VALCO MELTON MCP-4J Manual Download Page 127

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MC122 - MCP-4J Control Unit

Section 8 - Part Number List

117

General Layout with one Valve and Scanner, using the Vertical w/EPC Unit 074xx084, or
Horizontal w/EPC Unit 074xx087

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Summary of Contents for MCP-4J

Page 1: ...MCP 4J Control Unit w Jam Detection Manual Number MC122 Revision Date 9 2019 Software Version C003 0002 ...

Page 2: ...Freeway Drive Suite 490 Cincinnati Ohio 45246 http www valcomelton com Part Number MC122 Written and printed in the USA Valco Cincinnati Inc 497 Circle Freeway Drive Suite 490 Cincinnati OH 45246 Tel 513 874 6550 Fax 513 874 3612 Email sales valcomelton com Web http www valcocincinnatiinc com Valco Cincinnati Limited Hortonwood 32 Telford TFI 7YN England Tel 44 1952 677911 Fax 44 1952 677945 Email...

Page 3: ...ol Unit w Jam Detection complies with the following Council Directives Safety of Machinery 2006 42 EC Low Voltage Equipment 2014 35 EU EMC 2014 30 EU Reduction of Hazardous Substances RoHS 2011 65 EC and conforms to the following standards Safety EN60204 1 2006 EN13849 1 Risk ISO12100 2010 EMC Emissions EN61000 6 4 2007 EN61000 4 2 EMC Immunity EN61000 6 2 2005 EN61000 4 3 EN61000 4 4 EN61000 4 5 ...

Page 4: ......

Page 5: ...mes Occurs 7 What to Do if Adhesive Related Fire or Explosion Occurs 8 Hose Safety Information 9 Section 3 Basic features 11 MCP 4J Control 11 Front Panel 11 Back Panel 12 Pinouts Standard 13 Pinouts Tri Valve 17 MCP 4J Control Vertical No EPC 074xx084 20 Front Panel 20 Bottom Panel 20 MCP 4J Control Vertical with EPC 074xx085 21 Front Panel 21 Bottom Panel 21 MCP 4J Control Vertical 3NC Tipsealer...

Page 6: ...heel vs Single Digit Edit 35 The Status LEDs 35 Screen Contrast Adjustment 36 First Use Setup Wizard 36 Language 36 Application 37 Measurement Mode 38 Encoder 39 Valve Type 39 Jog Mode 40 Finish Configuration 40 Additional Setup Button Parameters 41 Language 41 Pattern Entry Mode 42 Jog Mode 42 Batch Counter 42 Jam Prevention 42 Purge Signal 43 External Enable Signal 43 Output Configuration 43 Men...

Page 7: ...mation 65 Scrolling Through Valve Numbers with the Pattern Button 65 Gluing Mode 66 Scanner Lockout 67 Valve to Scanner Distance 67 Scanner Number Z Pulse 68 Jog Mode Parameter 68 Batch Counter 69 Input Values Gluing Mode 69 Glue Mode Screen Information 70 Pattern Mode 70 Stitch Mode 73 Stitch Mode Menus 74 Auto Glue Mode 74 Auto Glue Mode Menus 74 Continuous Glue Mode 75 Continuous Glue Mode Menu...

Page 8: ...al with EPC 074xx084 94 MCP 4J Vertical w o EPC 074xx085 97 MCP 4J Vertical 3NC Tipsealer 074xx086 100 MCP 4J Horizontal with EPC 074xx087 103 MCP 4J Horizontal w o EPC 074xx088 106 MCP 4J Horizontal Folding Carton Tipsealer 074xx089 109 MCP 4J Horizontal Dual External EPC 074xx090 112 Glue System Layouts with the MCP 4J 115 Layout using FC Tipsealer Unit 074xx089 115 Layout using 3NC Tipsealer Un...

Page 9: ...Clearvision 127 MCP 8 127 MCP 4 128 Plugging the Control Gluer System in the BC7 Cabinet 129 Gluer Connection Setup with 1 Network Card 129 Gluer Connection Setup with 2 Network Cards 131 Hardware Installation 131 Windows Configuration 132 Adding the Gluer Tab in BC7 system 134 Appendix C Instruction Sheets for the MCP 4J 135 ...

Page 10: ...Table of Contents MC122 MCP 4J Control Unit 6 ...

Page 11: ...asy installation and quick start up Features Capabilities The MCP 4J Control Unit works with a variety of Valco s cold glue or hot melt adhesive dispensing valves Features Capabilities of the MCP 4J Unit include Suited to high speed converting such as folding carton production envelope manufacturing paper folders book and magazine production bag making corrugated box making Multiple valves complex...

Page 12: ...Section 1 Introduction MC122 MCP 4J Control Unit 2 ...

Page 13: ...can cause puncture wounds and risk exposure to bloodborne pathogens and other debris This symbol means that Working Gloves are required This symbol means that Goggles are required This symbol indicates a Shock Hazard There is a presence of non insulated dangerous voltage within the product s enclosure This voltage may cause electrical shock or fire This symbol indicates the need to Unplug Disconne...

Page 14: ...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 jurisdictiona...

Page 15: ... correct voltage type of current fuses and other power supplies Replace worn cords hoses etc immediately FAILURE TO OBSERVE WARNING MAY RESULT IN DEATH PERSONAL INJURY AND OR EQUIPMENT DAMAGE WARNING Poor ventilation smoking and open flames can cause overheated hot melt to ignite Adequate ventilation must be provided Smoking should be prohibited in the immediate vicinity of the molten adhesive Ope...

Page 16: ...NAL INJURY COULD OCCUR WARNING Disable all triggering devices relieve all residual pressure hydraulic and air and allow adhesive to cool before attempting to disconnect guns hoses valves etc Only qualified personnel should open and service the control OTHERWISE DEATH OR PERSONAL INJURY COULD OCCUR WARNING Never point an adhesive dispensing gun valve hose air hose or anything else at yourself or an...

Page 17: ...me to heat hot melt components or adhesive OTHERWISE DEATH PERSONAL INJURY OR DAMAGE TO EQUIPMENT COULD OCCUR What to Do if Contact with Hot Adhesive Occurs If hot adhesive comes in contact with the skin do the following WARNING Do not attempt to remove heated hot melt adhesive from the skin OTHERWISE SEVERE PERSONAL INJURY AND DEATH COULD OCCUR 1 Immediately immerse the contacted area in clean co...

Page 18: ...R DAMAGE TO EQUIPMENT COULD OCCUR WARNING Exposed arcing may ignite the fume air mixture Shield all electrical equipment from melt fumes to avoid exposed arcing OTHERWISE PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR WARNING Do not use a water extinguisher to extinguish the fire OTHERWISE PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR If the hot melt adhesive ignites promptly perform the follow...

Page 19: ...ed hooks to hang hoses Do not wrap hoses over or around objects Do use a hose hanging kit P N 781xx827 Do not use the one handed one wrench technique to attach or remove hoses Do not wrench on any surface other than the large hexagon swivel nuts Do use two hands and two wrenches to tighten or loosen connections on hoses Do wrench only on large hexagon swivel nuts Do not allow hoses to rub against ...

Page 20: ...Section 2 Safety and Use MC122 MCP 4J Control Unit 10 ...

Page 21: ...l Front Panel Figure 3 1 MCP 4J Operator Panel Purge Button Trigger LEDs Valve LEDs Valve Enable Buttons 1 4 Setup Button Left Arrow Button Diagnostics Button Job Storage Recall Button Plus Button Erase Button Pattern Button Pressure Button LCD Display Minus Button Power LED Right Arrow Button ...

Page 22: ...3 2 MCP 4J Back Panel Valve Output 1 4 blue Used on 074xx089 for FC Tipsealer Scanner Input 1 4 yellow Encoder Input Enc 2 or Enc 1 out option available via kit External Communication Port Ethernet Port USB Port EPC2 Output EPC Air Pressure Input see note above Beacon Relay Outputs for Jam not available in horizontal AC Power Cable Grounding Screw Pump Power Connector EPC Air Pressure Output ...

Page 23: ...uts Standard Valve Output Valve Output Pin Description Color 1 Coil Return Brown 2 Coil Out White 3 GND Blue 4 Purge Black 5 GNDE Gray Scanner Input Valve Output Pin Description Color 1 24V Fused Brown 2 PNP Input White 3 GND Blue 4 NPN Input Black 5 GNDE Gray ...

Page 24: ...acon Pin Description Color 1 COM Brown 2 White 3 NO Beacon Blue 4 Black 5 Beacon Light Gray Pinout Drawing 1 2 3 4 5 Encoder Output Input Encoder Output Input Pin Description 1 GND 2 MCP ENC A 3 MCP 24V 4 MCP ENC B 5 MCP ENC Z 6 MCP ENC Z 7 MCP ENC B 8 MCP ENC A Pinout Drawing ...

Page 25: ...ernal EPC External EPC Pin Description Color 1 24V FUSED Brown 2 GND White 3 GND Blue 4 SIGNAL Black 5 GND Gray Pinout Drawing External Communication Port External Communication Port Pin Description 1 2 RX IN 3 TX OUT 4 5 GNDE 6 7 8 9 5V ISO Pinout Drawing 2 ...

Page 26: ...Pump Pump Pin Description Color 1 24V FUSED Brown 2 GND White 3 GND Blue 4 RX IN Black 5 Gray Pinout Drawing Used on 074xx089 for the FC Tipsealer Tipsealer Pin Description Color 1 Tipsealer Output 24V Brown 2 GND White 3 Blue 4 Black 5 Gray Pinout Drawing ...

