VALCO MELTON D4 User manual

D4 Hot Melt Unit
Manual Number: MM147
Revision Date: 6/2018

© Valco Melton All Rights Reserved
This manual is provided with the D4 Hot Melt Unit and may be used only in accordance with the terms of purchase.
No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means,
electronic, mechanical, recording, or otherwise, without the prior written permission of Valco Cincinnati, Inc. The
information in this manual is furnished for educational purposes only, is subject to change without notice, and should
not be construed as a commitment by Valco Cincinnati, Inc.
This manual written and designed at Valco Melton, 497 Circle Freeway Drive, Suite 490, Cincinnati, Ohio 45246.
http://www.valcomelton.com
Part Number: MM147
Written and printed in the USA.
Valco Cincinnati, Inc.
497 Circle Freeway Drive
Suite 490
Cincinnati, OH 45246
Tel: [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: D4 Hot Melt Unit
complies with the following Council Directives:
Safety of Machinery: 2006/42/EC
Low Voltage Equipment: 2014/35/EU
EMC: 2014/30/EU
Reduction of Hazardous Substances (RoHS) 2011/65/EC
and conforms to the following standards:
Safety: EN60204-1:2006
EN13849-1
Risk: ISO12100:2010
EMC Emissions: EN61000-6-4:2007
EN61000-4-2
EMC Immunity: EN61000-6-2:2005
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
EN61000-4-8
EN61000-4-11
Place and Date: Cincinnati, Ohio USA
CE Mark first fixed 2006
Signature: Cincinnati, OH USA
David H. Swedes,
Vice President of
Engineering & Manufacturing
This Declaration of Conformity has been generated electronically and is legally binding without signature.

MM147 - D4 Hot Melt Unit Table of Contents
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 ...................................................................................13
Read Thoroughly Before Handling Equipment.......................................................................................................13
Symbols ...................................................................................................................................................................13
Owner Responsibilities ............................................................................................................................................14
Limitations of Use ....................................................................................................................................................14
Installation/Startup/Use Safety Information.............................................................................................................15
Shut Down Safety Information ................................................................................................................................16
Hot-Melt-Specific, General Safety Information .......................................................................................................16
What to Do if Contact with Hot Adhesive Occurs ...................................................................................17
What to Do if Inhalation of Adhesive Fumes Occurs ..............................................................................17
What to Do if Adhesive-Related Fire or Explosion Occurs .....................................................................18
Hose Safety Information ..........................................................................................................................................19
Section 3 - Basic Features ...................................................................................21
Key Features............................................................................................................................................................21
Section 4 - Installation .........................................................................................23
Choosing a Location ................................................................................................................................................23
Mounting Footprint ..................................................................................................................................24
Installation Kit...........................................................................................................................................................24
Routing Low-Voltage Leads ....................................................................................................................................24
Connecting the Electrical Power .............................................................................................................................25
Connecting the Hoses .............................................................................................................................................27
Connecting the Hot Melt Hoses to the Applicators.................................................................................................29
Wiring Diagram ........................................................................................................................................................30
Wiring Diagram - Before 5/18..................................................................................................................................31
Input/Output Connections........................................................................................................................................32
Input/Output Connections - Before 5/18 .................................................................................................................34
Section 5 - Setup .................................................................................................35
Control Panel ...........................................................................................................................................................35

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Power On/Off and Standby Mode...........................................................................................................................37
Display Contrast Adjustment...................................................................................................................................38
User Interface...........................................................................................................................................................39
Navigation............................................................................................................................................... 39
Memory Storage ..................................................................................................................................... 39
Thumbwheel vs. Single Digit Edit ........................................................................................................... 40
Entering Passwords.................................................................................................................................................41
Set Language...........................................................................................................................................................42
Set Temperature Units ............................................................................................................................................44
Programming Temperatures................................................................................................................... 45
Tank Temperature .................................................................................................................................. 46
Hose/Valve Temperature........................................................................................................................ 46
System/Pump Ready Temperature Offset .............................................................................................................48
Ready Delay Time ...................................................................................................................................................49
Over Temperature Alarm.........................................................................................................................................50
Under Temperature Alarm.......................................................................................................................................51
Maximum Temperature ...........................................................................................................................................52
Beacon/Alarm Setup................................................................................................................................................53
Beacon 2................................................................................................................................................. 55
Automatic Pump Mode ............................................................................................................................................56
Pressure Setup ........................................................................................................................................................57
Pot Fill Mode ............................................................................................................................................................60
Level Sensor Setup .................................................................................................................................................61
Hopper Feeder - Low Level Detection.................................................................................................... 61
Door Switch..................................................................................................................................61
Feeder Valve Operation ..............................................................................................................61
Filter Change Timer .................................................................................................................................................62
Clock and 7-Day Timer............................................................................................................................................62
Programming Shifts ................................................................................................................................ 63
Diagnostics...............................................................................................................................................................66
Setback ....................................................................................................................................................................67
Setback Temperature ............................................................................................................................. 67
Automatic Setback Timeout.................................................................................................................... 68
Startup Setup ...........................................................................................................................................................69
Sequential Start - Hose .......................................................................................................................... 69
History ......................................................................................................................................................................71
User Inputs and Outputs..........................................................................................................................................72
Configuration............................................................................................................................................................74
Zone Configuration ................................................................................................................................. 74
Auxiliary Zones ....................................................................................................................................... 74
Auxiliary I/O ............................................................................................................................................ 75
Pump Type ............................................................................................................................................. 75
Gramage Enable .................................................................................................................................... 75
Config Comm Menu................................................................................................................................ 76

