VALCO MELTON D4 User Manual

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D4 Hot Melt Unit

Manual Number: MM147

Revision Date: 6/2018

Table of Contents

Table of Contents5
Section 1 - Introduction11
- Description11
- Nameplate11
- S Number Configuration12
Section 2 - Safety and Use13
- Read Thoroughly before Handling Equipment13
- Symbols13
- Owner Responsibilities14
- Limitations of Use14
- Installation/Startup/Use Safety Information15
- Shut down Safety Information16
- Hot-Melt-Specific, General Safety Information16
- Hose Safety Information19
Section 3 - Basic Features21
- Key Features21
Section 4 - Installation23
- Choosing a Location23
  - Mounting Footprint24
- Installation Kit24
- Routing Low-Voltage Leads24
- Connecting the Electrical Power25
- Connecting the Hoses27
- Connecting the Hot Melt Hoses to the Applicators29
- Wiring Diagram30
- Wiring Diagram - before 5/1831
- Input/Output Connections32
- Input/Output Connections - before 5/1834
Section 5 - Setup35
- Control Panel35
Power On/Off and Standby Mode37
Display Contrast Adjustment38
User Interface39
- Navigation39
- Memory Storage39
- Thumbwheel Vs. Single Digit Edit40
Entering Passwords41
Set Language42
Set Temperature Units44
- Programming Temperatures45
- Tank Temperature46
- Hose/Valve Temperature46
System/Pump Ready Temperature Offset48
Ready Delay Time49
Over Temperature Alarm50
Under Temperature Alarm51
Maximum Temperature52
Beacon/Alarm Setup53
- Beacon 255
Automatic Pump Mode56
Pressure Setup57
Pot Fill Mode60
Level Sensor Setup61
- Hopper Feeder - Low Level Detection61
  - Door Switch61
  - Feeder Valve Operation61
Filter Change Timer62
Clock and 7-Day Timer62
- Programming Shifts63
Diagnostics66
Setback67
- Setback Temperature67
- Automatic Setback Timeout68
Startup Setup69
- Sequential Start - Hose69
History71
User Inputs and Outputs72
Configuration74
- Zone Configuration74
- Auxiliary Zones74
- Auxiliary I/O75
- Pump Type75
- Gramage Enable75
- Config Comm Menu76
  - Pump Configuration77
    - Number of Pumps77
    - Pump Configuration for Specific No. Pump77
  - Pump Setup Menu78
- Encoder Setup Menu80
- PID Setup Menu81
  - PID Settings81
  - Autotune Feature81
- Memory Menu82
- Restoring Factory Default Settings82
- Updating 152XX746 CPU Board Software Via USB Memory Stick82
- Initialization Instructions85
- Adjusting the Pressure Control Valve89
  - Adjusting the Single-Stage Relief Valve89
- Gramage Feature90
- D Series Variable Frequency Drive Configuration (if Equipped)91
  - Before 5/1892
Section 6 - Operation93
- Start the Unit93
- Temperature94
  - Setpoint and Actual Temperature94
  - Temperature Status Leds94
- Pump Operation95
  - Pump On/Off Key95
  - Pump Status Key95
    - Fixed Speed Unit95
    - Variable Speed Unit96
- Clock On/Off96
- Setback97
  - Automatic Setback97
- Pot Fill - External Low Level Detection98
- Hopper Feeder - Internal Low Level Detection98
- Beacon Alarm98
- External Input98
- Filling the Tank99
Section 7 - Maintenance101
- General101
- Cleaning the Exterior of the Unit101
- Changing the Adhesive102
- Flushing the System102
- Parts Replacement104
  - Changing Fuses104
  - Changing the Filter105
Section 8 - Troubleshooting and Repair107
Section 9 - Specifications109
- General109
- Dimensions110
Section 10 - Part Number List111
- How to Order Parts111
- D4 Unit112
- D4 Base Unit (776Xx392)120
  - D4 Base Unit (776Xx392) - before 5/18123
- Installation Kit (091Xx734)125
- Option Kits126
Section 11 - Warranty141
- Warranty Information141
  - Cold Glue Equipment and Electronic Controls141
  - Hot Melt Units, Hoses, Valves, Guns, and Related Equipment141
Section 12 - Service143
Appendix A - Password Levels145
Appendix B - Power Requirements147
- System Power Requirement Calculation - D Series Units147
Appendix C - Instruction Sheets for Option Kits149
Appendix D - Micro SD Backup & Restore151
- Functions151
- Error Codes152
Appendix E - Communication Protocols-Modbus153
- Communication Specifications153
- Hardware Considerations153
- Parameter List154
Appendix F - Communication Protocols-Ethernet IP163
- Hot Melt Unit to Ethernetip Communication Protocol163
- Data Packets Used for Ethernet/Ip Communication163
- Current Alarm Types168
  - Error Codes169
    - Examples169
  - Status Indicators170
    - Network Status LED170

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VALCO MELTON D4 Specifications

General

Brand	VALCO MELTON
Model	D4
Category	Melting Machines
Language	English

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