dd-1 pump · valcomelton 1-1 section 1 - introduction about this manual valco cincinnati has...

DD-1 PumpDD-1 PumpDD-1 PumpDD-1 PumpDD-1 Pump(built before 9/06)(built before 9/06)(built before 9/06)(built before 9/06)(built before 9/06)

Manual Number: MS005Revision Date: 7/2013

© 2013 Valco Cincinnati, Inc. All Rights Reserved

This manual is provided with the DD-1 Pump (built before 9/06) and may be used only in accordance withthe terms of purchase.

No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or byany means, electronic, mechanical, recording, or otherwise, without the prior written permission of ValcoCincinnati, Inc. The information in this manual is furnished for educational purposes only, is subject tochange without notice, and should not be construed as a commitment by Valco Cincinnati, Inc.

This manual written and designed at Valco Cincinnati, Inc., 411 Circle Freeway Drive, Cincinnati, Ohio45246. http://www.valcomelton.com

Part Number: MS005

Written and printed in the USA in the original language of English (US).

Valco Cincinnati IncorporatedValco Cincinnati IncorporatedValco Cincinnati IncorporatedValco Cincinnati IncorporatedValco Cincinnati Incorporated411 Circle Freeway DriveCincinnati, Ohio 45246, USATEL: (1) 513-874-6550FAX: (1) 513-874-3612

Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Pol. Industrial Agustinoscalle G, n. 3431160 Orcoyen, Navarra, SpainTEL: (34) 948-321-580FAX: (34) 948-326-584

Valco Cincinnati, Ltd.Valco Cincinnati, Ltd.Valco Cincinnati, Ltd.Valco Cincinnati, Ltd.Valco Cincinnati, Ltd.Unit 7-8Hortonwood 32Telford TF1 7YN EnglandTEL: (44) 1952-677911FAX: (44) 1952-677945

Valco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHStorkower Strasse 6D-15749 Gallun, GermanyTEL: (49) 33764 8700FAX: (49) 33764 87070

Declaration of ConformityDeclaration of ConformityDeclaration of ConformityDeclaration of ConformityDeclaration of Conformity(According to EN 45014)

This Declaration of Conformity has been generated electronically and is legally binding without signature

Manufacturer: Valco Melton A div ision of Valco Cincinnati, Incorporated 411 Circle Freeway Drive Cincinnati, OH 45246 USA

Autho rized Representatives in Europ e:

Valco Cincinnati, Ltd. Unit 7-8 Hortonwood 32 Telford TF1 7YN England

Melton S.L .UPol. Industrial Agustinos calle G, n. 34 31160 OrcoyeNavarra, Spain

declares that the product:

Produ ct Name: DD-1 Pump (built before 9/06)

complies with the following Council Directives:

Safety of Machinery: 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 Emission s: 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 f irst f ixed 2006

Signature: David H. Swedes, D irector of Eng ineering & Manufacturing

TOC-1Valco Cincinnati, Inc.

TABLE OF CONTENTSTABLE OF CONTENTSTABLE OF CONTENTSTABLE OF CONTENTSTABLE OF CONTENTS

Section 1 - Introduction.................................................. 1-1About this Manual ...................................................................................... 1-1Description of the DD-1 Pump ................................................................... 1-1

Section 2 - Safety and Use ............................................. 2-1Read Thoroughly Before Handling Equipment ........................................ 2-1Symbols ...................................................................................................... 2-1Owner Responsibilities.............................................................................. 2-3Limitations of Use ...................................................................................... 2-4Installation/Startup/Use Safety Information ............................................. 2-4Shut Down Safety Information ................................................................. 2-5Hot-Melt-Specific, General Safety Information ......................................... 2-6

What to Do if Contact with Hot Adhesive Occurs ........................ 2-7What to Do if Inhalation of Adhesive Fumes Occurs ................... 2-7What to Do if Adhesive-Related Fire or Explosion Occurs .......... 2-8

Hose Safety Information............................................................................ 2-9System-Specific Safety Information........................................................ 2-10

Section 3 - General Wiring Guidelines ......................... 3-1Routing Low-Voltage Leads ...................................................................... 3-1Connecting the Supply of Electrical Power .............................................. 3-1

Section 4 - Basic Features.............................................. 4-1Introduction ................................................................................................ 4-1DD-1 Pump Assembly ................................................................................ 4-1PCB Assembly ........................................................................................... 4-2

Light Sequence During the Pump Cycle ...................................... 4-3

TOC-2 Valco Cincinnati, Inc.

Table of Contents MS005 - DD-1 Pump (before 9/06)

Section 5 - Installation .................................................... 5-1Introduction ................................................................................................ 5-1Power Requirements ................................................................................. 5-1Power Connections ................................................................................... 5-1Air Requirements ....................................................................................... 5-1Typical Central Pumping System............................................................ 5-2Installing the Pump .................................................................................... 5-3

Installing the Single Inlet/Outlet Pump .......................................... 5-5Installing the Dual Inlet/Outlet Pump ............................................. 5-6Installing the Filter/Regulator Assembly ....................................... 5-7

Adjusting the Hall-Effect Switches for Single Inlet/Outlet Pumps ........... 5-8Adjusting the Hall-Effect Switches for Dual Inlet/Outlet Pumps ............. 5-9Reversing-Control Wiring Diagram ........................................................ 5-10PCB Assembly - Second Version ............................................................ 5-11Wiring the Control-Box Assembly to the Valves .................................... 5-12

Section 6 - Operation ...................................................... 6-1Introduction ................................................................................................ 6-1Operating the Pump ................................................................................... 6-1

Section 7 - Maintenance ................................................. 7-1Introduction ................................................................................................ 7-1Cleaning the Exterior of the Pump ............................................................ 7-1Shutdown Procedure ................................................................................. 7-1Disassembly Procedure for Pumps Manufactured after

May 1995 ............................................................................................... 7-2Disassembly Procedure for Pumps Manufactured before

May 1995 ............................................................................................... 7-2Disassembly Procedure for Check Valves ............................................... 7-3Cleanup Procedure for Recirculating/Ink Pumps ..................................... 7-4Cleaning the In-Line Filter ......................................................................... 7-5

Section 8 - Troubleshooting .......................................... 8-1Introduction ................................................................................................ 8-1

Section 9 - Specifications .............................................. 9-1Introduction ................................................................................................ 9-1

TOC-3Valco Cincinnati, Inc.

Table of ContentsMS005 - DD-1 Pump (before 9/06)

Section 10 - Part Number List ...................................... 10-1How to Order Parts .................................................................................. 10-1Pump Assemblies .................................................................................... 10-2Pump Kits ................................................................................................. 10-2DD-1 Pump Parts for Assemblies

562xx041,562xx040, 562xx043, and 562xx042 ................................. 10-3Suction Tube Conversion Kit (560xx636) .............................................. 10-724VDC Air-Valve Assembly (411xx434) .................................................. 10-8Diaphragm Shaft Assemblies .................................................................. 10-9Teflon/Stainless-Steel Diaphragm Shaft Assembly (560xx554) ............ 10-9EPDM/Stainless-Steel Diaphragm Shaft Assembly (560xx633) ........... 10-9Old-Style Diaphragm Shaft Assembly (560xx424) ................................. 10-9Replacement Parts Kits ......................................................................... 10-10Pump Seal Kits ....................................................................................... 10-11Pump Support Equipment ..................................................................... 10-13

Pump Support Equipment Kit 560xx768 .................................. 10-13Pump Support Equipment Kit 560xx433 .................................. 10-13Pump Support Equipment Kit 560xx430 .................................. 10-13

Miscellaneous ........................................................................................ 10-14Power Supply Cables................................................................. 10-14

Control Boxes ........................................................................................ 10-15Other ....................................................................................................... 10-15

Section11 - Warranty ......................................................11-1Warranty Information ............................................................................... 11-1

Cold Glue Equipment and Electronic Controls .......................... 11-1Hot Melt Units, Hoses, Valves, Guns, and Related Equipment . 11-1

Section 12 - Service ...................................................... 12-1

1-1ValcoMelton

SECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTION

About thisManual

Valco Cincinnati has prepared this manual as an aid for installing, operating,and servicing the DD-1 pump. It also contains a list of part numbers forreplacement parts. If you need more information, please contact your ValcoCincinnati representative.

