VALCOBABY MCP-25/MS User manual

MCP-25/MS Control
Manual Number: MC051
Release Date: June 2004

© 2003, 2004 Valco Cincinnati, Inc. All Rights Reserved.
This manual is furnished with the MCP-25/MS control and may only be used or copied 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 was written and designed at Valco Cincinnati, Inc., 411 Circle Freeway Drive, Cincinnati, Ohio 45246.
Part Number: MC051
Printed in the USA
Valco Cincinnati Incorporated
411 Circle Freeway Drive
Cincinnati, Ohio 45246
TEL: [phone]
FAX: [phone]
Valco Cincinnati Limited
Hortonwood 32
Telford, TF1 4 EU, England
TEL: [phone]
FAX: [phone]
Valco GmbH
Storkower Str.
15749 Gallun,Germany
TEL: [phone]
FAX: [phone]

CE Declaration of Conformity
(According to EN 45014)
Manufacturer: Valco Cincinnati, Incorporated
411 Circle Freeway Drive
Cincinnati, OH 45246
USA
declares that the product:
Product Name: Glue Control
Product Model: MCP-25 MS
Year of Manufacture: 2004
conforms to the following standards:
Safety: EN 60204-1
EMC Emissions: EN 50081-2
EN 55011, Class A
EMC Immunity: EN 50082-2
EN 61000-4-2
EN 61000-4-3
EN 61000-4-4
and complies with the requirements of:
Low Voltage Directive 73/23/EEC
EMC Directive 89/336/EEC
Office of CE Conformance
Cincinnati, Ohio
USA

Section 1—Introduction .................................................................................................................................. 1-1
About this Manual .................................................................................................................................. 1-1
Description of the MCP-25/MS Control ................................................................................................ 1-1
Section 2—Safety Information ....................................................................................................................... 2-1
General Information ............................................................................................................................... 2-1
Warnings ................................................................................................................................................. 2-1
Cautions .................................................................................................................................................. 2-2
What to do if Contact with Hot Adhesive Occurs .................................................................................. 2-3
What to do if Adhesive-Related Fire/Exposion Occurs ......................................................................... 2-3
What to do if Inhalation of Adhesive Fumes Occurs ............................................................................. 2-4
Section 3—General Wiring Guidelines .......................................................................................................... 3-1
Routing Low-Voltage Leads .................................................................................................................. 3-1
Connecting the Supply of Electrical Power............................................................................................ 3-1
Section 4—Basic Features ............................................................................................................................... 4-1
Introduction ............................................................................................................................................ 4-1
Front Panel .............................................................................................................................................. 4-1
Description of Front-Panel Features ............................................................................................ 4-2
Enclosure Options................................................................................................................................... 4-4
Back Panel of Field-Wirable Control ..................................................................................................... 4-5
Description of Back-Panel Features ............................................................................................ 4-5
Back Panel of Control with Connector ................................................................................................... 4-6
Description of Back-Panel Features ............................................................................................ 4-6
Internal Components .............................................................................................................................. 4-8
Skew Detection Option ........................................................................................................................... 4-9
MCP-25 Skew Detection System Components and Options ....................................................... 4-9
Section 5—Installation .................................................................................................................................... 5-1
Introduction ............................................................................................................................................ 5-1
MCP-25/MS Control Installation ........................................................................................................... 5-1
Connecting the Main Power Supply ............................................................................................ 5-1
Setting the Powerup-Selection Switch .............................................................................. 5-3
Scanner Installation ................................................................................................................................ 5-4
Mechanical Installation of the Scanner ........................................................................................ 5-4
Electrical Installation of the Scanner ........................................................................................... 5-4
Encoder Installation ................................................................................................................................ 5-6
Mechanical Installation of the Encoder ....................................................................................... 5-6
Electrical Installation of the Encoder........................................................................................... 5-6
Valve Installation .................................................................................................................................... 5-9
Mechanical Installation of the Valves ......................................................................................... 5-9
Electrical Installation of the Valves ............................................................................................. 5-9
Connections for Relay, Alarm, and 24VAC Outputs ............................................................................. 5-10
Electrical Installation of the Alarm/Beacon................................................................................. 5-10
Electrical Installation of the Machine Stop.................................................................................. 5-11
Electrical Installation of the DD-1 Pump .................................................................................... 5-12
Low-Level-Detector Installation ............................................................................................................ 5-13
Mechanical Installation of the Low-Level Detector .................................................................... 5-13
Electrical Installation of the Low-Level Detector ....................................................................... 5-13
Pressure-Transducer Installation ............................................................................................................ 5-14
Mechanical Installation of the Pressure Transducer .................................................................... 5-14
Electrical Installation of the Pressure Transducer ....................................................................... 5-14
Table of Contents

