VALCO MELTON D-90 User manual

D-90 Hot Melt UnitD-90 Hot Melt Unit
D-90 Hot Melt UnitD-90 Hot Melt Unit
D-90 Hot Melt Unit
Manual Number: MM125
Release Date: 3/2018

© Valco Cincinnati, Inc. All Rights Reserved
This manual is furnished with the D-90 Hot Melt Unit and may only be used in accordance with the terms 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 ValcoMelton, a division of Valco Cincinnati, Inc. 457 Circle Freeway
Drive, Cincinnati, Ohio 45246.
Part Number: MM125
Printed in the USA
Valco Cincinnati, Inc.Valco Cincinnati, Inc.
Valco Cincinnati, Inc.Valco Cincinnati, Inc.
Valco Cincinnati, Inc.
497 Circle Freeway Drive
Suite 490
Cincinnati, OH 45246
Tel: [phone]
Fax: [phone]
Email: [email protected]
Web: http://www.valcocincinnatiinc.com
Valco Cincinnati LimitedValco Cincinnati Limited
Valco Cincinnati LimitedValco Cincinnati Limited
Valco Cincinnati Limited
Hortonwood 32
Telford, TFI 7YN, England
Tel: [phone]
Fax: [phone]
Email: [email protected]
Web: http://www.valco.co.uk
Valco Cincinnati GmbHValco Cincinnati GmbH
Valco Cincinnati GmbHValco Cincinnati GmbH
Valco Cincinnati GmbH
Bonnerstrasse 349
40589 Dusseldorf-Benrath, Germany
Tel: [phone]
Fax: [phone]
Melton S.L.U.Melton S.L.U.
Melton S.L.U.Melton S.L.U.
Melton S.L.U.
Pol. Industrial Agustinos
calle G, n. 34
31160 Orcoyen, Navarra, Spain
Tel: [phone]
Fax: [phone]
Valco Melton FranceValco Melton France
Valco Melton FranceValco Melton France
Valco Melton France
Technoparc des Hautes Faventines
32 Rue Jean Bertin
26000 Valence
Tel: [phone]
Fax: [phone]

Declaration of ConformityDeclaration of Conformity
Declaration of ConformityDeclaration of Conformity
Declaration of Conformity
(According to EN 45014)
This Declaration of Conformity has been generated electronically and is legally binding without signature
The following declaration is issued under the sole responsibility of the manufacturer:
Manufacturer: Valco Melton
A division of Valco
Cincinnati, Incorporated
411 Circle Freeway Drive
Cincinnati, OH 45246
USA
Authorized Representatives in
Europe: Valco Cincinnati, Ltd.
Unit 7-8
Hortonwood 32
Telford TF1 7YN
England
Melton S.L.U.
Pol. Industrial
Agustinos
calle G, n. 34
31160 Orcoyen
Navarra, Spain
declares that the product:
Product Name: D-90 Hot Melt Unit
complies with the following Council Directives:
Safety of Machinery: 2006/42/EC
Low Voltage Equipment: 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

T-1ValcoMelton
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS
Section 1 - Introduction.................................................. 1-1
Description ................................................................................................ 1-1
Section 2 - Safety and Use ............................................. 2-1
Read Thoroughly Before Handling Equipment ....................................... 2-1
Symbols .................................................................................................... 2-1
Owner Responsibilities ............................................................................ 2-3
Limitations of Use..................................................................................... 2-4
Installation/Startup/Use Safety Information ........................................... 2-4
Shut Down Safety Information ................................................................ 2-5
Hot-Melt-Specific, General Safety Information........................................ 2-6
What to Do if Contact with Hot Adhesive Occurs .......................................... 2-7
What to Do if Inhalation of Adhesive Fumes Occurs .................................... 2-7
What to Do if Adhesive-Related Fire or Explosion Occurs........................... 2-8
Hose Safety Information .......................................................................... 2-9
Section 3 - Basic Features.............................................. 3-1
Overview ................................................................................................... 3-1
Main Power Disconnect .................................................................................. 3-3
CompressionLatches ...................................................................................... 3-3
Temperature Controller .................................................................................. 3-3
Fan.................................................................................................................... 3-3
Alarm Beacon .................................................................................................. 3-3
Lid..................................................................................................................... 3-3
Reservoir .......................................................................................................... 3-3
Casters .............................................................................................................. 3-3
Grid ................................................................................................................... 3-3
Collector ........................................................................................................... 3-3
Frame ............................................................................................................... 3-3
Manifold ........................................................................................................... 3-4
Filter ................................................................................................................. 3-5
Shut-Off Valve .................................................................................................. 3-5
Hose Receptacle.............................................................................................. 3-5
Level Sensor .................................................................................................... 3-5
Side Panel ....................................................................................................... 3-5
Pressure Relief Valves .................................................................................... 3-5
Pump ................................................................................................................ 3-5
Motor ................................................................................................................ 3-5
Hose Support ................................................................................................... 3-5
Dataplates ........................................................................................................ 3-6

