VALCO MELTON DD-1 User manual

DD-1 PUMP MANUALDD-1 PUMP MANUAL
DD-1 PUMP MANUALDD-1 PUMP MANUAL
DD-1 PUMP MANUAL
For Pumps Built after 09/2006For Pumps Built after 09/2006
For Pumps Built after 09/2006For Pumps Built after 09/2006
For Pumps Built after 09/2006
Manual Number: MS013
Release Date: 2/2017

© Valco Cincinnati, Inc. All Rights Reserved.
This manual is furnished with DD-1 pumps built after 09/2006 and may be used or copied 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 was written and designed at Valco Cincinnati, Inc., 411 Circle Freeway Drive, Cincinnati, Ohio
45246.
Part Number: MS013
Printed in the USA
Valco Cincinnati, Inc.Valco Cincinnati, Inc.
Valco Cincinnati, Inc.Valco Cincinnati, Inc.
Valco Cincinnati, Inc.
497 Circle Freeway Drive
Suite 490
Cincinnati, OH 45246
Tel: [phone]
Fax: [phone]
Email: [email protected]
Web: http://www.valcocincinnatiinc.com
Valco Cincinnati LimitedValco Cincinnati Limited
Valco Cincinnati LimitedValco Cincinnati Limited
Valco Cincinnati Limited
Hortonwood 32
Telford, TFI 7YN, England
Tel: [phone]
Fax: [phone]
Email: [email protected]
Web: http://www.valco.co.uk
Valco Cincinnati GmbHValco Cincinnati GmbH
Valco Cincinnati GmbHValco Cincinnati GmbH
Valco Cincinnati GmbH
Bonnerstrasse 349
40589 Dusseldorf-Benrath, Germany
Tel: [phone]
Fax: [phone]
Melton S.L.U.Melton S.L.U.
Melton S.L.U.Melton S.L.U.
Melton S.L.U.
Pol. Industrial Agustinos
calle G, n. 34
31160 Orcoyen, Navarra, Spain
Tel: [phone]
Fax: [phone]
Valco Melton FranceValco Melton France
Valco Melton FranceValco Melton France
Valco Melton France
Technoparc des Hautes Faventines
32 Rue Jean Bertin
26000 Valence
Tel: [phone]
Fax: [phone]

Declaration of ConformityDeclaration of Conformity
Declaration of ConformityDeclaration of Conformity
Declaration of Conformity
(According to EN 45014)
This Declaration of Conformity has been generated electronically and is legally binding without signature
Manufacturer: Valco Melton
A division of Valco
Cincinnati, Incorporated
411 Circle Freeway Drive
Cincinnati, OH 45246
USA
Authorized Representatives in
Europe:
Valco Cincinna ti, Ltd.
Unit 7-8
Hortonwood 32
Telford TF1 7YN
England
Melton S.L.U
Pol. Industrial
Agustinos
calle G, n. 34
31160 Orcoye
Navarra, Spain
declares that the product:
Product Name: DD-1 Pump
(built after 9/2006)
complies with t he following Council Directives:
Safety of M achinery: 2006/42/EC
Low Voltage Equipmen t: 2006/95/EC
EMC: 2004/108/EC
and conforms to the following standards:
Safety: EN60204-1:2006
EN13849-1
Risk: EN14121-1:2007
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: David H. Swedes,
Director of Engineering &
Manufacturing