Section 5—Installation, Continued
Sensor Installation .................................................................................................................................. 5-20
AS-301/601/700 Sensors ............................................................................................................. 5-20
Description ........................................................................................................................ 5-20
Specifications .................................................................................................................... 5-20
Mounting and Adjusting the AS-301 Sensor ..................................................................... 5-21
AS-701 Sensor and Mounting Brackets ............................................................................ 5-22
Sensor Suitability .............................................................................................................. 5-24
Limitations......................................................................................................................... 5-24
Installing the AS-301/601/700 Sensor .............................................................................. 5-24
Adjusting the Internal Scanner Signal for the AS-301/601/700 Sensor ........................... 5-26
CGS-30 Gate Sensor .................................................................................................................... 5-27
Description ........................................................................................................................ 5-27
Installing the CGS-30 Gate Sensor ................................................................................... 5-27
Cleaning the CGS-30 Gate Sensor ................................................................................... 5-27
CGS-40 Gate Sensor .................................................................................................................... 5-30
Description ........................................................................................................................ 5-30
Installing the CGS-40 Gate Sensor ................................................................................... 5-30
Cleaning the CGS-40 Gate Sensor ................................................................................... 5-30
D-12 Sensor ................................................................................................................................. 5-33
Description ........................................................................................................................ 5-33
Installing the D-12 Sensor ................................................................................................ 5-33
MW-101 Microwave Sensor ........................................................................................................ 5-34
Description ........................................................................................................................ 5-34
Specifications .................................................................................................................... 5-34
Sensor Suitability .............................................................................................................. 5-34
Limitations......................................................................................................................... 5-34
Installing the MW-101 Microwave Sensor ....................................................................... 5-36
Digital NPN/PNP Sensor ............................................................................................................. 5-37
Description ........................................................................................................................ 5-37
Installing the Digital NPN/PNP Sensor ............................................................................ 5-37
Section 6—Menu Overview ............................................................................................................................ 6-1
Introduction ............................................................................................................................................ 6-1
Initial Screen ........................................................................................................................................... 6-1
Initial Screen Function Keys........................................................................................................ 6-1
Learn-Function Screens .......................................................................................................................... 6-2
Main-Menu Screens ................................................................................................................................ 6-2
Section 7—Operation ...................................................................................................................................... 7-1
Introduction ............................................................................................................................................ 7-1
Creating a New Job................................................................................................................................. 7-1
Adjustments ............................................................................................................................................ 7-2
Adjusting the Glue-Pattern Position ............................................................................................ 7-2
Adjusting the Glue Volume ......................................................................................................... 7-3
Section 8—Setup Menu ................................................................................................................................... 8-1
Introduction ............................................................................................................................................ 8-1
Valve Configuration ............................................................................................................................... 8-1
Valve Configuration Parameters ............................................................................................................ 8-2
Valve-Type Parameters .......................................................................................................................... 8-3
Pressure-Transducer Configuration ........................................................................................................ 8-4
Pressure-Transducer Configuration Parameters ..................................................................................... 8-5
Table of Contents, Continued