The air-driven, electronically controlled, double-diaphragm pump is a processpump composed of two interchangeable diaphragm assemblies driven byshop 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 isbeing driven to deliver fluid under pressure, the other diaphragm assembly isbeing recharged with fluid.

Cycling is achieved electronically, instead of mechanically. Two hall-effectswitches are mounted in a control box and are activated by a magnetattached to the shaft coupler (chain link). The switch signal passes to anelectronic control circuit mounted in the control box that in turn operatesstandard 3-way solenoid air valves. Flow is controlled by check valves thatare mounted in the corner sections.

The DD-1 pump starts dependably, runs more smoothly, and operates atlower pressures and temperatures than ordinary mechanically controlleddiaphragm pumps due to its electronic control system. The DD-1 does notuse a spool valve that can stick or shorten the stroke of the pump. Theswitches are either open or closed. Therefore, the pump starts from anyposition at an inlet air pressure sufficient to overcome internal friction andsystem head pressure. Lower temperature operation is also achieved sincethere is no rapid expansion of drive air inside the pump. The 3-way valvesexhaust directly to the atmosphere. Reversal cannot occur until a switch istripped. Electronic reversal is also fast. The speed of reversal and theconsistency of volume on each stroke contributes to produce a very smoothflow of fluid.

The DD-1 pump can be ordered with one or two inlet ports and two dischargeports. Each diaphragm chamber is a single-acting pump. Because of itselectronic reversing control, the DD-1 has the unique advantage over anyother dual, single-acting diaphragm pump. The stroke can be offsetelectronically so that the output from one side is as much as 50% greaterthan the other. For closed-loop, recirculating systems like those used inflexographic printing, the pump can be set up so that the amount of fluid thatone side of the pump supplies to the reservoir is less than what the other sideis capable of pumping away. This assures that the reservoir never becomesover-filled.

Service is easy since the diaphragm assemblies are interchangeable andindividually accessible. Each check valve is externally accessible and the airvalves are standard devices that are coupled directly to the diaphragmhousing through quick-disconnect fittings. Most service requirements can beaccomplished without removing the pump from the system.

Five indicator lights are provided on the pump PC board to facilitate electricalservice.

Description ofthe DD-1Pump

2-1ValcoMelton

SECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USESECTION 2 - SAFETY AND USE

ReadThoroughlyBeforeHandlingEquipment

WARNING!WARNING!WARNING!WARNING!WARNING! Read and follow all safety precautions, warnings,cautions, and other recommendations in this manual.OTHERWISE, DEATH, PERSONAL INJURY OREQUIPMENT DAMAGE COULD OCCUR.

Read this entire section before handling the equipment.

SymbolsThe following symbols may be used on the equipment and/or in this manual.

This symbol represents a CautionCautionCautionCautionCaution or a WarningWarningWarningWarningWarning. Cautions drawspecial attention to anything that could damage equipment orcause the loss of data. Warnings draw special attention toanything that could injure or kill the reader. Both Cautions andWarnings are placed before the step they apply to.

This symbol represents a Hot SurfaceHot SurfaceHot SurfaceHot SurfaceHot Surface.

This symbol represents a Puncture Risk.Puncture Risk.Puncture Risk.Puncture Risk.Puncture Risk. It is usually used inregard to nozzle cleaning appliances and other sharpinstruments that can cause puncture wounds and risk exposureto bloodborne pathogens and other debris.

This symbol means that Working Gloves Working Gloves Working Gloves Working Gloves Working Gloves are required.

This symbol means that Goggles Goggles Goggles Goggles Goggles are required.

This symbol indicates a Shock HazardShock HazardShock HazardShock HazardShock Hazard. There is a presence ofnon-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 MS005 - DD-1 Pump (before 9/06)

Symbols - Continued

This symbol indicates a NoteNoteNoteNoteNote. Notes point out something ofspecial interest or importance to the reader. They give tips,hints, and information in addition to what is necessary for thestep preceding it.

This symbol indicates the need to Unplug/Disconnect All PowerUnplug/Disconnect All PowerUnplug/Disconnect All PowerUnplug/Disconnect All PowerUnplug/Disconnect All PowerSourcesSourcesSourcesSourcesSources and to let them de-energize before attempting any typeof work or maintenance. Remember that there can still be energyin equipment, cords, and wires even when unplugged/disconnected.

This symbol indicates the need to Lock Out All Power SourcesLock Out All Power SourcesLock Out All Power SourcesLock Out All Power SourcesLock Out All Power Sourcesand to let them de-energize before attempting any type of workor maintenance. If power is not locked out, the person workingon the equipment may be injured or killed if someoneunknowingly switches on the power to the equipment.

2-3ValcoMelton

Section 2 - Safety InformationMS005 - DD-1 Pump (before 9/06)

OwnerResponsibilities

The owner of the equipment is under obligation to manage all safetyinformation. Some examples include:

• Examine all safety materials and documents as well asjurisdictional 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 beread/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 accessto the safety information, training, and equipment according tojurisdictional authorities.

The owner of the equipment is under obligation to make certain that allinstructions, requirements, and jurisdictional laws are met. Some examplesinclude:

• Make sure there are regular inspections of equipment and safetydevices.

• Have regular safety drills and inspections supervised by theproper authorities.

• Provide all required safety items, first aid equipment, andtraining.

The owner of the equipment is under obligation to make certain that allpersonnel who will handle, install, maintain, operate, fix, and work around theequipment are qualified, trained, and up-to-date with all information regardingthe equipment. Some examples include:

• Make sure all personnel have the proper safety training,equipment, education, and abilities necessary for the job functionaccording to safety instructions and all jurisdictional laws andregulations.

• It is strongly advised that personnel receive first-respondermedical care training in case of burns, medical emergencies, orother injuries. Training should be kept up to date.

• Make sure all personnel understand and can follow safetypolicies and procedures for the organization as well as for thespecific equipment.

• Make sure that all personnel are consistently trained, evaluated,free of alcohol and medications that may impair judgment andreflexes, and are tested for banned substances according tojurisdictional authorities.

2-4 ValcoMelton


Limitations ofUse

Read this document and all information regarding the equipment beforehandling the equipment. The intended use of the equipment is stated inSection 1 of this manual.

Do not use this equipment for anything other than its intended use. Do notmodify, change, or alter the equipment in any way. If you are unsure of theintended use and the limitations of use for the equipment, contact your ValcoMelton Representative before handling the equipment.

Installation/Startup/UseSafetyInformation

WARNING!WARNING!WARNING!WARNING!WARNING! Only qualified personnel should install the equipment.Valco Melton strongly recommends that a Valco MeltonTechnician install all equipment. OTHERWISE, DEATH,PERSONAL INJURY, OR DAMAGE TO EQUIPMENTCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! The equipment should be installed so that it can be turnedoff at a location away away away away away from the equipment in case ofinjury, electrical problems, or malfunction. OTHERWISE,DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Properly route all electrical wires. Never tamper withequipment. Only use approved and correct voltage, typeof current, fuses, and other power supplies. Replace worncords, hoses, etc. immediately. FAILURE TO OBSERVEWARNING MAY RESULT IN DEATH, PERSONALINJURY, AND/OR EQUIPMENT DAMAGE.

WARNING!WARNING!WARNING!WARNING!WARNING! Poor ventilation, smoking, and open flames can causeoverheated hot melt to ignite. Adequate ventilation mustbe provided. Smoking should be prohibited in theimmediate vicinity of the molten adhesive. Open flamesmust be kept away from the area around molten adhesive.OTHERWISE, DEATH, PERSONAL INJURY, ORDAMAGE TO EQUIPMENT COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Never use any Valco Melton equipment in an explosiveenvironment. Explosive environments include, but are notlimited to, solvent-based cleaners or adhesives, explosivematerials, radioactive materials, etc. OTHERWISE,DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Equipment will start automatically when remotelycontrolled by triggering devices. Be sure to disable alltriggering devices, carefully release hydraulic pressure,and disconnect air pressure before servicing or workingnear guns, valves, and other triggered devices.OTHERWISE, DEATH OR PERSONAL INJURY COULDOCCUR.

