Valco Melton MCP-8 Control Unit User manual

Below you will find brief information for Control Unit MCP-8. The MCP-8 Control Unit from Valco Melton provides operators with a full-featured affordable solution to adhesive system pattern control. The control features 4-channel operation, multiple glue patterns, and an optional flow control capability. The unit allows program changes and adjustments, so you can get desired results immediately. The control has a compact design and features ‘plug-and-run’ connectors for easy installation and quick start up.

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MCP-8 Control Unit

Manual Number: MC095

Revision Date: 4/2015

This manual is provided with the MCP-8 Control and may be used only in accordance with the terms of purchase.

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

This manual written and designed at Valco Melton, 497 Circle Freeway Drive, Suite 490, Cincinnati, Ohio 45246. http://www.valcomelton.com

Part Number: MC095

Written and printed in the USA.

Valco Cincinnati, Inc.

497 Circle Freeway Drive

Suite 490

Cincinnati, OH 45246

874-6550

Fax: (513)

Email: [email protected]

Web: http://www.valcocincinnatiinc.com

Valco Cincinnati Limited

Hortonwood 32

Telford, TFI 7YN, England

Tel: (+44) 1952-677911

Fax: (+44)

Email: [email protected]

Web: http://www.valco.co.uk

Valco Cincinnati GmbH

Bonnerstrasse 349

40589 Dusseldorf-Benrath, Germany

Tel: +49 211 984 798-0

Fax: +49 211 984 798-20

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 Melton France

Technoparc des Hautes Faventines

32 Rue Jean Bertin

26000 Valence

Tel: +33 (0)4 75 78 13 73

Fax: +33 (0)4 75 55 74 20

Declaration of Conformity

(According to EN 45014)

Manufacturer:

Valco Melton

A division of Valco

Cincinnati, Incorporated

497 Circle Freeway Drive

Suite 490

Cincinnati, OH 45246

USA

Authorized Representatives in

Europe:

declares that the product:

Valco Cincinnati, Ltd.

Unit 7-8

Hortonwood 32

Telford TF1 7YN

England

Melton S.L.U.

Pol. Industrial

Agustinos calle G, n. 34

31160 Orcoyen

Navarra, Spain

Product Name:

complies with the following Council Directives:

MCP-8 Control Unit

Safety of Machinery:

Low Voltage Equipment:

2006/42/EC

2006/95/EC

EMC:

and conforms to the following standards:

Safety:

2004/108/EC

EN60204-1:2006

EN13849-1

Risk:

EMC Emissions:

EMC Immunity:

Place and Date:

Signature:

EN14121-1:2007

EN61000-6-4:2007

EN61000-4-2

EN61000-6-2:2005

EN61000-4-3

EN61000-4-4

EN61000-4-5

EN61000-4-6

EN61000-4-8

EN61000-4-11

Cincinnati, Ohio USA

CE Mark first fixed 2006

David H. Swedes,

Director of Engineering &

Manufacturing

MC095 – MCP-8 Control Unit Table of Contents

Table of Contents ................................................................................................ 5

Section 1 - Introduction ....................................................................................... 7

System Description .................................................................................................................................................. 7

Features/Capabilities ............................................................................................................................................... 7

Section 2 – Safety and Use .................................................................................. 9

Read Thoroughly Before Handling Equipment ....................................................................................................... 9

Symbols ................................................................................................................................................................... 9

Owner Responsibilities ............................................................................................................................................ 10

Limitations of Use .................................................................................................................................................... 10

Installation/Startup/Use Safety Information............................................................................................................. 11

Shut Down Safety Information ................................................................................................................................ 12

Hot-Melt-Specific, General Safety Information ....................................................................................................... 12

What to Do if Contact with Hot Adhesive Occurs ................................................................................... 13

What to Do if Inhalation of Adhesive Fumes Occurs .............................................................................. 13

What to Do if Adhesive-Related Fire or Explosion Occurs ..................................................................... 14

Hose Safety Information .......................................................................................................................................... 15

Section 3 - Basic Features ................................................................................... 17

MCP-8 Control ......................................................................................................................................................... 17

Front Panel .............................................................................................................................................. 17

Unpacking ................................................................................................................................................................ 17

Mounting the Encoder ............................................................................................................................................. 18

Installing the Glue Station ........................................................................................................................................ 19

MCP-8 Valve Driver Instructions ............................................................................................................................. 24

Wiring the Scanner Cable ....................................................................................................................... 24

Section 4 - Programming ..................................................................................... 27

Mounting .................................................................................................................................................................. 27

Programming ........................................................................................................................................................... 27

The Operator Interface Buttons .............................................................................................................. 27

The Status LEDs ..................................................................................................................................... 28

Navigation and Edit Buttons .................................................................................................................... 28

Enter Password ....................................................................................................................................... 29

Password Levels ..................................................................................................................................... 30

Level 2 Password Options ...................................................................................................................... 30

Protected Level Mode ............................................................................................................................. 30

Main Menu Buttons ................................................................................................................................. 30

Single Digit vs. Thumbwheel Edit ........................................................................................................... 31

Valve Buttons .......................................................................................................................................... 31

Table of Contents MC095 – MCP-8 Control Unit

Configuring the Valve/Channel Settings ................................................................................................................. 32

Valve Selection ....................................................................................................................................... 32

Valve Type .............................................................................................................................................. 33

Encoder Ratio ......................................................................................................................................... 34

Compensation Time ............................................................................................................................... 36

Parameter/Button Access Configuration ................................................................................................................. 38

Jam Detection .......................................................................................................................................................... 41

Jam Detection Setup Menu .................................................................................................................... 42

Tipsealer ................................................................................................................................................................... 43

Reversible Glue Station Setting.............................................................................................................. 47

Section 5 - Operation .......................................................................................... 49

Set the Pattern Menu Information ........................................................................................................................... 49

Set the Pressures .................................................................................................................................................... 53

Purge and Test Run ................................................................................................................................................ 55

Diagnostic Screen .................................................................................................................................................... 55

Job Screen ............................................................................................................................................................... 56

Loading a Job ......................................................................................................................................... 56

Saving a Job ........................................................................................................................................... 57

Deleting a Job ......................................................................................................................................... 58

Copying a Job ......................................................................................................................................... 58

Archive Screen ......................................................................................................................................................... 59

Service Screen ......................................................................................................................................................... 60

Section 6 - Maintenance ...................................................................................... 61

Purging the Adhesive .............................................................................................................................................. 61

Performing Downtime Maintenance ........................................................................................................................ 61

Flushing the Glue System ....................................................................................................................................... 62

Lubricating the System ............................................................................................................................................ 62

Section 7 - Specifications .................................................................................... 63

Section 8 - Part Number List ................................................................................ 65

How to Order Parts .................................................................................................................................................. 65

MCP-8 Unit (JWT5148) ........................................................................................................................................... 66

FlexoSEAL System with MCP-8 ............................................................................................................................. 68

Section 9 - Warranty ............................................................................................ 69

Warranty Information ............................................................................................................................................... 69

Cold Glue Equipment and Electronic Controls ....................................................................................... 69

Hot Melt Units, Hoses, Valves, Guns, and Related Equipment ............................................................. 69

Section 10 - Service ............................................................................................ 71

Appendix A - Job Charts ...................................................................................... 73

MC095 – MCP-8 Control Unit Section 1 - Introduction

Section 1 - Introduction

System Description

This manual has been prepared by Valco Cincinnati, Inc. to provide assistance in the installation, operation, and servicing of your MCP-8 Control Unit.