Section 8—Setup Menu, Continued
Encoder Configuration ........................................................................................................................... 8-6
Encoder-Configuration Parameters ........................................................................................................ 8-7
Sensor Configuration .............................................................................................................................. 8-8
Sensor Configuration Parameters ........................................................................................................... 8-8
Alarm Configuration ............................................................................................................................... 8-8
Alarm Configuration Parameters ............................................................................................................ 8-8
Marking-Valve Configuration ................................................................................................................ 8-9
Marking-Valve Configuration Parameters ............................................................................................. 8-9
Tolerance Configuration ......................................................................................................................... 8-10
Tolerance-Level Configuration Parameters ........................................................................................... 8-10
Report Configurations ............................................................................................................................ 8-11
Report Headers ............................................................................................................................ 8-11
Section Names ............................................................................................................................. 8-11
Programming Time, Date, and PIN Code .............................................................................................. 8-13
Selecting Language, Country Code, Date Format, and Length Unit ..................................................... 8-14
Section 9—Glue-Pattern-Edit Menu (Standard) .......................................................................................... 9-1
Introduction ............................................................................................................................................ 9-1
Types of Modes ...................................................................................................................................... 9-1
Glue-Pattern-Edit Parameters ................................................................................................................. 9-2
Glue-Pattern Example (Standard Mode) ................................................................................................ 9-4
Selecting a Mode .................................................................................................................................... 9-5
Entering/Editing a Glue Pattern .............................................................................................................. 9-6
Deleting a Glue Pattern........................................................................................................................... 9-7
Copying a Glue Pattern ........................................................................................................................... 9-8
Automatic Gluing Function .................................................................................................................... 9-9
Section 10—Glue-Pattern-Edit Menu (Flexoseal) ........................................................................................ 10-1
Introduction ............................................................................................................................................ 10-1
Flexoseal Modes ..................................................................................................................................... 10-1
Accessing the Glue-Pattern-Edit Main Menu ......................................................................................... 10-1
Main Screen for Mode 0—Top-Down Gluing, Tab Only ........................................................... 10-2
Main Screen for Mode 1—Top-Down Gluing, Tab and 4th Panel ............................................. 10-2
Main Screen for Mode 2—Top-Down, Bottom-Up Gluing, Tab and 4th Panel ......................... 10-3
Main Screen for Mode 3—Top-Down, Bottom-Up Gluing, Tab Only ....................................... 10-3
Glue-Pattern-Edit Parameters ................................................................................................................. 10-4
Selecting 4th-Panel or Tab Gluing............................................................................................... 10-5
Selecting a Glue-Pattern Mode .................................................................................................... 10-6
Selecting Extended-Tab or Normal-Tab Gluing .......................................................................... 10-7
Selecting Scanner Position and Assignment ................................................................................ 10-8
Programming the Automatic Gluing Function ............................................................................ 10-9
Glue Inspection ................................................................................................................. 10-9
Selecting A Channel .................................................................................................................... 10-10
Accessing the Glue-Pressure-Edit Main Menu ...................................................................................... 10-11
Glue-Pressure-Edit Parameters ............................................................................................................... 10-12
Section 11—Glue-Pressure-Edit Menu .......................................................................................................... 11-1
Introduction ............................................................................................................................................ 11-1
Glue-Pressure-Edit Parameters ............................................................................................................... 11-1
Creating a Glue-Pressure Curve ............................................................................................................. 11-3
Examples of Glue-Pressure Values ........................................................................................................ 11-3
Entering the Glue-Pressure Data Manually ............................................................................................ 11-4
Entering the Glue-Pressure Data with the Insert Function ..................................................................... 11-5
Changing the Glue Pressure ................................................................................................................... 11-6
Deleting a Current Glue-Pressure Curve ................................................................................................ 11-6