Page 27: ...Color J5 J6 J7 J8 1 24V FUSED Brown 2 SCAN PNP1 SCAN PNP2 SCAN PNP3 SCAN PNP4 White 3 GND Blue 4 SCAN NPN1 SCAN NPN2 SCAN NPN3 SCAN NPN4 Black 5 GNDE Gray Pinout Drawing Relay Relay Pin Description Color 1 COM Brown 2 N C White 3 N O Blue 4 COM Black Pinout Drawing Relay is rated to MAX 250VAC 3A or 30VDC 3A 4 1 2 3 ...

Page 28: ...Section 3 Basic features MC122 MCP 4J Control Unit 18 Alarm Beacon Same as Standard External Communication Port Same as Standard Encoder Output Input Same as Standard Relay Same as Standard ...

Page 29: ... J2 2 3 V2 RET White J1 3 4 PE Green J1 4 5 V3 RET Yellow J1 5 6 V3 OUT Gray J1 6 7 V4 RET Pink J1 7 8 V4 OUT Red J1 8 9 PURGE GND Black J1 9 10 PURGE V1 Orange J1 10 11 PE Tan J1 11 12 V2 OUT Violet J1 12 Ch 4 only 1 V4 RET Brown J7 1 2 V4 OUT White J7 2 3 NOT CONNECTED Blue J7 3 4 PURGE GND Black J7 4 5 PURGE V4 Gray J7 5 Pinout Drawing Ch 1 4 J1 Ch 4 Only J7 ...

Page 30: ...rol Vertical No EPC Front View Bottom Panel Figure 3 4 MCP 4J Control Vertical No EPC Bottom View Valve Output 1 4 blue Scanner Input 1 4 yellow Encoder Input External Communication Port Grounding Screw EPC2 Output Beacon Relay Outputs for Jam not available in horizontal Ethernet Port USB Port AC Power Cable Pump Power Connector ...

Page 31: ... Bottom Panel Figure 3 6 MCP 4J Control Vertical with EPC Bottom View Valve Output 1 4 blue Scanner Input 1 4 yellow Encoder Input External Communication Port Grounding Screw EPC2 Output EPC Air Pressure Input see note above Beacon Relay Outputs for Jam not available in horizontal EPC Air Pressure Output Ethernet Port USB Port AC Power Cable Pump Power Connector ...

Page 32: ...ttom Panel Figure 3 8 MCP 4J Control Vertical 3NC Tipsealer Bottom View Encoder Input External Communication Port Grounding Screw EPC2 Output EPC Air Pressure Input see note above Beacon Relay Outputs for Jam not available in horizontal EPC Air Pressure Output Ethernet Port USB Port AC Power Cable Pump Power Connector Valve Output Feeder Signal Connection Manifold Connection ...

Page 33: ...CP 4J Control Horizontal with EPC Front View Back Panel Figure 3 10 MCP 4J Control Horizontal with EPC Bottom View Valve Output 1 4 blue Scanner Input 1 4 yellow Encoder Input Grounding Screw EPC2 Output EPC Air Pressure Input see note above EPC Air Pressure Output Ethernet Port USB Port Pump Power Connector AC Power Cable ...

Page 34: ...4xx088 Front Panel Figure 3 11 MCP 4J Control Horizontal No EPC Front View Back Panel Figure 3 12 MCP 4J Control Horizontal No EPC Bottom View Valve Output 1 4 blue Scanner Input 1 4 yellow Encoder Input Grounding Screw EPC2 Output Ethernet Port USB Port Pump Power Connector AC Power Cable ...

Page 35: ...ntrol Horizontal Folding Carton Tipsealer Front View Back Panel Figure 3 14 MCP 4J Control Horizontal Folding Carton Tipsealer Bottom View Valve Output 1 4 blue Scanner Input 1 4 yellow Encoder Input Grounding Screw EPC2 Output EPC Air Pressure Input see note above EPC Air Pressure Output Ethernet Port USB Port Pump Power Connector AC Power Cable ...

Page 36: ...t Panel Figure 3 15 MCP 4J Control Horizontal Dual External EPC Front View Back Panel Figure 3 16 MCP 4J Control Horizontal Dual External EPC Bottom View Valve Output 1 4 blue Scanner Input 1 4 yellow Encoder Input Grounding Screw EPC2 Output EPC1 Output Ethernet Port USB Port Pump Power Connector AC Power Cable ...

Page 37: ...alves WARNING Disconnect all power and input signal wiring before attempting to install or replace any part of the glue system Otherwise personal injury or death may occur Wiring the Scanner Cable 1 Make sure the MCP 4J power switch is OFF and the unit is unplugged 2 Cut the female connector off of the Scanner 1 cable 3 Plug the male connector on the Scanner 1 cable into the Scanner 1 input port o...

Page 38: ...Section 3 Basic features MC122 MCP 4J Control Unit 28 Wiring the Scanner Cable Continued ...

Page 39: ... s bracket to the frame of the parent machine 2 Ensure that the wheel of the encoder rides securely against the belt and does not slip 3 In the level 4 menu screen set ratio compensation to 100 pulses Figure 3 17 Example of a Wheel Driven Encoder Gear Driven Encoder The following formula can be used to determine the correct combination of gear teeth and encoder for approximately 100 pulse per inch...

Page 40: ...gear 3 Raise or lower the encoder to tighten the belt against the driver gear Ensure that the two sides of the belt are not pressed together under the wheel Due to the low torque required the belt should not be extremely tight At least 7 9 teeth should engage in the line shaft driver gear It may be necessary to fabricate an adjustable bracket to connect the encoder base to the parent machine frame...

Page 41: ... 579xx322 Control Stand only that can be used to securely mount the MCP 4J Control Unit Please contact your Valco sales representative for purchasing information 3 The Vertical Control Units are vertically mounted See the mounting footprints in the Parts List Section 4 A swivel shelf mount 583xx564 is available for horizontal units Using the Operator Interface The Operator Interface Buttons The Op...

Page 42: ... Purge Button LED is on Manual Purge Mode is on In this Mode the Valve Buttons act as purge buttons When the LED is off the Valve Buttons turn the valves on and off Valve 1 4 Buttons Pressing the individual Valve Button s allows you to tell the MCP 4J Control Unit which valves you are going to use for the job you will run The LED in the upper Left hand side of the Buttons indicates which valve is ...

Page 43: ... left corner of the screen it indicates there is an additional menu screen to the left of the current display see Figure 4 3B Press the Left Arrow Button to view the menu screen to the left of the current display Flash Memory Storage The symbol consisting of two arrows in a circular pattern indicates that a value has been changed but the change is not yet stored in the flash memory see Figure 4 4 ...

Page 44: ... Minus Button Pressing the Minus Button allows you to decrease the value of the input Erase Button Pressing the Erase Button allows you to return to the factory default settings Holding the Erase Button longer than five seconds will change all pattern settings to 0 OK Button Pressing the OK Button opens and closes the thumbwheel control It also opens highlighted menu screens for editing see exampl...

Page 45: ...on and the Plus Minus Arrow Buttons to increase decrease the value of the selected digit The Status LEDs Status LEDs The Status Display LEDs show on off status When an LED is on lit up the corresponding input or output is activated see Figure 4 6 Be sure the encoder scanners valves and the MCP 4J Control Unit have been properly mounted to the parent machine before setting up the control The glue a...

Page 46: ...you through a series of menus in order to setup your control for your unique production needs If these needs change later the settings can be changed in the setup The first time the MCP 4J Control Unit is switched on the following screen will appear Use the Plus Minus Buttons to scroll though choices If asked to enter a numerical value press the OK Button for the Thumbwheel Mode or use the Plus Mi...

Page 47: ...to partial assembly points of corrugated material in a Flexofolder gluing system end product folded flat Folding Carton Applying glue to folding carton partial assembly points end product folded flat Envelope Applying glue to envelope assembly points Packaging Applying glue to erected and filled boxes for closing sealing Core Winding Applying glue to paper stock that is wound to create roll cores ...

Page 48: ...lding Carton Envelope Packaging Core Winding and Others Measurement Mode Sets the Encoder measurement to either mm or inch Timer Mode Sets the Encoder measurement to either ms or s To set the mode to Timer the Application must be set to Timer when setting initializing parameters OR ...

Page 49: ...een Red Encoder Wheel Pulses Setup Circumference 1000 Metric 250 mm Imperial 9 84 inches 500 Metric 250 mm Imperial 9 84 inches Black Encoder Wheel Pulses Setup Circumference 1000 Metric 254 mm Imperial 10 0 inches 500 Metric 254 mm Imperial 10 0 inches Valve Type Folding Carton Envelope Packaging Timer Valve Driver Core Winding and Others Valve Type Set the valve type for valves 1 4 If the defaul...

Page 50: ...n the machine is running below a certain speed V jog Enabling jog mode allows Jog Mode Setup Menus to appear during setup this is covered later in this manual Finish Configuration All Applications You must answer Yes to the Finish Configuration prompt and press the OK Button for all changes to take effect Choosing No will return the unit to the wizard application screen ...

Page 51: ...ton Menu Use the Plus Minus Buttons to scroll through all available choices Make sure the desired choice is highlighted on the screen before moving to the next parameter setting To move though the parameter screens use the Right Left Buttons Language All Applications Language Language is a global setting This means that all screens will appear in the chosen language x3 ...

