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
5
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

Table of Contents MM113 - D10/D16 Hot Melt Unit
6
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
7
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
8
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
9
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
10

MM113 - D10/D16 Hot Melt Unit Section 1 - Introduction
11
Section 1 - Introduction
ValcoMelton, a division of Valco Cincinnati, Inc., has prepared this manual as an aid for installing, operating, and
servicing the D10/D16 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 D10/D16 hot melt unit is a medium-volume system designed to melt and pump thermoplastic adhesives. The
D10/D16 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 six (6) 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 MM113 - D10/D16 Hot Melt Unit
12
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.

MM113 - D10/D16 Hot Melt Unit Section 1 - Introduction
13
S Number Configuration - Continued
Selection Number
–
D10/D16 Hot Melt Unit
Unit Code Code Description Code Description
D10/D16 Base unit prefix
Feature 1
Number of Exits
2S 2 exits 4S 4 Exits
6S 6 exits
Feature 2
Alternate Lid
0 None A Auto feed included
B Split lid assembly C Split lid assembly w/hose support
D Split lid assembly w/#6 hose fitting
Feature 3
Pump Enable
0 None 1 Pump control included 1 handgun
2 Pump control included 2 handguns
Feature 4
Motor/Pump Type
SF 3.18cc/rev pump, fixed speed SV 3.18cc/rev pump, variable speed
HF 1.59cc/rev pump, fixed speed HV 1.59cc/rev pump, variable speed
DF 6.36cc/rev pump, fixed speed DV 6.36cc/rev pump, variable speed
QF 12.72cc/rev pump, fixed speed QV 12.72cc/rev pump, variable speed
Feature 5
Hose Option –
Single for single
handgun kit
00 None J1 AD41, 230V 6ft, jetting
J2 AD41, 230V 8ft, jetting J3 AD41, 230V 10ft, jetting
J4 AD41, 230V 12ft, jetting J5 AD41, 230V16ft, jetting
S1 AD41, 230V 6ft, spray S2 AD41, 230V 8ft, spray
S3 AD41, 230V 10ft, spray S4 AD41, 230V 12ft, spray
S5 AD41, 230V 16ft, spray A1 AD31, 230V 6ft, includes handgun
A2 AD31, 230V 8ft, includes handgun A3 AD31, 230V 10ft, includes handgun
A4 AD31, 230V 12ft, includes handgun A5 AD31, 230V 16ft, includes handgun
Feature 6
Handgun Option -
Single
00 None 01 Handgun, bottom feed, jetting
02 Handgun, top feed, jetting 03 Handgun, bottom feed, spray
04 Handgun, top feed, spray 05 Handgun, bottom feed, wide spray
06 Handgun, top feed, wide spray
Feature 7
Pattern Control 00 None S6 Integrated pattern control included
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 05 High level sensor w/beacon
06 High level sensor w/beacon & alarm 07 Low & high level sensors
08 Low & high level sensors w/beacon 09 Low & high level sensors w/beacon &
alarm
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 T1 Pressure transducer
Feature 11
Communication
Options
0 None Y Auxiliary I/O board included
4 Ethernet IP included

Section 1 - Introduction MM113 - D10/D16 Hot Melt Unit
14
S Number Configuration - Continued
Before 12/17
Selection Number
–
D10/D16 Hot Melt Unit
Unit Code Code Description Code Description
D10/D16 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
F6 Fixed speed, 6 exit V6 Variable speed, 6 exit
Feature 2
Alternate Lid
0 None A Auto feed included
B Split lid assembly C Split lid assembly w/hose support
D Split lid assembly w/#6 hose fitting
Feature 3
Pump Enable
0 None 1 Pump control included 1 handgun
2 Pump control included 2 handguns
Feature 4
Motor/Pump Type
SC 3.18cc/rev pump, std pump HD coupling ST 3.18cc/rev pump, variseal pump HD
coupling
HS 1.54cc/rev pump, std pump HC 1.54cc/rev pump, std pump HD coupling
HT 1.54cc/rev pump, variseal pump HD
coupling VS 6.36cc/rev pump, std pump
VC 6.36cc/rev pump, std pump HD coupling VT 6.36cc/rev pump, variseal pump HD
coupling
Feature 5
Hose Option –
Single for single
handgun kit
00 None J1 AD41, 230V 6ft, jetting
J2 AD41, 230V 8ft, jetting J3 AD41, 230V 10ft, jetting
J4 AD41, 230V 12ft, jetting J5 AD41, 230V16ft, jetting
S1 AD41, 230V 6ft, spray S2 AD41, 230V 8ft, spray
S3 AD41, 230V 10ft, spray S4 AD41, 230V 12ft, spray
S5 AD41, 230V 16ft, spray A1 AD31, 230V 6ft, includes handgun
A2 AD31, 230V 8ft, includes handgun A3 AD31, 230V 10ft, includes handgun
A4 AD31, 230V 12ft, includes handgun A5 AD31, 230V 16ft, includes handgun
Feature 6
Handgun Option -
Single
00 None 01 Handgun, bottom feed, jetting
02 Handgun, top feed, jetting 03 Handgun, bottom feed, spray
04 Handgun, top feed, spray 05 Handgun, bottom feed, wide spray
06 Handgun, top feed, wide spray
Feature 7
Pattern Control 00 None S6 Integrated pattern control included
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 05 High level sensor w/beacon
06 High level sensor w/beacon & alarm 07 Low & high level sensors
08 Low & high level sensors w/beacon 09 Low & high level sensors w/beacon &
alarm
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

MM113 - D10/D16 Hot Melt Unit Section 2 - Safety and Use
15
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 MM113 - D10/D16 Hot Melt Unit
16
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.

MM113 - D10/D16 Hot Melt Unit Section 2 - Safety and Use
17
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.

Section 2 - Safety and Use MM113 - D10/D16 Hot Melt Unit
18
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.

MM113 - D10/D16 Hot Melt Unit Section 2 - Safety and Use
19
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.

Section 2 - Safety and Use MM113 - D10/D16 Hot Melt Unit
20
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 CO2fire extinguisher at the base of the flames.
•Aim a dry-powder fire extinguisher at the base of the flames.