The MCP-8 Control Unit from Valco provides operators with a full-featured affordable solution to adhesive system pattern control. The control features 4-channel operation, multiple glue patterns, and an optional flow control capability. The unit allows program changes and adjustments, so you can get desired results immediately. The control has a compact design and features “plug-and-run” connectors for easy installation and quick start up.

Features/Capabilities

The MCP-8 Control Unit works with a variety of Valco’s cold-glue or hot melt adhesive dispensing valves.

Features/Capabilities of the MCP-8 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

• Dual-encoder-based or timer mode

• Multi-valve, complex glue pattern capabilities

• “Continuous,” “Stitch” pattern and “Jogg” gluing

• Adjustable minimum speed

• Inch or metric calibration

• CE compliant

• Password protection for key system parameters

• Integral fluid-flow control option (EPC) and external EPC output

• Web break detection option

• Batch count/production count

• Job Storage Memory: Up to 1000 jobs

• Programmable valve output voltages depending upon base unit

• Jam Preventer w/Alarm and relay output

All hardware must be up-to-date for all new functions to work. Please see the Parts List for a compatibility chart.

Section 1 Introduction MC095 – MCP-8 Control Unit

MC095 – MCP-8 Control Unit Section 2 – Safety and Use

Section 2 – Safety and Use

Read Thoroughly Before Handling Equipment

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

COULD OCCUR.

Read this entire section before handling the equipment.

Symbols

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

This symbol represents a Caution or a Warning. Cautions draw special attention to anything that could damage equipment or cause the loss of data. Warnings draw special attention to anything that could injure or kill the reader. Both Cautions and Warnings are placed before the step they apply to.

This symbol represents a Hot Surface.

This symbol represents a Puncture Risk. It is usually used in regard to nozzle cleaning appliances and other sharp instruments that can cause puncture wounds and risk exposure to bloodborne pathogens and other debris.

This symbol means that Working Gloves are required.

This symbol means that Goggles are required.

This symbol indicates a Shock Hazard. There is a presence of non-insulated dangerous voltage within the product’s enclosure. This voltage may cause electrical shock or fire.

This symbol indicates the need to Unplug/Disconnect All Power Sources and to let them de-energize before attempting any type of work or maintenance. Remember that there can still be energy in equipment, cords, and wires even when unplugged/disconnected.

This symbol indicates the need to Lock Out All Power Sources and to let them de-energize before attempting any type of work or maintenance. If power is not locked out, the person working on the equipment may be injured or killed if someone unknowingly switches on the power to the equipment.

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

Section 2 – Safety and Use

Owner Responsibilities

MC095 – MCP-8 Control Unit

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

• Examine all safety materials and documents as well as jurisdictional laws and make certain all laws, recommendations, and other safety/hazard laws, certification requirements, training, and instructions are followed and kept current.

• Maintain all safety materials including tags, labels, documents, and MSDS information. Make certain they are distinct and can be read/understood. Replace any that are dirty, worn, or unreadable.

• Make sure all personnel who will handle, install, maintain, operate, fix, and work around the equipment have ready access to the safety information, training, and equipment according to jurisdictional authorities.

The owner of the equipment is under obligation to make certain that all instructions, requirements, and jurisdictional laws are met. Some examples include:

• Make sure there are regular inspections of equipment and safety devices.

• Have regular safety drills and inspections supervised by the proper authorities.

• Provide all required safety items, first aid equipment, and training.

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

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

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

• Make sure all personnel understand and can follow safety policies and procedures for the organization as well as for the specific equipment.

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

Limitations of Use

Read this document and all information regarding the equipment before handling the equipment. The intended use of the equipment is stated in Section 1 of this manual.

Do not use this equipment for anything other than its intended use. Do not modify, change, or alter the equipment in any way. If you are unsure of the intended use and the limitations of use for the equipment, contact your Valco Melton

Representative before handling the equipment.

MC095 – MCP-8 Control Unit Section 2 – Safety and Use

Installation/Startup/Use Safety Information

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

WARNING! Only qualified personnel should install the equipment. Valco Melton strongly recommends that a Valco Melton Technician install all equipment. OTHERWISE, DEATH, PERSONAL

INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR.

WARNING! The equipment should be installed so that it can be turned off at a location away from the equipment in case of injury, electrical problems, or malfunction. OTHERWISE, DEATH OR

PERSONAL INJURY COULD OCCUR.

WARNING! Properly route all electrical wires. Never tamper with equipment. Only use approved and correct voltage, type of current, fuses, and other power supplies. Replace worn cords, hoses, etc. immediately. FAILURE TO OBSERVE WARNING MAY RESULT IN DEATH,

PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE.

WARNING! Poor ventilation, smoking, and open flames can cause overheated hot melt to ignite.

Adequate ventilation must be provided. Smoking should be prohibited in the immediate vicinity of the molten adhesive. Open flames must be kept away from the area around molten adhesive. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT

COULD OCCUR.

WARNING! Never use any Valco Melton equipment in an explosive environment. Explosive environments include, but are not limited to, solvent-based cleaners or adhesives, explosive materials, radioactive materials, etc. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING! Equipment will start automatically when remotely controlled by triggering devices. Be sure to disable all triggering devices, carefully release hydraulic pressure, and disconnect air pressure before servicing or working near guns, valves, and other triggered devices.

OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

Section 2 – Safety and Use MC095 – MCP-8 Control Unit

Shut Down Safety Information

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

WARNING! Disconnect and lock out all power before maintenance or other need to open the equipment.

Only qualified personnel should open and service the control. OTHERWISE, DEATH OR

PERSONAL INJURY COULD OCCUR.

WARNING! Equipment may still be energized even if unplugged! When making adjustments or performing checkout procedures, stay clear of any moving mechanical parts and do not touch exposed electrical equipment or electrical connectors. OTHERWISE, DEATH OR PERSONAL INJURY

COULD OCCUR.