Page 52: ... be applied in a dot pattern when the machine is running below a certain speed Enabling jog mode allows Jog Mode Setup Menus to appear during setup see Section 5 Operation Batch Counter All Applications Batch Counter must be enabled in this menu Pattern Menu so individual Batch Count Menus will appear during setup see Section 5 Operation Jam Prevention Jam Prevention Enables or disables the Jam Pr...

Page 53: ...e adjusted number of cycles before running continuously open This promotes more reliable flow in case the valve is idle under high pressure for a prolonged period External Enable Signal All Applications External Enable Signal also known as web break detection When enabled this function uses Scanner 4 to enable and disable gluing Output Configuration All Applications Output Configuration Valves Set...

Page 54: ... number of patterns being used Up to ten patterns are available Menu Configuration Maximum Pressure Points Set the number of pressure points being used from two to four Tipsealer Enable Tipsealer Enables or disables the Tipsealer function which prevents valve nozzles from clogging with dried glue when the valves are not dispensing ...

Page 55: ... Section 4 Programming 45 COM Interface Option This function is an optional feature and is not included in the standard control unit Enable the Interface 1 Select System Setup menu and press OK 2 Scroll to the COM Interface x3 ...

Page 56: ...inputs There is a debounce time and signal inversion setting for each of the four inputs Each scanner input has its own screen Scanner X Setup Invert Signal ON or OFF If turned On the control will treat the scanner input as ON when the scanner signal is OFF and vice versa If turned Off the control will treat the scanner input normally Debounce Time us This is the amount of time the scanner input m...

Page 57: ... Unit Section 4 Programming 47 Enter Password To view setup and use the various functions of the MCP 4J Control Unit passwords are used This ensures safety and security of all settings To enter a password do the following ...

Page 58: ...t password level can be set individual valve settings can be viewed and changed jobs can be saved as well as loaded and the memory can be backed up The Level 2 password can be changed this is explained under the heading Level 2 Password Options Level 3 Service This password level is reserved for Authorized Service Personnel Level 4 Programmer This password level is reserved for Factory Programmers...

Page 59: ...MC122 MCP 4J Control Unit Section 4 Programming 49 Protected Level Mode Continued ...

Page 60: ...ange the Default Password for Level 2 do the following Use the Plus Minus Buttons to increase decrease the numbers and the Left Right Arrow Buttons to move from digit to digit To cancel without changing the password be sure the current password showing is correct and only after this confirmation press the OK Button When the desired password is entered press the OK Button to enter the new password ...

Page 61: ...e the Level 2 Default Password Continued The following is an example only The password can be changed to any four digit number desired If the new Level 2 password is forgotten you may call Valco Cincinnati Inc Technical Service for assistance at 513 874 6550 ...

Page 62: ... may result from improper settings All screens for configuring the valves channels are available in all applications Compensation Time On Compensation Time Ton This is the amount of time in milliseconds from when the valve is activated to when the glue is applied Increasing the ON Compensation Time will move the start of the pattern forward Off Compensation Time Toff This is the amount of time in ...

Page 63: ...nabled Valve Type The Plus Minus Buttons can be used to scroll through the different valve types available Scanner Settings Minimum Product Length The length of a product that is necessary to trigger a start signal If there are tabs and or dust causing false trigger signals increase the Minimum Product Length Maximum Product Length Only active in Auto Glue Determines the maximum pattern length in ...

Page 64: ...y Acceleration Voltage This is the voltage applied to the valve during the valve acceleration phase Spike Voltage This is the voltage applied to the valve during the spike phase Hold Voltage Value This is the voltage required to hold the valve after the Acceleration Phase and the Spike Phase Valve Timing Settings CAUTION Valve timing settings should be made by authorized Valco personnel only Accel...

Page 65: ...hannel 2 settings Repeat for all valves being used Memory The MCP 4J can store one full system backup on the internal Micro SD card as well as one on any USB flash drive If a backup is saved it will overwrite any existing backup When the system is restored from a backup it is irreversible X2 X2 X4 ...

Page 66: ...ckup saved to it it will show No Backup If a USB flash drive is inserted and has a valid backup saved to it it will show Backup Exists Pressing Save for either of these options will prompt the user with the following message SD If the Micro SD card has no backup saved to it it will show No Backup If the Micro SD card has a valid backup saved to it it will show Backup Exists Pressing Save for eithe...

Page 67: ...sh drive is inserted the control will display If a USB flash drive is inserted but has no backup saved to it it will show No Backup If pressing Load while no USB flash drive is inserted the control will display If a USB flash drive is inserted and has a valid backup saved to it it will show Backup Exists Pressing Load will prompt the user with the following message X2 X4 ...

Page 68: ...will prompt the user with the following message Initialize Settings The Initialize feature is only available for Level 4 Programmers Initialization will clear all settings back to the factory defaults all Job Files and Backup Configurations are lost Valco Cincinnati Inc highly recommends that Initialization is only performed by an authorized Valco Cincinnati Service Technician Programmer X2 X4 X2 ...

Page 69: ...om continuing normal operation or detecting further jams but serve only as an alert The messages will not clear when the detected jam is cleared They must be cleared with the OK key Depending on the settings and because the message is just a notification it is possible for the control to queue up many of these messages As a result when the OK key is pressed to clear a jam message the control will ...

Page 70: ...rmally open contact The Relay output is the male M12 on the back connector panel with the relay symbol next to it Brown and Black Pins 1 4 are common White Pin 2 is normally CLOSED and Blue Pin 3 is normally OPEN When enabled If a jam is detected the relay will turn on See the Rearm Mode section below for information on how the relay turns off Beacon Output This setting enables or disables the bea...

Page 71: ...it will scan for jams after a jam has occurred when the Rearm Mode is set to Wait for V 0 After a jam occurs and the machine stops the unit will not signal any more jams until the encoder speed is at or above this Rearm Speed setting Rearm Timeout This setting adjusts the forced stop time after a jam is detected The unit will not turn the Machine Stop Output or Beacon Output off until this time ha...

Page 72: ... Setup Wizard it is necessary to input the encoder parameters on this screen The following tables may be helpful Red Encoder Wheel Black Encoder Wheel Pulses Setup Circumference Pulses Setup Circumference 1000 Metric 250 mm 1000 Metric 254 mm Imperial 9 84 inches Imperial 10 0 inches 500 Metric 250 mm 500 Metric 254 mm Imperial 9 84 inches Imperial 10 0 inches 250 Metric 250 mm 250 Metric 254 mm I...

Page 73: ...ncoder input and no second option installed If a second encoder input is used there is a second set of menus to the right that configures that channel Direction Detection Clockwise Counter Clockwise Off When in Off the encoder can spin in either direction and the control will register the movement When in Clockwise or Counter Clockwise the control will only register encoder movement in the specifi...

Page 74: ...64 Status Bar Communication status is shown in the bottom right corner of the status bar The icon above indicates that the last transmission was successful If a is displayed the interface has not yet received data or the last transmission had errors ...

Page 75: ... highlighted value press the OK Button for the thumbwheel or press the Plus Minus Buttons for single digit editing see Section 4 Programming Thumbwheel vs Single Digit Edit The default screen always shows valve 1 Before entering any data it is advisable to check the left side of the screen for the valve number Make certain the desired valve number appears before entering data Depending on the pass...

Page 76: ... Mode is available in the following applications Corrugated Folding Carton Envelope Timer Core Winding Packaging and Others 2 Stitch Applies adhesive in a stitch like pattern The Stitch Glue Mode is available in the following applications Folding Carton Envelope Packaging Timer and Others 3 Continuous Applies adhesive continuously when speed is higher than the Vmin setting The Continuous Glue Mode...

Page 77: ...the product The Auto Glue Glue Mode is available in the following applications Corrugated Folding Carton Packaging Core Winding Timer Valve Driver and Others Scanner Lockout Available in Corrugated Folding Carton Envelope Packaging Timer Core Winding and Others Scanner Lockout Enter a product length to act as a scanner lockout when holes writing or other items produce a false trigger by the scanne...

Page 78: ...ht corner see Valve to Scanner Distance Scanner Number above Jog Mode Parameter Available in Corrugated Folding Carton Envelope Packaging Core Winding and Others The Jog Mode Parameter is only available when Jog Mode is enabled Jog Mode On Off Turn the jog mode on and off with the switch using the Plus Minus Buttons Jog Gap Distance This is the distance between the glue dots while the machine is r...

Page 79: ...products the adhesive pattern will be applied to one after the other without skipping any products Input Values Gluing Mode Depending on the application and the gluing mode chosen input your values The screens above are unique to each gluing mode Each screen is designed to show comprehensive information at a glance The following subsection Glue Mode Screen Information explains how Folding Carton E...

Page 80: ...e 1 Set the Delay Length for pattern 1 The Delay Length for pattern 1 is the measurement from the first edge of the product to where you want the first glue line to start Pattern Mode Example 2 Press the Right Arrow Button to view the Pattern Length for pattern 1 The Pattern Length is the length of the glue line for the pattern number indicated Press the OK Button to view the thumbwheel and use th...

Page 81: ...ay Length for pattern 2 so the next pattern does not interfere with the previous pattern This number can be adjusted if desired 4 Press the Right Arrow Button to view the Pattern Length for pattern 2 Press the OK Button to view the thumbwheel and use the Plus Minus Buttons to change Press the OK Button to enter the setting 5 Press the Right Arrow Button to view the Delay Length for pattern 3 ...

