VALCO MELTON D10 User manual

D10/D16 Hot Melt Unit
Manual Number: MM113
Revision Date: 8/2019

© Valco Melton All Rights Reserved
This manual is provided with the D10/D16 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: MM113
Written and printed in the USA.
Valco Cincinnati, Inc.
497 Circle Freeway Drive
Suite 490
Cincinnati, OH 45246
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Web: http://www.valcocincinnatiinc.com
Valco Cincinnati Limited
Hortonwood 32
Telford, TFI 7YN, England
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Web: http://www.valco.co.uk
Valco Cincinnati GmbH
Bonnerstrasse 349
40589 Dusseldorf-Benrath, Germany
Tel: [phone]
Fax: [phone]
Melton S.L.U.
Pol. Industrial Agustinos
calle G, n. 34
31160 Orcoyen, Navarra, Spain
Tel: [phone]
Fax: [phone]
Valco Melton France
Technoparc des Hautes Faventines
32 Rue Jean Bertin
26000 Valence
Tel: [phone]
Fax: [phone]

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: D10/D16 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.

MM113 - D10/D16 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 ...................................................................................15
Read Thoroughly Before Handling Equipment.......................................................................................................15
Symbols ...................................................................................................................................................................15
Owner Responsibilities............................................................................................................................................16
Limitations of Use ....................................................................................................................................................16
Installation/Startup/Use Safety Information.............................................................................................................17
Shut Down Safety Information ................................................................................................................................18
Hot-Melt-Specific, General Safety Information.......................................................................................................18
What to Do if Contact with Hot Adhesive Occurs ...................................................................................19
What to Do if Inhalation of Adhesive Fumes Occurs..............................................................................19
What to Do if Adhesive-Related Fire or Explosion Occurs.....................................................................20
Hose Safety Information..........................................................................................................................................21
Section 3 - Basic Features ...................................................................................23
Key Features............................................................................................................................................................23
Section 4 - Installation .........................................................................................25
Choosing a Location................................................................................................................................................25
Mounting Footprint..................................................................................................................................25
Installation Kit...........................................................................................................................................................26
Routing Low-Voltage Leads....................................................................................................................................26
Connecting the Electrical Power.............................................................................................................................27
Connecting the Hoses.............................................................................................................................................29
Connecting the Hot Melt Hoses to the Applicators.................................................................................................31
Wiring Diagram (After 5/18).....................................................................................................................................32
Wiring Diagram - Before 5/18..................................................................................................................................34
Input/Output Connections........................................................................................................................................35
Input/Output Connections - Before 5/18 .................................................................................................................37
Section 5 - Setup .................................................................................................38
Pump Setup Menu ..................................................................................................................................81
VFD Parameters .....................................................................................................................................84
After 5/18.......................................................................................................................................................84

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Before 5/18 ...................................................................................................................................................84
Encoder Setup Menu...............................................................................................................................................85
Section 6 - Operation ..........................................................................................99
Start the Unit............................................................................................................................................................99
Temperature ............................................................................................................................................................100
Setpoint and Actual Temperature...........................................................................................................100
Temperature Status LEDs......................................................................................................................100
Pump Operation.......................................................................................................................................................101
Pump On/Off Key ...................................................................................................................................101
Pump Status Key....................................................................................................................................101
Fixed Speed Unit..........................................................................................................................................101
Variable Speed Unit......................................................................................................................................102
Clock On/Off.............................................................................................................................................................102
Setback....................................................................................................................................................................103
Automatic Setback..................................................................................................................................103
Pot Fill - External Low Level Detection...................................................................................................................104
Hopper Feeder - Internal Low Level Detection.......................................................................................................104
Beacon Alarm ..........................................................................................................................................................104
External Input...........................................................................................................................................................104
Filling the Tank.........................................................................................................................................................105
Section 7 - Maintenance ......................................................................................107
General.....................................................................................................................................................................107
Cleaning the Exterior of the Unit.............................................................................................................................107
Changing the Adhesive...........................................................................................................................................108
Flushing the System................................................................................................................................................108
Parts Replacement..................................................................................................................................................109
Changing Fuses .....................................................................................................................................109
Units Produced After August, 2014..............................................................................................................110
Units Produced Before August, 2014 ..........................................................................................................111
Changing the Filter.................................................................................................................................112
Section 8 - Troubleshooting and Repair ...............................................................113
Section 9 - Specifications ....................................................................................115
General.....................................................................................................................................................................115
Dimensions - D10....................................................................................................................................................116
Dimensions - D16....................................................................................................................................................117
Section 10 - Part Number List .............................................................................. 119
How to Order Parts..................................................................................................................................................119
D10 Unit...................................................................................................................................................................120
D10 Unit, 2 exit (771xx001)....................................................................................................................123
D10 Unit, 4 exit (771xx002)....................................................................................................................123
D10 Unit, 6 exit (771xx003)....................................................................................................................124

