VALCO MELTON D4-E User manual

D4-E Hot Melt Unit
Manual Number: MM101
Release Date: 9/2009
Software Revision: C018

Declaration of conformity
The product:
Model no.:
Serial no.:
Year of manufacture:
Described in the enclosed documentation is in conformity with:
Directive 98/37/EC of 22 June 1998 relating to the approximation of the laws
of the Member States relating to machinery, combining in a single text
Directives 89/392/EEC of 14 June 1989, 91/368/EEC of 20 June 1991,
93/44/EEC of June 14, 1993 and 93/68/EEC of 22 July 1993.
Directive 73/23/EEC of 19 February 1973 relating to electric equipment.
Directive 89/336/EEC of 3 May 1989 relating to electromagnetic compatibility.
Directive 93/68/EEC of 22 July 1993, amending Directive 73/23/EEC, and
Directive 89/336/EEC.
within the scope of the specifications indicated in the chapter describing the equipment
with a B1 risk level. Since it is intended to form part of a set of machines which, to obtain
a result, are arranged and connected to perform together, it cannot be operated until the
set of machines has been declared in conformity with the applicable Directives by the
person responsible forthe final assembly.
Orcoyen, on :_____________
Signed.:______________________
Gonzalo Marco, Managing Director
VALCO MELTON S.L.U. Pol. Ind. Agu tino C/G 34 3116 0
TEL: [phone] Fax: [phone] melto[email protected]
www.valcomelton.com
ORCOYEN, NAVARRA (SPAIN)

APPLICATOR SERIAL
NUMBER
:
USER:...........................................................................................................................................
......
C NTACT:...................................................................................................................................
.......
ADDRESS:..........................................................................................TELEPH NE
:.......................
DISTRIBUT R:.........................................................................................................................
.......
C NTACT:................................................................................................................................
.......
EM:..........................................................................................................................................
.......
ADDRESS:.................................................................................................................................
......
GUARANTEE CARD
APPLICATOR SERIAL
NUMBER:
CONTROL REGISTRATION
C NTR L : .................................................................
DATE: .............................................................................
ELECTRIC CHECK: ❏
C NTR L B ARD CHECK: ❏
TEMPERATURE C NTR L CHECK 150/180°C: ❏
HYDRAULIC CHECK (100 bar): ❏
PNEUMATIC CHECK: ❏

MM101 – D-4E HOT MELT UNIT 4
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
TABLE OF CONTENTS
Section 1 – Introduction 7
Description 7
Section 2 – Safety Information 8
General Information 8
Warnings 8
Cautions 10
What to Do if Contact with Hot Adhesive Occurs 10
What to Do if Adhesive-Related Fire or Explosion Occurs 10
What to Do if Inhalation of Adhesive Fumes Occurs 11
Section 3 - Basic Features 12
Key Features 12
Section 4 - Installation 13
Choosing a Location 13
Mounting Footprint 14
Routing Low-Voltage Leads 15
Connecting the Electrical Power 15
Connecting the Hoses 19
Connecting the Hot Melt Hoses to the Applicators 23
Installing the Pneumatic Pressure Relief Valve Option 25
Wiring Diagram 27
Customer Connections 28
Section 5 – Setup 30
Control Panel 30
Power On/Off and Standby Mode 32
Navigation 33
Memory Storage 33
Editing 34
Thumbwheel vs. Single Digit Edit 34
Entering Passwords 35
Set Language 36
Set Temperature Units 38
Programming Temperaturas 39
Temperature Screens 39
Tank Temperature 40
Hose/Valve Temperature 41
System Ready Temperatura 43
Ready Delay Time 44
Over Temperature Alarm 45
Under Temperature Alarm 46
Maximum Temperature 47
Automatic Pump Mode 48
Setback Temperature 49

MM101 – D-4E HOT MELT UNIT 5
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
Automatic Setback Timeout 50
Sequential Start – Hose 51
Sequential Start – Valve 52
Peripherals 53
History 54
Diagnostics 55
Clock and 7-Day Timer 56
Set Day and Time 56
Shift Times/Setback Times 58
Moving Through the Shift Time/Day Screens 61
Adjusting the Pressure Control Valve 62
Adjusting the Single-Stage Relief Valve 62
Restoring Factory Default Settings 63
Section 6 – Operation 64
Start the Unit 64
Monitoring the Unit 67
Setpoint and Actual Temperatures 67
Status LEDs 68
Clock On/Off 69
Pump On/Off 69
Setback On/Off 70
Filling the Tank 71
Section 7 – Maintenance 72
General 72
Cleaning the Exterior of the Unit 73
Changing the Adhesive 73
Flushing the System 73
Parts Replacement 75
Changing Fuses 75
Changing the Filter 78
Section 8 – Troubleshooting 79
Sectio n 9 – Specifications 81
Dimensions 82
Section 10 - Part Number List 83
D4-E Unit 83
775xx850 (120VAC) 83
775xx851 (240VAC) 83
Base Unit (775xx852) 84
Tank Assembly 86
Manifold Assembly 87
Motor Assembly 87
Front Panel Assembly 88
Central Cover Assembly 89
Rear Panel Assembly 90