Valco Melton hot melt units, cold glue units, controllers, inspection systemsand all related accessories have the following universal safety precautions(this is not intended to be an exhaustive list; follow all instructions and safetyprecautions for the specific type of equipment involved):

2-5ValcoMelton


Shut DownSafetyInformation

Valco Melton hot melt units, cold glue units, controllers, inspection systemsand all related accessories have the following universal safety precautions(this is not intended to be an exhaustive list; follow all instructions and safetyprecautions for the specific type of equipment involved):

WARNING!WARNING!WARNING!WARNING!WARNING! Purge the fluid pressure and the air pressure from thesystem before disconnecting/disabling any part of thesystem. OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Disconnect and lock out all power before maintenanceor other need to open the equipment. Only qualifiedpersonnel should open and service the control.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Equipment may still be energized even if unplugged!When making adjustments or performing checkoutprocedures, stay clear of any moving mechanical partsand do not touch exposed electrical equipment orelectrical connectors. OTHERWISE, DEATH ORPERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Disconnect/disable all mechanical and/or electricaldevices that send activation signals to the gun(s),valve(s), melter pump(s), etc. This includes patterncontrols, timers, input/output signals, etc. Only qualifiedpersonnel should open and service the control.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Disable all triggering devices, relieve all residualpressure (hydraulic and air) and allow adhesive to coolbefore attempting to disconnect guns, hoses, valves,etc. Only qualified personnel should open and servicethe control. OTHERWISE, DEATH OR PERSONALINJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Never point an adhesive dispensing gun, valve, hose, airhose, or anything else at yourself or another person.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

2-6 ValcoMelton


Hot-Melt-Specific,General SafetyInformation

WARNING!WARNING!WARNING!WARNING!WARNING! Never Never Never Never Never process any polyurethane reactive (PUR) hotmelt or solvent-based material in a Valco Melton unitunless you are certain that the unit is compatible and ismarked “PUR”! Read all instructions and MSDS sheetscarefully, following manufacturer’s instructions,especially regarding heat levels. If you have anyquestion as to the compatibility of a Valco Melton unit forPUR hot melt, call your Valco Melton Representativebefore attempting to use the unit for PUR or solvent-based materials. OTHERWISE, HAZARDOUS FUMES,EXPLOSION, DEATH, OR PERSONAL INJURYCOULD OCCUR.

Valco Melton hot melt units have the following universal safety precautions in in in in inaddition to all other universal precautions previously mentioned addition to all other universal precautions previously mentioned addition to all other universal precautions previously mentioned addition to all other universal precautions previously mentioned addition to all other universal precautions previously mentioned (this is notintended to be an exhaustive list; follow all instructions and safetyprecautions for the specific type of equipment involved):

WARNING!WARNING!WARNING!WARNING!WARNING! Keep pump cover and electrical enclosures closedexcept during setup, service, and checkout procedures.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! People with respiratory problems (e.g., asthma,bronchitis, etc.) should not work in the vicinity of moltenadhesive. RESPIRATORY PROBLEMS MAY BEAGGRAVATED BY THE FUMES. Do not wear a facemask when working around molten adhesive. THEMASK MAY TRAP THE FUMES AND DEATH ORPERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Keep hot melt hoses away from walkways and themoving parts of hot melt systems. OTHERWISE,PERSONAL INJURY OR EQUIPMENT DAMAGECOULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Hot surfaces! Do not touch! Use extreme caution whenrefilling the unit by hand. OTHERWISE, PERSONALINJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Wear protective gloves and goggles at all times aroundall machinery, especially hot melt. OTHERWISE,SERIOUS PERSONAL INJURY COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Never use an open flame to heat hot melt componentsor adhesive. OTHERWISE, DEATH, PERSONALINJURY, OR DAMAGE TO EQUIPMENT COULDOCCUR.

2-7ValcoMelton


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 fromthe skin. OTHERWISE, SEVERE PERSONAL INJURYAND DEATH COULD OCCUR.

1. Immediately immerse the contacted area in clean, cold water.

It is strongly recommended that asource of clean, cold water be providednear the hot melt work area.

2. Cover the affected area with a clean, wet compress and call theemergency medical response system (such as 911) immediately.

3. Watch for and treat the subject for signs of shock while waitingfor professional help to arrive.

What to Do if Contactwith 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 ifInhalation of

Adhesive FumesOccurs

2-8 ValcoMelton


During the heating and melting process, the surface of the adhesive will beexposed to air. The mixture of polymer fumes and air can catch fire if the hotmelt is overheated.

WARNING!WARNING!WARNING!WARNING!WARNING! Poor ventilation, smoking, and open flames can causeoverheated hot melt to ignite. Adequate ventilation mustbe provided. Smoking should be prohibited in theimmediate vicinity of the molten adhesive. Open flamesmust be kept away from the area around moltenadhesive. OTHERWISE, DEATH, PERSONAL INJURY,OR DAMAGE TO EQUIPMENT COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Exposed arcing may ignite the fume/air mixture. Shieldall electrical equipment from melt fumes to avoidexposed arcing. OTHERWISE, PERSONAL INJURY OREQUIPMENT DAMAGE COULD OCCUR.

WARNING!WARNING!WARNING!WARNING!WARNING! Do not use a water extinguisher to extinguish the fire!OTHERWISE, PERSONAL INJURY OR EQUIPMENTDAMAGE 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.

IfIfIfIfIf you feel you can fight the fire safelysafelysafelysafelysafely, do oneoneoneoneone of the following:

- Smother the fire with a fire blanket.

- Aim a CO2 fire extinguisher at the base of the flames.

- Aim a dry-powder fire extinguisher at the base of theflames.

What to Do ifAdhesive-RelatedFire or Explosion

Occurs

2-9ValcoMelton


Do notDo notDo notDo notDo not use bindings, wire ties, or unapprovedfasteners around the hoses.

DoDoDoDoDo use approved wrapping (P/N 775xx827),making sure the wrapping is slightly snug butnot tight.

Do notDo notDo notDo notDo not place hoses close together.

DoDoDoDoDo allow at least 2 inches (5.1 cm)between hoses for proper ventilation.

Do notDo notDo notDo notDo not bend hoses sharply. Do notDo notDo notDo notDo not allowkinks or indentations in the hoses.

DoDoDoDoDo use a minimum bend radius of 10inches for a 20-inch diameter coil hose.

Do notDo notDo notDo notDo not use unapproved hooks to hang hoses.Do notDo notDo notDo notDo not wrap hoses over or around objects.

DoDoDoDoDo use a hose hanging kit (P/N 781xx827).

Do notDo notDo notDo notDo not use the “one handed/one wrench”technique to attach or remove hoses. DoDoDoDoDonotnotnotnotnot wrench on any surface other than thelarge hexagon swivel nuts.

DoDoDoDoDo use two hands and two wrenches totighten or loosen connections on hoses.DoDoDoDoDo wrench only on large hexagon swivelnuts.

Hose SafetyInformation

2-10 ValcoMelton


Do notDo notDo notDo notDo not allow hoses to rub againstobjects or to come into contact withsharp edges or points.

DoDoDoDoDo wrap the hoses in approved padding(P/N 795xx549) if the hoses must beinstalled where they will come intocontact with objects.

Do notDo notDo notDo notDo not use worn, damaged, or benthoses.

Do Do Do Do Do inspect all hoses regularly fordamage and/or wear and replacedamaged or worn hoses immediately.

Hose Safety Information -Continued

System-SpecificSafetyInformation

N/A

3-1ValcoMelton

SECTION 3 - GENERAL WIRING GUIDELINESSECTION 3 - GENERAL WIRING GUIDELINESSECTION 3 - GENERAL WIRING GUIDELINESSECTION 3 - GENERAL WIRING GUIDELINESSECTION 3 - GENERAL WIRING GUIDELINES

WARNING!WARNING!WARNING!WARNING!WARNING! Electrical connections should be made only byexperienced service personnel! OTHERWISE, DEATH,PERSONAL INJURY, OR EQUIPMENT DAMAGECOULD OCCUR.

When conencting 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, donot connect the control to a circuit thatsupplies high-amperage equipment—use another circuit such as a lightingcircuit. Otherwise, equipment may notfunction properly.

WARNING!WARNING!WARNING!WARNING!WARNING! Electrical installation should be accomplished only byexperienced service personnel! OTHERWISE, DEATH,PERSONAL INJURY, OR EQUIPMENT DAMAGECOULD OCCUR.

Routing Low-Voltage Leads

When routing low-voltage leads, follow these guidelines:

• Do not route low-voltage leads in the same conduit as wirescarrying a high-current load.

• Do not route low-voltage leads adjacent to, or across wirescarrying a high-current load. If low-voltage leads must crossor run parallel to wires carrying high current, keep the leadsat 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.

