MC075

MCP-4 Control UnitMCP-4 Control UnitMCP-4 Control UnitMCP-4 Control UnitMCP-4 Control UnitManual Number: MC075Release Date: 6/2009Software Version: C011

© 2006-2009 Valco Cincinnati, Inc. All Rights Reserved

This manual is furnished with the MCP-4 Control and may be used or copied only in accordance with theterms of purchase.

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

This manual written and designed at Valco Cincinnati, Inc., 411 Circle Freeway Drive, Cincinnati, Ohio45246.

Part Number: MC075

Printed in the USA

Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.411 Circle Freeway DriveCincinnati, OH 45246TEL: (513) 874-6550FAX: (513) 874-3612Email: [email protected]: http://www.valcocincinnatiinc.com

Valco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedHortonwood 32Telford, TFI 7YN, EnglandTEL: (+44) 1952-677911FAX: (+44) 1952-677945Email: [email protected]: http://www.valco.co.uk

Valco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHStorkower Strasse 6D-15749 Gallun, GermanyTEL: (+49) 337 648 700FAX: (+49) 337 648 7070Email: [email protected]

Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Pol. Industrial Agustinoscalle G, n. 3431160 Orcoyen, Navarra, SpainTEL: (34) 948-321-580FAX: (34) 948-326-584

Declaration of ConformityDeclaration of ConformityDeclaration of ConformityDeclaration of ConformityDeclaration of Conformity(According to EN 45014)

Manufacturer:

Authorized Representative in Europe:

declares that the product:

Product Name:

complies with the following directives:

Low Voltage:EMC:

and conforms to the following standards:

Safety:

EMC Emissions:

EMC Immunity:

Place and Date:

Signature:

This Declaration of Conformity has been generated electronically and is legally binding without signature

Valco Cincinnati, Incorporated411 Circle Freeway DriveCincinnati, OH 45246USA

Valco Cincinnati, Ltd.Hortonwood 32 TelfordTF1 4EUUK

MCP-4

73/23/EEC89/336/EEC

EN 61010-1EN 60204-1

EN 61000-6-4

EN 61000-6-2

Cincinnati, Ohio USA, June 1, 2009

David H. Swedes,Director of Engineering & Manufacturing

TOC-1Valco Cincinnati, Inc.

TABLE OF CONTENTSTABLE OF CONTENTSTABLE OF CONTENTSTABLE OF CONTENTSTABLE OF CONTENTS

Section 1 - Introduction .................................................. 1-1System Description ................................................................................................. 1-1Features/Capabilities ............................................................................................... 1-1

Section 2 - Safety Information ....................................... 2-1General Information ................................................................................................. 2-1Warnings................................................................................................................... 2-1Cautions.................................................................................................................... 2-3

What to Do if Contact with Hot Adhesive Occurs ...................................................................2-3What to Do if Adhesive-Related Fire or Explosion Occurs ....................................................2-3What to Do if Inhalation of Adhesive Fumes Occurs ..............................................................2-4

Section 3 - Basic features............................................... 3-1MCP-4 Control .......................................................................................................... 3-1

Front Panel ................................................................................................................................3-1Back Panel .................................................................................................................................3-2

Changing the Voltage .................................................................................................................................................................... 3-3

MCP-4P Control (24VDC) ......................................................................................... 3-5Front Panel ................................................................................................................................3-5Bottom Panel .............................................................................................................................3-5

MCP-4P Control (115/230VAC) ................................................................................ 3-7Front Panel ................................................................................................................................3-7Bottom Panel .............................................................................................................................3-7

MCP-4F Control ........................................................................................................ 3-8Front Panel ................................................................................................................................3-8Bottom Panel .............................................................................................................................3-8

MCP-4 Valve Driver Instructions............................................................................. 3-9Wiring Configurations for Triggering the Valves ....................................................................3-9

Section 4 - Programming................................................ 4-1Mounting ................................................................................................................... 4-1Using the Operator Interface .................................................................................. 4-2

The Operator Interface Buttons ...............................................................................................4-2The Main Menu Buttons............................................................................................................4-3The Valve Buttons .....................................................................................................................4-3The Navigation Buttons ............................................................................................................4-4The Edit Buttons .......................................................................................................................4-5The Status LEDs ........................................................................................................................4-7Language ...................................................................................................................................4-8

TOC-2 Valco Cincinnati, Inc.

Table of Contents MC075 - MCP-4 Control Unit

First Use Setup (Wizard) ......................................................................................... 4-8Application .................................................................................................................................4-8Encoder ......................................................................................................................................4-9Measurement Mode...................................................................................................................4-9Jog Mode .................................................................................................................................4-10Finish Configuration ...............................................................................................................4-10Valve Type ................................................................................................................................ 4-10

Enter Password ..............................................................4-11Password Levels .....................................................................................................................4-12Level 2 Password Options......................................................................................................4-12

Configure the Valve/Channel Settings ................................................................. 4-16Compensation Time ................................................................................................................4-17Speed Settings ........................................................................................................................4-17Valve Type ................................................................................................................................ 4-18Scanner Settings .....................................................................................................................4-18Encoder Settings .....................................................................................................................4-18Valve - Voltage Settings ..........................................................................................................4-19Valve - Timing Settings ........................................................................................................... 4-19

Check Other Valves/Channels ............................................................................. 4-19Memory (Backup) ................................................................................................... 4-20

Restore .....................................................................................................................................4-21Initialize Settings.................................................................................................... 4-22Additional Setup Button Parameters ................................................................... 4-24

Language .................................................................................................................................4-24Measurement Mode................................................................................................................. 4-25Pattern Entry Mode ................................................................................................................. 4-25Jog Mode .................................................................................................................................4-26Batch Counter .........................................................................................................................4-26External Purge Signal .............................................................................................................4-26External Enable Signal ............................................................................................................4-27Output Configuration .............................................................................................................. 4-27Menu Configuration ................................................................................................................4-27

Encoder Menu Screen ........................................................................................... 4-28Ratio Compensation ...............................................................................................................4-28Speed Calculation ...................................................................................................................4-29

Section 5 - Operation ...................................................... 5-1Set the Pattern Menu Information........................................................................... 5-1

Scrolling Through Valve Numbers with the Pattern Button...................................................5-1Gluing Mode ..............................................................................................................................5-2Scanner Lockout .......................................................................................................................5-3Valve to Scanner Distance ........................................................................................................5-4Jog Mode Parameter .................................................................................................................5-4Batch Counter ...........................................................................................................................5-5

TOC-3Valco Cincinnati, Inc.

Table of ContentsMC075 - MCP-4 Control Unit

Input Values/Gluing Mode ........................................................................................................5-5Pattern Mode ......................................................................................................................................... 5-6

Pattern Mode - Example ............................................................................................................................................................... 5-6Stitch Mode ........................................................................................................................................... 5-9

Stitch Mode Menus ........................................................................................................................................................................ 5-9Auto Glue Mode .................................................................................................................................. 5-10

Auto Glue Mode Menus .............................................................................................................................................................. 5-10Continuous Glue Mode ....................................................................................................................... 5-10

Continuous Glue Mode Menus .................................................................................................................................................... 5-10

Set the Pressures .................................................................................................. 5-11Pressure Offset Value ............................................................................................................. 5-11Purge Pressure %.................................................................................................................... 5-11Minimum Speed/Pressure ......................................................................................................5-12Maximum Speed/Pressure ......................................................................................................5-12

Speed/Pressure Graphs - Examples .................................................................................................. 5-13Helpful Hints about Pressures ............................................................................................... 5-13

Diagnostic Button .................................................................................................. 5-14Total Products/Products per Hour ......................................................................................... 5-14Valve Status ............................................................................................................................. 5-14Scanner and Trigger Status ....................................................................................................5-15Version Information ................................................................................................................5-15Event History ...........................................................................................................................5-15

Job Button .............................................................................................................. 5-16Load a Job ...............................................................................................................................5-16Save a Job ...............................................................................................................................5-17

Section 6 - Maintenance ................................................. 6-1Purging the Adhesive .............................................................................................. 6-1Performing Downtime Maintenance ....................................................................... 6-1Flushing the Glue System ....................................................................................... 6-2Lubricating the System ........................................................................................... 6-3

Section 7 - Specifications............................................... 7-1

Section 8 - Part Number List .......................................... 8-1How to Order Parts .................................................................................................. 8-1

USA: ...........................................................................................................................................8-1England: .....................................................................................................................................8-1Germany: ...................................................................................................................................8-1Spain: .........................................................................................................................................8-1

MCP-4 without EPC (074xx037) .............................................................................. 8-2MCP-4 with EPC (074xx038) .................................................................................... 8-3MCP-4P Unit - 24VDC (074xx041) .......................................................................... 8-4MCP-4P Unit - 115/230VAC (074xx040) .................................................................. 8-8MCP-4F Unit - 115/230VAC (074xx039) ................................................................ 8-12Glue System Layout with MCP-4 .......................................................................... 8-16Core Winding System with MCP-4........................................................................ 8-17

TOC-4 Valco Cincinnati, Inc.

Table of Contents MC075 - MCP-4 Control Unit

Section 9 - Warranty........................................................ 9-1Hoses, Valves, and Related Equipment ................................................................. 9-1

Section 10 - Service ...................................................... 10-1

Appendix A - Job Charts .................................................A-1

1-1Valco Cincinnati, Inc.

SECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTIONSECTION 1 - INTRODUCTION

This manual has been prepared by Valco Cincinnati, Inc. to provideassistance in the installation, operation, and servicing of your MCP-4Control Unit.

The MCP-4 Control Unit from Valco provides operators with a full-featuredaffordable solution to adhesive system pattern control. The control features4-channel operation, multiple glue patterns, and an optional flow controlcapability. The unit allows program changes and adjustments, so you canget desired results immediately. The control has a compact design andfeatures “plug-and-run” connectors for easy installation and quick start up.

The MCP-4 Control Unit works with a variety of Valco’s cold-glue or hot meltadhesive dispensing valves. Features/Capabilities of the MCP-4 Unitinclude:

• Suited to high-speed converting, such as:

-folding carton production-envelope manufacturing-paper-folders-book and magazine production-bag-making-corrugated box making

• Multiple valves, complex glue patterns

• 4 channels, 10 programmable patterns per channel

SystemDescription

Features/Capabilities

• Continuous, stitch, and auto glue patterns

• Large storage memory of 100 jobs

• EPC flow control option

• Encoder-based or timer mode

• Web break detection option

• CE Compliant

All hardware must be up-to-date for allnew functions to work. Please see theParts List for a compatibility chart.


SECTION 2 - SAFETY INFORMATIONSECTION 2 - SAFETY INFORMATIONSECTION 2 - SAFETY INFORMATIONSECTION 2 - SAFETY INFORMATIONSECTION 2 - SAFETY INFORMATION

GeneralInformation

It is the purchaser’s responsibility to ensure that all local, county, state, andnational codes, regulations, rules, and laws relating to safety and safeoperating conditions are met and followed.

The best safeguard is trained personnel. The purchaser is responsible forproviding personnel who are adequately trained to install, operate, andmaintain Valco components and systems.

This section contains information that is essential to the safety of personnel.Safety information is included throughout the rest of the manual as well. Thefollowing safety conventions are used to indicate potential safety hazards:

Warning!Warning!Warning!Warning!Warning! This symbol indicates the presence of un-insulateddangerous voltage within the product’s enclosure. Thisvoltage may cause electrical shock or fire. FAILURE TOOBSERVE WARNING MAY RESULT IN DEATH,PERSONAL INJURY, AND/OR EQUIPMENTDAMAGE.

Warning!Warning!Warning!Warning!Warning! This convention is used to alert the user to importantinstallation, operation, and/or maintenance information.FAILURE TO OBSERVE WARNING MAY RESULT INDEATH, PERSONAL INJURY, AND/OR EQUIPMENTDAMAGE.

Caution!Caution!Caution!Caution!Caution! This convention is used to alert the user to importantinstallation, operation, and/or maintenance information.FAILURE TO OBSERVE CAUTION MAY CAUSEEQUIPMENT DAMAGE.

All personnel involved with the installation, operation, and maintenance ofthe equipment must read and thoroughly understand the following warnings:

Warning!Warning!Warning!Warning!Warning! Disconnect all power before opening the control.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR. Only qualified personnel should openand service the control.

Warning!Warning!Warning!Warning!Warning! Promptly repair or replace all worn or damagedelectrical wiring and equipment wires. OTHERWISE,DEATH OR PERSONAL INJURY COULD OCCUR.

Warnings

2-2 Valco Cincinnati, Inc.

Section 2 - Safety Information MC075 - MCP-4 Control Unit

Warning!Warning!Warning!Warning!Warning! Properly route all electrical wires. OTHERWISE,DEATH, PERSONAL INJURY, OR DAMAGE TO THEMOVING PARTS OF THE MACHINE MAY OCCUR.

Warning!Warning!Warning!Warning!Warning! When making adjustments or performing checkoutprocedures, stay clear of any moving mechanical partsand do not touch exposed electrical equipment orelectrical connectors. OTHERWISE, DEATH ORPERSONAL INJURY COULD OCCUR.

Warning!Warning!Warning!Warning!Warning! Keep pump cover and electrical enclosures closedexcept during setup, service, and checkout procedures.OTHERWISE, DEATH OR PERSONAL INJURYCOULD OCCUR.

Warning!Warning!Warning!Warning!Warning! Promptly repair or replace all worn or damaged parts.OTHERWISE, PERSONAL INJURY OR EQUIPMENTDAMAGE COULD OCCUR.

Warning!Warning!Warning!Warning!Warning! Always wear insulated gloves and proper eyeprotection when working around hot melt equipment. Aprotective screen around the face is alsorecommended. OTHERWISE, DEATH OR PERSONALINJURY COULD OCCUR.

Warning!Warning!Warning!Warning!Warning! Purge the fluid pressure from the system beforedisconnecting any part of the system. OTHERWISE,DEATH OR PERSONAL INJURY COULD OCCUR.

Warning!Warning!Warning!Warning!Warning! People with respiratory problems (e.g., asthma,bronchitis, etc.) should not work in the vicinity of moltenadhesive. RESPIRATORY PROBLEMS MAY BEAGGRAVATED BY THE FUMES. Do not wear a facemask when working around molten adhesive. THEMASK MAY TRAP THE FUMES AND DEATH ORPERSONAL INJURY COULD OCCUR.

Warning!Warning!Warning!Warning!Warning! Keep hot melt hoses away from walkways and themoving parts of hot melt systems. OTHERWISE,PERSONAL INJURY OR EQUIPMENT DAMAGECOULD OCCUR.

Warning!Warning!Warning!Warning!Warning! The hot melt unit should be installed so that it can beturned off at a location away from the hot melt unit.OTHERWISE, DEATH, PERSONAL INJURY, OREQUIPMENT DAMAGE COULD OCCUR.

Warnings - Continued


MC075 - MCP-4 Control Unit Section 2 - Safety Information

Cautions All personnel involved with the installation, operation, and maintenance ofthe equipment must read and thoroughly understand the following cautions:

Caution!Caution!Caution!Caution!Caution! Never hose or steam-clean the unit. If the surroundingarea is cleaned in this manner, protect the unit bycovering it with plastic or other waterproof material.OTHERWISE, DAMAGE TO EQUIPMENT COULDOCCUR.

Caution!Caution!Caution!Caution!Caution! Do not bend hot melt hoses less than an 18-inch (460mm) radius. OTHERWISE, EQUIPMENT DAMAGECOULD OCCUR.

Caution!Caution!Caution!Caution!Caution! Place Material Safety Data Sheets for the adhesivenear the unit. OTHERWISE, DAMAGE TOEQUIPMENT COULD OCCUR.

Warning!Warning!Warning!Warning!Warning! The heat that is contained in hot melt material willcontinue to penetrate and deeply burn the skin unlessrapidly cooled by external means such as water. Do notattempt to remove set hot melt adhesive from the skin.OTHERWISE, PERSONAL INJURY COULD OCCUR.

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

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

It is recommended that a source ofclean, cold water be provided near thehot melt work area.

2. Cover the affected area with a clean, wet compress and see aphysician immediately.

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

Warning!Warning!Warning!Warning!Warning! Poor ventilation, smoking, and open flames can causeoverheated hot melt to ignite. Adequate ventilationmust be provided. Smoking should be prohibited in theimmediate vicinity of the molten adhesive. Open flamesmust be kept away from the area around moltenadhesive. OTHERWISE, DEATH, PERSONAL INJURY,OR DAMAGE TO EQUIPMENT COULD OCCUR.

Warning!Warning!Warning!Warning!Warning! Exposed arcing may ignite the fume/air mixture. Shieldall electrical equipment from melt fumes to avoidexposed arcing. OTHERWISE, PERSONAL INJURYOR EQUIPMENT DAMAGE COULD OCCUR.

What to Do if Contactwith Hot Adhesive

Occurs

What to Do ifAdhesive-RelatedFire or Explosion

Occurs


Section 2 - Safety Information MC075 - MCP-4 Control Unit

Warning!Warning!Warning!Warning!Warning! Do not use a water extinguisher to extinguish the fire!OTHERWISE, PERSONAL INJURY OR EQUIPMENTDAMAGE COULD OCCUR.

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

1. Sound a fire alarm.

2. Evacuate the immediate area.

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

4. Fight the fire in oneoneoneoneone of the following ways:

- Smother the fire with a fire blanket.

- Aim a CO2 fire extinguisher at the base of the flames.

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

If Adhesive fumes are inhaled, immediately follow these steps:

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

2. Provide victim with fresh air.

3. Call a qualified medical authority.

What to Do if Adhesive-RelatedFire or Explosion Occurs -Continued

What to Do ifInhalation of

Adhesive FumesOccurs


SECTION 3 - BASIC FEATURESSECTION 3 - BASIC FEATURESSECTION 3 - BASIC FEATURESSECTION 3 - BASIC FEATURESSECTION 3 - BASIC FEATURES

MCP-4 Control

Front Panel

Valve EnableButtons (1-4)

Figure 3-1. MCP-4 Operator Panel

Trigger LEDs

Valve LEDsLCD Display

Right ArrowButton

Purge ButtonPlus (+)Button

Left ArrowButton

Minus (-) Button

EraseButton

PatternButton

Diagnostics Button

PressureButton

Setup Button

PowerLED

Job Storage/Recall Button


Section 3 - Basic Features MC075 - MCP-4 Control Unit

Figure 3-2. MCP-4 Back Panel

Back Panel* Note!* Note!* Note!* Note!* Note! For the EPC Air Pressure Input, use an 8mm air line

OR use the 1/4” tube adapter that is included in yourInstallation Kit.

