VALCOBABY MELTON CP-40 User manual

INSTRUCTIONS
CP-40 EXTERNAL
Polígono Industrial Agustinos, calle G, nave D-34
Tel: +34.948.321.580 Fax: +34.948.326.584
31160 ORCOYEN (Navarra) ESPAÑA

Declaration of conformity
The product:
Model no.:
Serial no.:
Year of manufacture:
Described in the enclosed documentation is in conformity with:
Directive 98/37/EC of 22 June 1998 relating to the
approximation of the laws of the Member States relating to
machinery, combining in a single text Directives 89/392/EEC
of 14 June 1989, 91/368/EEC of 20 June 1991, 93/44/EEC of
June 14, 1993 and 93/68/EEC of 22 July 1993.
Directive 73/23/EEC of 19 February 1973 relating to electric
equipment.
Directive 89/336/EEC of 3 May 1989 relating to
electromagnetic compatibility.
Directive 93/68/EEC of 22 July 1993, amending Directive
73/23/EEC, and Directive 89/336/EEC.
within the scope of the specifications indicated in the chapter describing
the equipment with a B1 risk level. Since it is intended to form part of a
set of machines which, to obtain a result, are arranged and connected to
perform together, it cannot be operated until the set of machines has
been declared in conformity with the applicable Directives by the person
responsible for the final assembly.
Orcoyen, on :_____________
Signed.:______________________
Gonzalo Marco, Managing Director
Polígono Industrial Agustinos, calle G, nave D-34
Tel.: +34.948.321.580 Fax: +34.948.326.584
31160 ORCOYEN (Navarra) SPAIN

M007502200 12/07/2007
MELTON, S.L. - POLIGONO INDUSTRIAL AGUSTINOS CALLE G-34,31160 ORCOYEN, NAVARRA
TEL: [phone] Fax: [phone] e-mail:[e-mail] http://www.melton.es
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IMPORTANT!
THIS INSTRUCTION MANUAL SHOULD BE KEPT IN A PLACE
ACCESSIBLE TO AND KNOWN BY ALL OPERATORS AND
MAINTENANCE PERSONNEL.
BEFORE STARTING UP THE MACHINE, PLEASE READ ALL THE
INSTRUCTIONS CAREFULLY AND STRICTLY FOLLOW ALL
INDICATIONS.
FOR PROPER USE AND HANDLING OF THE EQUIPMENT IT IS
NECESSARY TO CARRY OUT THE SAFETY INSTRUCTIONS GIVEN
IN THIS MANUAL.
WARNING:
If you alter the function, performance or safety aspects of
the machine, replacing original parts with other similar but
not identical components (substantial alterations), without
the authorisation of MELTON and as specified in Directive
89/392/EEC, you will be classified as a manufacturer and
therefore become liable for the alterations made.

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TABLE OF CONTENTS:
CHAPTER 1 SAFETY INSTRUCTIONS _____________________ 3
1.1. SYMBOLS AND TERMS: __________________________________ 3
1.2. PURPOSE: _______________________________________________ 3
CHAPTER 2 DESCRIPTION_______________________________ 4
2.1. INTRODUCTION: ________________________________________ 4
Specifications: ________________________________________________ 4
Display:______________________________________________________ 5
Connections: _________________________________________________ 5
CHAPTER 3 MACHINE INSTALLATION ___________________ 6
CHAPTER 3 MACHINE INSTALLATION ___________________ 7
3.1. INTRODUCTION: ________________________________________ 7
3.2. POWER SUPPLY CONNECTION: __________________________ 7
3.3. CONNECTING THE SOLENOID VALVES: __________________ 7
3.4. CONNECTING THE PHOTOCELL:_________________________ 7
3.5. CONNECTING THE EXTERNAL PERMISSION: _____________ 7
3.6. CONNECTING THE ENCODER: ___________________________ 7
CHAPTER 4 MACHINE ADJUSTMENTS ___________________ 8
4.1. INTRODUCTION: ________________________________________ 8
4.2. SHOT CONTROL: ________________________________________ 8
4.2.1. Introduction:__________________________________________________8
4.2.2. Description of the CP-40 control panel:_____________________________9
4.3. GENERAL PARAMETERS CP-40: _________________________ 10
System Programming Menus: __________________________________ 10
4.3.1 Job data Menu:__________________________________________ 10
4.3.2 Format data menu:_______________________________________ 10
Format number: ___________________________________________________11
Application type: __________________________________________________11
Application Mode: _________________________________________________11
Format Data:______________________________________________________11
Bead programming: ________________________________________________12
4.3.3 Test Valve menu: ________________________________________ 12
4.3.4 Reset Counter menu: _____________________________________ 12
4.3.5 Configuration menu: _____________________________________ 13
Valves compensation: ______________________________________________13
Stitch pattern configuration:__________________________________________14
Photocells filter: ___________________________________________________14
Photocells allocation: _______________________________________________14
Minimum speed:___________________________________________________15
Cycle selection: ___________________________________________________15
Password:________________________________________________________16
Language selection: ________________________________________________16