Connectingthe Supply ofElectricalPower

4-1ValcoMelton

SECTION 4 - BASIC FEATURESSECTION 4 - BASIC FEATURESSECTION 4 - BASIC FEATURESSECTION 4 - BASIC FEATURESSECTION 4 - BASIC FEATURES

Introduction

DD-1 PumpAssembly

This section describes the basic features of the DD-1 pump.

Figure 4-1. DD-1 Pump Assembly

filter bracket

air filter/regulator assembly

DD-1 pump

fluid filter assembly

control box

air-purge valve assembly

discharge hose

suction hose

4-2 ValcoMelton

Section 4 - Basic Features MS005 - DD-1 Pump (before 9/06)

The control box contains the PCB assembly.

Figure 4-2. PCB Assembly Inside Control Box

PCBAssembly

Startup jumperStartup jumperStartup jumperStartup jumperStartup 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.

Yellow 3-way LED (left)Yellow 3-way LED (left)Yellow 3-way LED (left)Yellow 3-way LED (left)Yellow 3-way LED (left)This light comes on when the

left 3-way air valve is energized.

Yellow hall-effect LED (left)Yellow hall-effect LED (left)Yellow hall-effect LED (left)Yellow hall-effect LED (left)Yellow hall-effect LED (left)This light comes on when the left

hall-effect switch is operating.(Activated by presence of magnet.)

Green power LEDGreen power LEDGreen power LEDGreen power LEDGreen power LEDThis light comes on when circuitboard power is supplied. This LEDwill be illuminated if power supply andfuse are operating properly.

Yellow hall-effect LED (right)Yellow hall-effect LED (right)Yellow hall-effect LED (right)Yellow hall-effect LED (right)Yellow hall-effect LED (right)This light comes on when the righthall-effect switch is operating.(Activated by presence of magnet.)

Power connectionsPower connectionsPower connectionsPower connectionsPower connectionsBlack wire - 4White wire - 5

1-amp SLO-BLO fuse1-amp SLO-BLO fuse1-amp SLO-BLO fuse1-amp SLO-BLO fuse1-amp SLO-BLO fuse

Yellow 3-way LED (right)Yellow 3-way LED (right)Yellow 3-way LED (right)Yellow 3-way LED (right)Yellow 3-way LED (right)This light comes on when theright 3-way air valve is energized.

4-3ValcoMelton

Section 4 - Basic FeaturesMS005 - DD-1 Pump (before 9/06)

Light SequenceDuring the Pump

Cycle

Figure 4-3. Light Sequence During the Pump Cycle

The left three-way valve is energizedand the magnet moves toward theleft hall-effect switch.

The right hall-effect switch sensesthe magnet and switches power tothe left 3-way air valve.

The left hall-effect switchsenses the magnet and switchespower to the right 3-way air valve.

The right three-way valve is energized.and the magnet moves towards theright hall-effect switch.

5-1ValcoMelton

SECTION 5 - INSTALLATIONSECTION 5 - INSTALLATIONSECTION 5 - INSTALLATIONSECTION 5 - INSTALLATIONSECTION 5 - INSTALLATION

The pump requires filtered and regulated shop air; 100 psi (8 bar) maximum.

IntroductionThis section contains installation procedures for the DD-1 pump.

PowerRequirements

The pump includes a remote power supply that requires 100/120 VAC, 200/240 VAC, or 100/200VAC, 1-amp maximum, single-phase power supply withground, depending on the country where the pump is installed.

PowerConnections

The pump can be powered through either a 24-volt remote power supply, orthrough any of the following Valco controls:

• Flexoseal 350• VC450• VC850• VC9100• VC350A• VC3500• VC3700• MCP-25• MCP-42• MCP-25/MS• Modular Control System control

The 24-volt remote power supplyshould be plugged into a 110-volt walloutlet.

AirRequirements

5-2 ValcoMelton

Section 5 - Installation MS005 - DD-1 Pump (before 9/06)

Materials required for a central pumping system:

• Stainless steel pipe (schedule 40 USA)• PVC, threaded or glued (schedule 80 USA)

For long runs, it is best to position thepump in the middle.

Use “T” fittings, not “L” fittings.

Consult your adhesive supplier forspecific information about adhesivecompatibility.

Keep valve outlets plugged exceptwhen using valve to purge system.

TypicalCentralPumpingSystem

drop line.5-.75" (12-19 mm)

lateral line1.5-2" (38-51 mm)

purge valve

feed line1.5-2" (38-51 mm)

lateral line1.5-2" (38-51 mm)

purge valve (see note below)

drop line.5-.75" (12-19 mm)

optionalsparepump

1/2"reinforcedor high-pressure hose

Figure 5-1. Typical Central Pumping System

3/8"reinforcedhose

5-3ValcoMelton

Section 5 - InstallationMS005 - DD-1 Pump (before 9/06)

Installation of the DD-1 pump will depend upon the fluid you are using andyour particular application requirements. To install the DD-1 pump, followthese steps:

1. Bolt the pump to a suitable mounting structure.

The mounting-bolt pattern is rectangular—5.5" (140mm) wide by 6" (152 mm) deep (Figure 5-2). Wallmounting brackets and 55-gallon drum covers areavailable from Valco Cincinnati.

2. Install plant air supply to the solenoid valves.

If pump is equipped with a Valco Cincinnati air filter/regulator, plant air is connected to a quick-disconnectfitting in the input port of the regulator. A 10-foot air-supply hose with disconnect is available.

3. Install a second pump as a back-up if desired.

This type of installation is beneficial when the fluid issupplied in vats because vat replacement, pumpservice, and purging can be accomplished withoutsystem shutdown.

Installing thePump

4.5"(115 mm)

7.75" (197 mm)

2-1/8"(54 mm)

1/2" BSPP porton right side

7.75"(197 mm)

5.5" (140 mm)

12" (305 mm)7.5" (190 mm)

6" (152 mm)

13.75"(349 mm)

8.25"(210 mm)

2-5/8"(67 mm)

1/2" NPT porton left side

Figure 5-2. Mounting-Hole Dimensions

5-4 ValcoMelton


Figure 5-3. Wall-Mounted Pump Installation

Figure 5-4. Drum-Mounted Pump Installation

wall-mounteddiaphragm pump

55-gallon adhesive drum

Installing the Pump - Continued

5-5ValcoMelton


Installing the SingleInlet/Outlet Pump

To install a single inlet/outlet pump (Figure 5-5), follow these steps:

1. Connect the suction hose to the lower1/2" NPT orifice on the rear face of the pump.

2. Connect the other end of the suction hose to the fluid source.

Some applications will require a suction strainer. If thepump is drum mounted, the rubber suction hose canbe replaced with a drum suction tube kit that isavailable from Valco Cincinnati.

3. Connect the discharge hose to the top1/2" NPT orifice on the rear face of the pump.

In some cases, it will be necessary to connect a linefilter, air purge valve, and shutoff valve before enteringthe fluid discharge system. A surge suppressor mayalso be beneficial.

Figure 5-5. Single Inlet/Outlet Pump

suction hose

to fluid source

discharge hose

1/2" NPT inlet orifice1/2" NPT outlet orifice

5-6 ValcoMelton


To install a dual inlet/outlet pump (Figure 5-6), follow these steps:

1. Follow the steps above for connecting fittings and hoses.

All DD-1 pumps are set up for suction at the bottomports and for discharge at the top ports (front or rear).

This recirculating setup should draw more fluid intothe pump than is discharged. See Differential Flow,Dual Inlet/Outlet Pumps in this section for details.

Figure 5-6. Dual Inlet/Outlet Pump

Installing the DualInlet/Outlet Pump

5-7ValcoMelton


To install the filter/regulator assembly, follow these steps:

The glue supply lines must run from the shutoff valveto the fluid pressure regulator.

1. Install the small in-line glue filter (Figure 5-7) between the shutoffvalve (located at the end of the drop line) and the fluid regulator.

It is possible to install the filter directly onto the inputof the regulator assembly. This will eliminate the needfor a hose between the filter and regulator.

2. Connect the applicator supply hose to the output of the fluidpressure regulator.

3. Close the small valve on the end of the line.

It may be necessary to fabricate parent-machinemounting brackets for the glue regulator assembly, theencoder assembly, and the glue filter assembly.