WARNING! Disconnect/disable all mechanical and/or electrical devices that send activation signals to the gun(s), valve(s), melter pump(s), etc. This includes pattern controls, timers, input/output signals, etc. Only qualified personnel should open and service the control. OTHERWISE,

DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING! Disable all triggering devices, relieve all residual pressure (hydraulic and air) and allow adhesive to cool before attempting to disconnect guns, hoses, valves, etc. Only qualified personnel should open and service the control. OTHERWISE, DEATH OR PERSONAL

INJURY COULD OCCUR.

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

Hot-Melt-Specific, General Safety Information

Valco Melton hot melt units have the following universal safety precautions in addition to all other universal precautions previously mentioned (this is not intended to be an exhaustive list; follow all instructions and safety precautions for the specific type of equipment involved):

WARNING! Never process any polyurethane reactive (PUR) hot melt or solvent-based material in a Valco

Melton unit unless you are certain that the unit is compatible and is marked “PUR”! Read all instructions and MSDS sheets carefully, following manufacturer’s instructions, especially regarding heat levels. If you have any question as to the compatibility of a Valco Melton unit for PUR hot melt, call your Valco Melton Representative before attempting to use the unit for

PUR or solvent-based materials. OTHERWISE, HAZARDOUS FUMES, EXPLOSION,

DEATH, OR PERSONAL INJURY COULD OCCUR.

WARNING! Keep pump cover and electrical enclosures closed except during setup, service, and checkout procedures. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

MC095 – MCP-8 Control Unit Section 2 – Safety and Use

WARNING! People with respiratory problems (e.g., asthma, bronchitis, etc.) should not work in the vicinity of molten adhesive. RESPIRATORY PROBLEMS MAY BE AGGRAVATED BY THE FUMES.

Do not wear a face mask when working around molten adhesive. THE MASK MAY TRAP

THE FUMES AND DEATH OR PERSONAL INJURY COULD OCCUR.

WARNING! Keep hot melt hoses away from walkways and the moving parts of hot melt systems.

OTHERWISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR.

WARNING! Hot surfaces! Do not touch! Use extreme caution when refilling the unit by hand.

OTHERWISE, PERSONAL INJURY COULD OCCUR.

WARNING! Wear protective gloves and goggles at all times around all machinery, especially hot melt.

OTHERWISE, SERIOUS PERSONAL INJURY COULD OCCUR.

WARNING! Never use an open flame to heat hot melt components or adhesive. OTHERWISE, DEATH,

PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR.

What to Do if Contact with Hot Adhesive Occurs

If hot adhesive comes in contact with the skin, do the following:

WARNING! Do not attempt to remove heated hot melt adhesive from the skin. OTHERWISE, SEVERE

PERSONAL INJURY AND DEATH COULD OCCUR.

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

It is strongly recommended that a source of clean, cold water be provided near the hot melt work area.

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

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

What to Do if Inhalation of Adhesive Fumes Occurs

If adhesive fumes are inhaled, immediately follow these steps:

1. Take the victim away from the immediate work area.

2. Provide victim with fresh air.

3. Call the emergency medical response system (such as 911) immediately.

Section 2 – Safety and Use

What to Do if Adhesive-Related Fire or Explosion Occurs

MC095 – MCP-8 Control Unit

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

WARNING! Poor ventilation, smoking, and open flames can cause overheated hot melt to ignite.

COULD OCCUR.

WARNING! Exposed arcing may ignite the fume/air mixture. Shield all electrical equipment from melt fumes to avoid exposed arcing. OTHERWISE, PERSONAL INJURY OR EQUIPMENT

DAMAGE COULD OCCUR.

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

OR EQUIPMENT DAMAGE COULD OCCUR.

If the hot melt adhesive ignites, promptly perform the following steps:

1. Sound a fire alarm.

2. Evacuate the immediate area.

3. Turn off all local electrical equipment at the source.

4. Leave the area immediately if conditions are unsafe.

If you feel you can fight the fire safely, do one of the following:

• Smother the fire with a fire blanket.

• Aim a CO

fire extinguisher at the base of the flames.

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

MC095 – MCP-8 Control Unit

Hose Safety Information

DO NOT

Do not use bindings, wire ties, or unapproved fasteners around the hoses.

Do not place hoses close together.

Do not bend hoses sharply. Do not allow kinks or indentations in the hoses.

Do not use unapproved hooks to hang hoses. Do

not wrap hoses over or around objects.

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 not allow hoses to rub against objects or to come into contact with sharp edges or points.

Do not use worn, damaged, or bent hoses.

Section 2 – Safety and Use

DO

Do use approved wrapping (P/N

KAP0434), making sure the wrapping is slightly snug but not tight.

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

Do use a minimum bend radius of 10 inches for a

20-inch diameter coil hose.

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

Do use two hands and two wrenches to tighten or loosen connections on hoses. Do wrench only on large hexagon swivel nuts.

Do wrap the hoses in approved padding (P/N

795xx549) if the hoses must be installed where they will come into contact with objects.

Do inspect all hoses regularly for damage and/or wear and replace damaged or worn hoses immediately.

Section 2 – Safety and Use MC095 – MCP-8 Control Unit

MC095 – MCP-8 Control Unit Section 3 - Basic Features

Section 3 - Basic Features

MCP-8 Control

Front Panel

2 Valve Enable Buttons (1-8)

*Scrolling right reveals the Diagnostics,

Service and Archive Buttons.

10 Job Storage/Recall Button

12 Left Arrow Button

13 Right Arrow Button

14 Plus (+) Button

15 Minus (-) Button

Figure 3-1. MCP-8 Operator Panel

Unpacking

Carefully remove the box contents. The contents include the following items:

• MCP-8 Control

• Installation Kit - includes Manual, Quick Start Guide, power cable, 8 mm tube fitting, 1/4-inch tube adapter fitting, and spare fuses.

Caution!

Look carefully for small items inside the box! The adapters and fuses are in a small bag. Put them in a safe place for future use.

When the display states, “Please Wait...” do not touch any buttons and do not turn off the unit! Information is being retrieved or stored -- and any 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.

Section 3 - Basic Features

Mounting the Encoder

MC095 – MCP-8 Control Unit

An encoder must be installed in order for the control to determine the speed of the parent machine. Your MCP-8

Control system can use either a wheel-driven VDD encoder and a measuring wheel or a hollow shaft encoder. For optimal results, use a VDD-1000 encoder for one of the following resolutions: a 10 inch wheel = 100 pulses/inch; a

250mm wheel = 4 pulses/mm.

To install a wheel-driven encoder, follow these steps:

1. Mount the encoder bracket to the frame of the parent machine.

2. Mount the encoder to the bracket and securely affix the wheel.

3. Ensure that the wheel of the encoder rides securely against the belt and does not slip.

For best results, the wheel of the encoder assembly should ride on the bottom side of the belt on the drive side.

