VALCO MELTON MCP-4J User manual

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

© Valco Melton All Rights Reserved
This manual is provided with the MCP-4J Control Unit 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: MC122
Written and printed in the USA.
Valco Cincinnati, Inc.
497 Circle Freeway Drive
Suite 490
Cincinnati, OH 45246
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Web: http://www.valcocincinnatiinc.com
Valco Cincinnati Limited
Hortonwood 32
Telford, TFI 7YN, England
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Web: http://www.valco.co.uk
Valco Cincinnati GmbH
Bonnerstrasse 349
40589 Dusseldorf-Benrath, Germany
Tel: [phone]
Fax: [phone]
Melton S.L.U.
Pol. Industrial Agustinos
calle G, n. 34
31160 Orcoyen, Navarra, Spain
Tel: [phone]
Fax: [phone]
Valco Melton France
Technoparc des Hautes Faventines
32 Rue Jean Bertin
26000 Valence
Tel: [phone]
Fax: [phone]

Declaration of Conformity
(According to EN 45014)
The following declaration is issued under the sole responsibility of the manufacturer:
Manufacturer: Valco Melton
A division of Valco
Cincinnati, Incorporated
411 Circle Freeway Drive
Cincinnati, OH 45246
USA
Authorized Representatives in Europe: 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
declares that the product:
Product Name: MCP-4J Control 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
EN61000-4-6
EN61000-4-8
EN61000-4-11
Place and Date: Cincinnati, Ohio USA
CE Mark first fixed 2006
Signature: Cincinnati, OH USA
David H. Swedes,
Vice President of
Engineering & Manufacturing
This Declaration of Conformity has been generated electronically and is legally binding without signature

MC122 - MCP-4J Control Unit Table of Contents
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Table of Contents
Table of Contents ................................................................................................1
Section 1 - Introduction .......................................................................................1
System Description..................................................................................................................................................1
Features/Capabilities ...............................................................................................................................................1
Section 2 - Safety and Use ...................................................................................3
Read Thoroughly Before Handling Equipment.......................................................................................................3
Symbols ...................................................................................................................................................................3
Owner Responsibilities ............................................................................................................................................4
Limitations of Use ....................................................................................................................................................4
Installation/Startup/Use Safety Information.............................................................................................................5
Shut Down Safety Information ................................................................................................................................6
Hot-Melt-Specific, General Safety Information .......................................................................................................6
What to Do if Contact with Hot Adhesive Occurs ...................................................................................7
What to Do if Inhalation of Adhesive Fumes 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 (074xx086)............................................................................................22
Bottom Panel...........................................................................................................................................22
MCP-4J Control, Horizontal; with EPC (074xx087)................................................................................................23
Back Panel ..............................................................................................................................................23
MCP-4J Control, Horizontal; No EPC (074xx088) .................................................................................................24
Back Panel ..............................................................................................................................................24
MCP-4J Control, Horizontal; Folding Carton, Tipsealer (074xx089) .....................................................................25
Back Panel ..............................................................................................................................................25
MCP-4J Control, Horizontal; Dual External EPC (074xx090) ................................................................................26
Back Panel ..............................................................................................................................................26

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MCP-4J Valve Driver Instructions ...........................................................................................................................27
Wiring Configurations for Triggering the Valves..................................................................................... 27
Wiring the Scanner Cable ............................................................................................................................27
Encoder Installation .................................................................................................................................................29
Mechanical Installation of Encoder......................................................................................................... 29
Wheel-Driven Encoder .................................................................................................................................29
Gear-Driven Encoder ...................................................................................................................................29
Section 4 - Programming ..................................................................................... 31
Mounting ..................................................................................................................................................................31
Using the Operator Interface ...................................................................................................................................31
The Operator Interface Buttons.............................................................................................................. 31
The Main Menu Buttons ......................................................................................................................... 32
The Valve Buttons .................................................................................................................................. 32
The Navigation Buttons .......................................................................................................................... 32
Flash Memory Storage .................................................................................................................................33
The Edit Buttons ..................................................................................................................................... 34
Open a Highlighted Menu with the OK Button.............................................................................................34
Thumbwheel 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
Menu Configuration ................................................................................................................................ 44
Tipsealer Enable..................................................................................................................................... 44
COM Interface Option............................................................................................................................. 45
Enable the Interface .....................................................................................................................................45
Scanner Menu ........................................................................................................................................ 46
Scanner X Setup ..........................................................................................................................................46
Enter Password .......................................................................................................................................................47
Password Levels .................................................................................................................................... 48
Level 2 Password Options...................................................................................................................... 48
Protected Level Mode ..................................................................................................................................48
Change the Level 2 Default Password ........................................................................................................50
Configure the Valve/Channel Settings....................................................................................................................52
Compensation Time ............................................................................................................................... 52
Speed Settings ....................................................................................................................................... 53
Valve Type.............................................................................................................................................. 53