Installing the Filter/Regulator Assembly

3.5"(89 mm)

4.25"(108 mm)

6.25"(159 mm)

3"(76 mm)

6" (152 mm)

2-5/8" (67 mm)diameter

Figure 5-8. Glue Regulator with Gauge and ProtectorFigure 5-7. Glue Filter

2-3/8" (60 mm)

9/32" (7 mm) diameter holes

Figure 5-9. Glue-Filter Mounting-Hole Dimensions Figure 5-10. Regulator Mounting-Hole Dimensions

1.75"(44 mm)

1/4" (6 mm)diameter hole(2 places)

1-9/16"(40 mm) 7/8" (22 mm)

25/64" (10 mm) diameter hole

5-8 ValcoMelton


Adjusting theHall-EffectSwitches forSingle Inlet/Outlet Pumps

The positions of the hall-effect switches and the magnet bracket assemblyare critical for proper operation of the pump. To adjust the hall-effectswitches, follow these steps:

1. Position the magnet as close as possible to the control boxwithout touching it.

The magnet should be vertically centered on thehorizontal slot containing the sockethead capscrews.

2. Remove the cover of the control box.

3. Set the air pressure to the pump so that the pump can cycleslowly (about 10 psi/1.7 bar).

4. Loosen the sockethead capscrew that is connected to the leftproximity switch.

5. Slide the switch completely to the left side.

6. Slide the switch slowly back to the right until the pump justbegins to stroke.

7. Loosen the sockethead capscrew that is connected to the rightproximity switch.

8. Slide the switch completely to the right side.

9. Slide the switch slowly back to the left until the pump strokes.

The pump should now be cycling evenly and slowly.

10. Move both switches toward the center another 1/8" (3 mm).

11. Visually check the pump by removing the guard and observingthe shaft as the pump cycles.

Shaft travel should be approximately 3/16-1/4" (21mm-6 mm) (from air chamber to where shaft is turneddown (that is, where the shaft diameter becomesreduced).

12. Re-adjust the sockethead capscrews if necessary.

13. Tighten the sockethead capscrews.

5-9ValcoMelton


The positions of the hall-effect switches and the magnet bracket assemblyare critical for proper operation of the pump. To adjust the hall-effectswitches, follow these steps:

1. Follow steps 1-12 in the above procedure.

2. As you are looking at the pump from the control-box side,determine which side of the pump you want to pump more fluid.

3. Move the corresponding hall-effect switch towards the center1/8".

Adjusting theHall-EffectSwitches forDual Inlet/Outlet Pumps

5-10 ValcoMelton


When installing the hall-effect switches onto the PCboard, the printing “on”

*****Your PCB Assembly should have FIVE connections,as shown, above.If your PCB Assembly has SIX connections, see “PCBAssembly - Second Version,” on the following page

Valve-Reversing-Control Wiring Diagram

Figure 5-11. Reversing-Control Wiring Diagram

blue

brown

left 3-way air-valve

air-valve control-board assembly

right 3-way air-valve

brow

nbr

own

brow

n

brow

nleft hall-effect

right hall-effect

[24VAC power-input connector]

* See note* See note* See note* See note* See note

5-11ValcoMelton


PCBAssembly -SecondVersion

Between the PCB assembly described in this manual and the new version(after 9/06 - manual no. MS013), a short-term replacement was built intosome pumps. If your pump includes this model PCB assembly, refer to thefollowing figure.

Connections for Left 3-way Valve

Connections for Right 3-way ValvePower connections

Figure 5-12. Valve and Power Connections for PCB Assembly - Second Version

5-12 ValcoMelton


Wiring the Control-Box Assembly to the Valves

Figure 5-13. Control-Box Assembly

Terminal 1 to item ATerminal 2 to item BTerminal 3 to items A and B

control box assembly

wiring detail (see in Figure 4-4)C

3-way air valve (left)3-way air valve (left)3-way air valve (left)3-way air valve (left)3-way air valve (left)Activated by the right hall-effect switch.Moves magnet toward the left Hall-effect switch.

3-way air valve (right)3-way air valve (right)3-way air valve (right)3-way air valve (right)3-way air valve (right)Activated by the left hall-effect switch.

Moves magnet toward the right hall-effect switch.

B

A

Figure 5-14. Wiring Detail C

blue from item C

brown from item C

6-1ValcoMelton

SECTION 6 - OPERATIONSECTION 6 - OPERATIONSECTION 6 - OPERATIONSECTION 6 - OPERATIONSECTION 6 - OPERATION

Introduction This section contains operation procedures for the DD-1 pump.

WARNING!WARNING!WARNING!WARNING!WARNING! To avoid potential accidents, Valco Cincinnatirecommends that the air supply and electric power bedisconnected from the pump when your system is not inoperation or is left unsupervised for an extended periodof time. OTHERWISE, DEATH, PERSONAL IMJURYOR DAMAGE TO EQUIPMENT COULD OCCUR.

To operate the pump, follow these steps:

1. Ensure that the air filter/regulator pressure setting is zero psi:

1a. Pull up on the regulator knob to unlock it.

1b. Turn the regulator knob counterclockwise to reduce the air-pressure setting to zero.

2. Connect the electrical power.

3. Turn on the air supply to the pump.

4. Turn the regulator knob clockwise to slowly increase the airpressure to the desired flow rate.

For the most efficient operation, the air pressure should beadjusted to the lowest cycling rate that does not decrease flow rate.This may be the maximum flow rate for your particular serviceconditions.

The pump will not be damaged if operated dry or when the pumptemporarily stops due to system requirement fulfillment. It willautomatically begin to cycle when flow is needed.

During operation of the pump, you may notice that one solenoidbecomes warm. This is a normal condition.

If the pump speeds up noticeably without a proportionate increasein flow as air pressure is increased, the pump may be beginning tocavitate.This can be caused by excessive restriction in suctionlines, or the suction line diameter may need to be larger. If suctionline checks out for size and tightness, cavitation can be stopped byturning the regulator knob counterclockwise to reduce air pressure.

Operating thePump

7-1ValcoMelton

SECTION 7 - MAINTENANCESECTION 7 - MAINTENANCESECTION 7 - MAINTENANCESECTION 7 - MAINTENANCESECTION 7 - MAINTENANCE

WARNING!WARNING!WARNING!WARNING!WARNING! There will be a small amount of system fluid remainingin the manifold and fluid chamber. This material will bereleased as the diaphragm assemblies or lower checkvalves are removed. Have rags on hand to facilitatecleanup, and take safety precautions if necessary whenusing hazardous fluids. OTHERWISE, DEATH ORPERSONAL INJURY COULD OCCUR.

To shut down the system, follow these steps:

1. Disconnect electrical power.

2. Disconnect air line from pressure regulator.

3. Depressurize pump discharge line if check valves or diaphragmsare to be serviced.

IntroductionThis section contains maintenance instructions for the DD-1 pump.

Cleaning theExterior of thePump

CAUTION!CAUTION!CAUTION!CAUTION!CAUTION! Never hose or steam-clean the unit. If the surroundingarea is cleaned in this manner, protect the unit bycovering it with plastic or other waterproof material.OTHERWISE, EQUIPMENT DAMAGE COULDOCCUR.

When cleaning the pump, keep the electrical control boxenclosure closed. OTHERWISE, EQUIPMENTDAMAGE COULD OCCUR.

To clean the exterior of the pump, follow these steps:

1. Turn off the main power.

2. Using a damp cloth, clean the cabinet with a mild soap-and-watersolution.

ShutdownProcedure

7-2 ValcoMelton

Section 7 - Maintenance MS005 - DD-1 Pump (before 9/06)

To disassemble pumps manufactured after May 1995, follow these steps:

1. Follow the shutdown procedure on page 7-1.

2. Remove the guard assembly.

3. Remove control box and valve assembly from pump body. It ismounted to the pump frame by three quick-disconnect couplings.

4. Remove magnetic element holder (wing nuts) and chain-linkshaft coupler.

5. Remove the four bolts that pass through the frame lugs at theend of the housing. Remove the diaphragm housing from frame.

6. Remove the remaining two bolts in the diaphragm housing andopen the housing.

7. Remove the diaphragm shaft assembly from the housing.

DisassemblyProcedure forPumpsManufacturedafterMay 1995

To disassemble pumps manufactured after May 1995, follow these steps:


2. Remove the control box and the valve assembly from the pumpbody.

The control box is mounted to thehandle bracket with two screws. Thevalve assemblies are mounted to themanifold with quick-disconnect fittings.