Page 82: ... for pattern 3 Press the OK Button to view the thumbwheel and use the Plus Minus Buttons to change Press the OK Button to enter the setting 7 All three patterns are now set To review them use the Left Arrow Button 8 Use the Left and Right Arrow Buttons to review all information as desired All three patterns have been set and the Pattern Glue Mode for Valve 1 is now ready ...

Page 83: ... Not Possible Warning If a valve channel has a long pattern configured with a small stitch length and stitch gap it is possible to reach maximum table storage maximum is 500 positions If the pattern entered exceeds the maximum it may be cut short when gluing is attempted When a pattern is entered the control calculates each time the valve is turned off or on each transition between stitches storin...

Page 84: ... one Start Delay Length the length from the leading edge of the product to the beginning of the glue line and one End Delay Length the end of the glue line to the trailing edge of the product are entered The glue is applied automatically based on the length of the scanner signal Auto Glue Mode Menus ...

Page 85: ... In Continuous Glue Mode the glue will flow continuously as long as the speed is greater than Vmin Continuous Glue Mode Menus Glue Pattern Length Range When adjusting the glue pattern length the limits are Minimum Length 0 0mm Maximum Length 258 01 6554mm Pattern Length ...

Page 86: ... type message i e low voltage alarm or the end of the queue Jam Channel Configuration Menus There are four of these menus one for each of the scanner inputs They are located after the pattern screen for the last valve enabled i e if there are two valves on the unit these menus will show after the valve 2 pattern screen They are accessed by pressing the pattern key There are four screens one for ea...

Page 87: ...Value Used to increase decrease the current pressure The Pressure Offset is used to do minor pressure adjustments instantly It does not change the pressure table profile Minimum Speed Pressure All Applications V m min The machine speed P The percent of pressure Press the Left Right Buttons as indicated by Left Right Arrow Icons on the bottom of the screen see example at left to see all available p...

Page 88: ...re points on the pressure curve are input during setup See Section 4 Programming Additional Setup Button Parameters Menu Configuration Pressure Point 1 PT1 Pressure Point 2 PT2 Speed Pressure Graphs Examples The graph above illustrates two three and four points on the pressure curve with Jog Mode off and on The majority of projects will be fine with the Jog Mode off and only two points on the pres...

Page 89: ...he control is purging Purge Pressure All Applications Purge Pressure The pressure setting when the machine is at zero speed The number on the left side of the pressure screen refers to the EPC number two EPCs are available on some models of the MCP 4J Control Unit See the Parts List Section for details The second EPC is the 0 10 Volt output for speed tracking Both EPCs are programmed in the same w...

Page 90: ...annot set speeds to where you want them the Plus Minus Arrow Buttons will not increase or decrease the setting check all four of the settings Use the Left Arrow and Right Arrow Buttons to move through all pressures speeds and check them Reset them as necessary using the Plus Minus Arrow Buttons You can also go back to factory defaults by pressing the Erase Button until the setting will no longer c...

Page 91: ...s enabled or disabled A voltage reading of 0 0 could indicate a blown fuse See Section 8 Parts List for fuse numbers and placement Scanner and Trigger Status The scanner trigger information screen displays the scanner and trigger settings Version Information The version information screen displays the CPU the Logic PLD and the MCP 4J name Control Information The control information screen displays...

Page 92: ... The Job Save Recall Mode allows the MCP 4J Control Unit to save and recall up to 100 different jobs via a Micro SD card for fast programming Load Load a previously saved job Load a Job Any level including 0 can load a job When Load is highlighted press the OK Button to enter a job number Use the Plus Minus Buttons to change the job number ...

Page 93: ...aded Enter the job number and information in a chart see Appendix A Job Charts for quick job set up Also jobs can be overwritten so it is important to keep track of them Save a Job Only password levels 2 or higher can save a job Save Save all settings under a job number Press the Right Arrow Button to highlight Save and then press the OK Button Use the Plus Minus Buttons to change the job number ...

Page 94: ...on MC122 MCP 4J Control Unit 84 Save a Job Continued Press the Right Arrow Button to highlight OK Press the OK Button to save the job Be sure to write the job name and job number for reference see Appendix A Job Charts ...

Page 95: ...hold it so that the applicator head is at the top The fluid pressure should then be set to 4 bar and the solenoid should be fired until all the air is out and a flow of glue is present Performing Downtime Maintenance The type of downtime maintenance that is necessary for the MCP 4J Control Unit depends on the length of time the unit is down During short periods of downtime such as order changeover...

Page 96: ...p 5 Next remove the lid cover screws on the surface of the melt unit This allows you to remove the pump and heating grid from the tank itself 6 Once the screws are removed use gloves to lift the lid and pump assembly out of the molten tank 7 Place the lid and pump assembly in a vertical position on a clean solid flat surface and allow the excessive adhesive to slowly drip off of the fins 8 Take th...

Page 97: ...und in the installation kit 3 Turn on power to the control 4 Wait approximately 1 minute until the control starts normally 5 Turn off power to the control 6 Remove the programming USB Flash Drive 7 Resume normal use software has been updated The software version can be verified by pressing the Diagnostic button and using the left or right arrow keys to access the Version Information screen USB Fla...

Page 98: ...ection 6 Maintenance MC122 MCP 4J Control Unit 88 Replacing Micro SD Card 1 Loosen the four screws holding the control lid There are two on either side 2 Locate the Micro SD card Micro SD card and holder ...

Page 99: ...ntinued 3 With a fingertip slide the card holder in the direction shown by the arrow to release the holder cover 4 Lift the holder cover 5 Remove and replace the Micro SD card 6 Close the holder cover Replace the four 4 screws that hold the control lid Micro SD card holder open ...

Page 100: ...Section 6 Maintenance MC122 MCP 4J Control Unit 90 ...

Page 101: ... 6554mm Number of scanner inputs Up to 4 with scanner lockout Glue pattern tolerance Less than 1 mm 0 4 inches at 610 m min 2000 ft min Job storage memory 100 jobs Max Operating Ambient Temperature 60o C or 140 o F Miscellaneous Encoder based or timer mode Multi valve complex glue pattern capabilities Continuous and Stitch pattern gluing Adjustable minimum speed Inch or metric calibration CE compl...

Page 102: ...Section 7 Specifications MC122 MCP 4J Control Unit 92 ...

Page 103: ... England Valco Cincinnati Limited Hortonwood 32 Telford TFI 7YN England TEL 44 1952 677911 FAX 44 1952 677945 Email sales valco co uk Web http www valco co uk Germany alco Cincinnati GmbH Bonnerstrasse 349 40589 Dusseldorf Benrath Germany Tel 49 211 984 798 0 Fax 49 211 984 798 20 Spain Melton S L U Pol Industrial Agustinos calle G n 34 31160 Orcoyen Navarra Spain Tel 34 948 321 580 Fax 34 948 326...

Page 104: ...Section 8 Part Number List MC122 MCP 4J Control Unit 94 MCP 4J Vertical with EPC 074xx084 JWT6119 dwg ...

Page 105: ...12 CABLE ASSY 029XX821 1 13 RIBBON CABLE ASSY 033XX166 1 14 SCREW 091XX267 2 15 TRANSFORMER 551XX024 1 16 FLAT WASHER 784XX183 1 17 SCREW 798XX593 1 18 SCREW 784XX180 1 19 STUD GROUND 091XX519 1 20 LOCK WASHER 784XX375 2 21 HEX NUT 798XX301 1 22 HEX NUT 798XX299 1 23 LOCK WASHER 784XX308 3 24 PLUG ROUND HOLE 782XX667 1 25 SCREW 884XX486 8 26 NUT 884XX219 36 27 SCREW 784XX259 4 28 PLATE COVER MCP 4...

Page 106: ...REW CV10521 5 46 LABEL STOCK SILVER 781XX780 1 47 HOLE PLUG 781XX228 1 48 WIRE 540XX090 3 49 WIRE TERMINAL RING 075XX075 3 50 WIRE TERMINAL 075XX078 3 51 TERMINAL 091XX453 2 52 CABLE ASSY 029XX808 1 53 SOFTWARE MCP 4J BOOTLOADER 119XX304 1 54 SOFTWARE MCP 4J WITH JAM 119XX305 1 55 MEMORY MICRO SD 118XX187 1 56 INSTALLATION KIT ASSY MCP 4 091XX586 1 57 BOX MCP 4 MCP 4P 730XX060 1 58 FOAM FOR MCP 4 ...

Page 107: ...MC122 MCP 4J Control Unit Section 8 Part Number List 97 MCP 4J Vertical w o EPC 074xx085 KMP0153 dwg ...

Page 108: ...ASSY 029XX821 1 13 RIBBON CABLE ASSY 033XX166 1 14 SCREW 091XX267 2 15 TRANSFORMER TOROID MCP 4X 551XX024 1 16 FLAT WASHER 784XX183 1 17 WASHER 798XX593 1 18 SCREW 784XX180 1 19 STUD GROUND 091XX519 1 20 LOCK WASHER 784XX375 2 21 HEX NUT 798XX301 1 22 HEX NUT 798XX299 1 23 LOCK WASHER 784XX308 3 24 PLUG ROUND HOLE 782XX667 1 25 SCREW 884XX486 8 26 NUT 884XX219 36 27 SCREW 784XX259 4 28 PLATE COVER...