MM147 - D4 Hot Melt Unit Table of Contents
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Pump Configuration ................................................................................................................................77
Number of Pumps........................................................................................................................77
Pump Configuration for Specific No. Pump ................................................................................77
Pump Setup Menu ..................................................................................................................................78
Encoder Setup Menu...............................................................................................................................................80
PID Setup Menu ......................................................................................................................................................81
PID Settings ............................................................................................................................................81
AutoTune Feature ...................................................................................................................................81
Memory Menu..........................................................................................................................................................82
Restoring Factory Default Settings .........................................................................................................................82
Updating 152XX746 CPU Board Software via USB Memory Stick.......................................................................82
Required Materials ..................................................................................................................................82
Procedure................................................................................................................................................82
Hot Melt CPU uTasker Bootloader (119XX301) Error Codes.................................................................84
Initialization Instructions...........................................................................................................................................85
Navigating the Setup Wizard ..................................................................................................................85
Adjusting the Display...............................................................................................................................85
Selecting the Language ..........................................................................................................................85
Configuring the Unit Type .......................................................................................................................86
Selecting the Communication Protocol ...................................................................................................86
Selecting the RTD type ...........................................................................................................................87
Selecting the Number of Pumps .............................................................................................................87
Selecting the Number of Hose Outlets....................................................................................................87
Selecting the Temperature Units ............................................................................................................88
Selecting the Pattern Control ..................................................................................................................88
Finishing the Configuration .....................................................................................................................88
Adjusting the Pressure Control Valve .....................................................................................................................89
Adjusting the Single-Stage Relief Valve .................................................................................................89
Gramage Feature ....................................................................................................................................................90
D Series Variable Frequency Drive Configuration (If Equipped) ...........................................................................91
Before 5/18..............................................................................................................................................92
Section 6 - Operation...........................................................................................93
Start the Unit ............................................................................................................................................................93
Temperature ............................................................................................................................................................94
Setpoint and Actual Temperature ...........................................................................................................94
Temperature Status LEDs ......................................................................................................................94
Pump Operation.......................................................................................................................................................95
Pump On/Off Key ....................................................................................................................................95
Pump Status Key ....................................................................................................................................95
Fixed Speed Unit .........................................................................................................................95
Variable Speed Unit.....................................................................................................................96
Clock On/Off.............................................................................................................................................................96
Setback ....................................................................................................................................................................97
Automatic Setback ..................................................................................................................................97
Pot Fill - External Low Level Detection ...................................................................................................................98
Hopper Feeder - Internal Low Level Detection.......................................................................................................98
Beacon Alarm ..........................................................................................................................................................98