TOC-1Valco Cincinnati, Inc.
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTSTABLE OF CONTENTS
TABLE OF CONTENTS
Section 1 - Introduction.................................................. 1-1
Section 2 - Safety and Use ............................................. 2-1
Read Thoroughly Before Handling Equipment ........................................ 2-1
Symbols...................................................................................................... 2-1
Owner Responsibilities.............................................................................. 2-3
Limitations of Use ...................................................................................... 2-4
Installation/Startup/Use Safety Information............................................. 2-4
Shut Down Safety Information ................................................................. 2-5
Hot-Melt-Specific, General Safety Information ......................................... 2-6
What to Do if Contact with Hot Adhesive Occurs ........................ 2-7
What to Do if Inhalation of Adhesive Fumes Occurs ................... 2-7
What to Do if Adhesive-Related Fire or Explosion Occurs.......... 2-8
Hose Safety Information............................................................................ 2-9
Diaphragm Pump/Toxic Fluids Safety ..................................................... 2-10
Section 3 - Wiring Guidelines........................................ 3-1
Routing Low-Voltage Leads ...................................................................... 3-1
Connecting the Electrical Power ............................................................... 3-1
Section 4 - Basic Features.............................................. 4-1
DD-1 PumpAssembly (pumps built after 09/2006) .................................. 4-1
PCB Assembly ........................................................................................... 4-2
Light Sequence........................................................................................... 4-3
Section 5 - Installation.................................................... 5-1
Power Requirements ................................................................................. 5-1
Power Connections ................................................................................... 5-1
Power Cables.................................................................................. 5-1
Transformer Wiring......................................................................... 5-2
Air Requirements ....................................................................................... 5-2
Typical Central Pumping System .............................................................. 5-2
Installing the Pump .................................................................................... 5-4
Installing the Single
Inlet/Outlet Pump .................................................................................. 5-7
Installing the Dual
Inlet/Outlet Pump .................................................................................. 5-8

TOC-2 Valco Cincinnati, Inc.
Table of Contents MS013 - DD-1 Pump Manual (built after 9/06)
Installing the Filter/RegulatorAssembly .................................................. 5-9
Adjusting the Reed Switches (Single Inlet/Outlet Pumps) .................... 5-10
Adjusting the Reed Switches (Dual Inlet/Outlet Pumps) ....................... 5-11
Reversing-Control Wiring Diagram ......................................................... 5-12
Wiring the Control Box Assembly to the Valves .................................... 5-13
Section 6 - Operation ...................................................... 6-1
Operating the Pump ................................................................................... 6-1
Section 7 - Maintenance ................................................. 7-1
Cleaning the Exterior of the Pump............................................................ 7-1
Shutdown Procedure ................................................................................. 7-1
Disassembly Procedure (DD-1 Pumps Manufactured after
September 2006)................................................................................... 7-2
Disassembly Procedure for Check Valves ............................................... 7-3
Cleaning the In-Line Filter ......................................................................... 7-5
Section 8 - Troubleshooting .......................................... 8-1
Section 9 - Specifications .............................................. 9-1
Technical Information Charts .................................................................... 9-1
Specifications ................................................................................. 9-1
Flow Rate ........................................................................................ 9-2
Air Consumption ............................................................................ 9-3
Viscosity Correction....................................................................... 9-4
Section 10 - Part Number List ...................................... 10-1
How to Order Parts .................................................................................. 10-1
PumpAssemblies .................................................................................... 10-2
Pump Kits ................................................................................................. 10-2
Pump Parts ............................................................................................... 10-3
24VDC Air Valve Assembly (411xx434) .................................................. 10-6
Diaphragm ShaftAssemblies .................................................................. 10-7
Teflon/Stainless Steel (560xx554)................................................ 10-7
EPDM/Stainless Steel (560xx633)................................................ 10-7
Pump Seal Kits ......................................................................................... 10-8
Seal Kit (561xx174) for Teflon Check Valves,
EPDM Diaphragms.................................................................. 10-8
Seal Kit (561xx170) for Adhesive Containing Ethyl Acetate ...... 10-8
Seal Kit (561xx171) for Teflon Check Valves;
Solenoid and Fuse Pack Included......................................... 10-9
Seal Kit (561xx172) for Teflon Check Valves .............................. 10-9

TOC-3Valco Cincinnati, Inc.
Table of Contents
MS013 - DD-1 Pump Manual (built after 9/06)
Seal Kit (561xx173) for Stainless Steel Check Valves,
Teflon Diaphragms................................................................ 10-10
Pump Support Equipment ..................................................................... 10-11
Pump Support Equipment Kit (560xx768) ................................ 10-11
Pump Support Equipment Kit (560xx806) ................................ 10-11
Pump Support Equipment Kit - Suction Tube
With Check Valve (561xx078) ............................................... 10-12
Pump Support Equipment Kit - Suction Tube
Without Check Valve (560xx638).......................................... 10-12
Suction Tube Conversion Kits.............................................................. 10-13
Suction Tube Conversion Kit - With Check Valve
(561xx079).............................................................................. 10-14
Suction Tube Conversion Kit - Without Check Valve
(560xx636).............................................................................. 10-14
Power Supply Cables ............................................................................ 10-15
Transformer (036xx175) ........................................................................ 10-16
Control Box ............................................................................................ 10-18
Miscellaneous ........................................................................................ 10-18
Section 11 - Warranty.....................................................11-1
General Warranty Information................................................................. 11-1
Cold Glue Equipment and Electronic Controls.......................... 11-1
Hot-Melt Units, Hoses, Valves, Guns, and Related Equipment . 11-1
DD-1 Pump Exclusions ................................................................ 11-1
Section 12 - Service ...................................................... 12-1