Page 109: ...83XX824 1 45 SCREW CV10521 5 46 LABEL STOCK SILVER 781XX780 1 47 HOLE PLUG 781XX228 1 48 WIRE 540XX090 3 49 WIRE TERMINAL 075XX075 3 50 WIRE TERMINAL 075XX078 3 51 TERMINAL 091XX453 2 52 CABLE ASSY MCP 4 POWER INPUT 029XX808 1 53 SOFTWARE MCP 4J BOOTLOADER 119XX304 1 54 SOFTWARE MCP 4J WITH JAM 119XX305 1 55 MEMORY MICRO SD 118XX187 1 56 INSTALLATION KIT ASSY MCP 4 091XX586 1 57 BOX MCP 4 MCP 4P 7...

Page 110: ...Section 8 Part Number List MC122 MCP 4J Control Unit 100 MCP 4J Vertical 3NC Tipsealer 074xx086 JWT6546 dwg ...

Page 111: ...NIFOLD MCP 4J BR 029XX820 1 12 CABLE ASSY 029XX821 1 13 RIBBON CABLE ASSY 033XX166 1 14 SCREW 091XX267 2 15 TRANSFORMER TOROID MCP 4X 551XX024 1 16 FLAT WASHER 784XX183 1 17 WASHER 798XX593 1 18 SCREW 784XX180 1 19 STUD GROUND 091XX519 1 20 LOCK WASHER 784XX375 2 21 HEX NUT 798XX301 1 22 HEX NUT 798XX299 1 23 LOCK WASHER 784XX308 3 24 PLUG ROUND HOLE 782XX667 1 25 SCREW 884XX486 8 26 NUT 884XX219 ...

Page 112: ...K 583XX824 1 45 SCREW CV10521 5 46 LABEL STOCK SILVER 781XX780 1 48 WIRE 540XX090 3 49 WIRE TERMINAL 075XX075 3 50 WIRE TERMINAL 075XX078 3 51 TERMINAL 091XX453 2 52 CABLE ASSY MCP 4 POWER INPUT 029XX808 1 53 SOFTWARE MCP 4J BOOTLOADER 119XX304 1 54 SOFTWARE MCP 4J WITH JAM 119XX305 1 55 MEMORY MICRO SD 118XX187 1 56 INSTALLATION KIT ASSY MCP 4 091XX586 1 57 BOX MCP 4 MCP 4P 730XX060 1 58 FOAM FOR...

Page 113: ...MC122 MCP 4J Control Unit Section 8 Part Number List 103 MCP 4J Horizontal with EPC 074xx087 JWT6113 dwg ...

Page 114: ...1 13 HOLE PLUG 782XX675 1 15 TRANSFORMER 551XX024 1 16 FLAT WASHER 784XX183 1 17 WASHER 798XX593 1 18 SCREW 784XX180 1 19 STUD GROUND 091XX519 1 20 LOCK WASHER 784XX375 2 21 HEX NUT 798XX301 1 22 HEX NUT 798XX299 1 23 LOCK WASHER 784XX308 3 24 PLUG ROUND HOLE 782XX667 1 25 SCREW 884XX486 8 26 NUT 884XX219 26 27 SCREW 784XX259 4 28 SCREW 784XX660 8 29 PANEL OVERLAY MCP 4 782XX658 1 30 BEZEL MCP 4 H...

Page 115: ... WIRE 540XX090 3 47 WIRE TERMINAL 075XX075 3 48 WIRE TERMINAL 075XX078 3 49 TERMINAL TAB 091XX453 2 50 CABLE ASSY 029XX819 1 51 CABLE ASSY 029XX808 1 52 SOFTWARE MCP 4J BOOTLOADER 119XX304 1 53 SOFTWARE MCP 4J WITH JAM 119XX305 1 54 MEMORY MICRO SD 118XX187 1 55 INSTALLATION KIT ASSY MCP 4 091XX586 1 56 BOX MCP 4 MCP 4P 730XX060 1 57 FOAM FOR MCP 4 MCP 4P 730XX061 1 ...

Page 116: ...Section 8 Part Number List MC122 MCP 4J Control Unit 106 MCP 4J Horizontal w o EPC 074xx088 KMP0154 dwg ...

Page 117: ...ABLE ASSY 029XX821 1 13 HOLE PLUG 782XX675 1 15 TRANSFORMER 551XX024 1 16 FLAT WASHER 784XX183 1 17 WASHER 798XX593 1 18 SCREW 784XX180 1 19 STUD GROUND 091XX519 1 20 LOCK WASHER 784XX375 2 21 HEX NUT 798XX301 1 22 HEX NUT 798XX299 1 23 LOCK WASHER 784XX308 3 24 PLUG ROUND HOLE 782XX667 1 25 SCREW 884XX486 8 26 NUT 884XX219 26 27 SCREW 784XX259 4 28 SCREW 784XX660 8 29 PANEL OVERLAY MCP 4 782XX658...

Page 118: ...45 HOLE PLUG 781XX228 3 46 WIRE 540XX090 3 47 WIRE TERMINAL 075XX075 3 48 WIRE TERMINAL 075XX078 3 49 TERMINAL TAB 091XX453 2 50 CABLE ASSY 029XX819 1 51 CABLE ASSY 029XX808 1 52 SOFTWARE MCP 4J BOOTLOADER 119XX304 1 53 SOFTWARE MCP 4J WITH JAM 119XX305 1 54 MEMORY MICRO SD 118XX187 1 55 INSTALLATION KIT ASSY MCP 4 091XX586 1 56 BOX MCP 4 MCP 4P 730XX060 1 57 FOAM FOR MCP 4 MCP 4P 730XX061 1 ...

Page 119: ...MC122 MCP 4J Control Unit Section 8 Part Number List 109 MCP 4J Horizontal Folding Carton Tipsealer 074xx089 BAW 3667 dwg ...

Page 120: ...12 CABLE ASSY 029XX821 1 13 HOLE PLUG 782XX675 1 14 CABLE ASSY 029XX825 1 15 TRANSFORMER 551XX024 1 16 FLAT WASHER 784XX183 1 17 SCREW 798XX593 1 18 SCREW 784XX180 1 19 STUD GROUND 091XX519 1 20 LOCK WASHER 784XX375 2 21 HEX NUT 798XX301 1 22 HEX NUT 798XX299 1 23 LOCK WASHER 784XX308 3 24 PLUG ROUND HOLE 782XX667 1 25 SCREW 884XX486 8 26 NUT 884XX219 26 27 SCREW 784XX259 4 28 SCREW 784XX660 8 29 ...

Page 121: ...X090 3 47 WIRE TERMINAL 075XX075 3 48 WIRE TERMINAL 075XX078 3 49 TERMINAL TAB 091XX453 2 50 CABLE ASSY 029XX819 1 51 CABLE ASSY 029XX808 1 52 SOFTWARE MCP 4J BOOTLOADER 119XX304 1 53 SOFTWARE MCP 4J WITH JAM 119XX305 1 54 MEMORY MICRO SD 118XX187 1 55 INSTALLATION KIT ASSY MCP 4 091XX586 1 56 BOX MCP 4 MCP 4P 730XX060 1 57 FOAM FOR MCP 4 MCP 4P 730XX061 1 53 SOFTWARE MCP 4J WITH JAM 119XX305 1 54...

Page 122: ...Section 8 Part Number List MC122 MCP 4J Control Unit 112 MCP 4J Horizontal Dual External EPC 074xx090 KMP0159 dwg ...

Page 123: ... 029XX645 4 12 CABLE ASSY 029XX821 1 13 HOLE PLUG 782XX675 1 14 SCREW 784XX263 2 15 TRANSFORMER 551XX024 1 16 FLAT WASHER 784XX183 1 17 SCREW 798XX593 1 18 SCREW 784XX180 1 19 STUD GROUND 091XX519 1 20 LOCK WASHER 784XX375 2 21 HEX NUT 798XX301 1 22 HEX NUT 798XX299 1 23 LOCK WASHER 784XX308 3 24 PLUG ROUND HOLE 782XX667 1 25 SCREW 884XX486 8 26 NUT 884XX219 26 27 SCREW 784XX259 4 28 SCREW 784XX66...

Page 124: ...10521 5 44 LABEL STOCK SILVER 781XX780 1 45 HOLE PLUG 781XX228 3 46 WIRE 540XX090 3 47 WIRE TERMINAL 075XX075 3 48 WIRE TERMINAL 075XX078 3 49 TERMINAL TAB 091XX453 2 50 CABLE ASSY 029XX819 1 51 CABLE ASSY 029XX808 1 52 SOFTWARE MCP 4J BOOTLOADER 119XX304 1 53 SOFTWARE MCP 4J WITH JAM 119XX305 1 54 MEMORY MICRO SD 118XX187 1 55 INSTALLATION KIT ASSY MCP 4 091XX586 1 56 BOX MCP 4 MCP 4P 730XX060 1 ...

Page 125: ...l Unit Section 8 Part Number List 115 Glue System Layouts with the MCP 4J Layout using FC Tipsealer Unit 074xx089 Valco Cinc innati Inc 411 Circ le Freeway Drive Cincinnati OH 45246 513 874 6550 155XX304 REV ___ VDD 1000 ...

Page 126: ...Section 8 Part Number List MC122 MCP 4J Control Unit 116 Layout using 3NC Tipsealer Unit 074xx086 1 55 XX30 4 REV ___ VD D 1000 ...

