VALCO MELTON VCX User manual

VCX Service Manual
For Internal Use Only
Manual Number: MC083
Revision Date: 5/2022

©2022 Valco Melton All Rights Reserved
The VCX Service Manual is for internal, Valco use only.
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: MC083
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: VCX Service Manual
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/A1:2009
EN13849-1
Risk: ISO12100:2010
EMC Emissions: EN61000-6-4:2007/A1:2009
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

MC083 - VCX Service Manual Table of Contents
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Table of Contents
Table of Contents ................................................................................................. 5
Section 1 - Introduction ........................................................................................ 9
Section 2 - Safety and Use .................................................................................... 11
Read Thoroughly Before Handling Equipment ......................................................................................................... 11
Symbols ........................................................................................................................................................................ 11
Owner Responsibilities ................................................................................................................................................ 12
Limitations of Use ........................................................................................................................................................ 12
Installation/Startup/Use Safety Information ............................................................................................................... 13
Shut Down Safety Information .................................................................................................................................... 14
Hot-Melt-Specific, General Safety Information .......................................................................................................... 14
What to Do if Contact with Hot Adhesive Occurs ................................................................................... 15
What to Do if Inhalation of Adhesive Fumes Occurs .............................................................................. 15
What to Do if Adhesive-Related Fire or Explosion Occurs ..................................................................... 16
Hose Safety Information ............................................................................................................................................. 17
Section 3 - Basic Features .................................................................................... 19
VCX Control ................................................................................................................................................................. 19
VCX Specifications.................................................................................................................................. 20
Power Supply Module ............................................................................................................................. 20
Power Supply Module Connector Pinouts .............................................................................................. 22
Terminal Port ............................................................................................................................... 22
Control Link Port .......................................................................................................................... 23
Encoder Connections - Male/Output ........................................................................................... 23
Encoder Connections - Female/Input ......................................................................................... 24
Pump Connection ........................................................................................................................ 24
Beacon (Alarm) Connection ........................................................................................................ 25
Relay Feed Stop Connection ...................................................................................................... 25
Relay Machine Stop Connection ................................................................................................. 25
Pattern Control Module (PCM) ................................................................................................................ 26
Pattern Control Module Connector Pinouts ............................................................................................ 28
Valve Connections ....................................................................................................................... 28
Scanner Connections .................................................................................................................. 28
EPC 2 Connection ....................................................................................................................... 29
Scanner Junction Box (E-Box) Port ............................................................................................ 29
Valve Junction Box (E-Box) Port ................................................................................................. 30
Inspection Control Module (ICM) ............................................................................................................ 31
Sensor Adapter Modules ............................................................................................................. 32
Inspection Control Module Connector Pinouts ....................................................................................... 33
RS-232 Port ................................................................................................................................. 33
Marking Valve Connection .......................................................................................................... 34
Scanner Connection .................................................................................................................... 34
Sensors 1-2 (J-Box) Connections ............................................................................................... 35

Table of Contents MC083 - VCX Service Manual
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Sensors 3-4 (J-Box) Connections ...............................................................................................36
Tracking Control Module (TCM) - Cube/X49 .......................................................................................... 37
Tracking Control Module Connector Pinouts - Cube/X49 ...................................................................... 39
Sync Scanner Connection ...........................................................................................................39
CDS Sensor 1 and 2 Connection ................................................................................................39
Cube/X49 Connector (Bobst) ......................................................................................................40
Tracking Control Module (TCM) - Flipper Ejector................................................................................... 41
Tracking Control Module Connector Pinouts - Flipper ........................................................................... 43
Counter Output Connection .........................................................................................................43
Scanner Connection ....................................................................................................................43
CDS Connection ..........................................................................................................................44
Flipper Connection - 21=Belt - 25=Diverter .................................................................................44
Tracking Control Module (TCM) - Sprayer/Kicker .................................................................................. 45
Tracking Control Module Connector Pinouts - Sprayer/Kicker ............................................................... 47
Counter Output Connection .........................................................................................................47
CDS Connection ..........................................................................................................................48
Spray Valve Connection ..............................................................................................................49
Tracking Control Module (TCM) - MARS Ejector ................................................................................... 50
Tracking Control Module Connector Pinouts - MARS Ejector ................................................................ 52
Counter Output Connection .........................................................................................................52
CDS Connections 1 & 2 ...............................................................................................................53
Ejector Control Connection ..........................................................................................................54
Ejector Valve Connection ............................................................................................................54
Ejector Power Supply Connection ...............................................................................................55
OT-120 Terminal .................................................................................................................................... 56
OT-120 Terminal Connector Pinouts ...................................................................................................... 58
COM Port Connection .................................................................................................................58
CAN Port Connection ..................................................................................................................59
Power/Control Port Connection ...................................................................................................60
Top Switch Function Label ..................................................................................................................... 61
Mounting Bracket for OT-120 Control .................................................................................................... 62
Section 4 - Setup .................................................................................................. 63
Adding Modules ...........................................................................................................................................................63
Removing the Cover of the VCX Control ................................................................................................ 63
Add Modules ........................................................................................................................................... 64
Remove Modules .................................................................................................................................... 65
System Layout Example Illustration ...........................................................................................................................66
Bracket Mounting Patterns ..........................................................................................................................................67
VCX Control ............................................................................................................................................ 67
OT-120 Panel Mount .............................................................................................................................. 67
EPP-6 Pump ........................................................................................................................................... 68
3:1 Balancing Regulator ......................................................................................................................... 68
Linking Two VCX Controls ..........................................................................................................................................69
CDS Color-Code Reader ............................................................................................................................................71
Description .............................................................................................................................................. 71
Specifications.......................................................................................................................................... 71
Suitability ................................................................................................................................................ 71
CDS Connection Layout .............................................................................................................................................72
CDS Control Box Pinouts ............................................................................................................73
VCX Control .................................................................................................................................73
Head Trigger ................................................................................................................................74