T-2
Table of Contents
ValcoMelton
MM125-D-90 Hot MeltUnit
Section 4 - Installation.................................................... 4-1
Transport................................................................................................... 4-1
Choosing a Location ................................................................................ 4-1
Installation Kit ........................................................................................... 4-2
Routing Low-Voltage Leads..................................................................... 4-2
Connecting the Electrical Power.............................................................. 4-2
ElectricalPanel.......................................................................................... 4-5
VFD Board - Electrical Cabinet/Terminal Locations................................ 4-6
Connecting the Hoses.............................................................................. 4-8
Connecting the Hot Melt Hoses to theApplicators............................... 4-11
Customer Connections .......................................................................... 4-13
Units shipped with serial number 18031219 and later ................................ 4-13
Units shipped with serial number 18031218 and prior................................ 4-15
Section 5 - Setup............................................................. 5-1
Control Panel ............................................................................................ 5-1
Power On/Off and Standby Mode ............................................................ 5-3
DisplayAdjustment................................................................................... 5-4
User Interface............................................................................................ 5-6
Navigation ........................................................................................................ 5-6
Memory Storage .............................................................................................. 5-6
Editing .............................................................................................................. 5-6
Thumbwheel vs. Single Digit Edit .................................................................. 5-7
Entering Passwords ................................................................................. 5-8
Set Language ............................................................................................ 5-9
Set Temperature Units............................................................................ 5-11
Programming Temperatures ........................................................................ 5-12
Temperature Screens.................................................................................... 5-12
Grid Temperature .......................................................................................... 5-13
Hose/Valve Temperature............................................................................... 5-13
System/Pump Ready Temperature Offset ............................................. 5-15
Ready Delay Time ................................................................................... 5-16
Over TemperatureAlarm ........................................................................ 5-18
Under TemperatureAlarm ...................................................................... 5-19
Maximum Temperature........................................................................... 5-20
Beacon/Alarm Setup ............................................................................... 5-21
Beacon 2 ........................................................................................................ 5-22
Automatic Pump Mode ........................................................................... 5-23
Level Sensor Setup ................................................................................ 5-24
Internal Level
External Level ......................................................................................... 5-24
Filter Change Timer ................................................................................ 5-24
Clock and 7-Day Timer ........................................................................... 5-25
Set Day and Time .......................................................................................... 5-25
Shift Times/Setback Times ........................................................................... 5-26
Programming Shifts ...................................................................................... 5-26
Moving Through the Shift Time/Day Screens ............................................. 5-28

T-3
Table of Contents
ValcoMelton
MM125-D-90 Hot MeltUnit
Diagnostics ............................................................................................. 5-30
Setback.................................................................................................... 5-31
Setback Temperature.................................................................................... 5-31
Automatic Setback Timeout ......................................................................... 5-32
Startup Setup .......................................................................................... 5-33
Sequential Start – Hose ................................................................................ 5-33
Sequential Start – Valve ............................................................................... 5-34
History ..................................................................................................... 5-35
User Inputs and Outputs ........................................................................ 5-36
Configuration .......................................................................................... 5-37
Number of Hose Outlets ................................................................................ 5-37
Auxiliary I/O ................................................................................................... 5-37
Number of Pumps .......................................................................................... 5-38
Gramage Enable ........................................................................................... 5-38
RTD Type Selection ....................................................................................... 5-38
Pump Setup Menu .................................................................................. 5-39
Encoder Setup Menu .............................................................................. 5-41
PID Setup Menu...................................................................................... 5-41
PID Settings.................................................................................................... 5-41
AutoTune Feature .......................................................................................... 5-42
Initialize Screen ....................................................................................... 5-43
Restoring Factory Default Settings ....................................................... 5-43
Adjusting the Pressure Control Valve................................................... 5-44
Adjusting the Single-Stage Relief Valve ..................................................... 5-44
Gramage Feature .................................................................................... 5-45
Section 6 - Operation ...................................................... 6-1
Unit Startup ............................................................................................... 6-1
Filling the Tank.......................................................................................... 6-3
DispensingAdhesive................................................................................ 6-4
Section 7 - Maintenance ................................................. 7-1
General ...................................................................................................... 7-1
Cleaning the Exterior of the Unit ............................................................. 7-1
Filter Replacement.................................................................................... 7-2
Replacing the Tank Inlet Filter.................................................................. 7-3
Replacing the Manifold Filter.................................................................... 7-4
Changing theAdhesive ............................................................................ 7-5
Flushing the System................................................................................. 7-5
Parts Replacement.................................................................................... 7-6
ChangingFuses ............................................................................................... 7-7