PumpPower

Connector

Scanner Input 1-4 (yellow) DiagnosticPort

EncoderInput

EPC Air Pressure Input* (See Note above)

EPC AirPressureOutput

AC PowerCable

Valve Output 1-4 (blue)

On/OffSwitch

GroundingScrew

Input VoltageSelector


MC075 - MCP-4 Control Unit Section 3 - Basic Features

Input Voltage Selector

To change the voltage input, do the following:

1. Make certain the unit is OFF and unplugged.

2. Carefully open the input voltage selector compartment cover byprying up on the tab with a small screwdriver (see Figure 3-3A).

3. Remove the fuse drawer and make sure the fuse(s) in the holderremain in place.

WARNING! The setup may vary, depending on the country ofinstallation. It is the purchaser’s responsibility to ensurethat all local, county, state, and national codes,regulations, rules, and laws relating to safety and safeoperating conditions are met and followed.OTHERWISE, DEATH, PERSONAL INJURY, ORDAMAGE TO EQUIPMENT COULD OCCUR.

CAUTION! Check the Parts List carefully and only userecommended parts (especially fuses). Also be certainthe voltage in the Input Voltage Selector Window iscorrect before plugging in a power cord! OTHERWISE,DAMAGE TO EQUIPMENT COULD OCCUR.

Tab

Input Voltage Selector Window(view voltage through window)

SmallScrewdriver

Pry Indent for SmallScrewdriver

Fuse Drawer

4. If the control will be connected to 115VACIf the control will be connected to 115VACIf the control will be connected to 115VACIf the control will be connected to 115VACIf the control will be connected to 115VAC, rotate the drawer sothat 115V will show through the door opening. If the control willIf the control willIf the control willIf the control willIf the control willbe connected to 230VACbe connected to 230VACbe connected to 230VACbe connected to 230VACbe connected to 230VAC, rotate the drawer to the 230V position(see Figure 3-3A).

Figure 3-3A. Voltage Selector/Fuse Drawer (086xx055)

Changing the VoltageChanging the VoltageChanging the VoltageChanging the VoltageChanging the Voltage



Changing the Voltage - Continued 5. For line-to-neutral operationFor line-to-neutral operationFor line-to-neutral operationFor line-to-neutral operationFor line-to-neutral operation, use either the shorting clip andone fuse, or use two fuses. (The shorting clip will be on the leftside of the drawer when rotated to the correct voltage positionas shown in Figure 3-3B.) For line-to-line useFor line-to-line useFor line-to-line useFor line-to-line useFor line-to-line use,,,,, discard theshorting clip and use two fuses (see Parts List Section for partnumbers).

6. Replace the drawer in the fuseholder in the correct voltageposition and close the door of fuseholder.

7. Ensure that the correct operating voltage shows through thewindow in the fuse drawer.

Figure 3-3B. Shorting Clip and Fuses

Shorting Clip

Fuses



MCP-4PControl(24VDC)

Front Panel

Bottom Panel

The MCP-4P Control Unit is available in a 24VDC version and a 115/230VACversion with valve driver. Both units are vertically mounted. The operatorpanel is the same as the MCP-4 unit (see Figure 3-1).

The MCP-4P 24VDC version is field wirable (see Figure 3-6).

Figure 3-4. MCP-4P (24VDC version) Front View

Figure 3-5. MCP-4P (24VDC version) Bottom View (enlarged to show detail)

Valve Output 1-4 (blue)

Grounding Screw

Scanner Input 1-4 (yellow) 24VDC Power Input

Encoder Input Diagnostic Port



Figure 3-6. MCP-4P 24VAC Field Wirable Connections

12345

24VPNPGNDNPNSHLD

BROWN (RED)

BLUE (BLACK)BLACK (WHITE)

12345

24VPNPGNDNPNSHLD

BROWNWHITE (BLACK)BLUE

SCANNER

NPN SCANNER

PNP SCANNER

VALVE

12345

COILCOILPURGEPURGESHLD

BROWN

BLUEBLACK

WHITE

GRAY

ELECTRIC VALVE

12345

COILCOIL

SHLD/PE

MAC VALVE

EPC-6

5 4 3 2 1

0-10

VG

ND

GN

D24

V

BLAC

K

BRO

WN

RED

D10 HOT MELT UNIT

5 4 3 2 1

EPC2

GN

D

24V

SHLD

POWER

24V

0VPE

SCANNER1 2 3 4

12345 POWER

VALVE1 2 3 4

12345

EPC

5 4 3 2 1

MCP-4P CONNECTION DIAGRAM

14131211

1615

10

J13

MWS0728

0-10

V

EPC1

0-10

V

BROWNWHITE



MCP-4PControl (115/230VAC)

Front Panel

Bottom Panel

Figure 3-7. MCP-4P (115/230VAC version) Front View

Figure 3-8. MCP-4P (115/230VAC version) Bottom View (enlarged to show detail)

Valve Output 1-4 (blue) Scanner Input 1-4 (yellow)

Encoder Input

Diagnostic Port

Pump Power Connector

115/230VAC Power Input(Side of unit)

External EPC Connection

Grounding Screw



MCP-4FControl

Front Panel

Bottom Panel

Figure 3-9. MCP-4F Front View

Figure 3-10. MCP-4F Bottom View (enlarged to show detail)

The MCP-4F Control Unit is available in a 115/230VAC version featuring aninternal EPC flow control for variable speed applications. The operator panelis the same as the MCP-4 unit (see Figure 3-1).

Valve Output 1-4 (blue) Scanner Input 1-4 (yellow)

Encoder Input

Diagnostic Port

115/230VAC Power Input(Side of unit)

Secondary EPC Connection Pump Power Connector

Grounding Screw

EPC Air PressureInput

EPC AirPressureOutput



MCP-4 ValveDriverInstructions

Wiring Configurationsfor Triggering the

Valves

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

Warning!Warning!Warning!Warning!Warning! The triggering device used must must must must must be configured tooutput only 24VDConly 24VDConly 24VDConly 24VDConly 24VDC. If the control unit has a spike, itwill damage the input circuit for the scanner.

Wiring the Scanner Cable 1. Make sure the MCP-4 power switch is OFF and the unit isunplugged.

2. Cut the female connector off of the Scanner 1 cable.

Warning!Warning!Warning!Warning!Warning! Disconnect all power and input signal wiring beforeattempting to install or replace any part of the gluesystem. Otherwise, personal injury or death may occur!

3. Plug the male connector (on the Scanner 1 cable) into theScanner 1 input port on the back of the MCP-4 Control Unit.

Cut off and discard thefemale end of the cable.

Scanner cable (male connector) pluggedinto the Scanner 1 input port

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

5. Wire the modified scanner cable according to the WiringDiagram (next page).



Wiring the Scanner Cable -Continued


SECTION 4 - PROGRAMMINGSECTION 4 - PROGRAMMINGSECTION 4 - PROGRAMMINGSECTION 4 - PROGRAMMINGSECTION 4 - PROGRAMMING

MountingThe MCP-4 Control Unit can be mounted on any flat, stable surface close tothe machine glue station.

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

2. Valco makes a rolling cart (738xx878 Complete System Cart;579xx322 Control Stand only) that can be used to securelymount the MCP-4 Control Unit. Please contact your Valco salesrepresentative for purchasing information.

3. The MCP-4P and MCP-4F Control Units are vertically mounted.See the mounting footprints in the Parts List Section.

4. A swivel shelf mount (582xx780) is available for models074xx037 and 074xx038.


Section 4 - Programming MC075 - MCP-4 Control Unit

The Operator Interface Buttons can be grouped into four categories (seeFigure 4-1):

• Main Menu Buttons

• Valve Buttons

• Navigation Buttons

• Edit Buttons

Using theOperatorInterface

The OperatorInterface Buttons

Figure 4-1. The Operator Interface Buttons

NavigationButtonsMain Menu

Buttons

Valve Buttons Edit Buttons


MC075 - MCP-4 Control Unit Section 4 - Programming

There are 5 Main Menu Buttons. The LED in the upper Left hand side of theButtons indicates which Main Menu Button is selected.

Pattern Button - Pressing the Pattern Button allows you to beginto enter gluing patterns for valves 1-4.

Pressure Button - Pressing the Pressure Button allows you tobegin to enter the pressure settings.

Setup Button - Pressing the Setup Button allows you to beginto setup the MCP-4 Control Unit.

Diagnostics Button - Pressing the Diagnostics Button allows youto view the MCP-4 Control Unit diagnostics.

Job Button - Pressing the Job Button allows you to save a joband load a job.

The Main MenuButtons

The Valve Buttons There are 5 Valve Buttons:

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

When the Purge Button LED is on,Manual Purge Mode is on. In this Mode,the Valve Buttons act as “purgebuttons.” When the LED is off, theValve Buttons turn the valves on andoff.

Valve 1-4 Buttons - Pressing the individual Valve Button(s)allows you to tell the MCP-4 Control Unit which valves you aregoing to use for the job you will run. The LED in the upper Lefthand side of the Buttons indicates which valve is selected.



The NavigationButtons

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

Right Arrow Button - Pressing the Right Arrow Button moves thecursor to the right, highlighting each editable field (see Figure 4-2A through 4-2C).

When there are no more editable fields on the screen tohighlight, a Right Arrow Symbol may appear in the lower rightcorner of the screen (see Figure 4-2C). If this Right ArrowSymbol appears, there is an additional menu screen to the rightof the current display. Press the Right Arrow Button to view themenu screen to the right.