Figure 3-2. Example of a Wheel-Driven Encoder

Pulses

1000

500

Red Encoder Wheel

Setup Circumference

250

Black Encoder Wheel

Pulses Setup Circumference

MC095 – MCP-8 Control Unit Section 3 - Basic Features

Installing the Glue Station

Since the MCP-8 is compatible with any glue station, setup may vary depending on cell to gun distance and valves being used. These parameters can be programmed from the front panel of the MCP-8.

To install the Glue Station, do the following:

1. Mount the Glue Station to the parent machine.

2. Install nozzle or applicator head onto the valve if necessary.

Do not connect the glue hoses at this time. This will be done later in the setup procedure.

Section 3 - Basic Features

MCP-8 Connections

M12

MC095 – MCP-8 Control Unit

_____________________________________________________________________________________________

M12 - Tri-Valve, Non-Contact

Figure 3-3. MCP-8 Connections

MC095 – MCP-8 Control Unit

EPC2 Connection

Connector 12

Pin #

EPC Connection

Description

+24V

Color

Brown

OV (Signal)

Ground

0-20 mA*

Shield

White

Blue

Black

Shield/Gray

Pinout Drawing for Connector 12

Section 3 - Basic Features

*Can be switched to 0-10V via software

Feed Enable (Signal) Connection

Connector 14

Pin #

Feed Enable Connection

Description

+24V

Color

Brown

PNP

Ground

NPN

Shield

White

Blue

Black

Shield/Gray

Pinout Drawing for Connector 14

Section 3 - Basic Features

Valve Connections (1-4)

Connector

Pin #

Relay Machine Stop

Connection

Description Color

Brown

4 PE

Blue

White

Green

Yellow

Gray

Pink

Red

9 Purge-1

10 Purge-2

11 PE

Black

Orange

Tan

Violet

Pinout Drawing for Connector 10

MC095 – MCP-8 Control Unit

Valve Connection

Connector

Pin #

Valve Connections

Description

Coil

Color

Brown

White

Purge

Blue

Black

5 PE (Shield) Green/Yellow

Pinout Drawing for Connector 10

Section 3 - Basic Features

Manifold Connections

Connector 11 Relay Machine Stop Connection

Pin #

24V

Description

Scanner1 - PNP

Color

White

Brown

Ground

Scanner1 - NPN

Ext Purge

Auto/Man

Green

Yellow

Gray

Pink

Valve - 1

Valve - Ground

Valve - 2

Valve - Ground

Valve – 3 & 4

Blue

Red

Orange

Tan

Black

12 Valve - Ground Violet

Pinout Drawing for Connector 11

Section 3 - Basic Features

MCP-8 Valve Driver Instructions

MC095 – MCP-8 Control Unit

One of three wiring configurations can be used to trigger the valves. Choose the one that best fits the needs of your system. Detailed instructions for each configuration are given in the next section.

Warning! The triggering device used must be configured to output only 24VDC. If the control unit has a spike, it will damage the input circuit for the scanner.

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-8 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 on the back of the MCP-8 Control Unit (refer to Figure 3-2).

4. Carefully strip the scanner cable jacket back and strip the individual wire insulations about 0.25 inch.

5. Wire the modified scanner cable according to the Wiring Diagram (Figure 3-4).

MC095 – MCP-8 Control Unit

Wiring the Scanner Cable - Continued

Section 3 - Basic Features

Figure 3-4. Scanner Cable Wiring Diagram

Section 3 - Basic Features MC095 – MCP-8 Control Unit

MC095 – MCP-8 Control Unit Section 4 - Programming

Section 4 - Programming

Mounting

The MCP-8 Control Unit can be mounted on any flat, stable surface close to the machine glue station.

1. Be sure the four (4) rubber feet are firmly attached to the unit. The rubber feet reduce vibration to the unit. Do not remove the rubber feet from the unit for any reason.

2. Valco makes a rolling cart (738xx878 Complete System Cart; 579xx322 Control Stand only) that can be used to securely mount the MCP-8 Control Unit. Please contact your Valco sales representative for purchasing information.

3. The MCP-8 Control Unit is vertically mounted. See the mounting footprint in the Parts List

Section.

4. A swivel shelf mount (582xx780) is available for models 074xx037 and 074xx038.

Programming

The Operator Interface Buttons

2 Valve Enable Buttons (1-8)

*Scrolling right reveals the Diagnostics,

Service and Archive Buttons.

10 Job Storage/Recall Button

12 Left Arrow Button

13 Right Arrow Button

14 Plus (+) Button

15 Minus (-) Button

Figure 4-1. The Operator Interface Buttons

Section 4 - Programming MC095 – MCP-8 Control Unit

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 4-2).

Be sure the encoder, scanners, valves, and the MCP-8 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.

Figure 4-2. Status LEDs

Navigation and Edit Buttons

The MCP-8 is a touchscreen system, allowing screen buttons/fields to operate when touched. Screen navigation can also be performed using the buttons described below.

There are 2 Navigation Buttons: the Right Arrow Button and the Left Arrow Button.

Right Arrow Button - Pressing the Right Arrow Button moves the cursor to the right, highlighting each editable field.

Left Arrow Button - Pressing the Left Arrow Button moves the cursor to the left, highlighting each editable field.

There are three Edit Buttons: the Plus Button, the Minus Button and the OK Button. These Buttons are used to change/enter information.

You can only change a value when it is highlighted.

MC095 – MCP-8 Control Unit Section 4 - Programming

Navigation and Edit Buttons - Continued

Plus Button - Pressing the Plus Button allows you to increase the value of the input.

Minus Button - Pressing the Minus Button allows you to decrease the value of the input.

OK Button - Pressing the OK Button opens and closes the thumbwheel control. It also “opens” highlighted menu screens for editing.

Enter Password

To view, setup, and use the various functions of the MCP-8 Control Unit, passwords are used. This ensures safety and security of all settings. To enter a password, do the following:

1. Referring to the Operator Panel illustration/table on page 7, highlight the Lock/Unlock button

(#6) and click OK. a. The Password screen will appear.

2. Enter your password (PIN), and then highlight “UNLOCK.” a. The button icon will change to ‘unlocked,’ and the password level (number) will be displayed.

Section 4 - Programming MC095 – MCP-8 Control Unit

Password Levels

There are five password levels:

Level 0: Protected

When the unit is set to Level 0, only basic pattern settings can be entered or changed. Level 0 provides the ultimate safety settings to prevent unauthorized and/or accidental changes. This level can be set as the “Default” level by someone with a Level 2 (Supervisor) password.

Level 1: Operator (No password required)

This is the “Default” level of operation when the unit is first turned on (unless the “Default” setting has been changed to Level 0 by a Supervisor). Level 1 allows Operators to set patterns, pressures, load jobs, and enter basic parameters necessary to run jobs.

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. 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.

Level 2 Password Options

A Level 2 Supervisor has the ability to place the unit into the Protected Level Mode (Level 0) and to change the Level

2 password.