MC122 - MCP-4J Control Unit Table of Contents
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Scanner Settings.....................................................................................................................................53
Encoder Settings.....................................................................................................................................54
Valve - Voltage Settings..........................................................................................................................54
Valve - Timing Settings ...........................................................................................................................54
Check Other Valves/Channels................................................................................................................................55
Memory ....................................................................................................................................................................55
Backup ....................................................................................................................................................56
USB...............................................................................................................................................................56
SD .................................................................................................................................................................56
Restore....................................................................................................................................................57
USB...............................................................................................................................................................57
SD .................................................................................................................................................................58
Initialize Settings .....................................................................................................................................58
Jam Detection ..........................................................................................................................................................59
Jam Alarm Message ...............................................................................................................................59
Jam Setup Menus ...................................................................................................................................60
Encoder Menu Screen.............................................................................................................................................62
Ratio Compensation................................................................................................................................62
Speed Calculation ...................................................................................................................................63
Direction Detection..................................................................................................................................63
Prescale Factor .......................................................................................................................................63
Status Bar ...............................................................................................................................................64
Section 5 - Operation...........................................................................................65
Set the Pattern Menu Information ...........................................................................................................................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 Menus ....................................................................................................................75
Glue Pattern Length Range .........................................................................................................................75
Jam Detection ..........................................................................................................................................................76
Jam Alarm Message ...............................................................................................................................76
Jam Channel Configuration Menus.........................................................................................................76
Set the Pressures ....................................................................................................................................................77
Pressure Offset Value.............................................................................................................................77
Minimum Speed/Pressure.......................................................................................................................77
Pressure Point 1 (PT1).................................................................................................................................78
Pressure Point 2 (PT2).................................................................................................................................78
Speed/Pressure Graphs - Examples ...........................................................................................................78
Purge Pressure .......................................................................................................................................79

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Set Purge Pressure......................................................................................................................................79
Purge Pressure % ........................................................................................................................................79
Helpful Hints about Pressures................................................................................................................80
Diagnostic Button.....................................................................................................................................................80
Total Products/Products per Hour..........................................................................................................80
Valve Status............................................................................................................................................81
Scanner and Trigger Status....................................................................................................................81
Version Information ................................................................................................................................81
Control Information.................................................................................................................................81
Event History ..........................................................................................................................................82
Job Button................................................................................................................................................................82
Load a Job..............................................................................................................................................82
Save a Job..............................................................................................................................................83
Section 6 - Maintenance ......................................................................................85
Purging the Adhesive ..............................................................................................................................................85
Performing Downtime Maintenance........................................................................................................................85
Flushing the Glue System.......................................................................................................................................86
Lubricating the System............................................................................................................................................86
Reprogramming with a USB Flash Drive................................................................................................................87
Replacing Micro-SD Card........................................................................................................................................88
Section 7 - Specifications ....................................................................................91
Max Valve Chart......................................................................................................................................................91
Section 8 - Part Number List................................................................................93
How to Order Parts..................................................................................................................................................93
MCP-4J, Vertical 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 Unit 074xx086...........................................................................................116
General Layout with one Valve and Scanner, using the Vertical w/EPC Unit 074xx084,
or Horizontal w/EPC Unit 074xx087.......................................................................................................117
Layout for a Contact Boardrunner Setup using the Vertical w/EPC Unit 074xx084...............................118
Layout where an External EPC is used on the External EPC Unit 074xx090........................................119
Section 9 - Warranty............................................................................................ 121
Warranty Information...............................................................................................................................................121
Cold Glue Equipment and Electronic Controls.......................................................................................121
Hot Melt Units, Hoses, Valves, Guns, and Related Equipment .............................................................121

MC122 - MCP-4J Control Unit Table of Contents
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Section 10 - Service.............................................................................................123
Appendix A - Job Charts ......................................................................................125
Appendix B - System Connectivity (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

Table of Contents MC122 - MCP-4J Control Unit
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