3. Remove the magnetic element holder and the chain-link shaftcoupler.

4. Remove the four bolts that pass through the frame lugs at theend of the housing.

5. Remove the diaphragm housing from the frame.

6. Remove the remaining two bolts in the diaphragm housing.

7. Open the housing.

8. Remove the diaphragm shaft assembly from the housing.

DisassemblyProcedure forPumpsManufacturedbeforeMay 1995

7-3ValcoMelton

Section 7 - MaintenanceMS005 - DD-1 Pump (before 9/06)

Teflon check valves (ball type) are standard on the DD-1 pump. Teflon isused with fluid viscosity of 500-2500 cps. Other check-valve materials, suchas Viton and stainless-steel, are also available .

The 70-durometer brown balls are standard for ink pumps, and are designedto be used with low air pressure (less than 50 psi/4.5 bar) and low-viscosityfluids (500 cps or less). The 90-durometer black balls are available only byspecial order. These balls are used for air pressure above 50 psi (4.5 bar)and low viscosity fluids (500 cps or less).

To disassemble the check valves, follow these steps:


WARNING!WARNING!WARNING!WARNING!WARNING! Discharge line must be depressurized before removingcheck valves. OTHERWISE, PERSONAL INJURYCOULD OCCUR.

2. Remove the cap and the two cap O-rings.

3. Using a small screwdriver, remove the top and bottom checkballs .

You may also turn the pump on its side and the balls will fall out.

4. Inspect the valve seat.

5. Replace the cap and the two cap O-rings.

Installing 70-durometer brown balls in high-pressure applications(greater than 50 psi/4.5 bar) will cause the pump to stall, whichmeans that tear-down of the pump will be required.

DisassemblyProcedure forCheck Valves

Figure 7-1. Location of Check Valves

location of ball duringnormal operation

typical location of ball when pump stallsdue to incorrect usage of 70 durometer balls

capO-ring

7-4 ValcoMelton

Section 7 - Maintenance MS005 - DD-1 Pump (before 9/06)

Figure 7-2. Typical Pump ReCirculating System (Dual Inlet/Outlet)

To clean recirculating/ink pumps, follow these steps:

1. Remove suction hose from bucket.

2. Pump the remaining ink in the machine back to the bucket.

3. Remove the return line from the bucket and place it into thedrain-pit grate on the floor.

4. Place the suction line into a bucket filled with water.

CleanupProcedure forRecirculating/Ink Pumps

drain gate

ink collector tray

3/4" suction line

3/4"

i.d.

hose

gravity feedto reservoir

7-5ValcoMelton

Section 7 - MaintenanceMS005 - DD-1 Pump (before 9/06)

The in-line filter should be cleaned regularly. To clean the in-line filter, followthese steps:

1. Remove the filter cap.

2. Remove the filter screen.

3. Clean the filter screen with either a mild vinegar-and-watersolution or a propane torch.

Cleaning theIn-Line Filter

filter cap—593xx081

filter body—593xx249

filter screen, 50 mesh—593xx020

O-ring—745xx059

filter body—593xx028

filter screen,50 mesh—593xx029

filter-cap plug—797xx040

washer—593xx147

filter cap—593xx031

8-1ValcoMelton

SECTION 8 - TROUBLESHOOTINGSECTION 8 - TROUBLESHOOTINGSECTION 8 - TROUBLESHOOTINGSECTION 8 - TROUBLESHOOTINGSECTION 8 - TROUBLESHOOTING

This section contains troubleshooting procedures for the DD-1 pump.Introduction

Problem Possible Cause Possible Solution

ELECTRICAL:

Power input LED out Check line fuse. Check plant power supply. Replace PC board/transformer assembly.

No electrical service Check plant power supply.

Service cable faulty Repair or replace service cable.

Line fuses out Replace line fuses.

Faulty 3-way solenoid Replace solenoid.

Faulty reed or hall-effect switches Test switches. Replace if needed

PNEUMATIC:

Regulator pressure gauge at zero Check plant air supply. Open master air valve. Turn regulator adjusting knob clockwise.

Regulator pressure gauge not at zero; solenoid valves not operating

Check air lines to valves.

MECHANICAL:

Pump will not start

Pumped solidified fluid Check strainers and filters. Service the suction and discharge lines. Service the check valves. Service the pump.

Suction leakage Test and repair suction components.

One or more check valves not seating correctly

Shut pump down and service the check valves.

Fluid flow is not steady.

Diaphragm failure Check 3-way exhaust for contamination with pumped fluid to determine which diaphragm has failed. Replace diaphragm(s).

Suction leakage Test and repair suction components.

Blocked suction line Check and clean suction strainer if used. Check installation.

One or more check valves not seating Shut pump down and service check valves.

Diaphragm failure Replace diaphragm if necessary.

Pump runs without flow.

Pump is sucking in air Check all fittings. Use pipe sealant to seal fittings.

Pump speeds up noticeably without a proportionate increase in flow as air pressure is increased.

The pump may be beginning to cavitate due to excessive restriction in suction lines or insufficient suction-line diameter.

If suction line checks out for size and tightness, cavitation can be stopped by turning the regulator knob counterclockwise to reduce air pressure.

9-1ValcoMelton

SECTION 9 - SPECIFICATIONSSECTION 9 - SPECIFICATIONSSECTION 9 - SPECIFICATIONSSECTION 9 - SPECIFICATIONSSECTION 9 - SPECIFICATIONS

This section contains specifications for the DD-1 pump.

Air Inlet: 1/4 inch NPT

Inlet: One 1/2-inch NPT, one 1/2-inch BSPP

Outlet: One 1/2-inch NPT, one 1/2-inch BSPP

Suction Lift: 18 feet (5.5 m)

Power Requirements: 100/120 VAC, one amp, single-phase with ground,

100/200 VAC, one amp, single-phase with ground,

200/240 VAC, one amp, single-phase with ground

Air Requirements: Filtered and regulated shop air; 100 psi maximum

Figure 9-1. DD-1 Inlet and Outlet Ports

Introduction

1/2" BSP port on right side1/2" NPT port on left side

9-2 ValcoMelton

Section 9 - Specifications MS005 - DD-1 Pump (before 9/06)

Figure 9-3. Fluid Discharge (Based on Water) - Liters Per Minute

Figure 9-2. Fluid Discharge (Based on Water) - Gallons Per Minute

Dis

char

ge h

ead

(psi

)

Air consumptionSCFM

Airsupplypressure(psig )

Air consumption(dm3/s)

Airsupplypressure(bar)

Dis

char

ge h

ead

(bar

)

10-1Valco Cincinnati, Inc.

SECTION 10 - PART NUMBER LISTSECTION 10 - PART NUMBER LISTSECTION 10 - PART NUMBER LISTSECTION 10 - PART NUMBER LISTSECTION 10 - PART NUMBER LIST

How to OrderParts

To order parts, please contact your closest Valco office by mail, phone, orEmail:

Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.411 Circle Freeway DriveCincinnati, OH 45246TEL: (513) 874-6550FAX: (513) 874-3612Email: [email protected]: http://www.valcomelton.com

Valco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedHortonwood 32Telford, TFI 7YN, EnglandTEL: (+44) 1952-677911FAX: (+44) 1952-677945Email: [email protected]: http://www.valco.co.uk

Valco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHStorkower Strasse 6D-15749 Gallun, GermanyTEL: (+49) 337 648 700FAX: (+49) 337 648 7070Email: [email protected]

Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Pol. Industrial Agustinoscalle G, n. 3431160 Orcoyen, Navarra, SpainTEL: (34) 948-321-580FAX: (34) 948-326-584

Germany

England

USA

Spain

10-2 Valco Cincinnati, Inc.