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Fix/ Variable speed selection:_________________________________________16
CHAPTER 5 MAINTENANCE ____________________________ 17
5.1. INTRODUCTION: _______________________________________ 17
5.2. MAINTENANCE RECOMMENDATIONS: __________________ 17

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CHAPTER 1 SAFETY INSTRUCTIONS
1.1. SYMBOLS AND TERMS:
Qualified personnel:
This is personnel (technical staff) who has acquired sufficient know-how
in a specific field, either through training or from experience.
This personnel must be familiar with safety and accident prevention
standards, and have general knowledge of the technical aspects of the
machine.
1.2. PURPOSE:
This unit has been manufactured according to current safety standards.
This unit has been designed for the purpose described in chapter 2 of this
manual, Description.
To use the machine correctly, follow the instructions provided in the
Operating Manual, particularly:
The machine should only be installed and used by qualified
personnel, previously familiarised with the operating instructions
(contacting the manufacturer whenever necessary) and the risks
involved, the safety measures required, including adjustment and
maintenance, and expressly forbidden operations.
This unit has not been manufactured to operate in hazardous,
explosive and/or flammable atmospheres
Repairs should be performed by personnel with basic knowledge
of the machine and of electricity that will allow them to carry out
their tasks properly.
Make sure that the equipment is properly grounded.
Miscellaneous
prohibitions
Miscellaneous
precautions
Precaution: electric
current Note of special interest
European Community
markings

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CHAPTER 2 DESCRIPTION
2.1. INTRODUCTION:
The CP40 model is a pattern control device with 4 channels and a
working speed of up to 240 m/min (800 ft/min).
The control may work on timer mode on time basis or on encoder mode
with a recommended resolution of 1 pulse per millimetre.
To ensure the optimum functioning, the ENCODER must be installed in
such a way that, when this one gives a whole turn, the displacement in
millimetres of the line which we are working on is the same to the
resolution of the installed ENCODER.
The CP40 is equipped with 2 inputs for PNP photocells or any other
sensor of application start. These inputs will give the star signal of the 4
channels.
The calculation system for variable speed applications includes inertia
compensation for the opening and closing of the guns following two
programmable parameters.
The programming allow 4 application lines between 0 and 5000 ms/mm
with a gap of 0 to 5000 ms/mm from the input signal.
The control has 24 pattern formats for their use in different configurations.
It also offers the options of cycle application and stitch mode.
In variable speed applications, the control has a 0-10 v analogical output
that can be adjusted to the line speed following a Ratio.
Other characteristics offered by this system are:
•Cycle counter.
•External permission input
•External permission output
•Line noise filter programmable
•Language selection
•Manual value test system
•Led Indication of in/out signals
Specifications:
Power supply: 24 VDC
Output signal: 24VDC up to 25,5W per channel.
Photocells: PNP photocell at 15V
Encoder: 500 ppr at 15V, with a ratio with the movement of the
line of 500mm/turn
Proportional valve: Power supply 24VDC control signal 0-10VDC
Permission signals: Input signal: NO at 24VDC
Output signal NO voltage free contact.
Max line speed: 240m/min (800ft/min)

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Display:
Esc
4
2
3
1
2
1
CP - 40
PARAMETER
ON/OFF ESCAPE DOWN UP ENTER
READY
IN
OUT
Connections:
START-1 12 3 4
START-2 ENCODER READY I/O 0-10V POWER
24 VDC
RS-485

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START 1-2 (PHOTOCELL 1-2)READY I/O
1-2-3-4 (SOLENOID VALVE 1,2,3,4)
ENCODER
0-10V
POWER 24 VDC
67
12
4
53
1
23
4
2
134
13
2
4
1
25
3
3
2
15
4
+
+24V
0-10V
OUT (NO)
PERMISSION
PERMISSION
IN
+15V
SIGNAL
+15V
+24V
GND
-
+
GND
GND
GND
SIGNAL