Page 127: ...List 117 General Layout with one Valve and Scanner using the Vertical w EPC Unit 074xx084 or Horizontal w EPC Unit 074xx087 V a l co Cinci n n ati Inc 411 C i r cl e F r e e way Drive Cin cinnati OH 452 4 6 513 87 4 6 5 50 155X X304 REV ___ VDD 1000 ...

Page 128: ... MCP 4J Control Unit 118 Layout for a Contact Boardrunner Setup using the Vertical w EPC Unit 074xx084 Valco C in c i nn ati I nc 4 11 Cir c le Fr ee wa y D r iv e Cinci n n ati OH 4 524 6 513 8 74 6 550 155 XX 304 R EV _ __ VDD 1000 ...

Page 129: ...l Unit Section 8 Part Number List 119 Layout where an External EPC is used on the External EPC Unit 074xx090 Valco Ci n cinnat i I nc 411 Circle Fr eeway Dr i v e Cincinnati OH 45246 513 874 6550 155XX304 REV ___ VDD 1000 ...

Page 130: ...Section 8 Part Number List MC122 MCP 4J Control Unit 120 ...

Page 131: ...of the use of Valco Cincinnati products This warranty is conditioned upon the prepaid return of the equipment claimed to be defective to Valco Cincinnati Inc for examination and verification If claimed defect is verified repairs or replacements will be made F O B Cincinnati Ohio U S A or ex works Telford U K If the inspection of the equipment does not disclose any defect of workmanship or material...

Page 132: ...Section 9 Warranty MC122 MCP 4J Control Unit 122 ...

Page 133: ...oted at that time Any part that fails during the warranty period shall be returned prepaid to Valco Cincinnati Inc by the customer for disposition Upon request ValcoMelton personnel are available to repair or replace such parts at the customer s facility Charges for this service include travel time and expenses If an equipment problem is the result of customer abuse improper installation or operat...

Page 134: ...Section 10 Service MC122 MCP 4J Control Unit 124 ...

Page 135: ...x A Job Charts 125 Appendix A Job Charts Use the following tables to record saved jobs for quick reference and to prevent duplication erasure of important job information The tables may be copied for use Job Number Job Name Description ...

Page 136: ...Appendix A Job Charts MC122 MCP 4J Control Unit 126 Job Number Job Name Description ...

Page 137: ...tem Connectivity 127 Appendix B System Connectivity Clearvision MCP 8 1 Go to MCP 8 System and unlock the control to access level 4 2 Select the Setup Menu 3 Select option Ethernet Interface 4 Select the option 192 168 30 91 and apply changes ...

Page 138: ...ivity MC122 MCP 4J Control Unit 128 MCP 8 Continued 5 Reset the system using the main power switch MCP 4 1 Go to MCP 4 System and unlock the control to access level 4 2 Select the Setup Menu 3 Select the Communication COMM icon ...

Page 139: ...g on how many devices are connected to the Cabinet the system may have one or two 4 port network camera cards If BC7 Cabinet has one network card the Control Gluer System should be connected through the port NIC3 If BC7 Cabinet has a second network card the Control Gluer System should be connected through the port NIC7 Login in BC7 System as Level 4 user select the required option and follow its i...

Page 140: ...evice labeled NIC3 and select properties 4 Next click on Internet Protocol Version 4 5 Then click on the Properties button 6 Select the Use the following IP address option As above set the following IP address to 192 168 30 1 Subnet mask to 255 255 255 0 7 Click the OK button and close 8 Plug the Gluer Ethernet cable into the port NIC3 ...

Page 141: ...s installation follow the next steps If the network card is already placed in the Cabinet skip them and go directly to Windows Configuration 1 With the cabinet powered OFF insert the new network card into the MBM bottom expansion slot PCIe x16 shown here 2 Fasten the card to the chassis with an M3 screw eg 784XX433 M3 x 4 SS 3 Power on the BoxChek7 cabinet ...

Page 142: ...rk interfaces the card may not be seated properly In case the network card was installed previously the connection appears as NCI7 and with network cable unplugged 4 Connect the Gluer Ethernet cable to the NIC7 5 In case you are installing the second network card look for the network connection in Windows that changes state when the cable is plugged in This could say Identifying or Connected or an...

Page 143: ...hat the status changed to Identifying or Connected or anything except Network cable unplugged 6 Right click on the device and select properties 7 Next click on Internet Protocol Version 4 8 Then click on the Properties button 9 Select the Use the following IP address option As above set the following IP address to 192 168 30 1 Subnet mask to 255 255 255 0 10 Click the OK button and close ...

Page 144: ...C7 System the BC7 System needs to read the Glue Controller Follow the next steps in order to add the Gluer Tab a level 4 user login is required 1 Navigate to the Settings General 2 Locate the next available System System 2 3 4 and select Gluer 3 Use the upper left power button to restart the system 4 Once the system restarts the new Gluer tab is now available ...

Page 145: ... kits and functions associated with the MCP 4J control system Document Number Title IS0368 MCP 4J Control Unit Quick Start Guide IS0369 MCP 4J Encoder Option Kit Instructions IS0371 Adding External Comm Port to Horizontal MCP 4J Units IS0372 Adding Beacon and Relay Outputs for Jam Detection to Horizontal MCP 4J Units IS0373 Adding the Folding Carton Tipsealer to MCP 4J Units ...

Page 146: ...Appendix C Instruction Sheets for the MCP 4J MC122 MCP 4J Control Unit 136 ...

Page 147: ...MCP 4J MCP 4J MCP 4J MCP 4J MCP 4J Quick Start Guide Quick Start Guide Quick Start Guide Quick Start Guide Quick Start Guide IS0368 IS0368 IS0368 IS0368 IS0368 1 2018 1 2018 1 2018 1 2018 1 2018 ...

Page 148: ...y interruption will corrupt the data Follow all safety information carefully Only qualified personnel should install and service the equipment Read all safety information in all manuals before working with any equipment Mounting the Control Unit The Horizontal MCP 4J Control Unit can be mounted on any flat stable surface close to the machine glue station 1 Be sure the four 4 rubber feet horizontal...

Page 149: ...nd only that can be used to securely mount the MCP 4J Control Unit Please contact your Valco sales representative for purchasing information 3 The Vertical Control Units are vertically mounted See the mounting footprints below 4 A swivel shelf mount 583xx564 is available for horizontal units Mounting the Control Unit Continued ...

Page 150: ...0 pulses per inch 25 4 mm of product travel should be supplied to the VC3500 If less than 100 pulses per inch 25 4 mm are supplied poor resolution may result in pattern placement errors If more than 100 pulses per inch 25 4 mm are supplied the maximum specified speed of 2000 feet min 610 m min must be reduced There are two primary types of encoders Wheel driven encoder Gear driven encoder Red Enco...

Page 151: ...3 Raise or lower the encoder to tighten the belt against the driver gear Ensure that the two sides of the belt are not pressed together under the wheel Due to the low torque required the belt should not be extremely tight Mounting the Encoder Continued At least 7 9 teeth should engage in the line shaft driver gear It may be necessary to fabricate an adjustable bracket to connect the encoder base t...

Page 152: ...368 Valco Melton 6 Connecting the Cables and Air Lines MCP 4J Control For the EPC Air Pressure Input use an 8mm air line OR use the 1 4 tube adapter that is included in your Installation Kit MCP 4J Control Vertical No EPC 074xx084 ...

Page 153: ...Valco Melton 7 IS0368 MCP 4J Quick Start Guide MCP 4J Control Vertical with EPC 074xx085 MCP 4J Control Vertical 3NC Tipsealer 074xx086 ...

Page 154: ...MCP 4J Quick Start Guide IS0368 Valco Melton 8 MCP 4J Control Horizontal with EPC 074xx087 MCP 4J Control Horizontal No EPC 074xx088 ...

Page 155: ...Valco Melton 9 IS0368 MCP 4J Quick Start Guide MCP 4J Control Horizontal Folding Carton Tipsealer 074xx089 MCP 4J Control Horizontal Dual External EPC 074xx090 ...

Page 156: ...MCP 4J Quick Start Guide IS0368 Valco Melton 10 Operator Panel ...

Page 157: ...essure Button Pressure Button Pressure Button Pressure Button Pressing the Pressure Button allows you to begin to enter the pressure settings Setup Button Setup Button Setup Button Setup Button Setup Button Pressing the Setup Button allows you to begin to setup the MCP 4J Control Unit Diagnostics Button Diagnostics Button Diagnostics Button Diagnostics Button Diagnostics Button Pressing the Diagno...

Page 158: ...ou are going to use for the job you will run The LED in the upper Left hand side of the Buttons indicates which valve is selected Navigation Buttons There are 2 Navigation Buttons the Right Arrow Button and the Left Arrow Button Right Arrow Button Right Arrow Button Right Arrow Button Right Arrow Button Right Arrow Button Pressing the Right Arrow Button moves the cursor to the right highlighting e...

Page 159: ...Arrow Symbol appears in the lower left corner of the screen it indicates there is an additional menu screen to the left of the current display see Figure E Press the Left Arrow Button to view the menu screen to the left of the current display Navigation Buttons Continued Figure D Figure E Flash Memory Storage The symbol consisting of two arrows in a circular pattern indicates that a value has been...

