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

Table of Contents MM147 - D4 Hot Melt Unit
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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

MM147 - D4 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 D4 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 hot melt unit is a medium-volume system designed to melt and pump thermoplastic adhesives. The D4 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 four (4) 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 MM147 - D4 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.
Selection Number – D10/D16 Hot Melt Unit
Unit Code Code Description Code Description
D4 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
Feature 2
Alternate Lid 0 None 1 Auto feed included
Feature 3
Pump Enable
0 None 1 Pump control included 1 handgun
2 Pump control included 2 handguns
Feature 4
Motor/Pump Type ST 3.18cc/rev pump, variseal pump HT 1.54cc/rev pump, variseal pump
Feature 5
Not Used 00 None
Feature 6
Not Used 00 None
Feature 7
Pattern Control 00 None
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 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 P1 Pressure switch 50-130psi
P2 Pressure switch 160-400psi P3 Pressure switch 275-850psi
P4 Heavy duty pressure gauge T1 Pressure transducer
Feature 11
Auxiliary I/O
Board
0 None Y Auxiliary I/O board included
4 Ethernet IP included

MM147 - D4 Hot Melt Unit Section 2 - Safety and Use
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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 MM147 - D4 Hot Melt Unit
14
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.

MM147 - D4 Hot Melt Unit Section 2 - Safety and Use
15
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 MM147 - D4 Hot Melt Unit
16
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.

MM147 - D4 Hot Melt Unit Section 2 - Safety and Use
17
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 MM147 - D4 Hot Melt Unit
18
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.

MM147 - D4 Hot Melt Unit Section 2 - Safety and Use
19
Hose Safety Information
DO NOT DO
Do not use bindings, wire
ties, or unapproved
fasteners around the
hoses.
Do use approved wrapping
(P/N 775xx827), making
sure the wrapping is slightly
snug but not tight.
Do not place hoses close
together.
Do allow at least 2 inches
(5.1 cm) between hoses for
proper ventilation.
Do not bend hoses
sharply. Do not allow kinks
or indentations in the
hoses.
Do use a minimum bend
radius of 10 inches for a 20-
inch diameter coil hose.
Do not use unapproved
hooks to hang hoses. Do
not wrap hoses over or
around objects.
Do use a hose hanging kit
(P/N 781xx827).
Do not use the “one
handed/one wrench”
technique to attach or
remove hoses. Do not
wrench on any surface
other than the large
hexagon swivel nuts.
Do use two hands and two
wrenches to tighten or
loosen connections on
hoses. Do wrench only on
large hexagon swivel nuts.
Do not allow hoses to rub
against objects or to come
into contact with sharp
edges or points.
Do wrap the hoses in
approved padding (P/N
795xx549) if the hoses must
be installed where they will
come into contact with
objects.
Do not use worn,
damaged, or bent hoses.
Do inspect all hoses
regularly for damage and/or
wear and replace damaged
or worn hoses immediately.

Section 2 - Safety and Use MM147 - D4 Hot Melt Unit
20