Section 10 - Part Number List MS005 - DD-1 Pump (before 9/06)

PumpAssemblies

Description Part Number

DD-1 pump assembly—Teflon diaphragms and check valves, dual inlet/dual outlet, 120/240VAC

562xx041

DD-1 pump assembly—Teflon diaphragms and check valves, single inlet/single outlet

562xx040

DD-1 pump assembly—EPDM diaphragms, stainless-steel check valves, dual outlet

562xx043

DD-1 pump assembly—Teflon diaphragms, stainless-steel check valves

562xx042

Pump KitsKit Part # Includes 562xx024 DD-1 pump assembly, Teflon diaphragm, stainless steel check valves—562xx042

DD-1 transformer assembly—036xx175 Power plug, 16A, 250V—061xx170

562xx030 DD-1 ink pump assembly, Teflon diaphragm, Teflon check valves, dual outlet—562xx041 Cable assembly, valve, 33-ft.—030xx738

562xx031 DD-1 ink pump assembly, Teflon diaphragm, Teflon check valves, dual outlet—562xx041 DD-1 transformer assembly—036xx175 Cable assembly, extension, 15-ft.—030xx594

562xx032 DD-1 glue pump, Teflon diaphragms and check valves, single inlet/single outlet—562xx040 Cable assembly, valve, 33-ft.—030xx738

562xx033 DD-1 pump assembly, Teflon diaphragms and check valves, single inlet/single outlet—562xx040 DD-1 transformer assembly—036xx175

562xx034 DD-1 pump assembly, EPDM diaphragms, stainless-steel check valves, dual outlet—562xx043 Cable assembly, valve, 33-ft.—030xx738

562xx035 DD-1 pump assembly, EPDM diaphragms, stainless-steel check valves, dual outlet —562xx043 DD-1 transformer assembly—036xx175

562xx036 DD-1 pump assembly, Teflon diaphragms, stainless-steel check valves—562xx042 Cable assembly, valve, 33-ft.—030xx738

562xx037 DD-1 pump assembly, Teflon diaphragms, stainless-steel check valves—562xx042 DD-1 transformer assembly—036xx175


Section 10 - Part Number ListMS005 - DD-1 Pump (before 9/06)

DD-1 Pump Parts for Assemblies562xx041,562xx040, 562xx043, and 562xx042



DD-1 Pump Parts for Assemblies562xx041,562xx040, 562xx043,and 562xx042 - Continued




Item Number Part Number Description

1 791xx046 Handle

2 581xx106 Handle bracket

3 798xx923 Screw, 3/8-16 x 1/2

4 798xx619 Hex-head cap screw

5 798xx932 Hex nut

6 797xx040 Hex-head pipe plug

7 798xx926 Screw, 3/8-16 x 3-1/4

8 798xx755 Washer, 3/8

9 560xx882 Top corner, DD-1 pump

10 798xx925 Screw, 3/8-16 x 2-1/2

11 798xx679 Hex nut, 3/8-16

12 560xx881 Bottom corner, DD-1 pump

13 560xx565 Spacer

14 797xx038 Hex-head pipe plug, 1/4

15 784xx189 Hex-head capscrew, 5/16-18 x 2-3/4, SS

16 799xx041 Hex pipe plug, 1/4

17 797xx122 Nipple, M-M 1/4

18 793xx058 Retaining ring

19 745xx820 Seal

20 560xx554

560xx633

Teflon/stainless-steel diaphragm shaft assembly (562xx026, 027, and 029)

Diaphragm shaft assembly (562xx028)

21 560xx566 Plastic foot

22 745xx035 O-ring (562xx018)

23 799xx162 Tube connector, 1/4" tube

25 797xx378 Swivel elbow-90, 1/4 tube x 1/8 NPTM

26 560xx516 Air chamber

27 560xx515 Liquid chamber

28 745xx099 O-ring




29 560xx642

560xx410

560xx603

Brown ball (562xx028)

Teflon ball (562xx026 and 562xx027)

3/4 stainless-steel ball (562xx029)

30 745xx082 O-ring

31 798xx791 Screw, #12

32 745xx031 O-ring

33 560xx483 End cap

34 798xx932 Hex nut

35 798xx808 Screw, 5/16-18 x 1-1/4

36 560xx562

560xx563

Manifold connector pipe (562xx026 and 562xx029)

Manifold support bar (562xx027 and 562xx028)

37 581xx107 Bracket

38 798xx429 Screw, 10-32 x 1-3/4

39 580xx633 Support bar

40 788xx499 Link

43 750xx015 Female swivel fitting

45 797xx006 Elbow fitting, F-M 1/4 x 1/8

48 798xx085 Screw, 10-32 x 1/2

50 560xx761 Magnet and holder assembly

56 080xx577 DD-1 pump control box assembly

57 799xx444 Hex plug, 1/2-14 BSP, STL

58 781xx331 Tag, thread ID, NPT

59 781xx332 Tag, thread ID, BSPP




Suction TubeConversionKit (560xx636)


14 794xx538 Tube support bushing

19 794xx536 Bushing, 2 NPT x 1 NPT

15 560xx838 Drum tube assembly

30 794xx038 Plug (not shown)

wall-mounted pump

55-gallonadhesive drum

19

15

14



24VDC Air-ValveAssembly(411xx434)


1 755xx029 Tubing

2 066xx003 Cord grip

3 411xx066 Air valve

Push insulation tubing over the wiresand up to the rubber grommet inside thevalves’s housing.

Strip the end of each wire 0.16” (4 mm)from the end and solder. Do not solderthe wires together.

output

exhaust input



DiaphragmShaftAssemblies

Teflon/Stainless-SteelDiaphragmShaftAssembly(560xx554)


1 791xx045 Shaft

2 560xx556 Diaphragm plate

3 560xx625 Diaphragm


5 798xx919 Diaphragm retainer screw


1 791xx045 Shaft





EPDM/Stainless-SteelDiaphragmShaftAssembly(560xx633)


1 791xx045 Shaft





Old-StyleDiaphragmShaftAssembly(560xx424)



Quantity Part Number Description

1 411xx066 3-way

1 085xx112 Fuse, 1 amp (pkg. of 5)

2 745xx820 Shaft steel, Viton

4 745xx099 O-ring, nitrile, for diaphragm chamber

4 560xx410 Ball, Teflon

2 560xx625 Diaphgram, Teflon

4 745xx031 O-ring, for end cap

4 745xx082 O-ring, for manifold/diaphragm chamber seal

4 745xx035 O-ring, for manifold/connector pipe seal


1 411xx066 3-way

1 085xx005 Fuse, 1 amp (pkg. of 5)

2 485xx015 Reed switch

2 745xx820 Shaft seal, Viton

2 793xx058 Retaining ring, shaft steel

2 560xx625 Diaphragm, Teflon



4 745xx031 O-ring, for end cap

4 745xx082 O-ring, for manifold/diaphragm chamber seal

4 745xx035 O-ring, for manifold/connector pipe seal

ReplacementParts Kits

Replacement Parts Kit for DD-1/A or DD-1/C Aluminum or PolypropyleneReplacement Parts Kit for DD-1/A or DD-1/C Aluminum or PolypropyleneReplacement Parts Kit for DD-1/A or DD-1/C Aluminum or PolypropyleneReplacement Parts Kit for DD-1/A or DD-1/C Aluminum or PolypropyleneReplacement Parts Kit for DD-1/A or DD-1/C Aluminum or Polypropylenewith Viton Check Valves, SIngle or Dual Inlet/Outlet, and 080xx059 orwith Viton Check Valves, SIngle or Dual Inlet/Outlet, and 080xx059 orwith Viton Check Valves, SIngle or Dual Inlet/Outlet, and 080xx059 orwith Viton Check Valves, SIngle or Dual Inlet/Outlet, and 080xx059 orwith Viton Check Valves, SIngle or Dual Inlet/Outlet, and 080xx059 or080xx128 Control Box080xx128 Control Box080xx128 Control Box080xx128 Control Box080xx128 Control Box

Replacement Parts Kit for DD-1/A or DD-1/C Aluminum or PolypropyleneReplacement Parts Kit for DD-1/A or DD-1/C Aluminum or PolypropyleneReplacement Parts Kit for DD-1/A or DD-1/C Aluminum or PolypropyleneReplacement Parts Kit for DD-1/A or DD-1/C Aluminum or PolypropyleneReplacement Parts Kit for DD-1/A or DD-1/C Aluminum or Polypropylenewith Viton Check Valves, SIngle or Dual Inlet/Outlet and 080xx160 Controlwith Viton Check Valves, SIngle or Dual Inlet/Outlet and 080xx160 Controlwith Viton Check Valves, SIngle or Dual Inlet/Outlet and 080xx160 Controlwith Viton Check Valves, SIngle or Dual Inlet/Outlet and 080xx160 Controlwith Viton Check Valves, SIngle or Dual Inlet/Outlet and 080xx160 ControlBoxBoxBoxBoxBox



Pump SealKits Quantity Part Number Description


2 793xx058 Retaining ring, shaft seal

2 560xx425 Diaphragm, EPDM


4 560xx642 Brown ball, 70 Duro.