Page 160: ...inus Button Minus Button Pressing the Minus Button allows you to decrease the value of the input Erase Button Erase Button Erase Button Erase Button Erase Button Pressing the Erase Button allows you to return to the factory default settings Holding the Erase Button longer than five seconds will change all pattern settings to 0 OK Button OK Button OK Button OK Button OK Button Pressing the OK Butto...

Page 161: ...formation may be edited with the Plus Minus Buttons for single digit editing or the OK Button may be pressed to bring up a thumbwheel for more detailed editing In Thumbwheel Edit use the Right Left Arrow Buttons to select the digit position and the Plus Minus Arrow Buttons to increase decrease the value of the selected digit ...

Page 162: ...ding input or output is activated Be sure the encoder scanners valves and the MCP 4J Control Unit have been properly mounted to the parent machine before setting up the control The glue and air lines are not connected until after the control is programmed Screen ContrastAdjustment To adjust image contrast on the LCD Display Screen press the Setup Button and either the Plus or Minus Button simultan...

Page 163: ... needs If these needs change later the settings can be changed in the setup The first time the MCP 4J Control Unit is switched on the following screen will appear Use the Plus Minus Buttons to scroll though choices If asked to enter a numerical value press the OK Button for the Thumbwheel Mode or use the Plus Minus Buttons for single digit editing Press the Right Arrow Button to move to the next s...

Page 164: ...on Description Corrugated Applying glue to partial assembly points of corrugated material in a Flexofolder gluing system end product folded flat Folding Carton Applying glue to folding carton partial assembly points end product folded flat Envelope Applying glue to envelope assembly points Packaging Applying glue to erected and filled boxes for closing sealing Core Winding Applying glue to paper s...

Page 165: ...t Mode Measurement Mode Measurement Mode Measurement Mode Set the units to Inch or Millimeter Encoder Corrugated Folding Carton Envelope Packaging Core Winding and Others Encoder Encoder Encoder Encoder Encoder Set the encoder type If the Wizard does not list the encoder your system uses select other The ratio compensation settings will be entered at a later time using the Encoder Menu Screen ...

Page 166: ... 1 4 If the default valve type that appears is not applicable use the Plus Minus Buttons to scroll through the list of valve types available Jog Mode Corrugated Folding Carton Envelope Packaging and Others Jog Mode Jog Mode Jog Mode Jog Mode Jog Mode Adhesive will be applied in a dot pattern when the machine is running below a certain speed V jog Enabling jog mode allows Jog Mode Setup Menus to ap...

Page 167: ...e First Use Setup Wizard Continued Finish Configuration All Applications You must answer Yes to the Finish Configuration prompt and press the OK Button for all changes to take effect Choosing No will return the unit to the wizard application screen ...

Page 168: ...co Melton 22 Enter Password To view setup and use the various functions of the MCP 4J Control Unit passwords are used This ensures safety and security of all settings To enter a password Enter Password see Thumbwheel vs Single Digit Edit ...

Page 169: ...s pressures load jobs and enter basic parameters necessary to run jobs Level 2 Supervisor Level 2 Supervisor Level 2 Supervisor Level 2 Supervisor Level 2 Supervisor Default Password 1234 This is the highest user password level At this level the Default password level can be set individual valve settings can be viewed and changed jobs can be saved as well as loaded and the memory can be backed up ...

Page 170: ...creens are hidden Operation Glue Mode Glue Mode Glue Mode Glue Mode Glue Mode The gluing style Use the Plus Minus Buttons to scroll through the choices These are depending on the application chosen 1 Pattern Pattern Pattern Pattern Pattern Adhesive is applied in a pattern on each product 2 Stitch Stitch Stitch Stitch Stitch Applies adhesive in a stitch like pattern Gluing Mode The Pattern Glue Mod...

Page 171: ...from the leading edge of the product to the beginning of the glue line and the end delay the end of the glue line to the trailing edge of the product The Auto Glue Auto Glue Auto Glue Auto Glue Auto Glue Glue Mode is available in the following applications Corrugated Folding Carton Packaging Core Winding Timer Valve Driver and Others Available in Corrugated Folding Carton Envelope Packaging Timer ...

Page 172: ...tance between the valve shown on the left of the screen to the scanner number shown in the upper right corner see Valve to Scanner Distance Scanner Number above Valve to Scanner Distance All Applications Valve to Scanner Distance Scanner Number Valve to Scanner Distance Scanner Number Valve to Scanner Distance Scanner Number Valve to Scanner Distance Scanner Number Valve to Scanner Distance Scanne...

Page 173: ...lume Jog Mode Dot Jog Mode Dot Jog Mode Dot Jog Mode Dot Jog Mode Dot The size of the dots of adhesive from 1 smallest to 9 largest Batch Counter All Applications Batch Counter must be enabled under the Setup Menu see Section 4 Programming Batch Counter On Off Batch Counter On Off Batch Counter On Off Batch Counter On Off Batch Counter On Off Turn the batch counter on and off with the switch using...

Page 174: ...ection Glue Mode Screen Information explains how Glue Mode Screen Information Pattern Mode The Pattern Glue Mode can also be called pattern skip pattern mode or normal mode Delay Length For the Pattern Number shown Pattern Number Up to 10 patterns are available Valve Number 1 4 The number of patterns availabledependonthe Menu Configuration settings Pattern Length For the Pattern Number shown Passw...

Page 175: ... from the first edge of the product to where you want the first glue line to start Pattern Mode Example Pattern Mode Example Pattern Mode Example Pattern Mode Example Pattern Mode Example 2 Press the Right Arrow Button to view the Pattern Length for pattern 1 The Pattern Length is the length of the glue line for the pattern number indicated Press the OK Button to view the thumbwheel and use the Pl...

Page 176: ...trol automatically fills in the Delay Length for pattern 2 so the next pattern does not interfere with the previous pattern This number can be adjusted if desired 4 Press the Right Arrow Button to view the Pattern Length for pattern 2 Press the OK Button to view the thumbwheel and use the Plus Minus Buttons to change Press the OK Button to enter the setting ...

Page 177: ... Pattern Mode Continued 6 If the Delay Length is acceptable press the Right Arrow Button to view the Pattern Length for pattern 3 Press the OK Button to view the thumbwheel and use the Plus Minus Buttons to change Press the OK Button to enter the setting 7 All three patterns are now set To review them use the Left Arrow Button ...

Page 178: ...application of the glue The Pattern Mode applies a continuous strip of glue for the pattern length specified The Stitch Mode applies the glue in a stitch pattern for the pattern length specified To illustrate ST Stitch Mode Pattern Number Up to 10 patterns are available Valve Number 1 4 The number of patterns availabledependonthe Menu Configuration settings Pattern Length For the Pattern Number sh...

Page 179: ...de In Auto Glue Mode one Start Delay Length the length from the leading edge of the product to the beginning of the glue line and one End Delay Length the end of the glue line to the trailing edge of the product are entered The glue is applied automatically based on the length of the scanner signal ...

Page 180: ...rt Guide IS0368 Valco Melton 34 Operation Continued Auto Glue Mode Menus Continuous Glue Mode In Continuous Glue Mode the glue will flow continuously as long as the speed is greater than Vmin Continuous Glue Mode Menus ...

Page 181: ...et Value Pressure Offset Value Pressure Offset Value Pressure Offset Value Used to increase decrease the current pressure The Pressure Offset is used to do minor pressure adjustments instantly It does not change the pressure table profile Minimum Speed Pressure All Applications Press the Left Right Buttons as indicated by Left Right Arrow Icons on the bottom of the screen see example at left to se...

Page 182: ...n PT1 will appear When four pressure points are enabled screens PT1 and PT2 will appear These pressure points are set up just like the Maximum and Minimum Pressures The number of pressure points on the pressure curve are input during setup See Section 4 Programming Additional Setup Button Parameters Menu Configuration Pressure Point 1 PT1 Pressure Point 2 PT2 ...

Page 183: ...aphs Examples Purge Pressure The MCP 4J can have up to two EPC outputs EPC 2 is always for an external EPC EPC 1 can be an internal EPC external or no EPC Set Purge Pressure At Machine Stop On Demand Only At Machine Stop On Demand Only At Machine Stop On Demand Only At Machine Stop On Demand Only At Machine Stop On Demand Only If set to At Machine Stop The control will set the EPC output to the Pu...

Page 184: ...0 20 mA 0 10 VDC or 0 20 mA If EPC 2 is enabled the user can set the output signal to either 0 10 VDC or 0 20 mA Helpful Hints about Pressures The four pressures speeds are dependent upon each other For example the first speed setting can never be greater than the second speed setting and the second speed setting can never be greater than the third and so on Also the second speed setting can never...

Page 185: ...iagnostic Button All Applications Total Products Products per Hour The first diagnostic screen shows the total number of products and the number of products per hour The total number of products count can be reset to zero by pressing the Erase Button ...

Page 186: ...bottom numbers will switch back and forth from showing the valve voltage to showing the valve status enabled or disabled A voltage reading of 0 0 could indicate a blown fuse Scanner and Trigger Status The scanner trigger information screen displays the scanner and trigger settings Version Information The version information screen displays the CPU the Logic PLD and the MCP 4J name ...

Page 187: ...he current application and glue station if applicable Event History The event history screen displays error messages Job Button The Job Save Recall Mode allows the MCP 4J Control Unit to save and recall up to 100 different jobs via a Micro SD card for fast programming All Applications Load Load Load Load Load Load a previously saved job ...