Protected Level Mode

The Protected Level Mode (Level 0) increases security by changing the Default Level of the unit from Level 1 to Level

0. This means that when the unit is turned on, it will automatically be in Level 0 instead of Level 1 (until the supervisor changes the Default Mode to Level 1). Only someone with the Level 2 password can change the Default Level of the unit.

Main Menu Buttons

There are six Main Menu Buttons (refer to the operator panel illustration/table on the previous page). The “button depressed/ normal” appearance of the Buttons indicates which Main Menu Button is selected.

Pattern Button (#7) - Pressing the Pattern Button allows you to begin to enter gluing patterns for valves 1-8.

Pressure Button (#8) - Pressing the Pressure Button allows you to begin to enter the pressure settings.

Jam Button (#9) - Pressing the Jam Button allows you to set up the Jam Detection/Alarm parameters.

Job Button (#10) - Pressing the Job Button allows you to save a job and load a job.

Setup Button (#11) - Pressing the Setup Button allows you to begin to setup the MCP-8 Control Unit.

Diagnostics Button (#16) - Pressing the Diagnostics Button allows you to view the MCP-8 Control Unit diagnostics.

MC095 – MCP-8 Control Unit Section 4 - Programming

Single Digit vs. Thumbwheel Edit

When editable information is numerical, the information 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 using the Plus/Minus

Buttons.

In thumbwheel editing, “Cancel” closes the thumbwheel edit window, abandoning any changes. “Clear” clears all digits to zero. “Apply” confirms the new settings and closes the thumbwheel edit window.

Press the Right or Left Arrow Buttons until you highlight the desired key, and then press OK to select it.

Valve Buttons

There are 9 Valve Buttons: the Purge Button and Valve Buttons 1 through 8.

Pressing the Purge Button allows you to turn the Manual Purge Mode on and off.

When the 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.

Pressing the individual Valve Button(s) allows you to tell the MCP-8 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 selected.

Section 4 - Programming MC095 – MCP-8 Control Unit

Configuring the Valve/Channel Settings

The settings are preprogrammed for the specific application selected. It is best not to change any setting unless you are a trained technician and/or have assistance from a member of the Valco Technical Assistance Team.

Caution! Changing settings may bring unwanted consequences in the performance of your system.

Valco Cincinnati, Inc. recommends having a qualified technician setup your system parameters. Otherwise, loss of production time may result from improper settings.

All screens for configuring the valves/channels are available in all applications.

Valve Selection

The Valve Selection Keys allow the operator to scroll between active valves. The selected valve number and type are displayed. Use the arrow keys to highlight “+” or “-”, and then press OK to scroll.

MC095 – MCP-8 Control Unit

Valve Type

To set the valve type for each valve, proceed as follows:

1. Highlight the Valve Setup Key, and then press OK.

Section 4 - Programming

a. The setup menu for the selected valve number will open.

2. Using the Arrow Buttons, scroll to the ‘Scroll Down Key, and then use the Minus (“-”) button to scroll down to “Valve Type.”

3. Press OK twice to access the Valve Type menu.

If the default valve type that appears is “not applicable” (N/A), use the Plus/Minus buttons to scroll through the list of valve types available.

4. Set the highlighted valve type by highlighting “Apply” and clicking OK.

Selecting “Cancel” closes the menu without changing the valve type.

5. Set the valve type for each valve, as needed.

Section 4 - Programming MC095 – MCP-8 Control Unit

Encoder Ratio

Ratio Compensation Pulses and Repeat Length are scaling factors used to calculate the correction factor.

To input Pulses:

1. Highlight the General Setup Button . a. The General Setup Menu will open.

2. Highlight the Encoder you wish to edit, and then press OK. a. The Encoder Setup Menu will open.

To edit Pulses:

3. Highlight “Pulses,” and then press OK. a. The Pulse Edit Screen will open.

4. Use the Arrow Buttons to highlight the “plus” or “minus” key for the digit you wish to edit.

5. Use the Plus and Minus buttons to change the setting.

6. When all digits have been edited as desired, use the Arrow Keys to highlight “Apply,” and then press OK.

MC095 – MCP-8 Control Unit

Encoder Ratio - Continued

To edit Repeat Length:

7. Highlight “Repeat Length,” and then press OK. a. The Repeat Length Edit Screen will open.

Section 4 - Programming

8. Use the Arrow Buttons to highlight the “plus” or “minus” key for the digit you wish to edit.

9. Use the Plus and Minus buttons to change the setting.

10. When all digits have been edited as desired, use the Arrow Keys to highlight “Apply,” and then press OK.

The following tables may be helpful:

Pulses

Red Encoder Wheel

Setup Circumference

1000

500

250

Pulses

1000

500

Black Encoder Wheel

Setup Circumference

250

Section 4 - Programming

Compensation Time

To access Compensation Time Settings:

1. Highlight the Valve Setup Button, and then press OK.

MC095 – MCP-8 Control Unit

a. The Valve Setup list menu will open.

2. Scroll down to “Ton,” “Toff,” or “Tmin” as required (see below).

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 milliseconds) from when the valve is turned off to when the adhesive application is stopped. Increasing the Off compensation time will make the glue line shorter.

Minimum Compensation Time (Tmin) - This is the time the valve will be open, no matter what the pattern length, the machine speed, and the "OFF" Compensation Times are set at.

MC095 – MCP-8 Control Unit

Speed Calculation - Continued

Section 4 - Programming

3. Highlight “Speed Calculation,” and then press OK. a. The Speed Calculation Edit Screen will open.

4. Highlight the desired setting.

5. Highlight “Apply,” and then press OK.

Section 4 - Programming MC095 – MCP-8 Control Unit

Parameter/Button Access Configuration

For particular applications, at most password levels, parameter and function button access can be reconfigured.

Caution! Configuration changes should only be made by authorized Valco Melton personnel.

Level 4 (Programmer) cannot be reconfigured.

To configure parameters or buttons:

1. Select the Lock button.

2. Enter the assigned password for configuration access.

A “C” appears in the Lock icon.

In this configuration mode, selecting a parameter/button opens a menu that allows the programmer to designate one of the following settings:

Parameter: Enable; Hide; Disable

Button: Enable; Hide

MC095 – MCP-8 Control Unit

Parameter/Button Configuration – Continued

Example:

Section 4 - Programming

Parameter/Button Configuration – Continued

MC095 – MCP-8 Control Unit

When changing a Parameter access configuration, an option is included for changing either an individual channel, or ALL channels.

Option for changing either an Individual channel, or ALL channels (click to open selection window, below).

MC095 – MCP-8 Control Unit

Jam Detection

Selecting the Jam Detection Menu Button opens the Jam Detection Menu.

Section 4 - Programming

Jam Detection Menu

Dimension Length/Individual Scanner Length Settings:

Set an individual detection length for each active scanner. When the scanner detects any product longer than this length, it will signal a jam.