RightArrow

Symbol

Figure 4-2CFigure 4-2BFigure 4-2A

Left Arrow Button - Pressing the Left Arrow Button moves thecursor to the left, highlighting each editable field (see Figure 4-3A and 4-3B).

If a Left Arrow Symbol appears in the lower left corner of thescreen, it indicates there is an additional menu screen to the leftof the current display (see Figure 4-3B). Press the Left ArrowButton to view the menu screen to the left of the current display.

Figure 4-3BFigure 4-3A LeftArrow

Symbol



The Edit Buttons There are 4 Edit Buttons: the Plus Button, the Minus Button, the EraseButton, and the OK Button. These Buttons are used to change/enterinformation.

You can only change a value when it ishighlighted (see Figure 4-5).

Highlighted(Editable) Value

Figure 4-5. Highlighted Value

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

Minus Button - Pressing the Minus Button allows you todecrease the value of the input.

Erase Button - Pressing the Erase Button allows you to return tothe factory default settings. Holding the Erase Button longerthan five seconds will change all pattern settings to “0.”

OK Button - Pressing the OK Button opens and closes thethumbwheel control. It also “opens” highlighted menu screensfor editing (see example next page).

Flash Memory StorageThe symbol consisting of two arrows in a circular pattern indicates that avalue has been changed but the change is not yet stored in the flashmemory (see Figure 4-4).

Change made but not yetstored in flash memory.

Figure 4-4. The “Storing Information” Symbol



Open a Highlighted Menuwith the OK Button

Highlighted Menu(Valve 2)

The Valve 2Menu Screen

Opens

If a highlighted menu will not open withthe OK Button, check the passwordlevel. A higher password level may berequired to view the menu.

Thumbwheel vs. SingleDigit Edit

When editable information is numerical, the information may be edited withthe Plus/Minus Buttons for single digit editing, or the OK Button may bepressed to bring up a thumbwheel for more detailed editing.

Single Digit Editing

Thumbwheel Editing

In Thumbwheel Edit, use the Right/LeftArrow Buttons to select the digitposition, and the Plus/Minus ArrowButtons to increase/decrease the valueof the selected digit.



Status LEDs - The Status Display LEDs show on/off status. When an LED ison (lit up), the corresponding input or output is activated (see Figure 4-6).

Be sure the encoder, scanners, valves,and the MCP-4 Control Unit have beenproperly mounted to the parentmachine before setting up the control.The glue and air lines are notconnected until after the control isprogrammed.

The Status LEDs

Trigger StatusLED Display

Power StatusLED Display

Valve StatusLED Display

Figure 4-6. Status LEDs



First UseSetup(Wizard)

The first time the MCP-4 Control Unit is switched on, it will guide youthrough a series of menus in order to setup your control for your uniqueproduction needs. If these needs change later, the settings can be changedin the setup.

The first time the MCP-4 Control Unit is switched on, the following screenwill appear:

Use the Plus/Minus Buttons to scroll though choices. If asked to enter aUse the Plus/Minus Buttons to scroll though choices. If asked to enter aUse the Plus/Minus Buttons to scroll though choices. If asked to enter aUse the Plus/Minus Buttons to scroll though choices. If asked to enter aUse the Plus/Minus Buttons to scroll though choices. If asked to enter anumerical value, press the OK Button for the Thumbwheel Mode or usenumerical value, press the OK Button for the Thumbwheel Mode or usenumerical value, press the OK Button for the Thumbwheel Mode or usenumerical value, press the OK Button for the Thumbwheel Mode or usenumerical value, press the OK Button for the Thumbwheel Mode or usethe Plus/Minus Buttons for single digit editing. Press the Right Arrowthe Plus/Minus Buttons for single digit editing. Press the Right Arrowthe Plus/Minus Buttons for single digit editing. Press the Right Arrowthe Plus/Minus Buttons for single digit editing. Press the Right Arrowthe Plus/Minus Buttons for single digit editing. Press the Right ArrowButton to move to the next setup choice. Button to move to the next setup choice. Button to move to the next setup choice. Button to move to the next setup choice. Button to move to the next setup choice. Continue this until all selectionsare made. For example:

The following is anexample for the “other”application. Scrollthrough all choices tosee which fits yourneeds the best.Applications that havethe screen are listedafter the screen name.

Language

Application

Language Language Language Language Language - Language is a global setting. This means that all screens willappear in the chosen language.

Application Application Application Application Application - Many applications are available. Each application type has“built in, behind-the-scenes” default settings to assist you in programmingthe unit for the application type. If your application type is not listed, simplychoose “other.” (Use the Plus/Minus Buttons as needed to scroll through thechoices.)

x7x7x7x7x7

(All Applications)

(All Applications) (Press seven times)



Encoder

Encoder Encoder Encoder Encoder Encoder - Set the encoder type.

If the Wizard does not list the encoderyour system uses, select “other.” Theratio compensation settings will beentered at a later time using theEncoder Menu Screen (discussed inthis Section under “Encoder MenuScreen”).

Measurement Mode

Measurement Mode Measurement Mode Measurement Mode Measurement Mode Measurement Mode - Set the units to Inch or Millimeter.

(Corrugated, Folding Carton,Envelope, Packaging, CoreWinding, and Others)


Red Encoder Wheel

Pulses Setup Circumference

Metric 250 mm 1000 Imperial 9.84 inches Metric 250 mm 500 Imperial 9.84 inches

Black Encoder Wheel


Metric 254 mm 1000 Imperial 10.0 inches Metric 254 mm 500 Imperial 10.0 inches



Jog Mode

Finish Configuration

Jog ModeJog ModeJog ModeJog ModeJog Mode - Adhesive will be applied in a “dot” pattern when the machine isrunning below a certain speed (V-jog). (Enabling jog mode allows Jog ModeSetup Menus to appear during setup; this is covered later in this manual.)

You must answer “Yes” to the “Finish Configuration”prompt and press the OK Button for all changes totake effect. Choosing “No” will return the unit to theprevious settings with no changes made.

(All Applications)

(Corrugated, Folding Carton,Envelope, Packaging, andOthers)

(Finished)

Valve Type

Valve Type Valve Type Valve Type Valve Type Valve Type - Set the valve type for valves 1-4. If the default valve type thatappears is not applicable, use the Plus/Minus Buttons to scroll through the listof valve types available.

(All Applications)



EnterPassword

To view, setup, and use the various functions of the MCP-4 Control Unit,passwords are used. This ensures safety and security of all settings. Toenter a password, do the following:

Enter password (seeThumbwheel vs. SingleDigit Edit, this section)

Unlocked symbol appearswith password level.

“Unlock” changes to “Lock”



Password LevelsThere are five password levels:

Level 0: ProtectedLevel 0: ProtectedLevel 0: ProtectedLevel 0: ProtectedLevel 0: Protected

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

Level 1: Operator Level 1: Operator Level 1: Operator Level 1: Operator Level 1: Operator (No password required)

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

Level 2: Supervisor Level 2: Supervisor Level 2: Supervisor Level 2: Supervisor Level 2: Supervisor (Default Password = 1234)

This is the highest user password level. At this level, the “Default” passwordlevel can be set, individual valve settings can be viewed and changed, jobscan be saved (as well as loaded), and the memory can be backed up. TheLevel 2 password can be changed (this is explained under the heading“Level 2 Password Options”).

Level 3: ServiceLevel 3: ServiceLevel 3: ServiceLevel 3: ServiceLevel 3: Service

This password level is reserved for Authorized Service Personnel.

Level 4: ProgrammerLevel 4: ProgrammerLevel 4: ProgrammerLevel 4: ProgrammerLevel 4: Programmer

This password level is reserved for Factory Programmers.

Level 2 PasswordOptions

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

The Protected Level Mode (Level 0) increases security by changing theDefault Level of the unit from Level 1 to Level 0. This means that when theunit is turned on, it will automatically be in Level 0 instead of Level 1 (untilthe supervisor changes the Default Mode to Level 1). Only someone with theLevel 2 password can change the Default Level of the unit.

To change the Default Level of the unit, do the following:

Protected Level Mode



Protected Level Mode - Continued

The locked icon appears,indicating the unit is in

Protected Level Mode (Level 0)



Change the Level 2Default Password

The Level 2 Default Password (1234) can be changed to a differentnumerical password containing four digits.

To change the Default Password for Level 2, do the following:

Use the Plus/Minus Buttons to increase/decrease the numbers and the Left/Right Arrow Buttons to move from digit to digit.

To cancel without changing thepassword, be sure the currentbe sure the currentbe sure the currentbe sure the currentbe sure the currentpassword showing is correctpassword showing is correctpassword showing is correctpassword showing is correctpassword showing is correct, and(only after this confirmation), press theOK Button.

The old password usedto enter the system willappear on the screen.

Caution! Make certain the desiredpassword is enteredcorrectly before pressingthe OK Button!



Change the Level 2 DefaultPassword - Continued

When the desired password is entered, press the OK Button to enter thenew password.

The following is an example only. Thepassword can be changed to any fourdigit number desired.

Level 1(Factory Default) Protected Level

Mode (Level 0)

“Lock”changes to

“Unlock”

OR

“Lock”changes to

“Unlock”

If the Default Level is set atLevel 1, this screen appears.

If the Default Level is set atLevel 0, this screen appears.

The unit is now locked to the Set DefaultLevel (see above). The new passwordsaved for Level 2 access is required tounlock the system for Level 2 access(see the heading “Enter Password” in thissection).