Section 12—Inspection Menu ......................................................................................................................... 12-1
Introduction ............................................................................................................................................ 12-1
Glue-Volume Bar Graph ........................................................................................................................ 12-1
Glue-Pattern Bar Graph .......................................................................................................................... 12-2
Inspection-Menu Parameters .................................................................................................................. 12-3
Changing Inspection-Menu Parameters ................................................................................................. 12-4
Marking-Valve Data ............................................................................................................................... 12-5
Fault-Counter Data ................................................................................................................................. 12-6
Tolerance Data ........................................................................................................................................ 12-7
Fault Data................................................................................................................................................ 12-7
Jam Preventer ......................................................................................................................................... 12-8
Resetting the Alarm Contact ........................................................................................................ 12-8
Jam Function Overview ............................................................................................................... 12-9
Section 13—The Learn Function ................................................................................................................... 13-1
Introduction ............................................................................................................................................ 13-1
Accessing the Learn Function ................................................................................................................ 13-1
Learn Results Screens ............................................................................................................................. 13-2
Learning Glue Volume ........................................................................................................................... 13-3
Learning the Distance Between Sensor and Marking Valve/Ejector ..................................................... 13-4
Learning Reference Values .................................................................................................................... 13-5
Learning Glue-Pattern Positions ............................................................................................................. 13-6
Section 14—Job-Management Menu ............................................................................................................. 14-1
Introduction ............................................................................................................................................ 14-1
Function Keys on Page 1 ............................................................................................................. 14-1
Function Keys on Page 2 ............................................................................................................. 14-1
Function Keys on Screen 3 .......................................................................................................... 14-1
Saving a Job ............................................................................................................................................ 14-2
Loading a Job .......................................................................................................................................... 14-3
Copying a Job ......................................................................................................................................... 14-4
Deleting a Job ......................................................................................................................................... 14-5
Go To Screen 2 ....................................................................................................................................... 14-5
Creating a New Current Job ................................................................................................................... 14-6
Editing a Job in Memory ........................................................................................................................ 14-7
Preparing a New Job in Memory ............................................................................................................ 14-8
Renaming a Job ...................................................................................................................................... 14-9
Go To Screen 3 ....................................................................................................................................... 14-9
Backup and Restore Functions ............................................................................................................... 14-10
Back up to Flash memory ....................................................................................................................... 14-10
Restore Data from Flash memory........................................................................................................... 14-11
Restore Data from Flash memory after Software Update ...................................................................... 14-12
Erase the Flash memory ......................................................................................................................... 14-12
Section 15—Diagnostic Menu ......................................................................................................................... 15-1
Introduction ............................................................................................................................................ 15-1
Printing a Diagnostic Report .................................................................................................................. 15-1
Diagnostic Parameters ............................................................................................................................ 15-2
Obtaining CPU Version Number ............................................................................................................ 15-3
Viewing Sensor Diagnostics ................................................................................................................... 15-3
Table of Contents, Continued

Section 16—Troubleshooting ......................................................................................................................... 16-1
Introduction ............................................................................................................................................ 16-1
Section 17—Specifications .............................................................................................................................. 17-1
Introduction ............................................................................................................................................ 17-1
Section 18—Part-Number List ....................................................................................................................... 18-1
How to Order Parts ................................................................................................................................. 18-1
MCP-25/MS Spare Parts List ................................................................................................................. 18-1
MCP-25 Installation Kit (091xx441) ........................................................................................... 18-2
Accessories ............................................................................................................................................. 18-2
Encoders....................................................................................................................................... 18-2
Encoder Cables ............................................................................................................................ 18-3
Sensors ......................................................................................................................................... 18-3
Sensor Cables ............................................................................................................................... 18-4
Pressure Transducers ................................................................................................................... 18-4
Pressure-Transducer Cables ......................................................................................................... 18-5
Section 19—Warranty..................................................................................................................................... 19-1
Warranty Information ............................................................................................................................. 19-1
Cold-Glue Equipment and Electronic Controls ........................................................................... 19-1
Hot-Melt Units, Hoses, Valves, and Related Equipment ............................................................ 19-1
Section 20—Service ......................................................................................................................................... 20-1
Service Needs ......................................................................................................................................... 20-1
Appendix A—Maintenance Procedures ........................................................................................................ A-1
Introduction ............................................................................................................................................ A-1
Daily Maintenance .................................................................................................................................. A-1
Weekly Maintenance .............................................................................................................................. A-2
3-Month Maintenance ............................................................................................................................ A-3
6-Month Maintenance ............................................................................................................................ A-4
12-Month Maintenance .......................................................................................................................... A-5
Appendix B—Wiring Information (Older Generation Controls) ............................................................... B-1
Back Panel of Field-Wirable Control ..................................................................................................... B-1
Description of Back-Panel Features ............................................................................................ B-1
Back Panel of Control with Connector ................................................................................................... B-4
Description of Back Panel Features ............................................................................................. B-4
Alarm/Beacon Wiring Connections ....................................................................................................... B-5
Appendix C—Glue-Pressure Software (Older Generation Controls) ........................................................ C-1
Glue-Pressure-Edit Menu ....................................................................................................................... C-1
Accessing the Glue-Pressure-Edit Parameters ............................................................................. C-1
Glue-Pressure-Edit Parameters .................................................................................................... C-2
Creating a Glue-Pressure Curve .................................................................................................. C-3
Examples of Glue-Pressure Values.............................................................................................. C-3
Entering the Glue-Pressure Data Manually ................................................................................. C-4
Entering the Glue-Pressure Data with the Learn Function .......................................................... C-5
Changing the Glue Pressure ......................................................................................................... C-6
Deleting a Current Glue-Pressure Curve ..................................................................................... C-6
Copying a Glue-Pressure Curve .................................................................................................. C-7
Index