Repeat Dimension Length:

Use to set the Dimension Length for all scanners that are on (must press the Apply Button for this to take effect).

Jam Detection Setup Menu Button:

Opens Jam Detection Setup Menu.

Section 4 - Programming

Jam Detection Setup Menu

MC095 – MCP-8 Control Unit

Threshold Speed:

The active scanners will not scan for jams until the machine is running at or above this speed. The speed is measured in meters per minute.

Timeout:

Indicates a “forced-stop” time (1-10 seconds) before system can be restarted.

Output 1:

On or OFF

Output 2:

On or OFF

Function:

For either Output, includes the following options:

Off

Light

Buzzer

Relay

Mode:

For Output 1 only, includes the following options:

Wait V=0:

System looking for input “0” to signal it can be restarted.

Continue:

System looking for Encoder input.

MC095 – MCP-8 Control Unit Section 4 - Programming

Tipsealer

The Tipsealer function places the nozzles onto the Tipsealer Pad during brief workflow stops, to prevent the glue from drying out.

Tipsealer Control supports 3NC, 4NC and 3NCR (reversible) glue stations.

Selecting the Setup Menu Button opens the Setup Menu.

On the Setup Menu, make sure the Application is set to “Corrugated.”

Setup

The factory-default application setting is “Folding Carton,” which does not employ the Tipsealer feature. The application must be set to “Corrugated” to access the “Glue Station Setup.”

Press “Glue Station Setup” to select.

Section 4 - Programming MC095 – MCP-8 Control Unit

Tipsealer - Continued

Select the Glue Station Type, either Operator Side (OS) or Drive Side (DS), that you wish to configure.

When the station is selected, a sub-menu will open, allowing selection of a specific configuration to match the system.

Select the desired configuration and touch “Apply.”

Tipsealer Control:

Allows settings to be turned on or off by pressing the command. When turned on, options below “Tipsealer Control” will be accessible.

MC095 – MCP-8 Control Unit Section 4 - Programming

Feeder Timeout:

When the Feeder is stopped, a programmed timeout (from 5 to 60 seconds duration) delays station movement to or from the tipsealer pad. If the Feeder is restarted before the timeout ends, the system will continue to run as normal.

Feed Signal Polarity:

Allows the following Feed Signal options (polarity):

N.O.

Feeder is Normally Open (Off).

N.C.

Feeder is Normally Closed (On).

If the Valves move to the Tipsealer Pad when the Feeder is Active (ON), or move to the dispensing position when the

Feeder is Off, the polarity is incorrect.

Change the polarity setting to correct it.

Delay Time (1-4):

These settings, designated by number (1-4), set the delay (in miliseconds) for each valve motion to or from the

Tipsealer Pad (refer to the figure, below).

Output Manual Mode:

When the station is switched to Manual Mode, the controls allow an alarm to activate, or for a relay to shut down the system until the station is set back to Auto Mode.

Manual Mode output options:

Off

Alarm 1

Alarm 2

Relay

Section 4 - Programming MC095 – MCP-8 Control Unit

Tipsealer – Continued

Output Error Mode:

When an error occurs, the controls allow an alarm to activate, or for a relay to shut down the system until the error is corrected and the system restarted.

Error Mode output options:

Off

Alarm 1

Alarm 2

Relay

Jogg on Restart:

“Jogging” dispenses a series of glue dots, rather than a continuous line. This helps to clear the nozzles of dried glue and make sure the valves are dispensing correctly. “Jogg on Restart” sets the number of boxes (0-25) that will receive a “jogg” pattern, following a restart, before glue again dispenses in the normal, programmed pattern.

MC095 – MCP-8 Control Unit Section 4 - Programming

Reversible Glue Station Setting

When a selected glue station offers both top-down and bottom-up operation, a Reversing Button appears.

When this button is pressed, the control automatically re-programs the patterns for correct glue placement, according to their location.

The screen will now indicate that the station setting has been reversed.

Station set for Bottom-Up Gluing

Reversing Button

Caution! Selecting a Glue Station Type does not set a reversible station to the correct system configuration automatically.

The Reversible Gluing Button must still be used to set the station for top-down or bottom-up gluing.

If the glue lines are being dispensed in a ‘staggered’ pattern (see below), the Reversing Button must be pressed to correct the dispensing order.

Section 4 - Programming MC095 – MCP-8 Control Unit

MC095 – MCP-8 Control Unit Section 5 - Operation

Section 5 - Operation

Set the Pattern Menu Information

After completing the mounting and the programming of the MCP-8 Unit, the unit is ready to operate. The first task is to input all pattern data and other essential information.

Depending on the password level, some screens may not be seen and/or available. This is a security feature of the MCP-8.

Mode - The gluing style. Use the Left/Right arrows to scroll to the Pattern Setup Button, and then click on “OK.”

Use the Plus/Minus Buttons to scroll through the choices to “Mode” and then click on “OK.”

Mode choices include:

1. Standard - This is also called “pattern-skip-pattern” mode, “pattern mode” or “normal mode.”

Section 5 - Operation MC095 – MCP-8 Control Unit

Set the Pattern Menu Information - Continued

2. Stitch Mode is very similar to Standard Mode, with the exception that the glue “patterns” are applied in a stitch-like pattern.

3. Continuous - Applies adhesive continuously when speed is higher than the Vmin setting.

4. Auto - Applies a strip of adhesive based on the length of the scanner signal. Input the start delay (length 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).

Scanner Lockout - Enter a product length to act as a scanner lockout when holes, writing, or other items produce a false trigger by the scanner.

Batch Counter:

Batch Counter-On/Off- Turn the batch counter on and off with the “switch” using the Plus/Minus Buttons.

Batch Counter--Skip - The total number of products for which the pattern will be skipped (no adhesive will be applied).

Batch Counter--Glue - The total number of products the adhesive pattern will be applied to, one after the other without skipping any products.

The Batch Counter must be enabled under the Setup Menu.

MC095 – MCP-8 Control Unit Section 5 - Operation

Set the Pattern Menu Information – Continued

Scanner - Select a scanner from the scroll list, using the plus and minus keys to highlight, press the Left or Right arrow to highlight “Apply,” and then press OK.

Cell to Gun Distance - Measurement - The distance between the valve (gun; shown on the left of the screen) to the scanner (cell) number, shown in the upper right corner.

Jog Mode - 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” by clicking on the “OK” button.

Dot Size - The size of the dots of adhesive, from 1 (smallest) to 9 (largest).

Dot Gap - This is the distance between the glue dots while the machine is running below the jogging speed threshold.

Increase the distance to decrease the glue volume.

Jogg Speed - Controls jog speed in m/min.

SETUP EXAMPLE: The following is an example of setting up a pattern gluing mode (Standard) with three patterns for valve one:

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.