If the new Level 2 password isforgotten, you may call ValcoCincinnati, Inc. Technical Service forassistance at (513) 874-6550.



Configure theValve/ChannelSettings

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

Caution!Caution!Caution!Caution!Caution! Changing settings may bring unwanted consequencesin the performance of your system. Valco Cincinnati,Inc. recommends having a qualified technician setupyour system parameters. Otherwise, loss of productiontime may result from improper settings.

All screens for configuring thevalves/channels are available inall applications.



Compensation Time

x3x3x3x3x3

On Compensation Time (Ton)On Compensation Time (Ton)On Compensation Time (Ton)On Compensation Time (Ton)On Compensation Time (Ton) - This is the amount of time (in milliseconds)from when the valve is activated to when the glue is applied. Increasing the"ON" Compensation Time will move the start of the pattern forward.

Off Compensation Time (Toff)Off Compensation Time (Toff)Off Compensation Time (Toff)Off Compensation Time (Toff)Off Compensation Time (Toff) - This is the amount of time (in milliseconds)from when the valve is turned off to when the adhesive application isstopped. Increasing the Off compensation time will make the glue lineshorter.

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

Speed Settings

x2x2x2x2x2

V-min (Minimum Product Speed)V-min (Minimum Product Speed)V-min (Minimum Product Speed)V-min (Minimum Product Speed)V-min (Minimum Product Speed) -The minimum speed the machine mustreach before glue is applied to the product.

V-jog (Jog Speed) V-jog (Jog Speed) V-jog (Jog Speed) V-jog (Jog Speed) V-jog (Jog Speed) - Between minimum speed and jog speed, a glue line willbe separated into dots in order to make the glue volume even more precise.



Valve Type

Scanner Settings

x2x2x2x2x2

Encoder Settings

x2x2x2x2x2

Correction FactorCorrection FactorCorrection FactorCorrection FactorCorrection Factor - The scaling factor used to adjust an individual/systemratio for the selected channel. This feature is used on right angle machineswhen the valves are mounted in sections that are running at differentspeeds. To be as precise as possible, the encoder should always bemounted in the section that is running the fastest.

Minimum Product LengthMinimum Product LengthMinimum Product LengthMinimum Product LengthMinimum Product Length - The length of a product that is necessary totrigger a start signal. If there are tabs and/or dust causing false triggersignals, increase the Minimum Product Length.

Maximum Product LengthMaximum Product LengthMaximum Product LengthMaximum Product LengthMaximum Product Length - (Only active in Auto Glue) Determines themaximum pattern length in Auto Glue Mode. If this is set to “0” the function isdisabled.

Encoder Input Encoder Input Encoder Input Encoder Input Encoder Input - Use to choose a scanner (1 through 4) or the encoder Zpulse to trigger the selected channel.

The Plus/Minus Buttons canbe used to scroll through thedifferent valve typesavailable.

OROROROROR



Valve - VoltageSettings

x3x3x3x3x3

Valve - TimingSettings

Acceleration Voltage Acceleration Voltage Acceleration Voltage Acceleration Voltage Acceleration Voltage - This is the voltage applied to the valve during thevalve acceleration phase.

Spike Voltage Spike Voltage Spike Voltage Spike Voltage Spike Voltage - This is the voltage applied to the valve during the spikephase.

Hold Voltage Value Hold Voltage Value Hold Voltage Value Hold Voltage Value Hold Voltage Value - This is the voltage required to hold the valve after theAcceleration Phase and the Spike Phase.

Acceleration Time Acceleration Time Acceleration Time Acceleration Time Acceleration Time - This time (in milliseconds) represents the length(duration) of the valve acceleration phase.

Spike TimeSpike TimeSpike TimeSpike TimeSpike Time - This time (in milliseconds) represents the duration of the spikephase.

Boost Mode (On/Off)Boost Mode (On/Off)Boost Mode (On/Off)Boost Mode (On/Off)Boost Mode (On/Off) - To overcome problems when a valve sits idle for along time under high pressure, the Boost Mode can be enabled for eachindividual valve (1-4). If the Boost Mode is enabled, it will become activewhen the machine is idle for a specified amount of time. Then, the standardvalve parameters will be overwritten with higher values for a defined numberof products.

Check valve/channel 2 settings.Repeat for all valves being used.

Check OtherValves/Channels



Memory(Backup)

x2x2x2x2x2

Backup Backup Backup Backup Backup - Saves all configuration settings into memory so they are not lost.The backup can be used to restore the system configuration, if necessary.

Press the Right Arrow Button to highlight “OK.”



Memory (Backup) - Continued

Restore

Restore Restore Restore Restore Restore - Restores all configuration settings from the last backup.

Press the Right Arrow Button to highlight “OK.”

Press the OK Button to save the configuration.

Press the OK Button to load the configuration.



InitializeSettings

The Initialize feature is only available for Level 4 Programmers. Initializationwill clear all settings back to the factory defaults; all Job Files and BackupConfigurations are lost. Valco Cincinnati, Inc. highly recommends thatInitialization is only performed by an authorized Valco Cincinnati ServiceTechnician/Programmer.

x2x2x2x2x2

x2x2x2x2x2



Initialize Settings - Continued

The Wizard appears for “first use setup” (see Section 4 - Programming).



AdditionalSetup ButtonParameters

Language

Language Language Language Language Language - Language is a global setting. This means that all screens willappear in the chosen language.

(All Applications)

Use the Plus/MinusButtons to scroll throughall available choices.Make sure the desiredchoice is highlighted onthe screen beforemoving to the nextparameter setting. Tomove though theparameter screens, usethe Right/Left Buttons.

Some parameterscreens that appearedin the “Wizard” may alsoappear in the SetupButton Menu.



Measurement Mode Measurement Mode Measurement Mode Measurement Mode Measurement Mode - Timer Timer Timer Timer Timer - Set the units to Seconds (sec) orMilliseconds (ms).

Measurement Mode

OROROROROR


(Timer and Valve Driver)

Start/End ModeStart/End ModeStart/End ModeStart/End ModeStart/End Mode - The measurements used include the start of the glue linefrom the leading edge of the product and the end of the glue line from theleading edge of the product (see Section 5 - Operation). This Mode requiresan encoder and is not available for Timer applications

Pattern Entry Mode

Delay/Length Mode Delay/Length Mode Delay/Length Mode Delay/Length Mode Delay/Length Mode - There is a delay length from the leading edge of theproduct to the start of the glue line. These measurements, and the length ofthe glue line, will be input during the pattern setup (see Section 5 -Operation).

OROROROROR

(All Applications)

Measurement Mode Measurement Mode Measurement Mode Measurement Mode Measurement Mode - Encoder Encoder Encoder Encoder Encoder - Set the units to Inch or Millimeter (mm).

See the heading “Encoder MenuScreen” in this Section for additionalencoder settings.



External Purge Signal - External Purge Signal - External Purge Signal - External Purge Signal - External Purge Signal - This is a collective purge. When the External PurgeSignal is on, scanner 3 cannot be used as a trigger input.

External Purge Signal

Jog Mode

Batch Counter

(Corrugated, Folding Carton,and Others)

(All Applications)

(All Applications)

Batch Counter must be enabled in this menu (Pattern Menu) so individualBatch Count Menus will appear during setup (see Section 5 - Operation).

Jog ModeJog ModeJog ModeJog ModeJog Mode - Adhesive will be applied in a “dot” pattern when the machine isrunning below a certain speed. Enabling jog mode allows Jog Mode SetupMenus to appear during setup (see Section 5 - Operation).



External Enable Signal - External Enable Signal - External Enable Signal - External Enable Signal - External Enable Signal - (This was also known as “web break detection.”)When enabled, this function uses Scanner #4 to enable and disable gluing.

Output Configuration--Valves - Output Configuration--Valves - Output Configuration--Valves - Output Configuration--Valves - Output Configuration--Valves - Set the number of valves being used. Up tofour valves (channels) are available.

Output Configuration--Transducer- Output Configuration--Transducer- Output Configuration--Transducer- Output Configuration--Transducer- Output Configuration--Transducer- Set the number of transducers beingused. Up to two are available.

Menu Configuration--Maximum Patterns - Menu Configuration--Maximum Patterns - Menu Configuration--Maximum Patterns - Menu Configuration--Maximum Patterns - Menu Configuration--Maximum Patterns - Set the number of patterns beingused. Up to ten patterns are available.

Menu Configuration--Maximum Pressure Points - Menu Configuration--Maximum Pressure Points - Menu Configuration--Maximum Pressure Points - Menu Configuration--Maximum Pressure Points - Menu Configuration--Maximum Pressure Points - Set the number ofpressure points being used, from two to four.

External EnableSignal

Output Configuration

Menu Configuration

(All Applications)

(All Applications)

(All Applications)

caw

Text Box

X2



Ratio Compensation

Encoder MenuScreen

Ratio Compensation Pulses/Repeat Length Ratio Compensation Pulses/Repeat Length Ratio Compensation Pulses/Repeat Length Ratio Compensation Pulses/Repeat Length Ratio Compensation Pulses/Repeat Length - The scaling factors used tocalculate the correction factor.