T-4
Table of Contents
ValcoMelton
MM125-D-90 Hot MeltUnit
Section 8 - Troubleshooting and Repair...................... 8-1
Troubleshooting ....................................................................................... 8-1
Repair ........................................................................................................ 8-4
Replacing the Pump........................................................................................ 8-4
Replacing the Motor........................................................................................ 8-6
Replacing the Pressure Relief Valve ............................................................. 8-7
Replacing the Beacon Light Bulb .................................................................. 8-8
Section 9 - Specifications ............................................. 9-1
General ...................................................................................................... 9-1
Dimensions - D-90 .................................................................................... 9-2
Section 10 - Part Number List ...................................... 10-1
How to Order Parts ................................................................................. 10-1
D-90 Hot Melt Unit (776XX883) .............................................................. 10-2
Overall Assembly........................................................................................... 10-2
Reservoir, Collector, Grid, Frame Assembly................................................ 10-4
Sheet Metal Assembly................................................................................... 10-6
Motor, Pump and Manifold Assembly .......................................................... 10-9
D-90 Hot Melt Unit (776XX883) - Parts List ......................................... 10-11
Single Pump Manifold Assembly (776XX299)..................................... 10-13
Dual Pump Manifold Assembly (776XX300) ....................................... 10-16
D-90 HMU Electrical Panel Assembly (776XX281) ............................. 10-19
D90 Hot Melt Unit (EQM0690) .............................................................. 10-23
Recommended Spare Parts for EQM0690.................................................. 10-29
Electrical PanelAssembly .................................................................... 10-30
Section 11 - Warranty.....................................................11-1
Warranty Information ............................................................................. 11-1
Cold Glue Equipment and Electronic Controls............................................ 11-1
Hot Melt Units, Hoses, Valves, Guns, and Related Equipment ................... 11-1
Section 12 - Service ...................................................... 12-1
Appendix A - Password Levels .....................................A-1
Appendix B - Power Requirements ...............................B-1
System Power Requirement Calculation - D-90 Units............................B-1
Appendix C - Schematics ...............................................C-1

1-1ValcoMelton.
SECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTION
SECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTION
SECTION 1 - INTRODUCTION
Description
ValcoMelton, a division of Valco Cincinnati, Inc., has prepared this manual
as an aid for installing, operating, and servicing the D-90 hot melt unit. It also
contains a list of part numbers for replacement parts. If you need more
information, contact your ValcoMelton representative.
The D-90 hot melt unit is a high-volume system designed to melt and pump
thermoplastic adhesives. The unit features a precision electronic
temperature control, a digital multi-zone temperature display, a variable-
speed electric motor-driven gear pump, and an adjustable pressure
control.
Features and capabilities include:
• Precision electronic temperature control
• Capacity of up to four hoses and guns
• Positive displacement electric motor-driven gear pump
• Adjustable pressure control
• Integrated over-temperature protection
• User selectable inputs and outputs
• Variable frequency drive (VFD)
• Accepts encoder or tachometer inputs for Variable Speed Units
Other options are available. See the “Parts List” section, for additional
information.
See the “Schematics” section for wiring and pneumatic schematics.

2-1ValcoMelton
SECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USE
SECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USE
SECTION 2 - SAFETY AND USE
Read
Thoroughly
Before
Handling
Equipment
WARNING!WARNING!
WARNING!WARNING!
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 CautionCaution
CautionCaution
Caution or a WarningWarning
WarningWarning
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 SurfaceHot Surface
Hot SurfaceHot Surface
Hot Surface.
This symbol represents a Puncture Risk.Puncture Risk.
Puncture Risk.Puncture Risk.
Puncture Risk. It is usually used in
regard to nozzle cleaning appliances and other sharp
instruments that can cause puncture wounds and risk exposure
to bloodborne pathogens and other debris.
This symbol means that Working GlovesWorking Gloves
Working GlovesWorking Gloves
Working Gloves are required.
This symbol means that GogglesGoggles
GogglesGoggles
Goggles are required.
This symbol indicates a Shock HazardShock Hazard
Shock HazardShock Hazard
Shock Hazard. There is a presence of
non-insulated dangerous voltage within the product’s enclosure.
This voltage may cause electrical shock or fire.
Continued next page

2-2 ValcoMelton
Section 2 - Safety Information MM125-D-90 Hot MeltUnit
Symbols - Continued
This symbol indicates a NoteNote
NoteNote
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.
This symbol indicates the need to Unplug/Disconnect All PowerUnplug/Disconnect All Power
Unplug/Disconnect All PowerUnplug/Disconnect All Power
Unplug/Disconnect All Power
SourcesSources
SourcesSources
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 SourcesLock Out All Power Sources
Lock Out All Power SourcesLock Out All Power Sources
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.