MM101 – D-4E HOT MELT UNIT 6
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
Section 11 – Warranty 91
Hot Melt Units, Hoses, Valves, and Related Equipment 91
Section 12 – Service 92
Appendix A - Password Levels 93
Appendix B - Power Requirements 94
System Power Requirement Calculation - 120VAC D4-E Unit 94
System Power Requirement Calculation - 240VAC D4-E Unit 95
Appendix C - System Map 96
System Map 96
Main Programming Buttons - Setup Button and Temperature Button 96
Temperature Button Screens 97
Setup Button Sub Menu - Unlock/Lock* 98
Setup Button Sub Menu - System* 99
Setup Button Sub Menu - Clock* 100
Setup Button Sub Menu - PID Temp* 101
Setup Button Sub Menu - Setback* 102
Setup Button Sub Menu - Startup* 102
Setup Button Sub Menu - Peripherals* 103
Setup Button Sub Menu - History* 103
Setup Button Sub Menu - Diagnostics* 103

MM101 – D-4E HOT MELT UNIT 7
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
SECTION 1 – INTRODUCTION
ValcoMelton, a division of Valco Cincinnati, Inc., has prepared this manual
as an aid for installing, operating, and servicing the D4-E hot melt unit. It
also contains a list of part numbers for replacement parts. If you need more
information, contact your ValcoMelton representative.
Description The D4-E hot melt unit is a low-volume system designed to melt and pump
thermoplastic adhesives. The D4-E unit features a precision electronic
temperature control, a digital multi-zone temperature display, an electric
motor-driven gear pump, and an adjustable pressure control.
Features and capabilities include:
oPrecision electronic temperature control
oCapacity of up to (2) hoses and guns
oPositive displacement electric motor-driven gear pump
oAdjustable pressure control
oIntegrated over-temperature protection
oUser selectable inputs and output

MM101 – D-4E HOT MELT UNIT 8
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
SECTION 2 - SAFETY INFORMATION
General
Information It is the purchaser’s responsibility to ensure that all local, county, state, and
national codes, regulations, rules, and laws relating to safety and safe
operating conditions are met and followed.
The best safeguard is trained personnel. The purchaser is responsible for
providing personnel who are adequately trained to install, operate, and
maintain components and systems.
This section contains information that is essential to the safety of personnel.
Safety information is included throughout the rest of the manual as well.
The following safety conventions are used to indicate potential safety
hazards.
Warning! This symbol indicates the presence of un-insulated
dangerous voltage within the product’s enclosure. This
voltage may cause electrical shock or fire. FAILURE TO
OBSERVE WARNING MAY RESULT IN DEATH,
PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE
Warning! This convention is used to alert the user to important
installation, operation, and/or maintenance information.
FAILURE TO OBSERVE WARNING MAY RESULT IN
DEATH, PERSONAL INJURY, AND/OR EQUIPMENT
DAMAGE.
Caution! This convention is used to alert the user to important
installation, operation, and/or maintenance information.
FAILURE TO OBSERVE CAUTION MAY CAUSE
EQUIPMENT DAMAGE.
Warnings All personnel involved with the installation, operation, and maintenance of
the equipment must read and thoroughly understand the following
warnings:
Warning! Disconnect all power before opening the control
OTHERWISE, DEATH OR PERSONAL INJURY COULD
OCCUR. Only qualified personnel should open and service
the control.
Warning! Promptly repair or replace all worn or damaged electrical
wiring and equipment wires. OTHERWISE, DEATH OR
OCCUR. Only qualified personnel should open and service.