If the encoder type “Others” is entered in the Initial Setup (Wizard), it isnecessary to input the encoder parameters on this screen. The followingtables may be helpful:

x2x2x2x2x2



Speed Calculation Immediate/AverageSpeed Calculation Immediate/AverageSpeed Calculation Immediate/AverageSpeed Calculation Immediate/AverageSpeed Calculation Immediate/Average - “Average” is the default settingand will work for the majority of jobs. However, if an immediate reaction to achange of the encoder speed is needed, the setting should be changed to“Immediate.”

Speed Calculation

Ratio Compensation - Continued Red Encoder Wheel


Metric 250 mm 1000 Imperial 9.84 inches Metric 250 mm 500 Imperial 9.84 inches Metric 250 mm 250 Imperial 9.84 inches

Black Encoder Wheel


Metric 254 mm 1000 Imperial 10.0 inches Metric 254 mm 500 Imperial 10.0 inches Metric 254 mm 250 Imperial 10.0 inches


SECTION 5 - OPERATIONSECTION 5 - OPERATIONSECTION 5 - OPERATIONSECTION 5 - OPERATIONSECTION 5 - OPERATION

After completing the mounting and the programming of the MCP-4 Unit, theunit is ready to operate. The first task is to input all pattern data and otheressential information. Many of the options are “enabled” in the Setup Menu(see Section 4 - Programming). If you do not see a particular setting youneed, be sure to check the programming parameters that were set inSection 4 of this manual--the desired option may not be enabled, and thatoption’s menu screens are hidden.

To edit the highlighted value, press the OK Button for the thumbwheel orpress the Plus/Minus Buttons for single digit editing (see Section 4 -Programming, “Thumbwheel vs. Single Digit Edit”).

The default screen always shows valve 1. Before entering any data, it isadvisable to check the left side of the screen for the valve number. Makecertain the desired valve number appears before entering data.

Set thePattern MenuInformation

(ETC.)

Each press of the Pattern Button will increase the valve number by one.When valve 4 is reached, the valve numbers restart at valve 1. For example:

ValveNumber

Scrolling ThroughValve Numbers withthe Pattern Button

Depending on thepassword level,some screens maynot be seen and/oravailable. This is asecurity feature ofthe MCP-4.


Section 5 - Operation MC075 - MCP-4 Control Unit

3. ContinuousContinuousContinuousContinuousContinuous - Applies adhesive continuously when speed ishigher than the Vmin setting.

The Continuous Continuous Continuous Continuous Continuous Glue Mode is availablein the following applications: Others.

2. StitchStitchStitchStitchStitch - Applies adhesive in a stitch-like pattern.

The StitchStitchStitchStitchStitch Glue Mode is available inthe following applications: FoldingCarton, Envelope, and Others.

Gluing Mode

Glue Mode Glue Mode Glue Mode Glue Mode Glue Mode - The gluing style. Use the Plus/Minus Buttons to scroll throughthe choices. These are (depending on the application chosen):

1. PatternPatternPatternPatternPattern - Adhesive is applied in a pattern on each product.

The Pattern Pattern Pattern Pattern Pattern Glue Mode is available inthe following applications: Corrugated,Folding Carton, Envelope, Timer, CoreWinding, and Others.


Section 5 - OperationMC075 - MCP-4 Control Unit

Gluing Mode - Continued

4. Auto Glue - Auto Glue - Auto Glue - Auto Glue - Auto Glue - Applies a strip of adhesive based on the length ofthe scanner signal. Input the start delay (length from the leadingedge of the product to the beginning of the glue line) and theend delay (the end of the glue line to the trailing edge of theproduct).

The Auto GlueAuto GlueAuto GlueAuto GlueAuto Glue Glue Mode is availablein the following applications:Corrugated, Folding Carton, Packaging,and Others.

Scanner Lockout

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

(Available in Corrugated,Folding Carton, Envelope,Packaging, Timer, CoreWinding, and Others)



Jog Mode Parameter

Jog Mode--On/OffJog Mode--On/OffJog Mode--On/OffJog Mode--On/OffJog Mode--On/Off- Turn the jog mode on and off with the “switch” using thePlus/Minus Buttons.

Jog Gap DistanceJog Gap DistanceJog Gap DistanceJog Gap DistanceJog Gap Distance - This is the distance between the glue dots while themachine is running below the jogging speed threshold. Increase thedistance to decrease the glue volume.

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

The Jog Mode Parameter is only available when Jog Mode is enabled.

(Available in Corrugated,Folding Carton, Envelope,Packaging, Core Winding,and Others)

Valve to ScannerDistance

Valve to Scanner Distance - Measurement Valve to Scanner Distance - Measurement Valve to Scanner Distance - Measurement Valve to Scanner Distance - Measurement Valve to Scanner Distance - Measurement - The distance between thevalve (shown on the left of the screen) to the scanner number shown in theupper right corner (see “Valve to Scanner Distance - Scanner Number”above).

Valve to Scanner Distance - Scanner NumberValve to Scanner Distance - Scanner NumberValve to Scanner Distance - Scanner NumberValve to Scanner Distance - Scanner NumberValve to Scanner Distance - Scanner Number - The number of theassigned scanner.

To choose a scanner or the Z Pulse, press the Plus Button until the desiredscanner number or Z Pulse shows in the upper right corner of the screen.

(All Applications)

Scanner Number/Z Pulse

Distance (Measurement)

ValveNumber

Scanner Number

Enc. 1 = Z Pulse



Batch Counter

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

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

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

Batch Counter must be enabled under the Setup Menu (see Section 4 -Programming).

Input Values/GluingMode

Depending on the application and the gluing mode chosen, input yourvalues:

(All Applications)

Auto GlueAuto GlueAuto GlueAuto GlueAuto Glue(Corrugated, Folding Carton,

Packaging, and Others)

ContinuousContinuousContinuousContinuousContinuous(Others)

Pattern ModePattern ModePattern ModePattern ModePattern Mode(Corrugated, Folding Carton,

Envelope, Timer, Core Winding, andOthers)

StitchStitchStitchStitchStitch(Folding Carton, Envelope, and

Others)

The screens above are unique to each gluing mode. Each screen isdesigned to show comprehensive information at a glance. The followingsubsection “Glue Mode Screen Information” explains how.



Glue Mode ScreenInformation

Pattern ModePattern ModePattern ModePattern ModePattern Mode

The Pattern Glue Mode can also be called “pattern-skip-pattern” mode or“normal mode.”

The following is an example of setting up a pattern gluing mode with threepatterns for valve one:

1. Set the Delay Length for pattern 1. The Delay Length for pattern1 is the measurement from the first edge of the product to whereyou want the first glue line to start.

x4

x5

2. Press the Right Arrow Button to view the Pattern Length forpattern 1. The Pattern Length is the length of the glue line (forthe pattern number indicated). Press the OK Button to view thethumbwheel, and use the Plus/Minus Buttons to change. Pressthe OK Button to enter the setting.

Pattern Mode - ExamplePattern Mode - ExamplePattern Mode - ExamplePattern Mode - ExamplePattern Mode - Example

Valve Number(1-4)

Pattern Number(Up to ten patterns are available)*

Delay Length(For the Pattern Number shown)

MachineSpeed

Indicates a menu screen to the Left(Press the Left Arrow Button to see it.)

Password SecurityLevel

Pattern Length(For the Pattern Number shown)

*The number ofpatterns availabledepend on the MenuConfigurationsettings (see Section4 - Programming).



3. Press the Right Arrow Button to view the Delay Length forpattern 2. The control automatically fills in the Delay Length forpattern 2 (so the next pattern does not interfere with theprevious pattern). This number can be adjusted if desired.

Pattern Mode - Example -Continued

4. Press the Right Arrow Button to view the Pattern Length forpattern 2. Press the OK Button to view the thumbwheel, and usethe Plus/Minus Buttons to change. Press the OK Button to enterthe setting.

Pattern 2 (highlighted=active)

Delay Length for Pattern 2(automatically filled in)

Previous Pattern (Pattern 1)

Pattern Length forPattern 2

x3

5. Press the Right Arrow Button to view the Delay Length forpattern 3.



6. If the Delay Length is acceptable, press the Right Arrow Buttonto view the Pattern Length for pattern 3. Press the OK Button toview the thumbwheel, and use the Plus/Minus Buttons tochange. Press the OK Button to enter the setting.

Pattern Mode - Example -Continued

x6

7. All three patterns are now set. To review them, use the LeftArrow Button.

Pattern 2(highlighted=active)

Previous Pattern(Pattern 1)

Next Pattern(Pattern 3)

Notice this screen shows pattern3 to the right of pattern 2,confirming that there is a thirdpattern set.

The screen wherepattern 3 is highlighteddoes not show a patternfollowing it, becausethere is not a pattern 4set.

8. Use the Left and Right Arrow Buttons to review all informationas desired. All three patterns have been set and the PatternGlue Mode for Valve 1 is now ready.



Stitch ModeStitch ModeStitch ModeStitch ModeStitch Mode

Setting the patterns for Stitch Mode is very similar to setting the patterns forPattern Mode.

The difference between Pattern Mode and Stitch Mode is the application ofthe glue. The Pattern Mode applies a continuous strip of glue for the patternlength specified. The Stitch Mode applies the glue in a stitch pattern for thepattern length specified. To illustrate:

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

MachineSpeed

PasswordSecurity Level

Pattern Number(Up to ten patterns are available)*

*The number ofpatterns availabledepend on the MenuConfigurationsettings (see Section4 - Programming).

Delay Length(For the Pattern Number shown)

“ST” = Stitch Mode

Valve Number(1-4)

Indicates a menu screen to the Left(Press the Left Arrow Button to see it.)

