+24): Orange Pin 2 (+24): Orange

Pin 3 (GND): Blue Jumper Wire Pin 3 (GND): Blue Jumper Wire

Pin 4 (IN1-): Blue Jumper Wire Pin 6 (IN2-): Blue Jumper Wire

Pin 5 (IN1+): Yellow Pin 7 (IN2+): Yellow

If you use two handguns and want bothto activate an input, install the yellowand orange wires from each cable inparallel.If you want to use one handgun switchfor two different functions (ie Pump On/Off and Auto Setback), then you canconnect the cable as follows.

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Cable Connections - Continued

T w o In pu t s us in g o n e H a nd g u n

P in 1 (G N D ): B lu e Ju m pe r #1

P in 2 (+ 24 ): O ra ng e

P in 3 (G N D ): B lu e Ju m pe r #2

P in 4 (IN 1-): B lue J um p er # 1

P in 5 (IN 1+) : B r ow n Jum p er

P in 6 (IN 2-): B lue J um p er # 2

P in 7 (IN 2+) : B r ow n Jum p er a nd Y e llo w

1. Connect the power and turn the D4-E unit ON.

2. Press the Setup Button and unlock the system using password “6550.”

3. Once the system is unlocked, scroll right to “PERIPH.,” press OK Key.

4. Scroll to the Input that you have the Handgun Switch Cable connected to.

Input Setup

5. Choose the function that you want the Handgun Switch to control using the up and down arrowkeys.

a. ‘Pump On/Off’ will activate the pump when the handgun trigger is pulled.

b. ‘Auto. Setback’ resets the Auto Setback Timer when the trigger is pulled. If AutoSetback is enabled (see manual), when the Auto Setback Timer expires, the unit goesinto setback due to inactivity.


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1. Connect the hose/handgun to the D4- E Unit.

2. Connect the 4-pin circular connector from the Handgun Switch Cable installed, to the matingconnector from the hose.

3. Turn ON the unit and wait for all zones to reach temperature and for the System Ready light tocome on.

4. Enable the Pump by pressing the Pump On/Off Key on the Keypad .

5. Pull the handgun trigger to activate the pump. Testing is successful when the pump is enabledduring the time the trigger is held.

Testing

To tell if the pump is enabled when thetrigger is held, listen for the sound ofthe pump activating. Also, if there isglue in the system, the handgun willdispense glue.

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D Series w/ Old Control (Using Power Board 151xx614)

Cable Connections


2. Locate the 151xx614 Power Board, mounted vertically on the back wall in the cabinet. See figurebelow.

3. From underneath unit, run the flying lead end of the Handgun Switch Cable assembly through anavailable cord grip into the electronics cabinet of the unit.

4. Connect the Yellow and Orange wires from the included cable assembly to the customerconnector J13 on the Power Board as follows.

On J13 Customer Connector

Pin 5 (Remove Box GND): Orange

Pin 6 (Remote Box Sig): Yellow

If you use two handguns and want bothto activate an input, install the yellowand orange wires from each cable inparallel.

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Input Setup 1. On the Power Board (151xx614), set “Switch 1” UP to the FILLposition. See Figure above.

2. For Variable Speed Units (with a VFD) only: Locate the MotorControl Board on the back side of the keypad and make sureSW1 is in the FIX position. See figure below.

For Fixed SpeedUnits, skip step 2 andproceed to step 3.


Testing1. Connect the hose/handgun to the D10 Unit.

2. Connect the 4-pin circular connector from the Handgun SwitchCable installed, to the mating connector from the hose.

3. Turn ON the unit and wait for all zones to reach temperature andfor the System Ready light to come on.

4. Enable the Pump by pressing the Manual Pump On/Off on theKeypad.

5. Pull the handgun trigger to activate the pump. Testing issuccessful when the pump is enabled during the time the triggeris held.

To tell if the pump isenabled when thetrigger is held, listenfor the sound of thepump activating. Also,if there is glue in thesystem, the handgunwill dispense glue.

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D AND S SERIES PUMP CHANGE PROCEDUREIS02124 / 1 34 / 1 34 / 1 34 / 1 34 / 1 3

ImportantInformation: ReadBefore Use

Warning!Warning!Warning!Warning!Warning! Read and follow all instructions, warnings, tags, andlabels before operating the equipment. Only qualifiedpersonnel should perform this procedure. USE OF THISEQUIPMENT IN A MANNER OTHER THANDESCRIBED IN THIS INSTRUCTION SHEET ANDFAILING TO FOLLOW ALL INSTRUCTIONS COULDRESULT IN PERSONAL INJURY, DEATH, ORDAMAGE TO EQUIPMENT.

Warning!Warning!Warning!Warning!Warning! All equipment is to be installed and all connections areto be made ONLY by qualified personnel. Componentsand accessories are to be installed in accordance withthe instructions provided and applicable codes for theregion installed. Failure TO FOLLOW THESEINSTRUCTIONS COULD RESULT IN PERSONALINJURY, DEATH, OR DAMAGE TO EQUIPMENT.

Caution!Caution!Caution!Caution!Caution! The instructions and guidelines in this instruction sheetare general guidelines. Always follow the manufacturer’sdocumentation and instructions for each part of thesystem such as the valve, the solenoid, the applicationmechanism, etc. Failure TO FOLLOW THESEINSTRUCTIONS COULD RESULT IN DAMAGE TOEQUIPMENT.

Before Replacingthe Pump

If changing the pump in a D4 Unit, the tank must be drained beforeproceeding, to prevent glue leakage.

If changing the pump in a D10 or D16 Unit, it is not necessary to drain the tank.These units include a tank-connection shut-off plug that can be opened orclosed, using a screwdriver (see below). Turn the plug to CLOSED (slot tohorizontal position).

Shut-off Plug

Plug slot vertical (as shown):Plug slot vertical (as shown):Plug slot vertical (as shown):Plug slot vertical (as shown):Plug slot vertical (as shown):Tank valve is OPEN.

Plug slot horizontal: Plug slot horizontal: Plug slot horizontal: Plug slot horizontal: Plug slot horizontal: Tank valveis CLOSED.

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IS0212 D and S Series Pump Change Procedure

3. Cut the tie wrap as shown in the figure, below.

Replacing the DSeries Unit Pump

1. Locate the unit in which the pump needs to be changed.

Warning!Warning!Warning!Warning!Warning! Make sure that the unit is at room temperature.

2. Turn the unit on its side.

4. Remove motor bracket bolts

5. Slide the motor forward out of the way.

a. The coupling will come apart easily.

Motorbracket bolts

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IS0212D and S Series Pump Change Procedure

7. Remove the coupling half from the pump.

8. Remove the pump jacket (if installed).

9. Remove the 4 pump mounting bolts.

10. Remove the pump.

Replacing the D Series Unit Pump- Continued

6. Place the center disk aside for now.

Slide Motor and Bracket this way

Center Disk

Jacket

Pump Mounting Bolts

Coupling Half

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IS0212 D and S Series Pump Change Procedure

11. Install the new pump by reversing the above procedures.

Install new O-rings on the new pumpbefore installing.

Caution!Caution!Caution!Caution!Caution! Make sure the coupling orientation is correct (see thefigure, below). The arrows on the face should point to thebearing placement on the center disk.

Caution!Caution!Caution!Caution!Caution! Install by cross-tightening the four (4) mb x 90 socket-head cap screws. This will ensure the pump has auniform seal with the manifold, and will not leak.

Replacing the D Series Unit Pump- Continued

See the figure below for the correct motor bracket mounting hole (D Seriesunits).

998IS634.dwg

Double-width Pump

Standard-width Pump

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IS0212D and S Series Pump Change Procedure

Caution!Caution!Caution!Caution!Caution! Install by cross-tightening the four (4) mb x 90 socket-head cap screws. This will ensure the pump has auniform seal with the manifold, and will not leak.

Make sure the Spur Gear is under the sensor, otherwisethe unit will not function properly. If the spur gear is notunder the sensor, loosen the set screw and move thespur gear to the correct position.

Valco Cincinnati Incorporated411 Circle Freeway DriveCincinnati, Ohio 45246, USATEL: (1) 513-874-6550FAX: (1) 513-874-3612

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

Valco Cincinnati, Ltd.Unit 7-8Hortonwood 32Telford TF1 7YN EnglandTEL: (44) 1952-677911FAX: (44) 1952-677945

Valco Cincinnati GmbHStorkower Strasse 6

D-15749 Gallun, GermanyTEL: (49) 33764 8700

FAX: (49) 33764 87070

No part of this document may be reproduced without express permission from Valco Cincinnati, Inc. All rights reserved. Designs and other information may change without notice.

© 2013 Valco Cincinnati, Inc. www.valcomelton.com IS0212 4/13

To Replace an SSeries Unit Pump

1. Remove the right-side and lower-front panels from the unit byturning the latch and lifting up on the handle.

Warning!Warning!Warning!Warning!Warning! Make sure the unit is at room temperature.

2. Loosen, but do not remove, the set screw on the love joy couplingclosest to the pump.

3. Loosen, but do not remove, one of the screws on each of the shaftcollars, and on both sides of the motor.

4. Slide the shaft away from the pump until the coupling is no longeron the shaft.

5. Remove the four (4) m8 x 90 socket-head cap screws from thepump.

6. Remove the pump and O-rings.

7. Install the new pump by reversing the above procedures.

1Valco Melton

INTERNAL LEVEL SENSOR INSTRUCTIONSIS02327 / 1 67 / 1 67 / 1 67 / 1 67 / 1 6

WARNING!WARNING!WARNING!WARNING!WARNING! Read and follow all instructions, warnings, tag, and labelbefore operating the equipment. Only qualifiedpersonnel should perform this procedure.

All equipment is to be installed and all connections areto be made only by qualified personnel. Componentsand accessories are to be installed in accordance withthe instructions provided and applicable codes for theregion installed.

USE OF THIS EQUIPMENT IN A MANNER OTHERTHAN DESCRIBED IN THIS INSTRUCTION SHEETAND FAILING TO FOLLOW ALL INSTRUCTIONSCOULD RESULT IN PERSONAL INJURY, DEATH, ORDAMAGE TO EQUIPMENT.


All equipment must be properly grounded and fused inaccordance with rate current consumption (refer to theequipment identification plate).

Gauge and insulation for power supply must beadequate to handle rated current consumption.

FAILING TO FOLLOW ALL INSTRUCTIONS COULDRESULT IN PERSONAL INJURY, DEATH, ORDAMAGE TO EQUIPMENT.


DescriptionThis instruction sheet will cover how to install an internal level sensor in eitherthe low or high position. The sensor should be installed based on theassembly part number.

Part Number Position 776xx745 Low 776xx748 High 776xx751 Both 776xx892* Low

*For D4/D4E Hot Melt units only.

Installation 1. (For D4/D4E Hot Melt Units Only. Otherwise, proceed to(For D4/D4E Hot Melt Units Only. Otherwise, proceed to(For D4/D4E Hot Melt Units Only. Otherwise, proceed to(For D4/D4E Hot Melt Units Only. Otherwise, proceed to(For D4/D4E Hot Melt Units Only. Otherwise, proceed tostep 2.) step 2.) step 2.) step 2.) step 2.) Replace the current reservoir with the modified, low-level reservoir.