MM113 - D10/D16 Hot Melt Unit Table of Contents
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D10 Base Unit (776xx884)......................................................................................................................125
After 5/18.......................................................................................................................................................127
Before 5/18 and After 1/17...........................................................................................................................129
D10 Unit - Previous Version (before 1/2017 and after 1/2016)..............................................................................131
D10 Unit, Fixed speed, 2 exit (776xx703) - Previous Version (before 1/2017 and after 1/2016)...........133
D10 Unit, Fixed speed, 4 exit (776xx704) - Previous Version (before 1/2017 and after 1/2016)...........134
D10 Unit, Fixed speed, 6 exit (776xx705) - Previous Version (before 1/2017 and after 1/2016)...........135
D10 Unit, Variable speed, 2 exit (776xx706) - Previous Version (before 1/2017 and after 1/2016) .....136
D10 Unit, Variable speed, 4 exit (776xx707) - Previous Version (before 1/2017 and after 1/2016) .....137
D10 Unit, Variable speed, 6 exit (776xx708) - Previous Version (before 1/2017 and after 1/2016) .....138
D10 Unit - Previous Version (before 1/2016)..........................................................................................................139
D10 Unit, Fixed speed, 2H/2G (776xx853) - Previous Version (before 1/2016) ....................................143
Coupling Assembly (units produced before 1/2016)...................................................................................145
D10 Unit, Fixed speed, 4H/4G (776xx859) - Previous Version (before 1/2016) ....................................146
D10 Unit, Fixed speed, 6H/6G (776xx860) - Previous Version (before 1/2016) ....................................146
D10 Unit, Variable speed, 2H/2G (776xx858) - Previous Version (before 1/2016)................................146
D10 Unit, Variable speed, 4H/4G (776xx861) - Previous Version (before 1/2016)................................148
D10 Unit, Variable speed, 6H/6G (776xx862) - Previous Version (before 1/2016)................................148
D16 Unit...................................................................................................................................................................149
D16 Unit, 2 exit (771xx004) ....................................................................................................................152
D16 Unit, 4 exit (771xx005) ....................................................................................................................152
D16 Unit, 6 exit (771xx006) ....................................................................................................................153
D16 Base Unit (776xx885)......................................................................................................................................154
Before 5/18..............................................................................................................................................156
Before 5/18 and After 1/17......................................................................................................................157
D16 Unit-Previous Version (before 1/2017 and after 1/2016)................................................................................158
D16 Unit, Fixed Speed, 2 exit (776xx774) - Previous Version (before 1/2017 and after 1/2016) ..........160
D16 Unit, Fixed Speed, 4 exit (776xx775)-Previous Version (before 1/2017 and after 1/2016) ............161
D16 Unit, Fixed Speed, 6 exit (776xx776)-Previous Version (before 1/2017 and after 1/2016) ............162
D16 Unit, Variable Speed, 2 exit (776xx777)-Previous Version (before 1/2017 and after 1/2016)........163
D16 Unit, Variable Speed, 4 exit (776xx778)-Previous Version (before 1/2017 and after 1/2016)........164
D16 Unit, Variable Speed, 6 exit (776xx779)-Previous Version (before 1/2017 and after 1/2016).......165
D16 Unit - Previous Version (before 1/2016)..........................................................................................................166
D16 Unit, Fixed Speed, 2H/2G (776xx864) - Previous Version (before 1/2016)....................................170
Coupling Assembly (units produced before 1/2016)...................................................................................172
D16 Unit, Fixed Speed, 4H/4G (776xx865) - Previous Version (before 1/2016)....................................172
D16 Unit, Fixed Speed, 6H/6G (776xx866) - Previous Version (before 1/2016)....................................172
D16 Unit, Variable Speed, 2H/2G (776xx867) - Previous Version (before 1/2016) ...............................173
D16 Unit, Variable Speed, 4H/4G (776xx868) - Previous Version (before 1/2016) ...............................176
D16 Unit, Variable Speed, 6H/6G (776xx869) - Previous Version (before 1/2016) ...............................176
Installation Kit (091xx664).......................................................................................................................................176
Option Kits................................................................................................................................................................177
AutoFeed.................................................................................................................................................177
Vacuum Feeder Assembly 776xx157..........................................................................................................177
Split Lid Kits ............................................................................................................................................179
776xx610 ......................................................................................................................................................179
776xx203 ......................................................................................................................................................179
776xx613 ......................................................................................................................................................179
Pump Control..........................................................................................................................................180
Cable Assembly Handgun Pump Control (029xx553)................................................................................180
Motor/Pump Type....................................................................................................................................180
Pump Kit, Fixed, Standard Width (771XX007)............................................................................................181