Pattern Length(For the Pattern Number shown)

The length of patterns 1, 2, and 3 are all 5 mm for both glue modes.

Pattern Mode Stitch Mode

Pattern 1 Pattern 2 Pattern 3

Stitch Mode MenusStitch Mode MenusStitch Mode MenusStitch Mode MenusStitch Mode Menus



Auto Glue ModeAuto Glue ModeAuto Glue ModeAuto Glue ModeAuto Glue Mode In Auto Glue Mode, one Start Delay LengthStart Delay LengthStart Delay LengthStart Delay LengthStart Delay Length (the length from the leadingedge of the product to the beginning of the glue line) and one End DelayEnd DelayEnd DelayEnd DelayEnd DelayLengthLengthLengthLengthLength (the end of the glue line to the trailing edge of the product) areentered. The glue is applied automatically based on the length of thescanner signal.

Continuous Glue ModeContinuous Glue ModeContinuous Glue ModeContinuous Glue ModeContinuous Glue Mode In Continuous Glue Mode, the glue will flow continuously as long as thespeed is greater than Vmin.

MachineSpeed

Indicates a menu screen to the Left(Press the Left Arrow Button to see it.) Password Security

Level

“Cont.” = Continuous Glue Mode

Valve Number(1-4)

Start Delay Length

MachineSpeed

Indicates a menu screen to the Left(Press the Left Arrow Button to see it.) Password Security

Level

End Delay Length

“Auto” = Auto Glue Mode

Auto Glue Mode MenusAuto Glue Mode MenusAuto Glue Mode MenusAuto Glue Mode MenusAuto Glue Mode Menus

caw

Text Box

Continuous Glue Mode Menus



Set thePressures

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

The number on the left side of thepressure screen refers to the EPCnumber (two EPCs are available onsome models of the MCP-4 ControlUnit. See the Parts List Section fordetails). The second EPC is the 0-10Volt output for speed tracking. BothEPCs are programmed in the sameway; just be certain the desired EPCnumber appears on the screen beforeprogramming. To switch betweenEPCs, press the Pressure Button untilthe desired EPC number appears.

Pressure Offset ValuePressure Offset ValuePressure Offset ValuePressure Offset ValuePressure Offset Value - Used to increase/decrease the current pressure.The Pressure Offset is used to do minor pressure adjustments instantly. Itdoes not change the pressure table profile.

Pressure Offset Value

Purge Pressure %

(All Applications)

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

(All Applications)

Increase

Decrease



Minimum Speed/Pressure

V (m/min) V (m/min) V (m/min) V (m/min) V (m/min) - The machine speed.

P (%) P (%) P (%) P (%) P (%) - The percent of pressure.

Maximum Speed/Pressure

When one/two pressure points are enabled, the two screens will be named“PT1” and “PT2” respectively. These pressure points are set up just like theMaximum and Minimum Pressures.

Pressure Point 1 (PT1)

Pressure Point 2 (PT2)

(All Applications)

(All Applications)

Press the Left/RightButtons as indicated byLeft/Right Arrow Iconson the bottom of thescreen (see example atleft) to see all availablepressure setting menus.

The number of pressure points on thepressure curve are input during setup.See Section 4 - Programming,“Additional Setup Button Parameters” -“Menu Configuration”

Right Arrow Icon



Speed/Pressure Graphs -Speed/Pressure Graphs -Speed/Pressure Graphs -Speed/Pressure Graphs -Speed/Pressure Graphs -ExamplesExamplesExamplesExamplesExamples

The four pressures/speeds are dependent upon each other. For example,the first speed setting can never be greater than the second speed setting,and the second speed setting can never be greater than the third, and so on.Also, the second speed setting can never be less than the first speedsetting, the third speed setting can never be less than the second speedsetting, and so on. Therefore, if you cannot set speeds to where you wantthem (the Plus/Minus Arrow Buttons will not increase or decrease thesetting), check all four of the settings. Use the Left Arrow and Right ArrowButtons to move through all pressures/speeds and check them. Reset themas necessary using the Plus/Minus Arrow Buttons. You can also go back tofactory defaults by pressing the Erase Button until the setting will no longerchange.

Helpful Hints aboutPressures

The graph above illustrates two, three, and four points on the pressure curvewith Jog Mode off and on. The majority of projects will be fine with the JogMode off and only two points on the pressure curve. If more control isnecessary, try adjusting the number of points on the pressure curve. Alsosee the tips below.



DiagnosticButton

The first diagnostic screen shows the total number of products and thenumber of products per hour. The total number of products count can bereset to zero by pressing the Erase Button.

(All Applications)

The second diagnostic screen shows the valve status. The top numbersshow the valve type. The bottom numbers will switch back and forth fromshowing the valve voltage to showing the valve status (enabled or disabled).

Total Products/Products per Hour

Valve Status

A voltage reading of 0.0 couldindicate a blown fuse. See Section 8,Parts List, for fuse numbers andplacement.



Scanner and TriggerStatus

Version Information

Event History

The version information screen displays the CPU, the Logic (PLD), and theTimer (TPU) software version information.

The scanner/trigger information screen displays the scanner and triggersettings.

The event history screen displays error messages.

The number of pulses per product length.This number is helpful in setting up the

Ratio Compensation.



Job ButtonThe Job Save/Recall Mode allows the MCP-4 Control Unit to save and recallup to 100 different jobs for fast programming.

(All Applications)

Load - Load - Load - Load - Load - Load a previously saved job.

When “Load” is highlighted, press the OK Button to enter a job number. Usethe Plus/Minus Buttons to change the job number.

When the desired job number has been entered, press the Right ArrowButton to highlight “OK” and press the OK Button. The job is loaded.

Enter the job number and information ina chart (see Appendix A - Job Charts)for quick job set up. Also, jobs can beoverwritten, so it is important to keeptrack of them.

Load a Job

Any level (including 0)can load a job.



Save a Job

Save - Save - Save - Save - Save - Save all settings under a job number.

Press the Right Arrow Button to highlight “Save” and then press the OKButton.

Use the Plus/Minus Buttons to change the job number.

Press the Right Arrow Button to highlight “OK. ”Press the OK Button to savethe job. Be sure to write the job name and job number for reference (seeAppendix A - Job Charts).

Only password levels2 or higher can save ajob.


SECTION 6 - MAINTENANCESECTION 6 - MAINTENANCESECTION 6 - MAINTENANCESECTION 6 - MAINTENANCESECTION 6 - MAINTENANCE

This section contains maintenance procedures for the Valco MCP-4 Control.A regular maintenance program helps ensure longer life and efficientoperation of your system. A few minutes spent on maintenance greatlyreduces downtime.

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

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

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

The glue valves can be purgedmanually using an activator located onthe valve itself, by a solenoid-operatedair valve, or they can be purged usingthe toouchscreen panel and control.

When using any valve in the top-downposition for the first time, it might benecessary to remove the valve andhold it so that the applicator head is atthe top. The fluid pressure should thenbe set to 4 bar, and the solenoid shouldbe fired until all the air is out and a flowof glue is present.

The type of downtime maintenance that is necessary for the MCP-4 ControlUnit depends on the length of time the unit is down.

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

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

2. Wipe the valve clean before restarting production.

For longer periods of downtime, follow these steps:

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

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

3. Flush the applicator head with clean water.

Purging theAdhesive

PerformingDowntimeMaintenance


Section 6 - Maintenance MC075 - MCP-4 Control Unit

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

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

To flush the glue system, follow these steps:

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

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

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

If you use a glue that operates at 250degrees F, the tank only needs to beheated to the standard operatingtemperature.

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

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

5. Next, remove the lid cover screws on the surface of the meltunit. This allows you to remove the pump and heating grid fromthe tank itself.

6. Once the screws are removed, use gloves to lift the lid andpump assembly out of the molten tank.

7. Place the lid and pump assembly in a vertical position on aclean, solid, flat surface and allow the excessive adhesive toslowly drip off of the fins.

8. Take the pot, lifting from the edges, and pour the moltenmaterial into a sealed corrugated box.

9. Use a clean rag to wipe the tank clean thoroughly and disposeof the rag. Now, you can re-insert the lid and pump assemblyinto the pot and tighten the lid cover screws. This completes the“clean and flush” process.

Performing Downtime Maintenance- Continued

Flushing theGlue System


Section 6 - MaintenanceMC075 - MCP-4 Control Unit

Lubricatingthe System

To lubricate the system, follow these steps:

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

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


SECTION 7 - SPECIFICATIONSSECTION 7 - SPECIFICATIONSSECTION 7 - SPECIFICATIONSSECTION 7 - SPECIFICATIONSSECTION 7 - SPECIFICATIONS

Item MCP-4 Unit

(074xx037 & 074xx038)

MCP-4P (074xx041)

MCP-4P (074xx040)

MCP-4F (074xx039)

Control dimensions:

Height: 4.33" (110 mm) Depth: 9.57" (243 mm) Width: 9.41" (239 mm) Approximate weight: 8.5 lbs. (3.86 kg)

Height: 9.66" (245 mm) Depth: 4.19” (106 mm) Width: 11.12" (282 mm) Approximate weight: 5.5 lbs. (2.49 kg)



Input voltage: 100/115/200/230VAC, 50-60 Hz (field-selectable)

24VDC 100/115/200/230VAC, 50-60 Hz (field-selectable)

100/115/200/230VAC, 50-60 Hz (field-selectable)

Number of channels:

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

Glue pattern resolution:

0.01 in. or 1 mm

Number of scanner inputs:

Up to 4 with scanner lockout

Glue pattern tolerance:

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

Job storage memory:

100 jobs (C009 and above)

Miscellaneous: Encoder-based or timer mode Multi-valve, complex glue pattern capabilities “Continuous” and “Stitch” pattern gluing Adjustable minimum speed Inch or metric calibration CE compliant Password protection for key system parameters Integral fluid-flow control option (EPC) Web break detection option Batch count/production count Programmable valve output voltages depending upon base unit


SECTION 8 - PART NUMBER LISTSECTION 8 - PART NUMBER LISTSECTION 8 - PART NUMBER LISTSECTION 8 - PART NUMBER LISTSECTION 8 - PART NUMBER LIST

How to OrderParts

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

Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.Valco Cincinnati, Inc.