Valco Cincinnati 1-1
Section 1—Introduction
About this Manual
Valco Cincinnati has prepared this manual as an aid for installing, operating, and servicing the MCP-25/MS control.
The manual also contains a list of part numbers for replacement parts. If you need more information, please contact
your Valco Cincinnati representative.
Description of the MCP-25/MS Control
The MCP-25/MS is a modular microprocessor control system. It is designed to allow users to easily program
multiple and complex glue patterns. The control is capable of operating a combination of different styles and types
of glue valves and dispensing systems.
Programs or program changes may be made “on-the-fly” with the results immediately occurring on the product. The
system maintains precision through machine speeds up to 2000 m/min. (6500 ft./min.).
With user-friendly, multi-language software, valve outputs can be individually compensated and assigned to a
selection of scanner and encoder inputs. A two-channel pressure output with programmable curve and integrated
bypass functions interfaces with the most complex adhesive delivery systems.
The MCP-25/MS offers unequaled flexibility and performance for the most demanding adhesive dispensing
applications.

Valco Cincinnati 2-1
General Information
It is the purchaser’s responsibility to ensure that all local, county, state, and national codes, regulations, rules, and
laws relating to safety and safe operating conditions are met and followed.
The best safeguard is trained personnel. The purchaser is responsible for providing personnel who are adequately
trained to install, operate, and maintain Valco components and systems.
This section contains information that is essential to the safety of personnel. Safety information is included through-
out the rest of the manual as well. The following safety conventions are used to indicate potential safety hazards:
Warnings
All personnel involved with the installation, operation, and maintenance of the equipment must read and thoroughly
understand the following warnings:
WARNING! Disconnect all power before opening the control. OTHERWISE,
DEATH OR PERSONAL INJURY COULD OCCUR. Only qualified personnel
should open and service the control.
WARNING! Promptly repair or replace all worn or damaged electrical wiring
and equipment wires. OTHERWISE, DEATH OR PERSONAL INJURY COULD
OCCUR.
WARNING! Properly route all electrical wires. OTHERWISE, DEATH, PER-
SONAL INJURY, OR DAMAGE TO THE MOVING PARTS OF THE MACHINE
MAY OCCUR.
WARNING! This symbol indicates the presence of uninsulated dangerous
voltage within the product’s enclosure. This voltage may cause electrical
shock or fire. FAILURE TO OBSERVE WARNING MAY RESULT IN DEATH,
PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE.
WARNING! This convention is used to alert the user to important installation,
operation, and/or maintenance information. FAILURE TO OBSERVE WARN-
ING MAY RESULT IN DEATH, PERSONAL INJURY, AND/OR EQUIPMENT
DAMAGE.
CAUTION! This convention is used to alert the user to important installation,
operation, and/or maintenance information. FAILURE TO OBSERVE CAUTION
MAY CAUSE EQUIPMENT DAMAGE.
Section 2—Safety Information