Table of Contents MM147 - D4 Hot Melt Unit
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External Input...........................................................................................................................................................98
Filling the Tank.........................................................................................................................................................99
Section 7 - Maintenance ......................................................................................101
General.....................................................................................................................................................................101
Cleaning the Exterior of the Unit .............................................................................................................................101
Changing the Adhesive ...........................................................................................................................................102
Flushing the System ................................................................................................................................................102
Parts Replacement ..................................................................................................................................................104
Changing Fuses ..................................................................................................................................... 104
Changing the Filter ................................................................................................................................. 105
Section 8 - Troubleshooting and Repair ...............................................................107
Section 9 - Specifications ....................................................................................109
General.....................................................................................................................................................................109
Dimensions ..............................................................................................................................................................110
Section 10 - Part Number List .............................................................................. 111
How to Order Parts ..................................................................................................................................................111
D4 Unit .....................................................................................................................................................................112
D4 Unit, Fixed speed, 2 exit (776xx887) ................................................................................................ 114
D4 Unit, Fixed speed, 4 exit (776xx888) ................................................................................................ 115
D4 Unit, Variable speed, 2 exit (776xx889)............................................................................................ 116
D4 Unit, Variable speed, 4 exit (776xx890)............................................................................................ 117
D4 Unit, Variable speed, 2 exit (776xx889) - before 5/18 ...................................................................... 118
D4 Unit, Variable speed, 4 exit (776xx890) - before 5/18 ...................................................................... 119
D4 Base Unit (776xx392) ........................................................................................................................................120
D4 Base Unit (776xx392) - before 5/18.................................................................................................. 123
Installation Kit (091xx734) .......................................................................................................................................125
Option Kits................................................................................................................................................................126
AutoFeed ................................................................................................................................................ 126
Vacuum Feeder Assembly - 776xx305 .......................................................................................126
Pump Control.......................................................................................................................................... 128
Cable Assembly Handgun Pump Control (029xx552)................................................................128
Pump Kit, Standard Width (561xx216)........................................................................................129
Pump Kit, Half Width (561xx220) ................................................................................................129
Internal Level Sensors............................................................................................................................ 130
Internal Low-Level Sensor Kit (776xx892) ..................................................................................130
External Pot Fill ...................................................................................................................................... 131
External Pot Fill Kit (776xx757) ...................................................................................................131
Alarm Beacon ......................................................................................................................................... 133
Alarm Beacon Assembly, 24V (782xx701) .................................................................................133
Alarm Beacon Replacement Bulb ...............................................................................................134
Siren Element Kit (776xx762)......................................................................................................134
Pressure Relief ....................................................................................................................................... 135
Pneumatic Pressure Relief Kit (707xx212) .................................................................................135
Relief Valve Assembly (594xx189)..............................................................................................136
Pressure Monitoring ............................................................................................................................... 137

MM147 - D4 Hot Melt Unit Table of Contents
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Pressure Switch Kit, 50-130 PSI (481xx050)..............................................................................137
Pressure Switch Kit, 160-400 PSI (481xx051)............................................................................138
Pressure Switch Kit, 275-850 PSI (481xx052)............................................................................138
Heavy Duty Pressure Gauge (786xx129)...................................................................................138
Pressure Transducer Assembly (521xx019)...............................................................................139
Auxiliary I/O.............................................................................................................................................140
Optional I/O HMU PCB Assembly (098xx134) ...........................................................................140
Ethernet IP Kit (098xx133) ..........................................................................................................140
24V VDC Relay Kit (776xx537)...................................................................................................140
Section 11 - Warranty ..........................................................................................141
Warranty Information ...............................................................................................................................................141
Cold Glue Equipment and Electronic Controls .......................................................................................141
Hot Melt Units, Hoses, Valves, Guns, and Related Equipment..............................................................141
Section 12 - Service.............................................................................................143
Appendix A - Password Levels.............................................................................145
Appendix B - Power Requirements.......................................................................147
System Power Requirement Calculation - D Series Units .....................................................................................147
Appendix C - Instruction Sheets for Option Kits....................................................149
Appendix D - Micro SD Backup & Restore ............................................................151
Functions..................................................................................................................................................................151
Error Codes..............................................................................................................................................................152
Appendix E - Communication Protocols-Modbus ..................................................153
Communication Specifications ................................................................................................................................153
Hardware Considerations........................................................................................................................................153
Parameter List..........................................................................................................................................................154
Appendix F - Communication Protocols-Ethernet IP .............................................163
Hot Melt Unit to EthernetIP Communication Protocol ............................................................................................163
Data Packets used for Ethernet/IP communication................................................................................................163
Send Packet (PLC) Frame......................................................................................................................163
Bit Definitions for Control Byte 0 .............................................................................................................164
Command Byte 1 ....................................................................................................................................164
Data Index Byte 2....................................................................................................................................165
Channel Byte 3........................................................................................................................................165
Data Value Byte 4 and 5 .........................................................................................................................166
Pump1 speed%...Pump4 speed% Byte 6 - 13........................................................................................166
Receive Packet (Melter) Frame ..............................................................................................................166
Data Index Byte 2....................................................................................................................................167
Channel Byte 3........................................................................................................................................167
Channel Read Data Bytes 4 and 5 .........................................................................................................167
Channel Read Data + Bytes 6 - 15 .........................................................................................................167
Current Alarm Types................................................................................................................................................168
Error Codes.............................................................................................................................................169
Examples .....................................................................................................................................169
Status Indicators .....................................................................................................................................170
Network Status LED ....................................................................................................................170

Table of Contents MM147 - D4 Hot Melt Unit
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Module Status LED......................................................................................................................170
Link/Activity LED ..........................................................................................................................170