2. Turn off the unit and disconnect the power.

2 Valco Melton

IS0232 Internal Level Sensor Instructions

3. Open the back hose and front operator panels.

4. Remove the two (2) M4 X 12 socket head cap screws holding thelanyards to the top of the case.

5. Remove the quick disconnect ground wire from the top of thecase.


6. Remove the four (4) M5 flange nuts from the bottom corners of thecase.

7. Remove any other connections that are holding the case to thechassis.

8. Remove the case exposing the tank.

9. Rotate the metal tab on the amplifier box by the Lemo connectoraway from the base of the amplifier box to be able to access thetab while the case is on.

10. Attach the amplifier box to the appropriate mounting location onthe center bulkhead using two (2) M4 X 8 socket head cap screwsas shown below.

3Valco Melton

IS0232Internal Level Sensor Instructions


11. Remove the two (2) jam nuts from the level sensor.

12. Remove the plug on the side of the tank for the desired mountinglocation and discard.

13. Apply high-temperature silicone (RTV) to the sensor threads.

14. Thread the sensor into the tank so that the tip of the sensor is 1.5inches from the wall of the tank.

15. Feed the cable with the Lemo connector through the holes in thechassis, as shown below.

High InternalLevel Sensor

Low InternalLevel Sensor

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16. Reattach the case to the chassis by reversing steps 2-6.

17. Attach the Lemo connector to the bottom of the appropriateRechner amplifier box.

18. Attach the JST connector from the assembly to the appropriateposition as shown below.

Internal High (Ext. Level) Internal Low (Int. Level)

5Valco Melton


19. Attach the ground faston to the metal tab on the amplifier box nearthe Lemo connector.


20. Attach the ring terminal on the ground wire to one of the groundstuds on the chassis.

21. Close the back hose panel.

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Periodically check the level of adhesive to ensure thesensor is working properly.

1. Remove the protective screw on the amplifier box.

2. Reconnect the power and turn on the unit.

3. Fill the tank with adhesive until the adhesive level is in the centerof the desired sensor.

4. On the amplifier box, if the sensor light is green, carefully turn thescrew clockwise until the light changes to amber.

Calibrating theSensor

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5. On the amplifier box, if the sensor light is amber, carefully turn thescrew counter clockwise until the light changes to green andsubsequently back to amber.

6. Remove some adhesive so that the adhesive level is below thesensor and ensure that the sensor light changes to green.

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Periodically check the level of adhesive to ensure thesensor is working properly.

7. Reinsert the protective screw back into the amplifier box.


Adjusting the SensorTime Delay

1. Go to the setting screen by pressing .

2. Unlock the control by using the level 3 password “6550”.

3. Go to the setting screen by pressing again.

4. Go to the “System” screen.

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5. Select Internal (low) or External (high) ON Delay based on thedesired sensor and adjust the time depending on yourapplication. The default time for either sensor is 5 seconds.

Adjusting the Sensor Time Delay -Continued

1Valco Melton

EXTERNAL POT FILL INSTRUCTIONS

IS02341 / 1 31 / 1 31 / 1 31 / 1 31 / 1 3


WARNING!WARNING!WARNING!WARNING!WARNING! Read and follow all instructions, warnings, tags, andlabels before operating the equipment. Only qualifiedpersonnel should perform this procedure. USE OF THISEQUIPMENT IN A MANNER OTHER THANDESCRIBED IN THIS INSTRUCTION SHEET, ANDFAILING TO FOLLOW ALL INSTRUCTIONS, COULDRESULT IN PERSONAL INJURY, DEATH, OREQUIPMENT DAMAGE.

WARNING!WARNING!WARNING!WARNING!WARNING! All equipment is to be installed, and all connectionsmade, only by qualified personnel. Components andaccessories are to be installed in accordance with theinstructions provided, and applicable codes for theregion installed. FAILURE TO FOLLOW THESEINSTRUCTIONS COULD RESULT IN A PERSONALINJURY, DEATH, OR EQUIPMENT DAMAGE.

WARNING!WARNING!WARNING!WARNING!WARNING! The equipment may still be energized, even after thecircuit breaker or main power switch is off.

· All equipment must be properly grounded and fused inaccordance with rate current consumption (refer to the equipmentidentification plate)

· Gauge and insulation for the power supply must be adequate tohandle rated current consumption.

DescriptionThis instruction sheet will cover how to install an external pot fill system. Thissystem can be installed with any parent machine that has the universaltemperature control.

Installation1. Open the front operator panel on the parent machine.

To install the cord grip in a D-series parent machine, proceed toTo install the cord grip in a D-series parent machine, proceed toTo install the cord grip in a D-series parent machine, proceed toTo install the cord grip in a D-series parent machine, proceed toTo install the cord grip in a D-series parent machine, proceed tothe next step. If the parent machine is not a D-series, proceed tothe next step. If the parent machine is not a D-series, proceed tothe next step. If the parent machine is not a D-series, proceed tothe next step. If the parent machine is not a D-series, proceed tothe next step. If the parent machine is not a D-series, proceed tostep 5:step 5:step 5:step 5:step 5:

2. Remove one of the knockouts from the front of the chassis.

3. File down any remaining metal chips from the knockout hole.

4. Attach the provided cord grip to the new mounting hole.

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IS0234 External Pot Fill Instructions


To install cord grip in an alternate location proceed to the nextTo install cord grip in an alternate location proceed to the nextTo install cord grip in an alternate location proceed to the nextTo install cord grip in an alternate location proceed to the nextTo install cord grip in an alternate location proceed to the nextstep. If the cord grip is not going to be used, proceed to step 2 ofstep. If the cord grip is not going to be used, proceed to step 2 ofstep. If the cord grip is not going to be used, proceed to step 2 ofstep. If the cord grip is not going to be used, proceed to step 2 ofstep. If the cord grip is not going to be used, proceed to step 2 of“Installing to the External Pot Fill System,” below.“Installing to the External Pot Fill System,” below.“Installing to the External Pot Fill System,” below.“Installing to the External Pot Fill System,” below.“Installing to the External Pot Fill System,” below.

5. Drill a 0.80" diameter hole in the desired location.

6. File down any remaining metal chips in the hole.

7. Attach the provided cord grip to the new mounting hole.

Installing to theExternal Pot Fill

System

1. If the cord grip was installed earlier, feed the female Turck cablethrough so that the JST connector is inside the parent machine’selectrical enclosure. If the cord grip was not installed, route thecable into the parent machine’s electrical enclosure so that theJST connector is inside.

2. Attach the four-pin JST connector to the universal control on theparent machine.

3Valco Melton

IS0234External Pot Fill Instructions

Installing to the External Pot FillSystem - Continued

3. Tighten the cord grip until the cable is secure, if the cord grip wasinstalled earlier.

4. Attach the sensor bracket to the top of the lid of the unit beingfilled.

5. Adjust the hose fitting to the correct orientation, if needed.

6. Attach the hose to the fitting.

A #8 core hose fitting is included withthe assembly. Additional sizes can bepurchased separately. For partnumbers, please refer to the illustrationdrawing included with the assembly.

7. Remove the two (2) jam nuts from the sensor.

8. Insert the sensor into the mounting bracket, using the two (2) jamnuts from the previous step. The bottom of the sensor should beabout 0.75" above the desired adhesive level.

The minimum sensing distance for thissensor is 2mm, and the maximum is50mm.

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9. Attach the flying ground wire with the terminal ring to the base ofthe unit being filled.

10. Remove the lid from the enclosure box.

11. Mount the enclosure box to the desired location.

12. Attach the female Turck connector to the enclosure box.

18. Select “Pot Fill Mode,” and press the up arrow to enable it.

19. Enable the “External On Delay.”

13. Turn the parent machine on.


15. Unlock the control by using the level-3 password, “6550”.

16. Return to the setting screen by pressing again.


5Valco Melton

IS0234External Pot Fill Instructions


1. Remove the protective screw from the amplifier box.

2. Fill the tank with molten adhesive until it is at the desired shutofflevel.

3. If the sensor light is orange, turn the screw on the amplifier boxcounter-clockwise, carefully, until the light changes to green, andthen turn slowly clockwise until it chnges to orange.

Make sure the light changes to greenafter 3 seconds.

4. If the sensor light is green, turn the screw on the amplifier boxclockwise, carefully, until the light changes to orange.

5. Close the lid.

6. Remove some adhesive, so that the adhesive level is below thesensor. Make sure the sensor light changes to red, and that theparent machine begins to pump adhesive.

7. Verify that the pump on the parent machine turns off after the unit isfilled to the desired level.

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Check the level of adhesive periodically to ensure thesensor is working properly.


20. Close the front operator Panel on the parent machine.

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Adjusting the SensorDelay Time


11. Unlock the control, using the level-3 password, “6550”.



14. Select External ON Delay, based on the desired sensor, andadjust the time, dependent on the application.

The default time for either sensor is fiveseconds.

8. Reinsert the protective screw into the amplifier box.

9. If the desired adhesive level was not reached, adjust the sensorand repeat steps 18-19 of “Installing to the External Pot FillSystem” and 1-2 of “Calibrating the Sensor.” If the desiredadhesive level was reached, reattach the lid to the enclosurebox.

Calibrating the Sensor -Continued

1Valco Melton

BEACON ASSEMBLY INSTRUCTIONS

IS02331 0 / 1 11 0 / 1 11 0 / 1 11 0 / 1 11 0 / 1 1



WARNING!WARNING!WARNING!WARNING!WARNING! All equipment is to be installed, and all connectionsmade, by only qualified personnel. Components andaccessories are to be installed in accordance with theinstructions provided, and applicable codes for theregion installed. FAILURE TO FOLLOW THESEINSTRUCTIONS COULD RESULT IN A PERSONALINJURY, DEATH, OR EQUIPMENT DAMAGE.



· Gauge and insulation for the power supply must be adequate tohandle rated current consumption

DescriptionThis beacon assembly is for D series hot-melt units with the universal control.The beacon assembly is limited to two lights. It is also available with anoptional siren.

Parts Included with Kit P/N 2 Lights Siren

782xx347 X 782xx349 X X 776xx762 X

This instruction sheet will cover how to install the beacon assembly to the topof a D series hot-melt unit. It will also cover how to set up the beaconassembly using the universal control.

The beacon does not need to be installed to the top of the unit. If the beaconis installed on an alternative surface, a new female five-pin Turck cable willneed to be purchased separately.

2 Valco Melton

IS0233 Beacon Assembly Instructions

Installation

Installing the beaconto the top of the unit

1. Open the front operator panel.

2. Remove the five (5) knockouts at the top of the operator panel.

3. Attach the beacon assembly to the operator panel using the four(4) M5 X 8 socket head cap screws.

4. Attach the female connector, included in the bag, to the beaconassembly.

5. Attach the three (3) flying leads to the universal control, as shownbelow.

Wire Locations Pin 1 Pin 2 GND White Blue Brown

3Valco Melton

IS0233Beacon Assembly Instructions

Installing the beacon to the top ofthe unit - Continued

Universal Control

6. Check the electrical cabinet to ensure everything is connected,and the power is hooked up correctly.


Enabling the Beacon1. Turn the unit on.