MM101 – D-4E HOT MELT UNIT 9
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
Warning! Properly route all electrical wires. OTHERWISE, DEATH
PERSONAL INJURY, OR DAMAGE TO THE MOVING
PARTS OF THE MACHINE MAY OCCUR.
Warning! 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! Keep pump cover and electrical enclosures closed except
during setup, service, and checkout procedures.
OTHERWISE, DEATH OR PERSONAL INJURY COULD
OCCUR.
Warning! Promptly repair or replace all worn or damaged parts.
OTHERWISE, PERSONAL INJURY OR EQUIPMENT
DAMAGE COULD OCCUR
Warning! Always wear insulated gloves and proper eye protection
when working around hot-melt equipment. A protective
screen around the face is also recommended.
OTHERWISE, DEATH OR PERSONAL INJURY COULD
OCCUR.
Warning! Purge the fluid pressure from the system before
disconnecting any part of the system. OTHERWISE, DEATH
OR PERSONAL INJURY COULD OCCUR.
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! The hot-melt unit should be installed so that it can be turned
off at a location away from the hot-melt unit. OTHERWISE
DEATH, PERSONAL INJURY, OR EQUIPMENT DAMAGE
COULD OCCUR.

MM101 – D-4E HOT MELT UNIT 10
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
Cautions All personnel involved with the installation, operation, and maintenance of
the equipment must read and thoroughly understand the following cautions:
Caution! Never hose or steam-clean the unit. If the surrounding area
is cleaned in this manner, protect the unit by covering it with
plastic or other waterproof material. OTHERWISE,
DAMAGE TO EQUIPMENT COULD OCCUR.
Caution! Do not bend hot-melt hoses less than an 18-inch (460 mm)
radius. OTHERWISE, EQUIPMENT DAMAGE COULD
OCCUR.
Caution! Place Material Safety Data Sheets for the adhesive near the
unit. OTHERWISE, DAMAGE TO EQUIPMENT COULD
OCCUR.
Warning! Place Material Safety Data Sheets for the adhesive near the
unit. OTHERWISE, DAMAGE TO EQUIPMENT COULD
OCCUR.
If hot adhesive comes in contact with the skin, do the following:
1. Immediately immerse the contacted area in clean, cold water.
2. Cover the affected area with a clean, wet compress and see a
physician immediately
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
What to Do if
Contact with
Hot Adhesive
Occurs
What to Do if
Adhesive
Related Fire or
Explosion
Occurs
It is recommended that a source of
clean, cold water be provided near
the hot-melt work area

MM101 – D-4E HOT MELT UNIT 11
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
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. Fight the fire in one of the following ways:
•Smother the fire with a fire blanket.
•Aim a CO2 fire extinguisher at the base of the flames
•Aim a dry-powder fire extinguisher at the base of the
flames
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 a qualified medical authority.
What to Do if
Inhalation of
Adhesive
Fumes Occurs

MM101 – D-4E HOT MELT UNIT 12
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
SECTION 3 - BASIC FEATURES
Key Features
Item Name
1 Power switch
2 Control panel
3 Electrical enclosure door
4 Tank lid
5 Manifold
6 Filter
7 Pressure relief valve
8 Hose/Valve electrical receptacles
9 Hose hydraulic/fluid fittings
10 Data plate

MM101 – D-4E HOT MELT UNIT 13
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
SECTION 4 - INSTALLATION
The D4-E hot melt unit is assembled at the factory. However, the power
and the glue hoses must be connected by the customer. This section
contains instructions for making the necessary connections.
While choosing a location for the unit, keep in mind that:
•Service personnel will need access to the left and right sides of the
unit for electrical service, and the back of the unit for changing the
glue hoses and filter.
•The operator needs easy access to the front operator panel.
•If the unit will not be moved from one location to another, it should
be screwed or bolted to a suitable stable, flat, level surface.
•The unit should have clearance around the outside of the case to
allow air to circulate freely around it.
•The unit should have clearance above the top of the unit so it may
be filled easily without obstruction to the operator.
•The location should be near the glue station so that the glue hoses
can be routed to the applicators in as straight a line as possible.
•The location for the unit should be clean. Dirt in the glue tank
causes clogging of the applicator nozzles.
•The unit should be protected from high and low ambient
temperatures, as well as from rapid changes in ambient
temperature.
•The unit must be protected from condensate and water. The unit
must be protected from strong vibrations.
•The tank lid must be able to open fully back so there is no danger
of it falling onto operator’s hands while filling.
Choosing a
Location

MM101 – D-4E HOT MELT UNIT 14
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
Mounting Footprint