1-1Valco Cincinnati, Inc.
SECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTION
SECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTION
SECTION 1 - INTRODUCTION
This DD-1 air-driven, electronically controlled, double-diaphragm pump is a
process pump composed of two interchangeable diaphragm assemblies
driven by shop air to deliver fluid.
The DD-1 is designed to deliver fluid on a continuous or intermittent basis.
The two interchangeable diaphragm assemblies are mounted within a
frame. The shafts of each diaphragm assembly are coupled so as one
diaphragm is being driven to deliver fluid under pressure, the other
diaphragm assembly is being recharged with fluid.
Cycling is achieved electronically, instead of mechanically. Two reed
switches are mounted in a control box and are activated by a magnet
attached to the shaft coupler (chain link). The switch signal passes to an
electronic control circuit mounted in the control box that in turn operates
standard 3-way solenoid air valves. Flow is controlled by check valves that
are mounted in the corner sections.
The DD-1 pump starts dependably, runs more smoothly, and operates at
lower pressures and temperatures than ordinary mechanically controlled
diaphragm pumps due to its electronic control system. The DD-1 does not
use a spool valve that can stick or shorten the stroke of the pump. The
switches are either open or closed. Therefore, the pump starts from any
position at an inlet air pressure sufficient to overcome internal friction and
system head pressure. Lower temperature operation is also achieved since
there is no rapid expansion of drive air inside the pump. The 3-way valves
exhaust directly to the atmosphere. Reversal cannot occur until a switch is
tripped. Electronic reversal is also fast. The speed of reversal and the
consistency of volume on each stroke contributes to produce a very smooth
flow of fluid.
The DD-1 pump can be ordered with one or two inlet ports and two
discharge ports. Each diaphragm chamber is a single-acting pump. Because
of its electronic reversing control, the DD-1 has the unique advantage over
any other dual, single-acting diaphragm pump. The stroke can be offset
electronically so that the output from one side is as much as 50% greater
than the other. For closed-loop, recirculating systems like those used in
flexographic printing, the pump can be set up so that the amount of fluid that
one side of the pump supplies to the reservoir is less than what the other
side is capable of pumping away. This assures that the reservoir never
becomes over-filled.
Service is easy since the diaphragm assemblies are interchangeable and
individually accessible. Each check valve is externally accessible and the
air valves are standard devices that are coupled directly to the diaphragm
housing through quick-disconnect fittings. Most service requirements can be
accomplished without removing the pump from the system.
Five indicator lights are provided on the pump PC board to facilitate
electrical service.

2-1ValcoMelton
SECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USE
SECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USE
SECTION 2 - SAFETY AND USE
Read
Thoroughly
Before
Handling
Equipment
WARNING!WARNING!
WARNING!WARNING!
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 CautionCaution
CautionCaution
Caution or a WarningWarning
WarningWarning
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 SurfaceHot Surface
Hot SurfaceHot Surface
Hot Surface.
This symbol represents a Puncture Risk.Puncture Risk.
Puncture Risk.Puncture Risk.
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 GlovesWorking Gloves
Working GlovesWorking Gloves
Working Gloves are required.
This symbol means that GogglesGoggles
GogglesGoggles
Goggles are required.
This symbol indicates a Shock HazardShock Hazard
Shock HazardShock Hazard
Shock Hazard. There is a presence of
non-insulated dangerous voltage within the product’s enclosure.
This voltage may cause electrical shock or fire.
Continued next page

2-2 ValcoMelton
Section 2 - Safety Information MS013 -DD-1PumpManual(built after 9/06)
Symbols - Continued
This symbol indicates a NoteNote
NoteNote
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.
This symbol indicates the need to Unplug/Disconnect All PowerUnplug/Disconnect All Power
Unplug/Disconnect All PowerUnplug/Disconnect All Power
Unplug/Disconnect All Power
SourcesSources
SourcesSources
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 SourcesLock Out All Power Sources
Lock Out All Power SourcesLock Out All Power Sources
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.