3. Unlock the control using the level-3 password, “6550”.



4 Valco Melton

IS0233 Beacon Assembly Instructions

7. To enable any of the alarms, select the desired function from thelist below:

6. Select “Beacon/Alarm Setup”.Enabling the Beacon - Continued

Alarms Low Level Alarm Ready Pump On Setback On

8. Stick the correct labels onto each of the lights, based on thefunctions selected above.

Installing the AlarmSiren Element to an

Existing BeaconAssembly

1 Turn the unit off.

2. Remove the cap from the top of the existing beacon assembly.

3. Line up the white lines on the top of the light and on the bottom ofthe siren.

4. Twist the siren element clockwise until it locks.

5. Remove the beacon assembly and verify the black jumper wireis still connected to pins 2 and 3.

6. If the jumper is still connected, reattach the beacon assembly. Ifthe jumper is missing, install a new jumper.

7. Verify that the beacon is working. The siren will start when thesecond beacon light is on.

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1Valco Melton

Warning!Warning!Warning!Warning!Warning! Read and follow all instructions, warnings, tags, andlabels before operating the equipment. Only qualifiedpersonnel should perform this procedure. USE OF THISEQUIPMENT IN A MANNER OTHER THANDESCRIBED IN THIS INSTRUCTION SHEET ANDFAILING TO FOLLOW ALL INSTRUCTIONS COULDRESULT IN PERSONAL INJURY, DEATH, ORDAMAGE TO EQUIPMENT.

Warning!Warning!Warning!Warning!Warning! All equipment is to be installed and all connections areto be made ONLY by qualified personnel. Componentsand accessories are to be installed in accordance withthe instructions provided and applicable codes for theregion installed. FAILURE TO FOLLOW THESEINSTRUCTIONS COULD RESULT IN PERSONALINJURY, DEATH, OR DAMAGE TO EQUIPMENT.

PRESSURE SWITCH INSTALLATION INSTRUCTIONSIS02131 0 / 1 11 0 / 1 11 0 / 1 11 0 / 1 11 0 / 1 1


DescriptionThe pressure switch has a 316 stainless steel housing and are hermeticallysealed. The pressure switches have a set operating range and are providedbelow:

Part Number Operating Range (psi)

481XX050 50-130

481XX051 160-400

481XX052 275-850

These pressure switches are to be installed into the back or side of hot-meltunits. The fittings included with this kit are for 9/16" hose ports and 1/4" NPTgauge ports.



· Gauge and insulation for power supply must be adequate tohandle rated current consumption.

2 Valco Melton

IS0213 Pressure Switch Installation Instructions

1. Disconnect the power to the unit.

2. Coat the adapter fitting (792XX340) threads with anti-seizecompound.

WARNING!WARNING!WARNING!WARNING!WARNING! Be sure the unit is off and power is disconnected andlocked out before starting the replacement/installationprocedure. FAILURE TO TURN OFF ANDDISCONNECT/LOCK OUT ALL POWER CAN RESULTIN PERSONAL INJURY OR DEATH.

Installation

To install into a hose port or gauge port proceed to the next step.To install into a hose port or gauge port proceed to the next step.To install into a hose port or gauge port proceed to the next step.To install into a hose port or gauge port proceed to the next step.To install into a hose port or gauge port proceed to the next step.If the pressure switch is to be installed into the side of the manifoldIf the pressure switch is to be installed into the side of the manifoldIf the pressure switch is to be installed into the side of the manifoldIf the pressure switch is to be installed into the side of the manifoldIf the pressure switch is to be installed into the side of the manifoldproceed to “Installing the Pressure Switch into the Side of aproceed to “Installing the Pressure Switch into the Side of aproceed to “Installing the Pressure Switch into the Side of aproceed to “Installing the Pressure Switch into the Side of aproceed to “Installing the Pressure Switch into the Side of aManifold,” step 1.Manifold,” step 1.Manifold,” step 1.Manifold,” step 1.Manifold,” step 1.

3. Remove the hex plug from the desired hose ports.

4. Attach the adapter fitting to the open port on the back of themanifold.

5. Connect the desired pressure switch to the adapter fitting.

Installing thePressure Switch intothe Side of a Manifold

1. Remove the hex plug from side of the manifold as shown below.

2. Attach the adapter fitting to the open port on the side of themanifold.

3. Connect the desired pressure switch to the adapter fitting.

3Valco Melton

IS0213Pressure Switch Installation Instructions

Installing the Pressure Switch intothe Side of a Manifold - Continued

Calibrating thePressure Switch

1. Route and secure the cable, to ensure that it will not be caught inthe motor, using two (2) ty-raps and two (2) wire harnesses.

2. If the pressure switch is being hooked into the unit’s universalcontrol, route the cables through either the cord grip or the slotinto the electrical cabinet.

3. Bundle any remaining wire.


5. Connect the flying leads from the pressure switch to the universalcontrol, as detailed below.

Wire Color Function

Brown Common

Red N.C.

Blue N.O.

Green PE

6. Connect the brown wire into “GND” for the desired input.

a. If a pressure rise is desired, connect the blue wire tothe center pin.

b. If a pressure drop is desired, connect the red wire tothe center pin.

4 Valco Melton

IS0213 Pressure Switch Installation Instructions

Calibrating the Pressure Switch -Continued

7. Connect the ring terminal to the chassis, using one of the groundstuds.

8. Turn the unit on and allow the adhesive to become molten.

9. Adjust the pressure relief to the desired switch pressure.

10. Slide the adjustment cover forward, carefully, away from themanifold.

Warning!Warning!Warning!Warning!Warning! The pressure switch will be hot!

11. Use a 3/16" flathead screwdriver, or a 1/4" wide blade, to adjustthe castle nut.

a. Insert the screwdriver or blade and turn clockwise toincrease the set point, or counter-clockwise todecrease the set point. Adjust the nut accordinglyuntil the switch clicks.

12. Adjust the adhesive pressure to be below, and above, the setpoint while verifying that the led on the control board for that inputis turning on and off.

a. If the switch does not turn on and off as expected,repeat step 11.

13. Slide the adjustment cover closed carefully.

Warning!Warning!Warning!Warning!Warning! The pressure switch will be hot!


Enabling PressureSwitch Input


2. Turn the unit on, if it is not already.



5Valco Melton

IS0213Pressure Switch Installation Instructions

7. To enable any of the inputs, select the desired function from thelist below.

Input

Disabled

Hose On/Off

All Heaters On/Off

Pump On/Off

Auto Setback

Setback

Pressure Fault

The pressure switch can also behooked into another controller. Ifanother controller is used, follow thewiring chart provided in “Calibrating thePressure Switch,” step 5, and verify thepin location for that controller.

The pressure fault setting can be usedwith a beacon, to give a visual/audiblesignal, by setting the beacon to “Alarm”.

Valco Cincinnati Incorporated411 Circle Freeway DriveCincinnati, Ohio 45246, USATEL: (1) 513-874-6550FAX: (1) 513-874-3612

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

Valco Cincinnati, Ltd.Unit 7-8Hortonwood 32Telford TF1 7YN EnglandTEL: (44) 1952-677911FAX: (44) 1952-677945

Valco Cincinnati GmbHStorkower Strasse 6

D-15749 Gallun, GermanyTEL: (49) 33764 8700

FAX: (49) 33764 87070

No part of this document may be reproduced without express permission from Valco Cincinnati, Inc. All rights reserved. Designs and other information may change without notice.

© 2011 Valco Cincinnati, Inc. www.valcomelton.com IS0213 10/11


6. Select the “Input” screen.

IS0377 - D Series Pressure Transducer Instructions

1

IS0377 - D Series Pressure Transducer Instructions 4/18

Important Information WARNING! Read and follow all instructions, warnings, tags, and labels before operating the equipment. Only

qualified personnel should perform this procedure. USE OF THIS EQUIPMENT IN A MANNER OTHER THAN DESCRIBED IN THIS INSTRUCTION SHEET, AND FAILING TO FOLLOW ALL INSTRUCTIONS, COULD RESULT IN PERSONAL INJURY, DEATH, OR EQUIPMENT DAMAGE.

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

WARNING! The equipment may still be energized, even after the circuit breaker or main power switch is off. · All equipment must be properly grounded and fused in accordance with rate current consumption (refer to the equipment identification plate) · Gauge and insulation for the power supply must be adequate to handle rated current consumption.

WARNING! This product is an electrostatic-discharge-sensitive component. Take the necessary precautions while installing. · All equipment must be properly grounded and fused in accordance with rate current consumption (refer to the equipment identification plate) · Gauge and insulation for power supply must be adequate to handle rated current consumption.


2

Installation 1. Remove the pressure gauge and plug for the transducer from the back of the manifold.

2. Install the 1/4 npt pipe plug into the pressure gauge port. Ensure the plug is wrapped with Teflon tape.

3. Install the pressure transducer into the open port on the manifold. Orient the electrical connector as

shown by loosening the adjustment nut and rotating the connector. Once the desired orientation is achieved tighten the adjustment nut.

Do not over rotate the electrical connector as it may over strain the internal wire and break the connections.


3


4. Route the cable along the side of the unit and through the support bracket on the chassis.

5. Route the cable into the electrical cabinet through the “D” shaped hole on the chassis.

6. Secure the cable using ty-raps and connect it to J5 on the temperature control board (152XX746).


4

Setup

1. Access the Setting screen by pressing the button.

2. Press the “OK” button and unlock the control using the level 3 password, 6550.

3. Access the Pressure screen by pressing the button three times, followed by the “OK” button.

4. Press the right arrow button and select the desired unit of measure using the “+” or “-“ arrow buttons.

Pressure Units of Measure

Bar PSI


5

Setup - Continued

5. Press the right arrow button and set the delay times for low and high pressure fault alarms if desired.

6. Press the right arrow button to get to the next screen and enable the pressure monitoring by pressing the “+” button.

7. Press the right arrow and set the sensor range based on the table below.

P/N S Number Code Sensor Range KJC3344 D10/D16…T1 100 bar (1450 psi)

8. Press the right arrow twice and set the desired high pressure alarm.


6

Setup - Continued

9. Press the right arrow and set the desired low pressure alarm.

© Valco Cincinnati, Inc. www.valcomelton.com IS0377 4/18 No part of this document may be reproduced without express permission from Valco Cincinnati, Inc. All rights reserved. Designs and other information may change without notice. Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati, Ohio 45246, USA TEL: (1) 513-874-6550 FAX: (1) 513-874-3612

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

Valco Cincinnati, Ltd. Unit 7-8 Hortonwood 32 Telford TF1 7YN England TEL: (44) 1952-677911 FAX: (44) 1952-677945

Valco Cincinnati GmbH Bonnerstrasse 349 40589 Dusseldorf-Benrath, Germany Tel: +49 211 984 798-0 Fax: +49 211 984 798-20

Valco Melton France Technoparc des Hautes Faventines 32 Rue Jean Bertin 26000 Valence Tel: +33 (0)4 75 78 13 73 Fax: +33 (0)4 75 55 74 20

1Valco Melton

ANYBUS INSTALLATION

IS03436 / 1 76 / 1 76 / 1 76 / 1 76 / 1 7



WARNING!WARNING!WARNING!WARNING!WARNING! All equipment is to be installed, and all connectionsmade, only by qualified personnel. Components andaccessories are to be installed in accordance with theinstructions provided, and applicable codes for theregion installed. FAILURE TO FOLLOW THESEINSTRUCTIONS COULD RESULT IN A PERSONALINJURY, DEATH, OR EQUIPMENT DAMAGE.

WARNING!WARNING!WARNING!WARNING!WARNING! The equipment may still be energized, even after thecircuit breaker or main power switch is off.


· Gauge and insulation for the power supply must be adequate tohandle rated current consumption.

2 Valco Melton

IS0343 Anybus Installation

2. Check the electrical cabinet to make sure everything isconnected, and the power is hooked up correctly.

3. Turn the unit on.

4. Verify the auxiliary I/O board is receiving power by checking thatthe “24V” led is on.


ITEM NO. DESCRIPTION PART NO. QTY.