MM101 – D-4E HOT MELT UNIT 15
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
Warning! Failure to observe could result in personal injury, death, or
damage to equipment.
When routing low-voltage leads, follow these guidelines:
•Do not route low-voltage leads in the same conduit as wires
carrying a high-current load.
•Do not route low-voltage leads adjacent to, or across wires carrying
a high-current load. If low-voltage leads must cross or run parallel
to wires carrying high current, keep the leads at least 6" (152 mm)
from high-current wires.
•Do not splice or solder leads.
•Trim leads to the required length. Leads should be only as long as
necessary for installation.
•All wiring should be in conduits or wireways.
Warning! Electrical connections should be made only by experienced
service personnel! Failure to observe could result in
personal injury, death, or damage to equipment.
When connecting the supply of electrical power, follow these guidelines:
•Connect the unit to a “clean” supply of electrical power. Use a
dedicated circuit if posible.
Routing Low-
Voltage Leads
Connecting
the Electrical
Power
If a dedicated circuit is not available,
do not connect the unit to a circuit
that supplies high-amperage
equipment— use another circuit such
as a lighting circuit. Otherwise,
equipment may not function properly

MM101 – D-4E HOT MELT UNIT 16
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
Warning! The external power source must be turned off before
connecting power to the unit! Failure to observe could result
in personal injury, death, or damage to injury, death, or
damage to equipment.
Warning! Only experienced service personnel should connect power
to the unit! Failure to observe could result in personal injury,
death, or damage to equipment.
Warning! The use of an earth-leakage or ground-fault power Electrical
connections should be made only by experienced service
personnel! Failure to observe could result in personal injury,
death, or damage to equipment.
The D4-E hot melt units are configured at the factory to use one of the
following power sources:
•110/120VAC 20 Amp single phase power with ground.
•200/240VAC 20 Amp single phase power with ground.
The voltage configuration is located on the data plate of each unit. Always
check the data plate before hooking up power to the unit.
D4-E units are shipped from the factory with an attached power cable. Units
configured for 120V operation have a power cable with a molded plug that
can be connected to a 120V 20 Amp receptacle. Units configured for 240V
operation have a power cable with flying leads that can be connected to a
240V 20 Amp circuit with disconnect.
The unit may also be used in a static type of installation. In this case, the
system should be connected via a suitable type of flexible conduit from a
supply isolator and ground-fault power breaker. The supply should be clean
and free from excess interference from other machines.
If it is necessary to use a power cable that has NOT been supplied with the
unit, you MUST follow these steps to connect power to the unit, or personal
injury and/or damage to the unit may result.
1. Open the electrical enclosure door by unlocking the two spring cam
catches on the top of the unit.
2. Run the power cable through the cord grip in the chassis of the
unit.
3. Connect the power to the terminals marked L1, L2, and GND.

MM101 – D-4E HOT MELT UNIT 17
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
“E” Series 5 Zones Borrad
151xx616 (120V) Rev D

MM101 – D-4E HOT MELT UNIT 18
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
“E” Series 5 Zone Borrad
151xx606 (240V) Rev D

MM101 – D-4E HOT MELT UNIT 19
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
Warning! Never disconnect the hot melt hoses from a running unit.
Hot melt is under high pressure. Turn off the pump. Shut off
power of the unit, and actuate the gun to relieve residual
pressure before removing the hoseElectrical connections
should be made only by experienced service personnel!
Failure to observe could result in personal injury, death, or
damage to equipment.
Caution! Electrical connections should be made only by experienced
service personnel! Failure to observe could result in
personal injury, death, or damage to equipment.
When routing and installing heated hoses, follow these guidelines:
•Avoid creating sharp corners and edges.
•Do not bend hoses sharper than 18" (460 mm) radius.
•Do not group heated hoses so that they contact one another.
•Avoid positioning hoses where they can be stepped on or have a
chance of being crushed or cut.
•Avoid the use of unnecessarily long hoses where the hose is
looped or curled on the floor. Excess twisting of the hose can cause
irreparable damage to it.
•Maintain separation between hoses to avoid hot spots.
Connecting
the Hoses
Connecting
the Hoses

MM101 – D-4E HOT MELT UNIT 20
VALCO MELTON S.L.U. Pol. Ind. Agustinos C/G 34 3116 0 O COYEN, NAVA A
TEL: [phone] Fax: [phone] melt[email protected] www.valcomelton.com
To connect the hot melt hoses to the unit, follow these steps:
1. Using a pair of wrenches, one on the fluid outlet fitting and
the other on the fluid cap, remove the protective caps from
the fluid outlet fittings.
2. Ensure that the fluid outlet fitting is tight into the machine.
3. Ensure that the fluid outlet ports are clean.
4. Select the end of the glue hose that has the lead assembly
with the male electrical connector (Figure 5-1).