2-3ValcoMelton
Section 2 - Safety Information
MS013 -DD-1PumpManual(built after 9/06)
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.

2-4 ValcoMelton
Section 2 - Safety Information MS013 -DD-1PumpManual(built after 9/06)
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.
Installation/
Startup/Use
Safety
Information WARNING!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
WARNING! The equipment should be installed so that it can be turned
off at a location awayaway
awayaway
away from the equipment in case of
injury, electrical problems, or malfunction. OTHERWISE,
DEATH OR PERSONAL INJURY COULD OCCUR.
WARNING!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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.
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):

2-5ValcoMelton
Section 2 - Safety Information
MS013 -DD-1PumpManual(built after 9/06)
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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.

2-6 ValcoMelton
Section 2 - Safety Information MS013 -DD-1PumpManual(built after 9/06)
Hot-Melt-
Specific,
General Safety
Information
WARNING!WARNING!
WARNING!WARNING!
WARNING! NeverNever
NeverNever
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.
Valco Melton hot melt units have the following universal safety precautions inin
inin
in
addition to all other universal precautions previously mentionedaddition to all other universal precautions previously mentioned
addition to all other universal precautions previously mentionedaddition to all other universal precautions previously mentioned
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!WARNING!
WARNING!WARNING!
WARNING! Keep pump cover and electrical enclosures closed
except during setup, service, and checkout procedures.
OTHERWISE, DEATH OR PERSONAL INJURY
COULD OCCUR.
WARNING!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
WARNING! Hot surfaces! Do not touch! Use extreme caution when
refilling the unit by hand. OTHERWISE, PERSONAL
INJURY COULD OCCUR.
WARNING!WARNING!
WARNING!WARNING!
WARNING! Wear protective gloves and goggles at all times around
all machinery, especially hot melt. OTHERWISE,
SERIOUS PERSONAL INJURY COULD OCCUR.
WARNING!WARNING!
WARNING!WARNING!
WARNING! Never use an open flame to heat hot melt components
or adhesive. OTHERWISE, DEATH, PERSONAL
INJURY, OR DAMAGE TO EQUIPMENT COULD
OCCUR.

2-7ValcoMelton
Section 2 - Safety Information
MS013 -DD-1PumpManual(built after 9/06)
If hot adhesive comes in contact with the skin,,
,,
, do the following:
WARNING!WARNING!
WARNING!WARNING!
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 Contact
with Hot Adhesive
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.
What to Do if
Inhalation of
Adhesive Fumes
Occurs

2-8 ValcoMelton
Section 2 - Safety Information MS013 -DD-1PumpManual(built after 9/06)
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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!WARNING!
WARNING!WARNING!
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.
IfIf
IfIf
If you feel you can fight the fire safelysafely
safelysafely
safely, do
oneone
oneone
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.
What to Do if
Adhesive-Related
Fire or Explosion
Occurs

2-9ValcoMelton
Section 2 - Safety Information
MS013 -DD-1PumpManual(built after 9/06)
Do notDo not
Do notDo not
Do not use bindings, wire ties, or unapproved
fasteners around the hoses.
DoDo
DoDo
Do use approved wrapping (P/N 775xx827),
making sure the wrapping is slightly snug but
not tight.
Do notDo not
Do notDo not
Do not place hoses close together.
DoDo
DoDo
Do allow at least 2 inches (5.1 cm)
between hoses for proper ventilation.
Do notDo not
Do notDo not
Do not bend hoses sharply. Do notDo not
Do notDo not
Do not allow
kinks or indentations in the hoses.
DoDo
DoDo
Do use a minimum bend radius of 10
inches for a 20-inch diameter coil hose.
Do notDo not
Do notDo not
Do not use unapproved hooks to hang hoses.
Do notDo not
Do notDo not
Do not wrap hoses over or around objects.
DoDo
DoDo
Do use a hose hanging kit (P/N 781xx827).
Do notDo not
Do notDo not
Do not use the “one handed/one wrench”
technique to attach or remove hoses. DoDo
DoDo
Do
notnot
notnot
not wrench on any surface other than the
large hexagon swivel nuts.
DoDo
DoDo
Do use two hands and two wrenches to
tighten or loosen connections on hoses.
DoDo
DoDo
Do wrench only on large hexagon swivel
nuts.
Hose Safety
Information