1 PCB ASSEMBLY; ANYBUS I/O EXTEND BJK0347 1

3 SPACER, PCB 14MM LONG, SNAP IN NYLON 091XX644 1

4 STANDOFF,6MM HEX, M3 X 0,5 THREAD 091XX563 2

5 SCREW BUTTON HEAD CAP M3 X 6 784XX541 2

Installation1. Attach the auxiliary I/O board to the universal control, as shown

below.

3Valco Melton

IS0343Anybus Installation


9. Select Auxiliary I/O and press the ‘up’ arrow to enable it.




8. Access the Configuration screen.

11. Select input or output, depending on your application.

4 Valco Melton

IS0343 Anybus Installation

Installation - Continued 12. To enable any of the inputs or outputs, select the desired function.Use the diagram below to hook up an input or output.

4 Opto Isolated Inputs

See the table on thefollowing page for inputwiring options

See the table on thefollowing page for outputwiring options

4 Output Relay Contacts

5Valco Melton

IS0343Anybus Installation


IS0344 Anybus Installation and Setup

ValcoMelton 1

IS0344 - Anybus Installation and Setup 2/18

Description The Melter Communication Interface PCB is a communication interface between the Hot Melt Unit and a parent-machines PLC. This interface allows the user to set and monitor parameters and data from the Hot Melt Unit. For a list of accessible parameters, see the Data Index and Control Byte sections in Section 3 - Configuring the Melt Unit .

There are two operation modes when interfacing with the Melter:

1. Remote mode: The PLC acts as the master in a master-slave system. The user can read and write all parameters that are available through the interface. In this mode, many parameters cannot be changed from the Hot Melt Unit display because they are set from the Melter Communication Interface.

2. Local mode: The PLC is serves only as an observer of the Melter, and can only read, but not change, system parameters. The Melter becomes an information resource for the connected system.

Physical Installation The Melter Communication Interface PCB is mounted to the back of the Melt Unit CPU board, and is connected to J4 and J2 on the CPU board. A ribbon cable and standoffs are included in the mounting kit.

Remove Nuts

*


2 ValcoMelton

Physical Installation - Continued

ITEM NO. DESCRIPTION PART NO. QTY.

1 PCB ASSEMBLY; ANYBUS I/O EXTEND BJK0347 1

2 MODULE, ANYBUS, ETHERNET/IP, JTS0021 098XX123 1

3 SPACER, PCB 14MM LONG, SNAP IN NYLON 091XX644 1

4 STANDOFF,6MM HEX, M3 X 0,5 THREAD 091XX563 2

5 SCREW BUTTON HEAD CAP M3 X 6 784XX541 2

6 CABLE RIBBON 30P 2MM M/M 2.0" * BJK0389 1

*Ribbon Cable is only needed for 151xx650 Control Boards.

Configuring the Melt Unit The Communication Interface can be enabled and set up in the Melter CONFIG menu. When any of these network settings are changed, the Melter must have the power reset in order for the new address to take effect. The default network settings are shown below. The network settings should be changed to match your network.

Remote Communication: The interface can be enabled by changing the Protocol from Disabled to Ethernet IP. The operation mode should also have “Local” selected, as shown below.

Network Settings: The network settings should be configured for your network. The default settings are shown below.

Installation and Setup are completed.

Configuring PLC for Ethernet/IP Communication Using the Correct EDS File

Many vendor EtherNet/IP configuration tools support importing an EDS file, and then uses the contents of this file to correctly configure a number of internal settings. Some configuration tools, however (most notably RSLogix 5000 as of this writing), do not use EDS files to configure EtherNet/IP I/O connections.


ValcoMelton 3

RSLogix 5000 Setup

1. In communication tree, choose “New Module” under the Ethernet port.

2. Select “Generic Ethernet Module” from the list of available modules.


4 ValcoMelton

RSLogix 5000 Setup - Continued

3. Name the module, and set up the Comm Format and Connection parameters as shown.

4. Set the module to the appropriate IP address.

The new modules Output connection will be “Send Packet,” as described in Data Packets used for Ethernet/IP communication, below, and the new module Input connection will be “Receive Packet.”

Modules Output Connection


ValcoMelton 5

Modules Input Connection

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

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

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

Data Packets used for Ethernet/IP communication This section describes the Process Data packets needed to operate between the Melter and PLC. There are two types of packets: Send Packets that have the control information from the PLC and, Receive Packets that have the status information from the Melter.

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


6 ValcoMelton

Send Packet (PLC) Frame

Bit Definitions for Control Byte 0

These are control bits executed with each message by the Melter. When in remote mode, these functions are controlled only by the PLC, and cannot be updated at the Melter. In local mode, this byte is ignored, and full control is at the Melter.

For each of the control bits, ON has a value of 1 and OFF has a value of 0.

Bit 0: Control Power ON/OFF

Bit 1: Master Pump Enable ON/OFF

Bit 2: Pump 1 ON/OFF




Bit 6: Temperature Setback ON/OFF

Bit 7: Auto Pump Enable ON/OFF

Command Byte 1

This command byte tells the Melter what to do with the Data Index and Channel bytes. The following command codes (in hex) are defined:

Command Description 0x01 Control Byte Only 0x03 Read 0x06 Write

If the Melter is put into local mode, the Write Command will return a local mode fault. All other commands not listed will return a wrong command fault.

Byte0 Byte1 Byte2 Byte3 Byte4, 5

Control Data Index

Pump1 speed%Command

Byte6, 7 Byte8, 9

Channel

Data Value

Byte10, 11 Byte12, 13 Byte14, 15

Pump2 speed%

Pump3 speed%

Pump4 speed%

Not Used


ValcoMelton 7

Data Index Byte 2

The Data Index is equal to the Melter Parameters that may be accessed through the Ethernet/IP protocol. Only those parameters listed can be accessed through remote mode. Parameters that require a system restart, including most setup parameters, will still need to be accessed at the Melter.

The following is the Data Index list and valid parameters.

If the system is in Local Operation mode, all Data Types become Read Only and, in the case of Write Only Indexes, become unavailable.

Data Index Channel Data Type Range Description

4 - RO 0 - 1 Remote Operation Mode (0=Local, 1=Remote) 7 - WO 0 - 1 Clear Fault 11 - RO 0 - 120 min Ready Delay Time Remaining 23 - RO 0x0000-0xFFFF Current Alarm Type (See Table Below) 110 - RW 0 – 1 Temperature Units (0=C, 1=F) 111 0-19 RW 0 – 1 Activate Temperature Zone 112 0-7 RW 0 – 1 Activate Hose/Gun Zone Pair 115 0-19 RW 40 – 230 C Zone Temperature Set Point 120 0-19 RO 40 – 230 C Zone Current Temperature 128 - RW 5 – 190 C Standby Temperature 135 - RW 0 – 1440 min AutoSetback Time 136 - RW 0 – 1440 min AutoStandby Time 142 - RW 5 – 60 C UnderTemp Fault Offset 152 - RW 5 – 60 C OverTemp Fault Offset 160 - RW 1 – 180 min Exit Standby Time 170 0-3 RW 0 – 2 Pump Auto Mode Input Speed Type

(0=0-10V, 1=0-2.8V, 2=Encoder) 171 0-3 RW 0 – 9999 m/min Pump Minimum Speed - Encoder 172 0-3 RW 0 – 9999 RPM Pump Creep Speed 173 0-3 RW 0 – 9999 Pump Ratio 174 0-3 RO 0 – 100% Pump Manual Speed 175 0-3 RW 0 - 1 Pump Mode 176 0-3 RW 0 – 200 Pump Gain 177 0-3 RO 0 – 1 Pump Enable 178 0-3 RW 0 – 1 Grammage Enable 179 0-3 RW 10 – 3000 mm Application Width (Grammage Only) 180 0-3 RW 1 – 200 g/m² Application Weight (Grammage Only) 181 0-3 RW 0.8 – 100 Density (Grammage Only) 182 0-3 RO 0 – 9999 RPM Pump Speed 183 0-3 RW 0 – 9999 mV Pump Minimum Speed - Tach 200 - RW 0 – 1 Seven-Day Clock Enabled 201 - RO 0 – 1 Seven-Day Clock Status 202 - RW 0 – 6 Clock – Day 203 - RW 0 – 24 Clock – Hour 204 - RW 0 - 60 Clock – Minute


8 ValcoMelton

Channel Byte 3

This is the location targeted within parameters having multiple zones. For example - In Data Index 182 (Pump Speed):

Sending a read to channel 0, the Melter will send back the value for the Pump 1 current pump speed (channel 1 = Pump 2, etc.)

Data Value Byte 4 and 5

This is the data that the PLC sends to the Melter to update a given parameter. This value is limited to the range listed in the Data Index table, and will return an Outside Range fault otherwise.

Pump1 speed%...Pump4 speed% Byte 6 - 13

With each message from the PLC to the Melter, the PLC can send the Pump Manual speed down, to change the pump pressures dynamically.

Receive Packet (Melter) Frame

Bit Definitions for Status Bytes 0 and 1

These are the response bytes sent back from the Melter at every message.

Bit 0: Melter Ready for Operation – 1 = Ready, 0 = Not Ready Bit 1: Ready Delay Enabled – 1 = Enabled, 0 = OFF Bit 2: System is in Alarm State – 1 = Alarm, 0 = No Alarm Bit 3: System is in Fault State – 1 = Fault, 0 = No Fault Bit 4: Melter is Shutdown – 1 = Shutdown, 0 = Not Shutdown Bit 5: Melter in Warmup State – 1 = Warmup active, 0 = Warmup not active Bit 6: Melter in Setback – 1 = Setback active, 0 = Setback not active Bit 7: Pump 1 Active – 1 = On, 0 = OFF Bit 8: Pump 2 Active – 1 = On, 0 = OFF Bit 9: Pump 3 Active – 1 = On, 0 = OFF Bit 10: Pump 4 Active – 1 = On, 0 = OFF Bit 11: Not used Bit 12: Not used Bit 13: Not used Bit 14: Communication Fault (See Error Codes Section) Bit 15: Communication Fault (See Error Codes Section)

Byte0, 1 Byte2 Byte3 Byte4, 5

Status

Data Index

Ch+1 Data

Byte6, 7 Byte8, 9

Channel

Ch Read Data

Byte10, 11 Byte12, 13 Byte14, 15

Ch+2 Data

Ch+3 Data

Ch+4 Data

Ch+5 Data


ValcoMelton 9

Data Index Byte 2

This is the same Data Index as in Send Packet. This is used as an acknowledgement back to the PLC, to confirm the message.

Channel Byte 3

This is the same Channel as in Send Packet. This is used as an acknowledgement back to the PLC, to confirm the message.

Channel Read Data Bytes 4 and 5

This is the value returned during a read command, for the Data Index and Channel requested.

Channel Read Data + Bytes 6 - 15

When a read command is requested for a parameter with multiple zones, the next channel value will also return to the PLC, unless the requested channel is already the maximum channel.

For example - A read request to Data Index 182 (Pump Speed), channel 0:

Channel Read Data (Bytes 4 and 5) returns Pump1 speed Channel Read Data +1 (Bytes 6 and 7) returns Pump2 speed Channel Read Data +2 (Bytes 8 and 9) returns Pump3 speed Channel Read Data +3 (Bytes 10 and 11) returns Pump4 speed.

Current Alarm Types When Reading the Current Alarm Type (Data Index 23), a specific code is returned on Read Data (Byte 4, 5). For Zone Errors, The Zone with the error is returned in Byte 4.