MC083 - VCX Service Manual Table of Contents
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Head Lamp .................................................................................................................................. 74
Head Signals ............................................................................................................................... 75
Operation - Startup.................................................................................................................................. 75
White Value Calibration Procedure ......................................................................................................... 76
Changing the Halogen Lamp .................................................................................................................. 76
Establishing a Baseline for the CDS Sensor .......................................................................................... 76
Code-Reading Hints ................................................................................................................................ 77
Encoder Installation ..................................................................................................................................................... 77
Mechanical Installation of Encoder ......................................................................................................... 77
Wheel-Driven Encoder ................................................................................................................ 78
Gear-Driven Encoder................................................................................................................... 78
Section 5 - Operation ............................................................................................ 81
Power Up Sequence ................................................................................................................................................... 81
Power Down Sequence .............................................................................................................................................. 82
Notes regarding OT and TCM .................................................................................................................................... 82
Section 6 - Part Number List ................................................................................. 83
How to Order Parts ...................................................................................................................................................... 83
VCX-4 Control Base (074xx042) ................................................................................................................................ 84
Power Supply Module (148xx063) ............................................................................................................................. 86
Pattern Control Module with EPC (074xx043) .......................................................................................................... 88
Pattern Control Module with EPC; Junction Box (E Box) Port (074xx044) ............................................................. 90
Pattern Control Module without EPC (074xx050) ..................................................................................................... 93
Inspection Control Module (074xx065) ...................................................................................................................... 97
Adapter Modules ..................................................................................................................................... 99
Tracking Control Module - TCMEJ (074xx049) ......................................................................................................... 100
Tracking Control Module - TCMF (074xx048) ........................................................................................................... 103
Tracking Control Module - TCMCube/49 (074xx047) ............................................................................................... 105
Junction Box (029xx439) ............................................................................................................................................ 108
Junction Box (029xx440) ............................................................................................................................................ 110
Panel Mount OT-120 (138xx019) ............................................................................................................................... 112
Standard OT-120 (138xx018) ..................................................................................................................................... 114
Panel Mount OT-120 - previous version (138xx008) ................................................................................................ 117
Cables .......................................................................................................................................................................... 122
OT-120 Cables ........................................................................................................................................ 122
Scanner Cables ....................................................................................................................................... 123
Link Cables ............................................................................................................................................. 124
Valve Cables ................................................................................................................................................................ 125
CDS Color-Code Reader ............................................................................................................................................ 125
CDS Control Box (098xx102-01) ................................................................................................................................ 126
Section 7 - Button Configurations ......................................................................... 129
Password Access Configuration................................................................................................................................. 129

Table of Contents MC083 - VCX Service Manual
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Appendix A - Parameters ...................................................................................... 131
Appendix B - Test and Diagnostic Monitor ............................................................ 201
System Requirements .................................................................................................................................................201
Hyperterminal Setup ....................................................................................................................................................201
Monitor Functions ........................................................................................................................................................203
Boot Message ......................................................................................................................................... 203
Help Function.......................................................................................................................................... 203
Print Parameter Function ............................................................................................................................................204
Use the Disk Utilities for Unit Data Recovery ............................................................................................................205
Use the VTerminal for Software Updates ..................................................................................................................209
System Requirements ............................................................................................................................ 209
Start the Update Function and Initialize the CPU ................................................................................... 209
Download the new software and program the CPU ............................................................................... 211
Appendix C - Monitor Commands .......................................................................... 213
Tracking Control Module Monitor Commands ...........................................................................................................213

MC083 - VCX Service Manual Section 1 - Introduction
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Section 1 - Introduction
The VCX Control is a modular, integrated system for gluing control and quality assurance. Pattern Control Modules,
Inspection Control Modules, and Tracking/Ejecting Modules can be combined with one or two VCX Controls to
provide all functions of glue application, inspection, and quality assurance.
This manual provides the information necessary to setup, maintain, and troubleshoot the VCX Control hardware.
(Software programming and operation information is not included in this manual.) A parts list with options
is also included.
Valco Cincinnati, Inc. recommends reading this manual before beginning to use the VCX Control.

Section 1 - Introduction MC083 - VCX Service Manual
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