2-10 ValcoMelton
Section 2 - Safety Information MS013 -DD-1PumpManual(built after 9/06)
Do notDo not
Do notDo not
Do not allow hoses to rub against
objects or to come into contact with
sharp edges or points.
DoDo
DoDo
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 notDo not
Do notDo not
Do not use worn, damaged, or bent
hoses.
DoDo
DoDo
Do inspect all hoses regularly for
damage and/or wear and replace
damaged or worn hoses immediately.
Hose Safety Information -
Continued
WARNING!WARNING!
WARNING!WARNING!
WARNING! All diaphragm pumps can experience diaphragm failure.
If they do, the pumped fluid can enter the air chambers
and be exhausted through the air valves. It is also
possible for the compressed air to mix with the pumped
fluid and be expelled through the pump discharge line.
Depending upon the nature of the pumped fluid,
CATCHING AND CONTROLLING EXHAUSTED
FLUIDS AND VAPORS MAY BE REQUIRED TO AVOID
EXPLOSIONS. SINCE FLUIDS CAN BE TOXIC AND
HAZARDOUS TO PERSONNEL,
Valco Cincinnati recommends that you seek advice
from:
Your company’s safety policy and procedures
Fluid suppliers (MSDS information)
Personnel skilled in handling and processing
hazardous fluids
Local, state, and federal agencies.
Diaphragm
Pump/Toxic
Fluids Safety

3-1Valco Cincinnati, Inc.
SECTION 3 - WIRING GUIDELINESSECTION 3 - WIRING GUIDELINES
SECTION 3 - WIRING GUIDELINESSECTION 3 - WIRING GUIDELINES
SECTION 3 - WIRING GUIDELINES
Warning!Warning!
Warning!Warning!
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!Warning!
Warning!Warning!
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 control to a “clean” supply of electrical power. Use
a dedicated circuit if possible.
If a dedicated circuit is not available, do
not connect the control to a circuit that
supplies high-amperage equipment—
use another circuit such as a lighting
circuit. Otherwise, equipment may not
function properly.
Routing Low-
Voltage Leads
Connecting
the Electrical
Power

4-1Valco Cincinnati, Inc.
SECTION 4 - BASIC FEATURESSECTION 4 - BASIC FEATURES
SECTION 4 - BASIC FEATURESSECTION 4 - BASIC FEATURES
SECTION 4 - BASIC FEATURES
DD-1 Pump
Assembly
(pumps built
after 09/2006)
Figure 4-1 - DD-1 Pump Assembly
(built 09/2006 and later)
Control Box
Fluid Filter Assembly
DD-1 Pump
Air Purge Valve Assembly
Filter Bracket
Suction Hose
Air Filter/Regulator Assembly
Discharge Hose

4-2 Valco Cincinnati, Inc.
Section 4 - Basic Features MS013 - DD-1 Pump Manual (built after 9/06)
PCB
Assembly
The Control Box contains the PCB Assembly.
Yellow Reed LED (left)
This light comes on when the left
reed switch is operating.
(Activated by presence of magnet.)
Yellow 3-way LED (left)
This light comes on when the
left 3-way air valve is energized. Green Power LED
This light comes on when circuit
board power is supplied. This LED
will be illuminated if power supply
and fuse are operating properly.
Yellow 3-way LED (right)
This light comes on when the
right 3-way air valve is energized.
Yellow Reed LED (right)
This light comes on when the right
reed switch is operating.
(Activated by presence of magnet.)
1-amp SLO-BLO fuse
Startup jumper
-Jumper first and second pins.
Upon startup, left 3-way activates
and shaft is pulled to the left.
-Jumper second and third pins.
Upon startup, right 3-way activates
and shaft is pulled to the right.
Figure 4-2 - PCB Assembly
(Inside the Control Box)