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CHAPTER 3 MACHINE INSTALLATION
3.1. INTRODUCTION:
This chapter explains how to install the machine correctly.
WARNING: The operations described in this chapter should be
performed by qualified personnel, following safety instructions.
3.2. POWER SUPPLY CONNECTION:
The CP-40 model has a power supply of 24 VDC.
3.3. CONNECTING THE SOLENOID VALVES:
The CP-40 model allows for the possibility of connecting four solenoid
valves with a pluggable connector per output.
The solenoid valves are connected to the CP-40 using pluggable
connectors. Each output (solenoid valve) supports up to 25.5W.
3.4. CONNECTING THE PHOTOCELL:
The CP-40 model has two input from the optoisolated PNP type shot
photocell or sensor with a power supply of 24 VDC.
The photocell is connected to the CP-40 using pluggable connectors.
3.5. CONNECTING THE EXTERNAL PERMISSION:
The CP-40 model has an external permission input
The gluing equipment sends a permission signal to the CP-40 as soon as
the programmed temperature has been reached.
The CP-40 sends a permission signal to the gluing equipment as soon as
the CP-40 is ON.
3.6. CONNECTING THE ENCODER:
The CP-40 model has an input from en encoder with a ratio with the
movement of the line of 500mm/turn.

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CHAPTER 4 MACHINE ADJUSTMENTS
4.1. INTRODUCTION:
The following adjustments should be made before the machine is
switched on or while it is operating. They will ensure that the machine
works properly and safely.
4.2. SHOT CONTROL:
4.2.1. Introduction:
Pattern diagram for each channel:
Note:
The values of the spaces (L1 – L7) should always be longer
than the end of the previous bead i.e.: L5 should be longer
than L3 + L4..
In case of a wrong programming the control will add the
following line to the previous one.
i.e.: If L5 is programmed shorter than L3 + L4 the control will
take automatically a value of L3 + L4 obtaining a space of L3
and a bead of L4 + L5.
When 0 is assigned to a value, this remains deactivated
T1 T2
T3 T4
T5 T6
T7
T8

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4.2.2. Description of the CP-40 control panel:
Esc
4
2
3
1
2
1
CP - 40
PARAMETER
ON/OFF ESCAPE DOWN UP ENTER
READY
IN
OUT
Keyboard:
The CP- 40A has six control keys that allow access to the programming
menus and general operating functions:
KEY ESCAPE: Exit the menu.
KEY PARAMETER:
KEY UP: This key is used to change the format number and parameter
and time values.
KEY DOWN: The same as key UP but in ascending order.
KEY ENTER: The ENTER key is used to validate the data modified in the
programming modes. In operating mode, it is not operative.
To validate a programming value, the ENTER key must be held
down until the display blinks (approx. 0.5 s), which is when the
value will be recorded in the non volatile memory.
If the ENTER key is not held long enough, the value is not
recorded and the previous one remains valid. This prevents
accidental changes in programming.
Esc

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KEY ON/OFF: This key is used to test the solenoid valves.
LEDs :
IN: Indicates photocells activation.
OUT: Indicates solenoid valves activation.
READY: Indicates test valves.
4.3. GENERAL PARAMETERS CP-40:
System Programming Menus:
For choosing the working menu, press the key . When the wanted
menu is displayed press .
Once the wanted menu is entered, use key for moving among the
parameters and to change the value of the parameter. Press
to validate the new value.
Press
Esc
to exit the menu.
The available menus are:
•Job data
•Format data
•Test Valves
•Reset counter
•Configuration
4.3.1 Job data Menu:
This menu displays the active format, the number of cycles made since
the last reset and the line speed in m/min.
Format: XX No. XXXXXX
Speed: XXX m/min.
Format: XX No. XXXXXX
Timer = 60 m/min.
4.3.2 Format data menu:
When entered it displays the following parameters:

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Format number:
The display will show:
* Format data *
Num: xx
Where XX is the pattern format that the system is using. This parameter
can be modified between 1 and 24.
Application type:
The display shows:
* Format data *
mould type: x
Where X can be modified between 0 and 1.
When application type is 0 the control will make a complete cycle every
time it receives an input signal.
When application type is 1 it will repeat the cycle until the input signal is
finished.
Application Mode:
The display will show:
* Format data *
Channel x mode x
Where mode can be set in either 0 or 1 for each channel.
When mode is 1 the control will enable the stitch system, making dashed
lines on the application in order to save adhesive.
Format Data:
The display will show:
* format data *
vref.: xxx m/min
Where XXX is the reference speed for the pressure control (maximum line
speed). Press to validate the changes. The display will then show:
* format data *
Press. At vref. Xx %