Numbers shown in Hex.

Byte 4 Description 0x00 No Alarm

0x01 – 0x14 Zone Error 0x15 System Error

Zone Error (0x01 – 0x14)

Byte 5 Description 0x00 No Alarm / Fault 0x01 RTD Fault 0x02 Low Temperature Fault 0x03 High Temperature Fault

System Error (0x15)

Byte 5 Description 0x00 No Alarm / Fault 0x02 System Fault 0x03 Filter Alarm 0x04 Pump 1 Fault 0x05 Pump 2 Fault 0x06 Pump 3 Fault 0x07 Pump 4 Fault 0x08 Communication Error


10 ValcoMelton

Error Codes

On an Error, the Status (byte 0, 1) will send back a 0x4000 hex, indicating an error has occurred. When this occurs, the Data Index (byte 2) will be set to the corresponding error code:

Error Code Description 0x00 No Fault 0x01 Wrong Command Received 0x02 Wrong Data Index Received 0x03 Wrong Channel Received 0x04 Object is Read only 0x05 No Channel 0x06 Outside Range 0x07 Local Mode

Examples

1) Enable Melter and set the zone 1 temperature setpoint Control = 0x01 (Heater enable only)

Command = Write 0x06

Data Index = 115 (0x73) Setpoint

Channel = 0

Data =70 degrees (0x46)

PLC CPU: 0x01,0x06,0x73,0x00,0x46,0x00,0x00,0x00,0x00,0x00,0x00,0x00,0x00,0x00,0x00,0x00

CPU PLC:

0x00,0x01,0x73,0x00,0x46,0x00,0x00,0x00,0x00,0x00,0x00,0x00,0x00,0x00,0x00,0x00

2) Read current zone 1 temperature Control = 0x01 (Heater enable only)

Command = Read 0x03

Data Index = 120 (0x78)

Channel = 0


CPU PLC:


This example also assumes zones 1-5 are available, and that all are at 70 degrees


ValcoMelton

Status Indicators

1 – Network Status LED 2 – Module Status LED 3 – Link/Activity LED port 1 4 – Link/Activity LED port 2

Network Status LED

LED State Description OFF NO POWER OR IP ADDRESS GREEN ONLINE WITH CONNECTIONS

ESTABLISHED FLASHING GREEN ONLINE WITHOUT CONNECTIONS

ESTABLISHED RED FATAL ERROR FLASHING RED CONNECTION TIMED OUT

Module Status LED

LED State Description OFF NO POWER GREEN CONTROLLED BY A SCANNER IN RUN

STATE FLASHING GREEN NOT CONFIGURED OR SCANNER IN IDLE

STATE RED MAJOR FAULT FLASHING RED RECOVERABLE FAULT

Link/Activity LED

LED State Description OFF NO LINK, NO ACTIVITY GREEN LINK 100Mbit/s FLASHING GREEN ACTIVITY 100Mbit/s YELLOW LINK 10Mbit/s FLASHING YELLOW ACTIVITY 10Mbit/s

11

1Valco Melton

D SERIES HOSE/GUN CABLEASSEMBLY INSTRUCTIONS

IS0227DATE [7/28/11]DATE [7/28/11]DATE [7/28/11]DATE [7/28/11]DATE [7/28/11]


WARNING!WARNING!WARNING!WARNING!WARNING! Read and follow all instructions, warnings, tag, and labelbefore operating the equipment. Only qualifiedpersonnel should perform this procedure. USE OF THISEQUIPMENT IN A MANNER OTHER THANDESCRIBED IN THIS INSTRUCTION SHEET ANDFAILING TO FOLLOW ALL INSTRUCTIONS COULDRESULT IN PERSONAL INJURY, DEATH, ORDAMAGE TO EQUIPMENT.

All equipment is to be installed and all connections areto be made only by qualified personnel. Componentsand accessories are to be installed in accordance withthe instructions provided and applicable codes for theregion installed. FAILURE TO FOLLOW THESEINSTRUCTIONS COULD RESULT IN A PERSONALINJURY, DEATH, OR DAMAGE TO EQUIPMENT.


· All equipment must be properly grounded andfused in accordance with rate current consumption(refer to the equipment identification plate)

· Gauge and insulation for power supply must beadequate to handle rated current consumption.

· Protective clothing and gear should be worn at alltimes when performing hot-melt tasks.

2 Valco Melton

IS0227 D Series Hose/Gun Cable Assembly Instructions

Installation1. Disconnect and lockout electrical power to the unit.

If hoses 5 and 6 are not being used proceed to the next section.

To install the 5/6 zone power board, do the following:


3. Remove the 5/6 zone board from the static bag.

4. Connect the green Phoenix connector on the 5/6 zone board tothe main power board.

5. Fix the board to the electrical panel using two (2) M4 X 6 pan headmachine screws.

6. Connect the 5/6 zone power cable to both of the boards.

3Valco Melton

IS0227D Series Hose/Gun Cable Assembly Instructions

Installation - Continued 7. Open the back hose panel.

8. Feed the hose/gun cable assembly through the back of the unit indown through the slot on the right side of the tank. The connectorwith the flange should be in the back of the unit.

9. Remove the knockout on the back hose panel for the appropriateslot if necessary.

10. Attach the flanged connector to the inside of the hose panel usingfour (4) M3 lock washers and four (4) M3 hex nuts into theappropriate numbered slot.

11. Attach the flying connectors in the operator panel to theappropriate position on the board.

4 Valco Melton

IS0227 D Series Hose/Gun Cable Assembly Instructions


12. Repeat steps 8, 9, 10 and 11 for the additional hose/gun cableassemblies.

13. Close the back hose panel.

14. Check the electrical cabinet to ensure everything is connectedand the power is hooked up correctly.


16. Turn on the unit.


18. Unlock the control by using the level 3 password “6550”.

19. Go to the setting screen by pressing again.

20. Go the “Config” screen.

5Valco Melton

IS0227D Series Hose/Gun Cable Assembly Instructions


21. Select “Zone Configuration” and adjust the number of hoses.

To test the new hoses and zones, do the following:To test the new hoses and zones, do the following:To test the new hoses and zones, do the following:To test the new hoses and zones, do the following:To test the new hoses and zones, do the following:

22. Attach the new hose(s) to the manifold and back hose panel.

23. Turn on the new hose and gun and set to the desiredtemperature.

24. Verify that the hose and gun heat up and maintain temperature.

IS0299 - D Series Coupling Upgrade Procedure

1

IS0299 - D Series Coupling Upgrade Procedure 1/16

Important Information: Read Before Use WARNING! Read and follow all instructions, warnings, tags, and labels before operating the equipment.

Only qualified personnel should perform this procedure. Use of this equipment in a manner other than described in this instruction sheet and failing to follow all instructions could result in personal injury, death, or damage to equipment. All equipment is to be installed and all connections are to be made ONLY by qualified personnel. Components and accessories are to be installed in accordance with the instructions provided and applicable codes for the region installed. Failure to follow these instructions could result in personal injury, death, or damage to equipment.

CAUTION! The instructions and guidelines in this instruction sheet are general guidelines. Always follow the manufacturer’s documentation and instructions for each part of the system such as the valve, the solenoid, the application mechanism, etc. Failure to follow these instructions could result in damage to equipment.

WARNING! Equipment will be hot. Wear safety glasses and heat resistant gloves during this procedure. Otherwise, personal injury may result.

See product manuals MM101 and MM113 for additional safety guidelines

Tool Requirements • Ratchet Wrench

• 10mm Socket

• 13mm Socket

• 7/16 Socket

• 6 in. Drive Extension

• Torque Wrench

• 3/32 Hex Key

• 1/8 Tee Handle Hex Key

• 2.5mm Hex Key

• Wire Snips

• Square

• Safety Glasses

• Heat Resistant Gloves


2

Parts Included The jaw coupling upgrade kit for the D series hot melt units (776XX490) contains the following components:

1 776XX313 1.000 EA BRACKET MOTOR

2 783XX370 1.000 EA HUB JAW COUPLING 1/2” BORE

3 783XX371 1.000 EA HUB JAW COUPLING 3/4" BORE

4 783XX372 1.000 EA SPIDER JAW COUPLING

5 776XX314 1.000 EA BRACKET MOUNTING LEFT

6 776XX315 1.000 EA BRACKET MOUNTING RIGHT

7 884XX003 2.000 EA HEX HEAD CAP SCREW M8 X 90 ZINC

8 784XX476 2.000 EA SPLIT LOCK WASHER M8 ZINC

9 884XX223 8.000 EA HEX HEAD CAP SCREW M6 X 14 ZINC

10 798XX302 8.000 EA WASHER FLAT M6 ZINC

11 884XX004 4.000 EA HEX HEAD CAP SCREW 1/4-28 X 3/4 ZINC

12 798XX735 4.000 EA SPLIT LOCK WASHER 1/4 ZINC

90 782XX596 1.000 EA FEELER GAUGE .040”

91 782XX427 1.000 EA ANTI-SEIZE LUBRICANT

98 998IS796 1.000 EA ILLUSTRATION DRAWING

99 IS0299 1.000 EA INSTRUCTION SHEET

Before Starting This Procedure Before starting this procedure, the unit should be heated to operating temperature, the tank completely emptied, and the unit disconnected from power.

WARNING! Failure to empty the tank completely could cause adhesive to spill from the tank, which could result in personal injury or damage to equipment. Failure to disconnect the unit from power could cause electric shock or inadvertent operation of the equipment, which could result in personal injury or damage to equipment.

The unit must be heated to operating temperature to allow the pump and motor shafts to be rotated manually in order to access the coupling set screws.


3

Installing the Coupling

1. With the tank completely empty and the unit disconnected from power, gently lay the unit on its side.

2. Using a pair of wire snips, cut the tie wrap securing the motor cable to the chassis as shown in the figure below.


4

3. Using a ratchet, drive extension, and 10mm socket, remove the (4) M6 hex head cap screws securing the motor bracket to the chassis as shown in the figure below.

4. Slide the motor forward out of the way. The coupling should separate easily. Remove the black center disk and set it aside.

5. Using a 3/32 or 2.5mm hex key, loosen the set screws on both coupling hubs. The motor or pump shafts may need to be rotated manually in order to access the set screws. Remove the coupling hubs from the motor shaft and the pump shaft and set them aside.

CAUTION! The set screw used in the coupling hubs may require a 3/32 or 2.5mm hex key, depending on

the date of manufacture. Be sure the hex key fits snugly before attempting to loosen the set screw, otherwise damage to the set screw may result.

WARNING! Equipment will be hot. Wear safety glasses and heat resistant gloves during this procedure. Otherwise, personal injury may result.

CAUTION! The key in the motor shaft may slide out easily. Set the key aside to avoid losing it.


5

6. Using a ratchet and 7/16 socket, remove the (4) 1/4-28 hex head cap screws securing the motor to the motor bracket. Remove the motor bracket and set it aside.

7. Using a ratchet and 13mm socket, remove ONLY the (2) M8 hex head cap screws and washers that

secure the pump to the manifold, as shown in the figure below.


6

CAUTION! Remove only the (2) M8 hex head cap screws shown. Removing all of the bolts is not necessary unless replacing the pump at the same time.

If the pump insulation blanket interferes with the installation of the motor bracket, remove it and if desired, reinstall after completeing this procedure.