4 745xx031 O-ring, Viton, for end cap

4 745xx035 O-ring, Viton, for manifold/connector pipe seal

4 745xx082 O-ring, Viton, for manifold/diaphragm chamber seal





4 745xx332 O-ring, EPDM, for diaphragm chamber


4 745xx334 O-ring, EPDM, for end cap

4 745xx335 O-ring, EPDM, for manifold/connector pipe seal

4 745xx333 O-ring, EPDM, for manifold/diaphragm chamber seal

Pump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene (forPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene (forPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene (forPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene (forPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene (forAdhesive Containing Ethyl Acetate) — 560xx635Adhesive Containing Ethyl Acetate) — 560xx635Adhesive Containing Ethyl Acetate) — 560xx635Adhesive Containing Ethyl Acetate) — 560xx635Adhesive Containing Ethyl Acetate) — 560xx635

Pump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonCheck Valves, EPDM Diaphragms, SIngle or Dual Inlet/Outlet — 560xx594Check Valves, EPDM Diaphragms, SIngle or Dual Inlet/Outlet — 560xx594Check Valves, EPDM Diaphragms, SIngle or Dual Inlet/Outlet — 560xx594Check Valves, EPDM Diaphragms, SIngle or Dual Inlet/Outlet — 560xx594Check Valves, EPDM Diaphragms, SIngle or Dual Inlet/Outlet — 560xx594






2 560xx425 Diaphragm, EPDM


4 560xx653 Ball, stainless-steel













Pump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonPump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene, VitonCheck Valves, SIngle or Dual Inlet/Outlet — 560xx560Check Valves, SIngle or Dual Inlet/Outlet — 560xx560Check Valves, SIngle or Dual Inlet/Outlet — 560xx560Check Valves, SIngle or Dual Inlet/Outlet — 560xx560Check Valves, SIngle or Dual Inlet/Outlet — 560xx560

Pump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene,Pump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene,Pump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene,Pump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene,Pump Seal Kit for DD-1/A or DD-1/C, Aluminum or Polypropylene,Stainless-Steel Check Valves, EPDM Diaphragms, SIngle or Dual Inlet/Stainless-Steel Check Valves, EPDM Diaphragms, SIngle or Dual Inlet/Stainless-Steel Check Valves, EPDM Diaphragms, SIngle or Dual Inlet/Stainless-Steel Check Valves, EPDM Diaphragms, SIngle or Dual Inlet/Stainless-Steel Check Valves, EPDM Diaphragms, SIngle or Dual Inlet/Outlet — 560xx863Outlet — 560xx863Outlet — 560xx863Outlet — 560xx863Outlet — 560xx863

Pump Seal Kits - Continued




1 755xx012 Input air hose

1 594xx113 Air filter/regulator assembly

1 703xx334 Ball valve (for 3-way valve assembly)

799xx104 Fitting, 1/2 x 1/2 NPT swivel

1 580xx941 Filter support bracket



1 795xx502 Fitting, 3/4 x 1/2 NPT steel JIC

1 755xx090 Hose, 3/4" ID, 10 ft. (3 m) with swivel fitting on both ends

1 755xx089 Hose, 3/4" ID, 6 ft. (1.8 m) with swivel fitting on both ends


1 594xx048 Air regulator assembly





1 755xx090 Hose, 3/4" ID, 10 ft. (3 m) with swivel fitting on both ends


1 594xx048 Air filter/regulator assembly



Pump SupportEquipment Kit

560xx768


560xx433


560xx430

Pump SupportEquipment



Miscellaneous

Part Number Description

030xx594 13-foot (4.0 m) connector cable, M12 5-pin connector both ends

030xx604 20-foot (6.0 m) (field-wireable)

030xx604 20-foot (6.0 m) connector cable (field-wireable)

030xx596 33-foot (10.0 m) connector cable (field-wireable)

030xx738 33-foot (10.0 m) connector cable M12 5-pin connector both ends—STANDARD CABLE

030xx739 50-foot (15.0 m) connector cable M12 5-pin connector both ends

030xx740 66-foot (120.0 m) connector cable M12 5-pin connector both ends

Power Supply Cables



Other Part Number Description

411xx434 Air valve assembly

560xx588 Drum cover (55-gallon drum)

558xx855 Pail lid for DD-1 pump with LLD

560xx813 Pail lid for DD-1 pump

560xx589 W all-mount bracket

594xx113 Air filter for DD-1 pump, 0-160 psi, 1 outlet

560xx012 Repair kit, 5:1 piston pump (Graco)

560xx013 Repair kit, 5:1 air motor (Graco)

560xx602 Seal kit for DD-1 pump

Control Boxes Part Number Description

080xx160 Hall-effect switch control box, 24V (110VAC step down to 24VAC)

080xx577 Hall-effect switch control box, 24V

11-1ValcoMelton

SECTION 11 - WARRANTYSECTION 11 - WARRANTYSECTION 11 - WARRANTYSECTION 11 - WARRANTYSECTION 11 - WARRANTY

Cold Glue Equipmentand Electronic

Controls

WarrantyInformation

Hot Melt Units,Hoses, Valves, Guns,

and RelatedEquipment

Valco Cincinnati, Inc. warrants its equipment worldwide against defects inmaterial and workmanship as outlined in this section.

Liability of the company is limited to repair of the product, or replacement ofany part shown to be defective, and does not extend to defects caused byaccidents, misuse, abuse, neglect, tampering or deterioration by corrosion.This warranty does not cover those items determined by Valco Cincinnati,Inc. to be normal wear items such as seals, O-rings, diaphragms, springs,etc.

Reconditioned equipment, unless specified otherwise at the time of purchase,will be warranted as described above for a period of ninety (90) days from thedate of shipment by Valco Cincinnati.

Components purchased by Valco Cincinnati, Inc. from others for inclusion inits products are warranted only to the extent of the original manufacturer’swarranty. In no event shall Valco Cincinnati, Inc. be liable for indirect orconsequential damages arising out of the use of Valco Cincinnati products.

This warranty is conditioned upon the prepaid return of the equipmentclaimed to be defective to Valco Cincinnati, Inc. for examination andverification. If claimed defect is verified, repairs or replacements will be madeF.O.B. Cincinnati, Ohio, U.S.A. or ex-works Telford, U.K. If the inspection ofthe equipment does notnotnotnotnot disclose any defect of workmanship or material, anynecessary repairs will be made at a reasonable charge and returntransportation will be charged.

This is the only authorized Valco Cincinnati, Inc. warranty and is in lieu of allother expressed or implied warranties, representations or any otherobligations on the part of Valco Cincinnati, Inc.

All hot melt components except cast-in heating elements are warranted for aperiod of six (6) months from the date of shipment by Valco Cincinnati. Cast-in heaters carry an additional, pro-rated warranty not to exceed three (3)years from the date of shipment by ValcoMelton, a Valco Cincinnati, Inc.company.

The warranty for cold glue equipment and electronic controls for a period ofone (1) year from the date of shipment by Valco Cincinnati, Inc.

12-1ValcoMelton

SECTION 12 - SERVICESECTION 12 - SERVICESECTION 12 - SERVICESECTION 12 - SERVICESECTION 12 - SERVICE

If a problem with your system persists, contact a ValcoMelton TechnicalSupport representative. If your need is urgent, we encourage you to contactour corporate office in Cincinnati, Ohio, U.S.A. at (513) 874-6550. If theproblem cannot be resolved, Valco Cincinnati, Inc. will promptly arrange tohave a technical representative visit your facility. Any charges for a servicecall will be quoted at that time. Any part that fails during the warranty periodshall be returned prepaid to Valco Cincinnati, Inc. by the customer fordisposition.

Upon request, ValcoMelton personnelare available to repair or replace suchparts at the customer’s facility. Chargesfor this service include travel time andexpenses.

If an equipment problem is the result of customer abuse, improper installationor operation, all travel time, labor, parts, and expenses will be charged to thecustomer.

If the responsibility for a problem cannot be absolutely determined, thecustomer will be charged for travel time and expenses only. No charge will bemade for parts and labor.

dd-1 pump · valcomelton 1-1 section 1 - introduction about this manual valco cincinnati has...

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