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Press to validate the changes. The display will then show:
* format data *
minimum press. Xx %
Where XX is the minimum pressure in % of the line pressure.
The control will maintain the minimum pressure until the calculation of
pressure is over that value.
Bead programming:
Following, the display shows the application parameters that can be set
between 0 and 5000.
When working in timer mode the display will show parameters T1 to T8.
Data Format xx
Channel x T1:xxxx ms
When working in encoder mode the display will show parameters L1 to
L8.
Data Format xx
Channel x L1:xxxx MM
Odd parameters are the spaces between the input signal and the start of
each of the 4 lines. Pair parameters represent the length of the line.
4.3.3 Test Valve menu:
This menu is used for the manual testing of the good operation of the
values mounted on each channel.
On/Off must be Off.
The display will show
Test Valve
Valve x
Where X is the channel to be tested. Modify this channel with the arrows
and press to fire that values connected to that channel. This menu is
only available hen the control is enabled to work.
4.3.4 Reset Counter menu:
When entered, the display shows:
Reset Counter
Press ENTER 2 sec
Value 1 selects programming with rising edge and falling edge of
the start sensor (photocell).

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Counter reset
Counter to 0 Esc
The cycles counter is activated when the application type is normal
(Application type: 0) in the menu “DATA FORMAT”; This counter counts
the made cycles through outlet channel 1 to solenoid valve. In case of
work with more than one outlet channel , we recommend to connect the
solenoid valve with the most extensive cycle device to the outlet channel
1 of the CP40.
4.3.5 Configuration menu:
When entered, the control request an access password
Configuration
Password:
If Password is ON, press at the same time and to enter the
menu.
Valves compensation:
* Configuration *
-- Compes. valves
Press to enter the menu or
Esc
to exit.
The display will show:
* compens. Valves *
Activ.: xx,x ms
Where XX,X is the time in milliseconds that the guns need to close (the
time from the control signal until the adhesive stops). Press to validate
the change. Use key for moving among the parameters.
* compens. Valves *
Deactiv.: xx,x ms
Where XX,X is the time in milliseconds that the guns need to open. Press
to validate the change.
Standard values for these parameters are:
Simple
effect Double effect
Deactivatio
n 19,0 ms 9,0 ms
Activation 8,0 ms 9,0 ms

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Stitch pattern configuration:
* Configuration *
-- Mould at dots
Press to enter the menu or
Esc
to exit.
When entered, the display shows:
* mould to dots *
total cycle: xx ms
Where XX is the total cycle time for the dashed line. This means the time
between the beginning of two consecutive dots. Press to validate the
changes. Use key for moving among the parameters.
* mould to dots *
on dot: xx ms
Where XX is the time length of the dot of the stitch pattern.
Photocells filter:
* Configuration *
-- FTCs Filter
Press to enter the menu or
Esc
to exit.
* FTCs filter *
T. Filter: xx ms
This menu is used for the selection of the photocell used as start signal
for every channel.
Where XX,X is the time in milliseconds that the photocell needs to give
the start signal to that channel.
Photocells allocation:
* Configuration *
-- Allocate PTCs
Press to enter the menu or
Esc
to exit.
This menu is used for the selection of the photocell
used as start signal for every channel.
The display will show:

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* Alloctation ftcs *
Ftc for channel x: X
Where X is the number of the photocell that will give the start signal to
that channel. If this parameter is set to 0 the channel is disabled.
Minimum speed:
* Configuration *
-- Minimun speed
Press to enter the menu or
Esc
to exit.
The display will show:
* minimum speed *
Vmin.: xxx m/min
Where XXX is the minimum speed at which the pattern control has to
work. When the line speed is below the programmed value, the control
disables all the programming automatically.
Cycle selection:
This control only works if mould type = 1.
* Configuration *
-- Close Cycle
Press to enter the menu or
Esc
to exit.
The display will show:
* Close Cycle *
By FTC Signal
When FTC Signal is ON the control finish with the photocell.
Use the arrows to change the selection.
The display will show:
* Close Cycle *
By Pattern ended
Press to choose the selection. In this way The CP-40 finish all cycle.