Section 5 - Operation

Set the Pattern Menu Information - Continued

MC095 – MCP-8 Control Unit

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 Plus/Minus Buttons to change. Press the right arrow button until

“Apply” is highlighted, and then press the OK Button to enter the setting.

3. Press the Right Arrow Button until the scroll right button is highlighted, and then press Okay to view the Delay Length for pattern 2. The control 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.

MC095 – MCP-8 Control Unit Section 5 - Operation

Set the Pattern Menu Information - Continued

4. Press the Right Arrow Button until the scroll right button is highlighted, and then press OK 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 Right Arrow Button to highlight “Apply,” and then press

OK to enter the setting.

5. Repeat the above procedure to set pattern 3.

All three patterns are now set. You may review them using the left and right scroll buttons.

The Pattern Glue Mode for Valve 1 is now ready.

Set the Pressures

The Pressure Button is used to enter/change the Electronic Pressure Control (EPC) parameter values.

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.

Highlight the Pressure Setup Button, and then press OK, to access the Pressure Setup screen. This screen allow scrolling (plus and minus keys) through a set of pressure setup menu keys.

Purge Pressure - The pressure setting when the machine is at zero speed.

Speed 1 - Speed (m/min) for pressure point 1.

Pressure1 - Pressure setting at point 1 in the pressure curve (%).

Speed 2 - Speed (m/min) for pressure point 2.

Pressure 2 - Pressure setting at point 2 in the pressure curve (%).

Speed 3 - Speed (m/min) for pressure point 3.

Section 5 - Operation

Set the Pressures - Continued

Pressure3 - Pressure setting at point 3 in the pressure curve (%).

Speed 4 - Speed (m/min) for pressure point 4.

Pressure4 - Pressure setting at point 4 in the pressure curve (%).

Encoder - Select encoder number.

MC095 – MCP-8 Control Unit

The number of pressure points on the pressure curve are input during setup.

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 pressure curve. If more control is necessary, try adjusting the number of points on the pressure curve.

MC095 – MCP-8 Control Unit Section 5 - Operation

Purge and Test Run

1. Purge all air from the glue line, and then connect to the valve. Purge the valve by activating the push button switch on the valve.

Scanner and valve cables must be connected before any purging can take place. Be certain all cables and lines are connected.

2. Run adhesive through the valve(s) until no air is present in the line.

3. Run the parent machine and stop it when the product reaches the glue station.

4. Adjust the glue station vertically 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 the products, refer to the

MCP-8 Manual (MC075) for fine tune adjustment procedures.

8. If the glue is in the proper place on the products tested, you can run the machine at normal operating speed!

Diagnostic Screen

Selecting the Diagnostic Button opens the Diagnostic Screen.

The top screen section displays the software version information, while the bottom section displays the valve status.

The top numbers show the valve type. The 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. See the Parts

List section for fuse numbers and placement.

Section 5 - Operation

Job Screen

MC095 – MCP-8 Control Unit

Selecting the Job Button opens the Job Screen (not accessible at all levels).

Job Screen

Loading a Job

To load a job:

1. Select the job you wish to load from the list.

2. Select the Load Button.

A prompt will appear. If you wish to save any changes to the current job, select “Yes.”

Selecting “No” opens a keyboard, allowing the current job, with any changes, to be saved as a new job name (alphabetic or numerical).

Enter the new job name and select “Save.”

MC095 – MCP-8 Control Unit

Loading a Job - Continued

Section 5 - Operation

Saving a Job

To save the current job:

1. Select the Save Button.

A prompt will appear. Select “Yes” to overwrite the current job with the new changes. For a “save as” option, select “No” to open the keypad described in “Loading a Job.”

Section 5 - Operation MC095 – MCP-8 Control Unit

Deleting a Job

To delete a job:

1. Select the job you wish to delete from the list.

The Current Job cannot be deleted.

2. Select the Delete Button.

A prompt will appear. Select “Yes” to delete the selected job. Select

“No” to cancel.

Copying a Job

To copy a job:

1. From the list, select the job you wish to copy.

2. Select the Copy Button.

A keyboard will open, to assign a new job name (alphabetic or numerical) to the copied job. Once saved, the new

(copied) job appears on the list.

MC095 – MCP-8 Control Unit

Archive Screen

Section 5 - Operation

Selecting the Archive Button (not accessible at all levels) opens the Archive Screen.

Archive Screen

Restore:

Restores selected backup to its previously-saved version.

Backup:

Creates a new backup (keyboard appears to enter ne name).

Delete:

Deletes selected backup from the list.

Re-Init:

Re-initializes all settings.

The Default configuration is locked and cannot be rewritten or deleted.

Section 5 - Operation

Service Screen

Selecting the Service Button opens the Service Screen.

MC095 – MCP-8 Control Unit

Service Screen

The Service Screen keeps an update on service intervals.

When a service period/count is down to 20% from the ‘deadline,’ the green LED icon for that item turns yellow.

When it is down to 10%, the icon turns red.

When a deadline is reached without service being performed, the screen indicates “Service Now,”

Beyond the deadline, the screen indicates “Overdue.”

Selecting an item from the service list opens a prompt:

If scheduled service has been performed, select “Yes” to reset the service period/count.

MC095 – MCP-8 Control Unit Section 6 - Maintenance

Section 6 - Maintenance

This section contains maintenance procedures for the Valco MCP-8 Control. A regular maintenance program helps ensure longer life and efficient operation of your system. A few minutes spent on maintenance greatly reduces downtime.

Purging the Adhesive

The system should be purged of air at every startup or shift change. To purge the system, follow these steps:

1. Install the applicator head onto the contact glue valve.

2. Purge adhesive until no air is present and the glue flows evenly.

The glue valves can be purged manually using an activator located on the valve itself, by a solenoid-operated air valve, or they can be purged using the touchscreen panel and control.

When using any valve in the top-down position for the first time, it might be necessary to remove the valve and 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-8 Control Unit depends on the length of time the unit is down.

During short periods of downtime, such as order changeover, follow these steps:

1. Apply lithium grease or petroleum jelly to the orifice of the applicator head (contact extrusion valve) to prevent dried adhesive from clogging the valve.

2. Wipe the valve clean before restarting production.

For longer periods of downtime, follow these steps:

1. Remove the applicator head from the contact glue valve.

2. Install a stopper onto the contact glue valve in place of the applicator head.

3. Flush the applicator head with clean water.

If the system is idle for 30 days or longer, follow these steps:

1. Flush the entire glue supply system (including the pump or tank) with clean water (see Flushing the Glue System in this section).

Section 6 - Maintenance MC095 – MCP-8 Control Unit

Flushing the Glue System

To flush the glue system, follow these steps:

Follow the procedures for your system. These are general guidelines only.