Table of Contents MM113 - D10/D16 Hot Melt Unit
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Pump Kit, Variable, Standard Width (771XX008) - After 5/18....................................................................182
Pump Kit, Variable, Standard Width (771XX008) - Before 5/18 and After 1/17........................................183
Pump Kit, Fixed, Half Width (771XX009) ....................................................................................................184
Pump Kit, Variable, Half Width (771XX010) - After 5/18.............................................................................185
Pump Kit, Variable, Half Width (771XX010) - Before 5/18 and After 1/17.................................................186
Pump Kit, Fixed, Double Width (771XX011)...............................................................................................187
Pump Kit, Variable, Double Width (771XX012) - After 5/18 .......................................................................188
Pump Kit, Variable, Double Width (771XX012) - Before 5/18 and After 1/17............................................189
Pump Kit, Fixed, Quad Width (771XX013)..................................................................................................190
Pump Kit, Variable, Quad Width (771XX014) - After 5/18..........................................................................191
Pump Kit, Variable, Quad Width (771XX014) - Before 5/18 and After 1/17...............................................192
Pump Type - Previous (before 1/2017)..................................................................................................193
Pump Kit, Standard Width (560xx886)........................................................................................................193
Pump Kit, Standard Width (561xx216)........................................................................................................193
Pump Kit, Double Width (560xx887)............................................................................................................193
Pump Kit, Double Width (561xx221)............................................................................................................194
Pattern Control .......................................................................................................................................194
Valve Driver Kit, PCM-6 (776xx733)............................................................................................................194
Internal Level Sensors............................................................................................................................195
Internal Low-Level Sensor Kit (776xx745)...................................................................................................195
Internal High-Level Sensor Kit (776xx748)..................................................................................................196
External Pot Fill ......................................................................................................................................197
External Pot Fill Kit (776xx757)....................................................................................................................197
Alarm Beacon.........................................................................................................................................199
Alarm Beacon Assembly, 24V (782xx701)..................................................................................................199
Alarm Beacon Replacement Bulb................................................................................................................200
Siren Element Kit (776xx762)......................................................................................................................200
Pressure Relief.......................................................................................................................................200
Pneumatic Pressure Relief Kit (707xx212)..................................................................................................200
Relief Valve Assembly (594xx189)..............................................................................................................201
Pressure Monitoring ...............................................................................................................................202
Pressure Switch Kit, 50-130 PSI (481xx050)..............................................................................................202
Pressure Switch Kit, 160-400 PSI (481xx051)............................................................................................202
Pressure Switch Kit, 275-850 PSI (481xx052)............................................................................................203
Heavy Duty Pressure Gauge (786xx129)....................................................................................................203
Pressure Transducer Assembly (098xx134)...............................................................................................204
Auxiliary I/O ............................................................................................................................................205
Optional I/O HMU PCB Assembly (098xx134)............................................................................................205
Ethernet IP, Anybus Installation Kit (098xx133)..........................................................................................205
Section 11 - Warranty..........................................................................................207
Warranty Information...............................................................................................................................................207
Cold Glue Equipment and Electronic Controls.......................................................................................207
Hot Melt Units, Hoses, Valves, Guns, and Related Equipment .............................................................207
Section 12 - Service ............................................................................................ 209
Appendix A - Password Levels.............................................................................211
Appendix B - Power Requirements ...................................................................... 213
System Power Requirement Calculation - D Series Units.....................................................................................213
Appendix C - Micro SD Backup & Restore............................................................ 215
Functions..................................................................................................................................................................215
Error Codes..............................................................................................................................................................216

MM113 - D10/D16 Hot Melt Unit Table of Contents
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Appendix D - Communication Protocols-Modbus..................................................217
Appendix E - Communication Protocols-Ethernet IP .............................................227
Hot Melt Unit to EthernetIP Communication Protocol ............................................................................................227
Data Packets used for Ethernet/IP communication................................................................................................227
Send Packet (PLC) Frame......................................................................................................................227
Bit Definitions for Control Byte 0.............................................................................................................228
Command Byte 1 ....................................................................................................................................228
Data Index Byte 2....................................................................................................................................229
Channel Byte 3........................................................................................................................................229
Data Value Byte 4 and 5.........................................................................................................................230
Pump1 speed%...Pump4 speed% Byte 6 - 13........................................................................................230
Receive Packet (Melter) Frame..............................................................................................................230
Data Index Byte 2....................................................................................................................................231
Channel Byte 3........................................................................................................................................231
Channel Read Data Bytes 4 and 5 .........................................................................................................231
Channel Read Data + Bytes 6 - 15.........................................................................................................231
Current Alarm Types................................................................................................................................................232
Error Codes.............................................................................................................................................233
Examples......................................................................................................................................................233
Status Indicators .....................................................................................................................................234
Network Status LED.....................................................................................................................................234
Module Status LED.......................................................................................................................................234
Link/Activity LED...........................................................................................................................................234
Appendix F - Instruction Sheets for Option Kits ....................................................235

Table of Contents MM113 - D10/D16 Hot Melt Unit
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