Page 188: ...enter a job number Use the Plus Minus Buttons to change the job number When the desired job number has been entered press the Right Arrow Button to highlight OK and press the OK Button The job is loaded Enter the job number and information in a chart see Appendix A Job Charts for quick job set up Also jobs can be overwritten so it is important to keep track of them ...

Page 189: ...ve Save Save Save all settings under a job number Press the Right Arrow Button to highlight Save and then press the OKButton Use the Plus Minus Buttons to change the job number Press the Right Arrow Button to highlight OK Press the OK Button to save the job Be sure to write the job name and job number for reference see Appendix A Job Charts ...

Page 190: ... to ensure the product is level 5 Slowly jog the product through the glue station making any needed adjustments to the glue station guides and brackets as you go 6 Start up the parent machine and run 2 4 products through the glue station 7 Measure the glue line with a tape measure Make certain the glue line is in the correct place on the products tested If the glue is not in the proper place on th...

Page 191: ...co Melton 45 IS0368 MCP 4J Quick Start Guide Copyright by Valco Cincinnati Inc All Rights Reserved IS0368 www valcomelton com www valcomelton com www valcomelton com www valcomelton com www valcomelton com ...

Page 192: ...it 091XX763 MCP 4J Encoder 2 Input Option Consisting of Item Description Part Number Qty 1 PCB ASSY ADAPTER RIBBON TO 8 PIN 151XX688 1 2 Wrench Receptacle Spanner Am CV10902 1 3 IS MCP 4J ENC1 OUT OR ENC2 IN IS0369 1 Or Encoder Kit 091XX764 MCP 4J Encoder 1 Output Option Consisting of Item Description Part Number Qty 1 PCB SUBASSY ENCODER OUT MCP 8 152XX722 1 2 Wrench Receptacle Spanner Am CV10902...

Page 193: ...ertical Units 074XX084 074XX085 074XX086 1 Remove the four screws holding the lid on 2 Remove the hole plug 3 Prep the Encoder 2 IN Connector for the Enc 2 IN kit For the Encoder 1 OUT kit skip to step 7 a Remove the retaining ring from the connector ...

Page 194: ...lign and plug Encoder 2 IN Connector for Enc 2 IN kit a Insert the connector to the backplate in the orientation shown b Plug in the connector as shown 5 Tighten the Encoder 2 IN Connector for Enc 2 IN kit using the included tool 6 Replace the lid a Replace and tighten the four screws holding the lid on ...

Page 195: ...T Connector for Enc 1 OUT kit a Remove the retaining ring from the connector 8 Align and plug the Encoder 1 OUT Connector for Enc 1 OUT kit a Insert the connector to the backplate in the orientation shown b Plug the connector in as shown 9 Tighten the Encoder 1 OUT Connector for Enc 1 OUT kit using the included tool item 2 ...

Page 196: ...IS0369 MCP 4J Encoder Option Kit Instructions 5 Vertical Units 074XX084 074XX085 074XX086 Continued 10 Replace the lid a Replace and tighten the four screws holding the lid on ...

Page 197: ...ntal Units 074XX087 074XX088 074XX090 074XX089 1 Remove the four screws holding the lid on 2 Remove the hole plug 3 Prep the Encoder 2 IN Connector for the Enc 2 IN kit For the Encoder 1 OUT kit skip to step 7 a Remove the retaining ring from the connector ...

Page 198: ...ed 4 Align and plug Encoder 2 IN Connector for Enc 2 IN kit a Insert the connector to the backplate in the orientation shown b Plug in the connector as shown 5 Tighten the Encoder 2 IN Connector for Enc 2 IN kit using the included tool 6 Replace the lid a Replace and tighten the four screws holding the lid on ...

Page 199: ...r 1 OUT Connector for Enc 1 OUT kit a Remove the retaining ring from the connector 8 Align and plug the Encoder 1 OUT Connector for Enc 1 OUT kit a Insert the connector to the backplate in the orientation shown b Plug the connector in as shown 9 Tighten the Encoder 1 OUT Connector for Enc 1 OUT kit using the included tool item 2 ...

Page 200: ...hout notice Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati Ohio 45246 USA TEL 1 513 874 6550 FAX 1 513 874 3612 Melton S L U Pol Industrial Agustinos calle G n 34 31160 Orcoyen Navarra Spain TEL 34 948 321 580 FAX 34 948 326 584 Valco Cincinnati Ltd Unit 7 8 Hortonwood 32 Telford TF1 7YN England TEL 44 1952 677911 FAX 44 1952 677945 Valco Cincinnati GmbH Bonnerstrasse 349 40589 ...

Page 201: ...Port to Horizontal MCP 4J Units 2 18 Required Materials KIT 091XX766 ITEM PART ITEM DESCRIPTION QTY 1 033XX166 RIBBON CABLE ASSY 1 2 091XX267 SCREW 2 Required Tools Phillips screwdriver 3 16 Nut driver Procedure 1 Remove the four 4 screws holding the lid on using using a Phillips screwdriver ...

Page 202: ...zontal MCP 4J Units 2 Procedure Continued 2 Remove the hole plug 3 Align and plug in the external comm port a Insert the DB9 connector ref 033xx166 to the backplate in the orientation shown b Plug the connector into J12 on the board as shown ...

Page 203: ...ther information may change without notice Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati Ohio 45246 USA TEL 1 513 874 6550 FAX 1 513 874 3612 Melton S L U Pol Industrial Agustinos calle G n 34 31160 Orcoyen Navarra Spain TEL 34 948 321 580 FAX 34 948 326 584 Valco Cincinnati Ltd Unit 7 8 Hortonwood 32 Telford TF1 7YN England TEL 44 1952 677911 FAX 44 1952 677945 Valco Cincinnat...

Page 204: ...on to Horizontal MCP 4J Units 2 18 Required Materials Kit 091XX767 ITEM ITEM DESCRIPTION PART QTY 1 CABLE ASSY 029XX599 1 2 CABLE TIE 067XX154 2 Required Tools Phillips screwdriver 4MM Allen wrench 19MM Socket or Wrench Cutting tool to remove cable ties Procedure 1 Remove the four 4 feet from the bottom of the unit using a 4mm Allen wrench ...

Page 205: ...y Outputs for Jam Detection to Horizontal MCP 4J Units 2 Procedure Continued 2 Remove the four 4 screws holding the bottom cover using a Phillips screwdriver 3 Remove the hole plugs on the back plate for the beacon and relay holes ...

Page 206: ...Remove the existing pump cable a Remove the nut holding the pump connector in place on the back plate using a 19mm socket or wrench b Carefully cut and remove the cable ties holding the pump cable in place inside the unit c Unplug the pump cable from the board inside the unit d Remove the cable from the unit ...

Page 207: ...e nut from each connector on the 029xx599 cable and set them aside 1 Verify the O ring stays in place on each connector 6 Align and plug in the beacon relay pump cable a Insert the connectors to the backplate in the orientation and locations shown 7 Use the 19mm socket or wrench to tighten each nut back onto the connectors securing them to the back plate ...

Page 208: ...9 pin connector 029xx599 cable into J20 on the board inside the unit 9 Secure the cable to the inside of the unit using the included cable ties 067xx154 as shown 10 Carefully cut off excess cable tie length 11 Replace the bottom cover 12 Tighten the four 4 screws holding the cover in place using a Phillips screwdriver ...

Page 209: ...t notice Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati Ohio 45246 USA TEL 1 513 874 6550 FAX 1 513 874 3612 Melton S L U Pol Industrial Agustinos calle G n 34 31160 Orcoyen Navarra Spain TEL 34 948 321 580 FAX 34 948 326 584 Valco Cincinnati Ltd Unit 7 8 Hortonwood 32 Telford TF1 7YN England TEL 44 1952 677911 FAX 44 1952 677945 Valco Cincinnati GmbH Bonnerstrasse 349 40589 Dus...

Page 210: ...s 2 18 Required Materials Kit 091XX768 ITEM ITEM DESCRIPTION PART QTY 1 CABLE ASSY FC TIPSEAL MCP 4J 029XX825 1 Required Tools Phillips screwdriver 19mm Socket or Wrench Procedure 1 Remove the four 4 screws holding the lid on Vertical Units 074XX084 074XX085 074XX086 Horizontal Units 074XX087 074XX088 074XX090 074XX089 ...

Page 211: ...Remove the hole plug 3 Prepare the FC Tipsealer cable a Remove the nut from the connector on the 029xx825 cable and set it aside 1 Verify the O ring stays in place 4 Align and plug in the FC Tipsealer cable a Insert the connector into the hole on the backplate in the orientation shown ...

Page 212: ... Procedure Continued b Route the cable between the scanner cables as shown c Plug the 8 pin connector into J14 on the board inside the unit 5 Use the 19mm socket or wrench to tighten the nut back onto the connector securing it to the back plate 6 Replace the lid ...

Page 213: ...nge without notice Valco Cincinnati Incorporated 411 Circle Freeway Drive Cincinnati Ohio 45246 USA TEL 1 513 874 6550 FAX 1 513 874 3612 Melton S L U Pol Industrial Agustinos calle G n 34 31160 Orcoyen Navarra Spain TEL 34 948 321 580 FAX 34 948 326 584 Valco Cincinnati Ltd Unit 7 8 Hortonwood 32 Telford TF1 7YN England TEL 44 1952 677911 FAX 44 1952 677945 Valco Cincinnati GmbH Bonnerstrasse 349...

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VALCO MELTON MCP-4J, Manual

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