1. Turn on the tank and any hoses or valves that are to be cleaned.

2. Pump out the old hot-melt adhesive, and then fill the tank with hot-melt purge. Allow it to heat to at least 350 degrees F.

If you use a glue that operates at 250 degrees F, the tank only needs to be heated to the standard operating temperature.

3. Once the tank is molten, turn on the pump and engage the valves.

4. Flow the old adhesive and purge through the valves until only purge is extruding from the valves. When you reach this point, turn the system power OFF and remove air from the pump.

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 the pot, lifting from the edges, and pour the molten material into a sealed corrugated box.

9. Use a clean rag to wipe the tank clean thoroughly and dispose of the rag. Now, you can reinsert the lid and pump assembly into the pot and tighten the lid cover screws. This completes the “clean and flush” process.

Lubricating the System

To lubricate the system, follow these steps:

1. Use lithium grease on all machined threads and fittings when servicing the system.

2. Grease quick-disconnect fittings frequently to prevent dried glue from causing excessive wear.

MC095 – MCP-8 Control Unit Section 7 - Specifications

Section 7 - Specifications

Item

Control dimensions:

MCP-8 Unit

Height: 9.95 (252.6 mm)

Depth: 7.81 (198.3 mm)

Width: 13.95 (354.2 mm)

100-240 VAC, 50-60 Hz (auto-selectable)

Input voltage:

Number of channels:

Glue pattern resolution:

8-channel operation with up to 8 programmable patterns per channel

0.01 in. or 1 mm

Number of scanner inputs:

Up to 8 with scanner lockout

Glue pattern tolerance:

Job storage memory:

Miscellaneous:

Less than 1 mm (0.4 inches) at 610 m/min (2000 ft/min)

Up to 1000 jobs

Dual-encoder-based or timer mode

Multi-valve, complex glue pattern capabilities

“Continuous,” “Stitch” pattern and “Jogg” gluing

Adjustable minimum speed

Inch or metric calibration

CE compliant

Password protection for key system parameters

Integral fluid-flow control option (EPC) and external EPC output

Web break detection option

Batch count/production count

Programmable valve output voltages depending upon base unit

Jam Preventer w/Alarm and relay output

[2 2 m ]

1 .9

[3 4 m ]

[1 8 m ]

[1 5 m ]

Section 7 - Specifications MC095 – MCP-8 Control Unit

MC095 – MCP-8 Control Unit Section 8 - Part Number List

Section 8 - Part Number List

How to Order Parts

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

USA

Valco Cincinnati, Inc.

497 Circle Freeway Drive

Suite 490

Cincinnati, OH 45246

Email: [email protected]

Web: http://www.valcomelton.com

England

Valco Cincinnati Limited

Hortonwood 32

Telford, TFI 7YN, England

Email: [email protected]

Web: http://www.valco.co.uk

Germany

Valco 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) 948-326-584

France

Valco Melton France

Technoparc des Hautes Faventines

32 Rue Jean Bertin

26000 Valence

Tel: +33 (0)4 75 78 13 73

Fax: +33 (0)4 75 55 74 20

Section 8 - Part Number List

MCP-8 Unit (JWT5148)

MC095 – MCP-8 Control Unit

MCP-8 Unit (JWT5148) – Continued

Item

Description

1 COVER ASSY.; MCP-8 CONTROL

2 PCB RACK ASSY, MCP-8 CONTROL

3 MOUNTING RAIL, CABINET

4 MOUNTING RAIL, WALL

5 POWER SUPPLY; SWITCHING

7 SCREW

8 ENCLOSURE WELDMENT ASSY.

9 GASKET

11 SCREW

13 STUD

20 SCREW

22 SCREW

24 SCREW

25 SCREW

26 MOUNTING FOOT; MCP-8 CONTROL

27 SCREW

29 POWER ENTRY MODULE;NO FUSE

Section 8 - Part Number List

Part Number QTY

JWT4679 1

JWT5147

JWT4798

JWT4797

RMK0536

784XX097 1

784XX050 2

JWT5145 1

JWT4661 47

MMO0039 1

884XX069 1

784XX476 1

091XX519 1

781XX780 1

784XX308 5

784XX375 2

798XX301 1

798XX299 1

TSW1060 1

798XX069 8

784XX475 5

784XX374 5

784XX976 4

784XX049 4

784XX656 2

JWT4799 2

784XX310 1

784XX600 4

086XX075 1

Section 8 - Part Number List

FlexoSEAL System with MCP-8

MC095 – MCP-8 Control Unit

MC095 – MCP-8 Control Unit Section 9 - Warranty

Section 9 - Warranty

Warranty Information

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

Liability of the company is limited to repair of the product, or replacement of any part shown to be defective, and does not extend to defects caused by accidents, 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, Orings, 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 the date of shipment by Valco Cincinnati.

Components purchased by Valco Cincinnati, Inc. from others for inclusion in its products are warranted only to the extent of the original manufacturer’s warranty. In no event shall Valco Cincinnati, Inc. be liable for indirect or consequential damages arising out 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, any necessary repairs will be made at a reasonable charge and return transportation will be charged.

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

Cold Glue Equipment and Electronic Controls

The warranty for cold glue equipment and electronic controls for a period of one (1) year from the date of shipment by

Valco Cincinnati, Inc.

Hot Melt Units, Hoses, Valves, Guns, and Related Equipment

All hot melt components except cast-in heating elements are warranted for a period 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.

Section 9 - Warranty MC095 – MCP-8 Control Unit

MC095 – MCP-8 Control Unit Section 9 - Warranty

Section 10 - Service

If a problem with your system persists, contact a ValcoMelton Technical Support representative. If your need is urgent, we encourage you to contact our corporate office in Cincinnati, Ohio, U.S.A. at (513) 874-6550. If the problem cannot be resolved, Valco Cincinnati, Inc. will promptly arrange to have a technical representative visit your facility.

Any charges for a service call will be quoted 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 operation, all travel time, labor, parts, and expenses will be charged to the customer.

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

Section 9 - Warranty MC095 – MCP-8 Control Unit

MC095 – MCP-8 Control Unit Appendix A - Job Charts

Appendix A - Job Charts

Use the following table to record saved jobs for quick reference, and to prevent duplication/erasure of important job information. The table may be copied for use.

Job Number Job Name Description

Key features

4-channel operation
Multiple glue patterns
Optional flow control capability
Compact design
Plug-and-run connectors
Program changes and adjustments
Easy installation
Quick start up

Frequently asked questions

The MCP-8 Control Unit features 4-channel operation, multiple glue patterns, an optional flow control capability, a compact design, 'plug-and-run' connectors for easy installation and quick start up, and allows program changes and adjustments.

The installation process involves mounting the encoder, scanners, valves, and the MCP-8 Control Unit to the parent machine. The glue and air lines are not connected until after the control is programmed.