8. Apply a small amount of antisieze to the threads of the (2) M8 hex head cap screws provided (884XX003). Use the (2) M8 hex head cap screws and (2) M8 lock washers provided (784XX476) to fasten the new motor bracket (776XX313) to the pump. Tighten the fasteners by hand first, ensuring that the bore in the bracket mates with the hub on the pump. There will be a small gap of approximately 1/16” between the bracket and pump to minimize heat transfer.

9. Using a square, ensure that the motor bracket is perpendicular to the chassis before tightening the (2) M8 hex head cap screws.

10. Using a ratchet, drive extension, 13mm socket, and torque wrench, tighten the (2) hex head cap screws

to 20 ft-lbs (27.1 N-m) evenly in increments of 5 ft-lbs (6.8 N•m). Using the square, verify that the motor bracket is still perpendicular to the chassis.

11. Fasten the support brackets provided (776XX314 & 776XX315) to the new motor bracket using the M6

hex head cap screws (884XX223) and M6 washers (798XX302) provided. Be sure to start the threads of each screw before tightening. Tighten all screws by hand to seat the brackets, then use a torque wrench to tighten each screw to 106 in-lbs (12 N-m).


7

The right hand mounting bracket is shown in the figure below. The left hand mounting bracket is mounted to the same bolt pattern on the opposite side of the new motor bracket.

12. Place the new ½” bore jaw coupling (783XX370) on the pump shaft. Use the .040” feeler gauge provided

(782XX596) to position the hub on the pump shaft .040” from the motor bracket (see figure below). Using a 1/8 tee handle hex key, tighten the set screw in the jaw coupling hub on the pump shaft.

13. Position the spider (783XX372) in the hub on the pump shaft as shown.


8

14. Replace the key in the motor shaft if removed earlier.

15. Place the new ¾” bore jaw coupling hub (783XX371) on the motor shaft. Do not tighten the set screw yet, as the motor side hub needs to be positioned after assembly.

16. Using the 1/4-28 hex head cap screws provided (884XX004) and 1/4 split lock washers provided (798XX735), fasten the motor to the new motor bracket. Tighten all screws by hand to seat the motor, then use a torque wrench to tighten each screw to 106 in-lbs (12 N-m).

17. Manually rotate the motor shaft as needed in order to align the jaws of both couplings with the spider.

18. Slide the jaw coupling hub on the motor shaft toward the pump, engaging the spider. Verify that the hub slides freely when engaging the spider. With the jaw coupling hub on the motor shaft just touching the spider, tighten the set screw in the jaw coupling hub using a 1/8 tee handle hex key.

CAUTION! If the hub does not slide freely when engaging the spider, the pump and motor shafts may not be properly aligned. Proceeding without correcting misalignment could cause damage to the pump!


9

19. There should be some play in the spider after the coupling is assembled. Verify that the coupling can be moved easily, by hand, approximately .020” (.50mm) in each direction shown in the figure below.

CAUTION! If the spider does not have some play in the directions shown, the pump and motor shafts may not be properly aligned, or there may not be sufficient axial clearance between the hubs and the spider. Proceeding without correcting misalignment or axial clearance could cause damage to the pump!

20. Turn the unit upright, reconnect power, and fill the tank with adhesive. Once the unit has reached operating temperature and the adhesive has melted, start the pump. Verify that there is no noise from the pump, and check the unit for vibration. If no abnormal conditions are observed, the unit is ready to be put back in service.

© Valco Cincinnati, Inc. www.valcomelton.com IS0299 1/16 No part of this document may be reproduced without express permission from Valco Cincinnati, Inc. All rights reserved. Designs and other information may change without notice. Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati, Ohio 45246, USA TEL: (1) 513-874-6550 FAX: (1) 513-874-3612

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

Valco Cincinnati, Ltd. Unit 7-8 Hortonwood 32 Telford TF1 7YN England TEL: (44) 1952-677911 FAX: (44) 1952-677945

Valco Cincinnati GmbH Bonnerstrasse 349 40589 Dusseldorf-Benrath, Germany Tel: +49 211 984 798-0 Fax: +49 211 984 798-20

Valco Melton France Technoparc des Hautes Faventines 32 Rue Jean Bertin 26000 Valence Tel: +33 (0)4 75 78 13 73 Fax: +33 (0)4 75 55 74 20

MM147 - D4 Hot Melt Unit Appendix D - Micro SD Backup & Restore

151

Appendix D - Micro SD Backup & Restore

Functions Backup (Level 3 Permission Required):

• Deletes any existing backup on the micro SD card

• Lookup and copy object IDs and their values to the card (all user configurable parameters)

• Calculate CRC16 checksum and append that and file size to beginning of file

• If the function fails, an error code will be displayed that is explained at the end of this doc

Restore (Level 3 Permission Required):

• Open file and calculate CRC16 checksum and compare that and file size to those in the file

• Read and load all object IDs and values to the CPU (overwriting all parameter settings prior to running Restore

• If the function fails, an error code will be displayed that is explained at the end of this doc

Init (Level 4 Permission Required):

• Same function as previous, sets all parameters back to default and opens the Config wizard

Backups from any 152XX746 board will be able to be loaded onto any other 152XX746 board. However, because there are different versions of software used on the board, performing a backup on one type and restoring it on another may result in some parameters not being restored as they may not have existed in one version or the other. Example: If a backup is made on a unit with 2 hose/gun pairs and loaded onto a unit with 4 hose/gun pairs, hose/gun 3 & 4 will be left as defaults, since there was no user-defined setting for them.

Appendix D - Micro SD Backup & Restore MM147 - D4 Hot Melt Unit

152

Error Codes Code 1: SD card failed to initialize

• It is likely there is not a card installed, it is damaged, or it is not formatted as FAT32

Code 2: SD failed to mount

Code 3: SD card failed to unmount Code 4: CPU failed to open the backup file

Code 5: CPU failed to close the backup file

Code 6: CPU failed to write information to the backup file during backup creation Code 7: CPU failed to read information from the backup file during restore

Code 8: Backup file is invalid

• Upon creation, a checksum is calculated and saved at the beginning of the file. A file should only be invalid if it was edited outside of the CPU

MM147 - D4 Hot Melt Unit Appendix E - Communication Protocols-Modus

153

Appendix E - Communication Protocols-Modbus

Communication Specifications 1) The CPU board only supports Modbus RTU

2) Baud Rate is defaulted to 19200 but has the option to run at 9600 or 19200 configurable in the settings menu.

3) No parity, 8 data bits, 1 stop bit

4) Max Node/Slave ID is 31. This is selectable in the settings menu

5) Only two Modbus functions are configured in the CPU:

(0x03): Read Multiple Holding Registers

(0x10): Write Multiple Holding Registers

6) Errors Returned:

Modbus Exception Code 0x01: Illegal function (0x03 and 0x10 are the only supported functions)

Modbus Exception Code 0x02: Illegal data address (if any address is out of range)

7) All current temperatures have a 25 ºC offset added to them before being sent by the CPU board. The Master PLC must subtract this offset to properly display current temperatures

Hardware Considerations 8) The Modbus interface connector is J2 on the CPU board:

Figure 1

Appendix E - Communication Protocols-Modus MM147 - D4 Hot Melt Unit

154

Hardware Considerations - Continued

9) With jumpers installed on JP1-4 (currently installed), the board is configure for 2-wire RTU. Can also be configured for 4-wire (without jumpers JP1-4).

10) From RJ45 port (J2 on CPU board) Pin 1 is the Negative “A” comm. line and Pin 2 is the Positive “B” comm. line. Pin 8 is the Ground reference. See Figure 2 below for RJ45 pin numbering.

Figure 2

11) The 120 ohm load resistor for the Modbus network is built into the transceiver chip and can be toggled by going into Setup Menu > ”Config” Menu > “Comm. Load Resistors” and Enabling “Modbus RTU”.

Parameter List Short Name

(Melton) Modbus Hex Address

(NC Spec) Write/Read Description Comments

Dep prog 0x0100 W/R Tank Temperature Setpoint All Temperatures in ºC

M1 prog 0x0101 W/R Hose 1 Temperature Setpoint All Temperatures in ºC

P1 prog 0x0102 W/R Gun 1 Temperature Setpoint All Temperatures in ºC








P5 prog 0x010A W/R Gun 5 Temperature Setpoint All Temperatures in ºC

M6 prog 0x010B W/R Hose 6 Temperature Setpoint All Temperatures in ºC

P6 prog 0x010C W/R Gun 6 Temperature Setpoint All Temperatures in ºC

B1 0x010D W/R Tank Standby % Not Used by Valco CPU

B2 0x010E W/R Hoses Standby % Not Used by Valco CPU


155

Parameter List - Continued

Short Name

(Melton) Modbus Hex Address


B3 0x010F W/R Guns Standby % Not Used by Valco CPU

P1 0x0110 W/R Access level

P2 0x0111 W/R Temperature Units 0 = ºC, 1 = ºF

P3 0x0112 W/R Delay Time

P4 0x0113 W/R Maximum Temperature All Temperatures in ºC

P5 0x0114 W/R Temperature deviation in tank Not Used by Valco CPU

P6 0x0115 W/R Temperature deviation in hoses Not Used by Valco CPU

P7 0x0116 W/R Temperature deviation in Guns Not Used by Valco CPU

P8 0x0117 - - - Time for Gun function Not Used by Valco CPU

P11 0x0118 W/R Habilitation of channel 1 Not Used by Valco CPU

P12 0x0119 W/R Habilitation of channel 2 Not Used by Valco CPU

P13 0x011A W/R Habilitation of channel 3 Not Used by Valco CPU

P14 0x011B W/R Habilitation of channel 4 Not Used by Valco CPU

P15 0x011C W/R Habilitation of channel 5 Not Used by Valco CPU

P16 0x011D W/R Habilitation of channel 6 Not Used by Valco CPU

P17 0x011E W/R Number of terminal Not Used by Valco CPU

P18 0x011F W/R Spare Not Used by Valco CPU

P19 0x0120 W/R Spare Not Used by Valco CPU








HC1 0x0128 W/R Monday Hour ON 1 Not Used by Valco CPU

MC1 0x0129 W/R Monday Minute ON 1 Not Used by Valco CPU

TC1 0x012A W/R Monday Type ON 1 Not Used by Valco CPU

HD1 0x012B W/R Monday Hour OFF 1 Not Used by Valco CPU

MD1 0x012C W/R Monday Minute OFF 1 Not Used by Valco CPU

TD1 0x012D W/R Monday Type OFF 1 Not Used by Valco CPU

HC2 0x012E W/R Monday Hour ON 2 Not Used by Valco CPU

MC2 0x012F W/R Monday Minute ON 2 Not Used by Valco CPU

TC2 0x0130 W/R Monday Type ON 2 Not Used by Valco CPU

HD2 0x0131 W/R Monday Hour OFF 2 Not Used by Valco CPU


156


Short Name (Melton)

Modbus Hex Address (NC Spec)

Write/Read Description Comments

MD2 0x0132 W/R Monday Minute OFF 2 Not Used by Valco CPU

TD2 0x0133 W/R Monday Type OFF 2 Not Used by Valco CPU

HC1 0x0134 W/R Tuesday Hour ON 1 Not Used by Valco CPU

MC1 0x0135 W/R Tuesday Minute ON 1 Not Used by Valco CPU

TC1 0x0136 W/R Tuesday Type ON 1 Not Used by Valco CPU

HD1 0x0137 W/R Tuesday Hour OFF 1 Not Used by Valco CPU

MD1 0x0138 W/R Tuesday Minute OFF 1 Not Used by Valco CPU

TD1 0x0139 W/R Tuesday Type OFF 1 Not Used by Valco CPU

HC2 0x013A W/R Tuesday Hour ON 2 Not Used by Valco CPU

MC2 0x013B W/R Tuesday Minute ON 2 Not Used by Valco CPU

TC2 0x013C W/R Tuesday Type ON 2 Not Used by Valco CPU

HD2 0x013D W/R Tuesday Hour OFF 2 Not Used by Valco CPU

MD2 0x013E W/R Tuesday Minute OFF 2 Not Used by Valco CPU

TD2 0x013F W/R Tuesday Type OFF 2 Not Used by Valco CPU

HC1 0x0140 W/R Wednesday Hour ON 1 Not Used by Valco CPU

MC1 0x0141 W/R Wednesday Minute ON 1 Not Used by Valco CPU

TC1 0x0142 W/R Wednesday Type ON 1 Not Used by Valco CPU

HD1 0x0143 W/R Wednesday Hour OFF 1 Not Used by Valco CPU

MD1 0x0144 W/R Wednesday Minute OFF 1 Not Used by Valco CPU

TD1 0x0145 W/R Wednesday Type OFF 1 Not Used by Valco CPU

HC2 0x0146 W/R Wednesday Hour ON 2 Not Used by Valco CPU

MC2 0x0147 W/R Wednesday Minute ON 2 Not Used by Valco CPU

TC2 0x0148 W/R Wednesday Type ON 2 Not Used by Valco CPU

HD2 0x0149 W/R Wednesday Hour OFF 2 Not Used by Valco CPU

MD2 0x014A W/R Wednesday Minute OFF 2 Not Used by Valco CPU

TD2 0x014B W/R Wednesday Type OFF 2 Not Used by Valco CPU

HC1 0x014C W/R Thursday Hour ON 1 Not Used by Valco CPU

MC1 0x014D W/R Thursday Minute ON 1 Not Used by Valco CPU

TC1 0x014E W/R Thursday Type ON 1 Not Used by Valco CPU

HD1 0x014F W/R Thursday Hour OFF 1 Not Used by Valco CPU

MD1 0x0150 W/R Thursday Minute OFF 1 Not Used by Valco CPU

TD1 0x0151 W/R Thursday Type OFF 1 Not Used by Valco CPU

HC2 0x0152 W/R Thursday Hour ON 2 Not Used by Valco CPU

MC2 0x0153 W/R Thursday Minute ON 2 Not Used by Valco CPU

TC2 0x0154 W/R Thursday Type ON 2 Not Used by Valco CPU


157


Short Name (Melton)

Modbus Hex Address (NC Spec)

Write/Read Description Comments

HD2 0x0155 W/R Thursday Hour OFF 2 Not Used by Valco CPU

MD2 0x0156 W/R Thursday Minute OFF 2 Not Used by Valco CPU

TD2 0x0157 W/R Thursday Type OFF 2 Not Used by Valco CPU

HC1 0x0158 W/R Friday Hour ON 1 Not Used by Valco CPU

MC1 0x0159 W/R Friday Minute ON 1 Not Used by Valco CPU

TC1 0x015A W/R Friday Type ON 1 Not Used by Valco CPU

HD1 0x015B W/R Friday Hour OFF 1 Not Used by Valco CPU

MD1 0x015C W/R Friday Minute OFF 1 Not Used by Valco CPU

TD1 0x015D W/R Friday Type OFF 1 Not Used by Valco CPU

HC2 0x015E W/R Friday Hour ON 2 Not Used by Valco CPU

MC2 0x015F W/R Friday Minute ON 2 Not Used by Valco CPU

TC2 0x0160 W/R Friday Type ON 2 Not Used by Valco CPU

HD2 0x0161 W/R Friday Hour OFF 2 Not Used by Valco CPU

MD2 0x0162 W/R Friday Minute OFF 2 Not Used by Valco CPU

TD2 0x0163 W/R Friday Type OFF 2 Not Used by Valco CPU

HC1 0x0164 W/R Saturday Hour ON 1 Not Used by Valco CPU

MC1 0x0165 W/R Saturday Minute ON 1 Not Used by Valco CPU

TC1 0x0166 W/R Saturday Type ON 1 Not Used by Valco CPU

HD1 0x0167 W/R Saturday Hour OFF 1 Not Used by Valco CPU

MD1 0x0168 W/R Saturday Minute OFF 1 Not Used by Valco CPU

TD1 0x0169 W/R Saturday Type OFF 1 Not Used by Valco CPU

HC2 0x016A W/R Saturday Hour ON 2 Not Used by Valco CPU

MC2 0x016B W/R Saturday Minute ON 2 Not Used by Valco CPU

TC2 0x016C W/R Saturday Type ON 2 Not Used by Valco CPU

HD2 0x016D W/R Saturday Hour OFF 2 Not Used by Valco CPU

MD2 0x016E W/R Saturday Minute OFF 2 Not Used by Valco CPU

TD2 0x016F W/R Saturday Type OFF 2 Not Used by Valco CPU

HC1 0x0170 W/R Sunday Hour ON 1 Not Used by Valco CPU

MC1 0x0171 W/R Sunday Minute ON 1 Not Used by Valco CPU

TC1 0x0172 W/R Sunday Type ON 1 Not Used by Valco CPU

HD1 0x0173 W/R Sunday Hour OFF 1 Not Used by Valco CPU

MD1 0x0174 W/R Sunday Minute OFF 1 Not Used by Valco CPU

TD1 0x0175 W/R Sunday Type OFF 1 Not Used by Valco CPU

HC2 0x0176 W/R Sunday Hour ON 2 Not Used by Valco CPU

MC2 0x0177 W/R Sunday Minute ON 2 Not Used by Valco CPU


158


Short Name (Melton)

Modbus Hex Address


TC2 0x0178 W/R Sunday Type ON 2 Not Used by Valco CPU

HD2 0x0179 W/R Sunday Hour OFF 2 Not Used by Valco CPU

MD2 0x017A W/R Sunday Minute OFF 2 Not Used by Valco CPU

TD2 0x017B W/R Sunday Type OFF 2 Not Used by Valco CPU

DIA 0x017C W/R Day Sunday = 0 -> Saturday = 6

HORA 0x017D W/R Hour 0-23

MINUTOS 0x017E W/R Minute 0-59

RELOJ 0x0180 W/R Clock – weekly connection and disconnection hours Not Used by Valco CPU

BAJO MANT 0x0181 W/R Setback 0 = Normal, 1 = Setback

P10 0x0182 W/R Time until filter change

P9 0x0183 R Total Hours Unit On Time

Dep actual 0x0184 R Tank Temperature All Temperatures in ºC w/ 25 ºC offset added

M1 actual 0x0185 R Hose 1 Temperature All Temperatures in ºC w/ 25 ºC offset added

P1 actual 0x0186 R Gun 1 Temperature All Temperatures in ºC w/ 25 ºC offset added




P3 actual 0x018A R Gun 3 Temperature All Temperatures in ºC w/ 25 ºC offset added

M4 actual 0x018B R Hose 4 Temperature All Temperatures in ºC w/ 25 ºC offset added

P4 actual 0x018C R Gun 4 Temperature All Temperatures in ºC w/ 25 ºC offset added

M5 actual 0x018D R Hose 5 Temperature All Temperatures in ºC w/ 25 ºC offset added

P5 actual 0x018E R Gun 5 Temperature All Temperatures in ºC w/ 25 ºC offset added

M6 actual 0x018F R Hose 6 Temperature All Temperatures in ºC w/ 25 ºC offset added


ESTADO EQUIPO 0x0191 R Status Word Not Used by Valco

0x0192 W/R Tank 2 Temperature Setpoint All Temperatures in ºC

0x0193 W/R Aux 1 Temperature Setpoint All Temperatures in ºC

0x0194 W/R Aux 2 Temperature Setpoint All Temperatures in ºC

0x0195 W/R Hose 7 Temperature Setpoint All Temperatures in ºC

0x0196 W/R Gun 7 Temperature Setpoint All Temperatures in ºC

0x0197 W/R Hose 8 Temperature Setpoint All Temperatures in ºC

0x0198 W/R Gun 8 Temperature Setpoint All Temperatures in ºC

0x0199 W/R Spare Not Used by Valco CPU


159


Short Name (Melton)

Modbus Hex Address


0x019A W/R Spare Not Used by Valco CPU

0x019B R Tank 2 Temperature All Temperatures in ºC w/ 25 ºC offset added

0x019C R Aux 1 Temperature All Temperatures in ºC w/ 25 ºC offset added

0x019D R Aux 2 Temperature All Temperatures in ºC w/ 25 ºC offset added

0x019E R Hose 7 Temperature All Temperatures in ºC w/ 25 ºC offset added

0x019F R Gun 7 Temperature All Temperatures in ºC w/ 25 ºC offset added

0x01A0 R Hose 8 Temperature All Temperatures in ºC w/ 25 ºC offset added

0x01A1 R Gun 8 Temperature All Temperatures in ºC w/ 25 ºC offset added

0x01A2 W/R Shift A Standby Start Time

0x01A3 W/R Shift A Standby End Time

0x01A4 W/R Shift A Standby Enable

0x01A5 W/R Shift A Setback Start Time

0x01A6 W/R Shift A Setback End Time

0x01A7 W/R Shift A Setback Enable

0x01A8 W/R Shift B Standby Start Time

0x01A9 W/R Shift B Standby End Time

0x01AA W/R Shift B Standby Enable

0x01AB W/R Shift B Setback Start Time

0x01AC W/R Shift B Setback End Time

0x01AD W/R Shift B Setback Enable

0x01AE W/R Shift C Standby Start Time

0x01AF W/R Shift C Standby End Time

0x01B0 W/R Shift C Standby Enable

0x01B1 W/R Shift C Setback Start Time

0x01B2 W/R Shift C Setback End Time

0x01B3 W/R Shift C Setback Enable

0x01B4 W/R Sunday Shift Selection

0x01B5 W/R Monday Shift Selection

0x01B6 W/R Tuesday Shift Selection

0x01B7 W/R Wednesday Shift Selection

0x01B8 W/R Thursday Shift Selection

0x01B9 W/R Friday Shift Selection

0x01BA W/R Saturday Shift Selection

0x01BB W/R Sequential Start Hose On/Off


160


Short Name (Melton)

Modbus Hex Address


0x01BC W/R Sequential Start Hose Temp Offset All Temperatures in ºC

0x01BD W/R Sequential Start Gun On/Off

0x01BE W/R Sequential Start Gun Temp Offset All Temperatures in ºC

0x01BF W/R Pressure Units 0 = bar, 1 = PSI

0x01C0 W/R Pressure Monitor Low Alarm Delay Seconds – Common for all 4 Pressure Monitors

0x01C1 W/R Pressure Monitor High Alarm Delay Seconds – Common for all 4 Pressure Monitors

0x01C2 W/R Pressure Monitor 1 Enable/Disable

0x01C3 W/R Pressure Monitor 1 Max Value PSI

0x01C4 W/R Pressure Monitor 1 Low Alarm PSI

0x01C5 W/R Pressure Monitor 1 High Alarm PSI

0x01C6 R Pressure Monitor 1 Value PSI

0x01C7 W/R Pressure Monitor 2 Enable/Disable

0x01C9 W/R Pressure Monitor 2 Low Alarm PSI

0x01CA W/R Pressure Monitor 2 High Alarm PSI

0x01CB R Pressure Monitor 2 Value PSI

0x01CC W/R Pressure Monitor 3 Enable/Disable

0x01CD W/R Pressure Monitor 3 Max Value PSI

0x01CE W/R Pressure Monitor 3 Low Alarm PSI

0x01CF W/R Pressure Monitor 3 High Alarm PSI

0x01D0 R Pressure Monitor 3 Value PSI

0x01D1 W/R Pressure Monitor 4 Enable/Disable

0x01D2 W/R Pressure Monitor 4 Max Value PSI

0x01D3 W/R Pressure Monitor 4 Low Alarm PSI

0x01D4 W/R Pressure Monitor 4 High Alarm PSI

0x01D5 R Pressure Monitor 4 Value PSI

0x01D6 R Total Hours Unit Heating Time

0x01D7 W/R Zone 1 Enable/Disable



0x01DA W/R Zone 4 Enable/Disable


161


Short Name (Melton)

Modbus Hex Address


0x01DB W/R Zone 5 Enable/Disable

0x01DC W/R Zone 6 Enable/Disable

0x01DD W/R Zone 7 Enable/Disable

0x01DE W/R Zone 8 Enable/Disable

0x01DF W/R Zone 9 Enable/Disable

0x01E0 W/R Zone 10 Enable/Disable










0x01EA W/R Zone 20 Enable/Disable

0x01EB W/R Hose/Gun 1 Enable/Disable

0x01EC W/R Hose/Gun 2 Enable/Disable

0x01ED W/R Hose/Gun 3 Enable/Disable

0x01EE W/R Hose/Gun 4 Enable/Disable

0x01EF W/R Hose/Gun 5 Enable/Disable

0x01F0 W/R Hose/Gun 6 Enable/Disable




162

MM147 - D4 Hot Melt Unit Appendix F - Communication Protocols-Ethernet IP

163

Appendix F - Communication Protocols-Ethernet IP

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

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

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

Data Packets used for Ethernet/IP communication This section describes the Process Data packets needed to operate between the Melter and PLC. There are two types of packets: Send Packets that have the control information from the PLC and, Receive Packets that have the status information from the Melter.

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

Send Packet (PLC) Frame

Byte0 Byte1 Byte2 Byte3 Byte4, 5

Control Data Index

Pump1 speed%Command

Byte6, 7 Byte8, 9

Channel

Data Value

Byte10, 11 Byte12, 13 Byte14, 15

Pump2 speed%

Pump3 speed%

Pump4 speed%

Not Used

Appendix F - Communication Protocols-Ethernet IP MM147 - D4 Hot Melt Unit

164

Bit Definitions for Control Byte 0

These are control bits executed with each message by the Melter. When in remote mode, these functions are controlled only by the PLC, and cannot be updated at the Melter. In local mode, this byte is ignored, and full control is at the Melter.

For each of the control bits, ON has a value of 1 and OFF has a value of 0.

Bit 0: Control Power ON/OFF

Bit 1: Master Pump Enable ON/OFF





Bit 6: Temperature Setback ON/OFF

Bit 7: Auto Pump Enable ON/OFF

Command Byte 1

This command byte tells the Melter what to do with the Data Index and Channel bytes. The following command codes (in hex) are defined:

Command Description 0x01 Control Byte Only 0x03 Read 0x06 Write

If the Melter is put into local mode, the Write Command will return a local mode fault. All other commands not listed will return a wrong command fault.


165

Data Index Byte 2

The Data Index is equal to the Melter Parameters that may be accessed through the Ethernet/IP protocol. Only those parameters listed can be accessed through remote mode. Parameters that require a system restart, including most setup parameters, will still need to be accessed at the Melter.

The following is the Data Index list and valid parameters.

If the system is in Local Operation mode, all Data Types become Read Only and, in the case of Write Only Indexes, become unavailable.

Data Index Channel Data Type Range Description

4 - RO 0 - 1 Remote Operation Mode (0=Local, 1=Remote) 7 - WO 0 - 1 Clear Fault

11 - RO 0 - 120 min Ready Delay Time Remaining 23 - RO 0x0000-0xFFFF Current Alarm Type (See Table Below) 110 - RW 0 – 1 Temperature Units (0=C, 1=F) 111 0-19 RW 0 – 1 Activate Temperature Zone 112 0-7 RW 0 – 1 Activate Hose/Gun Zone Pair 115 0-19 RW 40 – 230 C Zone Temperature Set Point 120 0-19 RO 40 – 230 C Zone Current Temperature 128 - RW 5 – 190 C Standby Temperature 135 - RW 0 – 1440 min AutoSetback Time 136 - RW 0 – 1440 min AutoStandby Time 142 - RW 5 – 60 C UnderTemp Fault Offset 152 - RW 5 – 60 C OverTemp Fault Offset 160 - RW 1 – 180 min Exit Standby Time 170 0-3 RW 0 – 2 Pump Auto Mode Input Speed Type

(0=0-10V, 1=0-2.8V, 2=Encoder) 171 0-3 RW 0 – 9999 m/min Pump Minimum Speed - Encoder 172 0-3 RW 0 – 9999 RPM Pump Creep Speed 173 0-3 RW 0 – 9999 Pump Ratio 174 0-3 RO 0 – 100% Pump Manual Speed 175 0-3 RW 0 - 1 Pump Mode 176 0-3 RW 0 – 200 Pump Gain 177 0-3 RO 0 – 1 Pump Enable 178 0-3 RW 0 – 1 Grammage Enable 179 0-3 RW 10 – 3000 mm Application Width (Grammage Only) 180 0-3 RW 1 – 200 g/m² Application Weight (Grammage Only) 181 0-3 RW 0.8 – 100 Density (Grammage Only) 182 0-3 RO 0 – 9999 RPM Pump Speed 183 0-3 RW 0 – 9999 mV Pump Minimum Speed - Tach 200 - RW 0 – 1 Seven-Day Clock Enabled 201 - RO 0 – 1 Seven-Day Clock Status 202 - RW 0 – 6 Clock – Day 203 - RW 0 – 24 Clock – Hour 204 - RW 0 - 60 Clock – Minute

Channel Byte 3

This is the location targeted within parameters having multiple zones.

For example - In Data Index 182 (Pump Speed):

Sending a read to channel 0, the Melter will send back the value for the Pump 1 current pump speed (channel 1 = Pump 2, etc.)


166

Data Value Byte 4 and 5

This is the data that the PLC sends to the Melter to update a given parameter. This value is limited to the range listed in the Data Index table, and will return an Outside Range fault otherwise.

Pump1 speed%...Pump4 speed% Byte 6 - 13

With each message from the PLC to the Melter, the PLC can send the Pump Manual speed down, to change the pump pressures dynamically.

Receive Packet (Melter) Frame

Bit Definitions for Status Bytes 0 and 1 These are the response bytes sent back from the Melter at every message.

Bit 0: Melter Ready for Operation – 1 = Ready, 0 = Not Ready

Bit 1: Ready Delay Enabled – 1 = Enabled, 0 = OFF

Bit 2: System is in Alarm State – 1 = Alarm, 0 = No Alarm

Bit 3: System is in Fault State – 1 = Fault, 0 = No Fault

Bit 4: Melter is Shutdown – 1 = Shutdown, 0 = Not Shutdown

Bit 5: Melter in Warmup State – 1 = Warmup active, 0 = Warmup not active

Bit 6: Melter in Setback – 1 = Setback active, 0 = Setback not active

Bit 7: Pump 1 Active – 1 = On, 0 = OFF




Bit 11: Not used

Bit 12: Not used

Bit 13: Not used

Bit 14: Communication Fault (See Error Codes Section)

Bit 15: Communication Fault (See Error Codes Section)

Byte0, 1 Byte2 Byte3 Byte4, 5

Status

Data Index

Ch+1 Data

Byte6, 7 Byte8, 9

Channel

Ch Read Data

Byte10, 11 Byte12, 13 Byte14, 15

Ch+2 Data

Ch+3 Data

Ch+4 Data

Ch+5 Data


167

Data Index Byte 2

This is the same Data Index as in Send Packet. This is used as an acknowledgement back to the PLC, to confirm the message.

Channel Byte 3

This is the same Channel as in Send Packet. This is used as an acknowledgement back to the PLC, to confirm the message.

Channel Read Data Bytes 4 and 5

This is the value returned during a read command, for the Data Index and Channel requested.

Channel Read Data + Bytes 6 - 15

When a read command is requested for a parameter with multiple zones, the next channel value will also return to the PLC, unless the requested channel is already the maximum channel.

For example - A read request to Data Index 182 (Pump Speed), channel 0:

Channel Read Data (Bytes 4 and 5) returns Pump1 speed

Channel Read Data +1 (Bytes 6 and 7) returns Pump2 speed

Channel Read Data +2 (Bytes 8 and 9) returns Pump3 speed

Channel Read Data +3 (Bytes 10 and 11) returns Pump4 speed.


168

Current Alarm Types When Reading the Current Alarm Type (Data Index 23), a specific code is returned on Read Data (Byte 4, 5). For Zone Errors, The Zone with the error is returned in Byte 4.

Numbers shown in Hex.

Byte 4 Description 0x00 No Alarm 0x01 – 0x14 Zone Error 0x15 System Error

Zone Error (0x01 – 0x14)

Byte 5 Description 0x00 No Alarm / Fault 0x01 RTD Fault 0x02 Low Temperature Fault 0x03 High Temperature Fault

System Error (0x15)

Byte 5 Description 0x00 No Alarm / Fault 0x02 System Fault 0x03 Filter Alarm 0x04 Pump 1 Fault 0x05 Pump 2 Fault 0x06 Pump 3 Fault 0x07 Pump 4 Fault 0x08 Communication Error


169

Error Codes

On an Error, the Status (byte 0, 1) will send back a 0x4000 hex, indicating an error has occurred. When this occurs, the Data Index (byte 2) will be set to the corresponding error code:

Error Code Description 0x00 No Fault 0x01 Wrong Command Received 0x02 Wrong Data Index Received 0x03 Wrong Channel Received 0x04 Object is Read only 0x05 No Channel 0x06 Outside Range 0x07 Local Mode

Examples

1) Enable Melter and set the zone 1 temperature setpoint Control = 0x01 (Heater enable only)

Command = Write 0x06

Data Index = 115 (0x73) Setpoint

Channel = 0

Data =70 degrees (0x46)


CPU PLC:


2) Read current zone 1 temperature Control = 0x01 (Heater enable only)

Command = Read 0x03

Data Index = 120 (0x78)

Channel = 0


CPU PLC:


This example also assumes zones 1-5 are available, and that all are at 70 degrees


170

Status Indicators

1 – Network Status LED

2 – Module Status LED

3 – Link/Activity LED port 1

4 – Link/Activity LED port 2

Network Status LED

LED State Description OFF NO POWER OR IP ADDRESS GREEN ONLINE WITH CONNECTIONS

ESTABLISHED FLASHING GREEN ONLINE WITHOUT CONNECTIONS

ESTABLISHED RED FATAL ERROR FLASHING RED CONNECTION TIMED OUT

Module Status LED

LED State Description OFF NO POWER GREEN CONTROLLED BY A SCANNER IN RUN

STATE FLASHING GREEN NOT CONFIGURED OR SCANNER IN IDLE

STATE RED MAJOR FAULT FLASHING RED RECOVERABLE FAULT

Link/Activity LED

LED State Description OFF NO LINK, NO ACTIVITY GREEN LINK 100Mbit/s FLASHING GREEN ACTIVITY 100Mbit/s YELLOW LINK 10Mbit/s FLASHING YELLOW ACTIVITY 10Mbit/s

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