411 Circle Freeway DriveCincinnati, OH 45246TEL: (513) 874-6550FAX: (513) 874-3612Email: [email protected]: http://www.valcocincinnatiinc.com

Valco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati LimitedValco Cincinnati Limited

Hortonwood 32Telford, TFI 7YN, EnglandTEL: (+44) 1952-677911FAX: (+44) 1952-677945Email: [email protected]: http://www.valco.co.uk

Valco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbHValco Cincinnati GmbH

Storkower Strasse 6D-15749 Gallun, GermanyTEL: (+49) 337 648 700FAX: (+49) 337 648 7070Email: [email protected]

Germany:

England:

USA:

Spain:Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Melton S.L.U.Pol. Industrial Agustinoscalle G, n. 3431160 Orcoyen, Navarra, SpainTEL: (34) 948-321-580FAX: (34) 948-326-584


Section 8 - Part Number List MC075 - MCP-4 Control Unit

MCP-4 withoutEPC(074xx037)

Bumper Foot (4)

Front Panel Assembly

Part Number Description

137xx012 MCP-4 Front Panel Assembly

085xx017 Fuse, 2 Amp Slo/Blo, Power Entry

091xx274 Bumper Foot

085xx220 2A Mini Fuse, PCB Main Board


Section 8 - Part Number ListMC075 - MCP-4 Control Unit

MCP-4 withEPC(074xx038)

2A Main Fuses (5)

24v DC Power

EPC

2A Power Entry Fuse (2)

Part Number Description

137xx012 MCP-4 Front Panel Assembly

085xx017 Fuse, 2 Amp Slo/Blo, Power Entry

091xx274 Bumper Foot

085xx220 2A Mini Fuse, PCB Main Board

753xx436 Manifold Assembly, MCP-4 0-10V



MCP-4P Unit -24VDC(074xx041)

VIEW SHOWN WITHOUT COVER

GASKET TO BE FLUSHWITH BOTTOM OFMOUNTING PANEL

CONNECT OVERLAY RIBBON CABLE (ITEM #37)

CONNECT DISPLAY RIBBON CABLE (ITEM #45)

ATTACH COVER SO THATGASKET SURFACE OF COVERIS FLUSH WITH CORD GRIP PANEL

6.0 [153 mm](MAKE TWO CABLES)

ATTACH 6" LONG CABLE. OTHEREND OF CABLE ATTACHED TO UPPERRIGHT STUD OF TOUCHPANEL.

ATTACH 6" LONG CABLE. OTHEREND OF CABLE ATTACHED TO UPPERLEFT STUD OF TOUCHPANEL.

4.0 [102 mm]GROUND STUD TO PIN #1 OF "J3" CONNECTOR (ITEM #19)

9.0 [229 mm]GROUND STUD TO TAB TERMINAL

ON ACCESS COVER (ITEM #1)

PIN #1 OF "J3" CONNECTOR

ATTACH 9" AND 4" LONGCABLE TO GROUND STUD

074xx041.DWG

SECTION B-BSCALE 1 / 2

* ATTACH GASKET TO BACKSIDE OF TOUCHSCREEN #8 BEFORE ASSEMBLY.



MCP-4P Unit - 24VDC (074xx041)- Continued 11.12 [282.4 mm] REF.

9.66 [245.4 mm]

REF.

MUST COMPRESS GASKETTO ALIGN MOUNTING HOLES

4.19 [106.3 mm]REF.

APPLY LIGHT COATOF LITHIUM GREASETO PLUG BEFORE ASS'Y.

074xx041.DWG



MCP-4P Unit - 24VDC (074xx041)- Continued

Item Description Part Number Quantity

1 Access Cover 026xx178 1 2 Mounting panel 026xx177 1 4 PCB, Ext EPC, CAN 151xx625 1 5 Cord Grip 066xx160 9 7 Flat Washer 784xx435 3 8 Overlay 782xx127 1 9 Display, Yellow Graphic 137xx009 1 11 Stud 091xx519 1 12 Gasket 746xx145 1 13 Mounting Clip 782xx079 2 17 Gasket 746xx150 1 18 Gasket 746xx147 1 19 PCB assy, DC Filter 151xx599 1 20 Screw 784xx541 9 22 Screw 784xx575 4 23 Cover 026xx210 1 24 Baseplate, Mounting 026xx183 1 25 Nut 798xx489 9 28 Mounting Rail 582xx849 1 29 Plug 092xx019 2 30 Plug 092xx018 6 33 Spacer 091xx599 4 35 Screw 784xx985 3 36 Cable Assy 029xx367 1 37 Cable Assy 033xx164 1 38 Screw 784xx347 2 39 Mounting Foot 582xx848 2 40 Screw 784xx051 4 41 Connector 070xx566 8 42 Screw 784xx491 2 43 Split Lock Washer 784xx600 2



MCP-4P Unit - 24VDC (074xx041)- Continued


44 Installation Kit, MCP-4P 24VDC 091xx605 1 45 Cable 029xx407 1 46 Software 119xx207 1 47 Wire 540xx090 3 48 Wire Terminal 075xx073 4 49 Lock Washer 798xx774 2 50 Ferrule 075xx306 1 51 Terminal 091xx453 1 52 Wire Terminal 075xx078 1 53 Wire Terminal 075xx075 2 54 Lock Washer 784xx308 6 55 Hex Nut 798xx299 2 56 Lock Washer 784xx375 2 57 Nut 793xx491 1



MCP-4P Unit -115/230VAC(074xx040)

DETAIL ESCALE 1 : 1

1245

ATTACH MARKER STRIP LABEL &CONNECT WIRES FROM TRANSFORMER (ITEM #21)

#1 = BLUE WIRE #2 = YELLOW WIRE #4 = GREEN WIRE #5 = ORANGE WIRE

CONNECT PUMP CABLE (ITEM #49)


CONNECT DISPLAY RIBBON CABLE (ITEM#68)

"X"

CONNECT EXTERNAL EPC CABLE (ITEM #48)


MUST COMPRESS GASKETTO ALIGN MOUNTING HOLES.

6.69 [169.8 mm]



MCP-4P Unit - 115/230VAC(074xx040) - Continued

ATTACH GASKET (#14) TOBACKSIDE OF TOUCHSCREEN (#8)BEFORE ASSEMBLY.

ATTACH GASKET TO INSIDEOF ACCESS COVER #1BEFORE ASSEMBLY.

.175 [4.45 mm]COMPRESSED

GASKET THICKNESS

"Z"

11.12 [282.4 mm]

9.66 [245.4 mm]

SECTION C-CSCALE 1 / 2

"Y"

SECTION F-FSCALE 1 / 2

MAKE (4) GROUND CABLE ASSEMBLIESBY CUTTING THE WIRE INTO (4)SEPARATE PIECES AT THE FOLLOWINGLENGTHS: 3", 12", 16", & 20"

GROUND CABLE CONNECTION POINTS

3" GROUND STUD TO ON/OFF SWITCH "W" 12" GROUND STUD TO CONNECTOR PANEL LUG "X" 16" GROUND STUD TO TOUCH PANEL LUG "Y" 20" GROUND STUD TO ACCESS COVER LUG "Z"

SECTION G-GSCALE 1 : 1



MCP-4P Unit - 115/230VAC(074xx040) - Continued Item Description Part Number Quantity

1 Access Cover Assy, MCP-4P 026xx178 1 2 Mounting Panel 026xx173 1 4 PCB Assy, MCP-4, w/ext EPC 151xx625 1 5 Cable Assy 029xx317 4 7 Flat Washer 784xx435 3 8 Overlay, MCP-4 Front Panel 782xx127 1 9 Display, LCD Yellow 137xx009 1 11 Stud, Ground 091xx519 1 12 Screw 784xx374 10 13 Grommet 092xx020 2 14 Gasket, Touchscreen 746xx145 1 15 Gasket, Power Supply Encl. 746xx149 1 16 Clip, Mounting 782xx079 2 19 Power Entry Module 086xx055 1 21 Transformer 550xx138 1 22 Screw 784xx180 1 23 Split Lock Washer 784xx600 3 25 Gasket, Enclosure Base 746xx150 1 26 Gasket, Access Cover 746xx147 1 27 Screw 784xx541 7 29 Screw 784xx575 4 30 Cover; MCP-4P Enclosure 026xx210 1 31 Baseplate, Mounting, MCP-4P 026xx183 1 32 Enclosure, Power Supply, MCP-4P 026xx184 1 33 Mounting Rail, MCP-4P 582xx849 1 35 Cable Assembly 029xx318 4 37 Hex Nut 798xx489 9



MCP-4P Unit - 115/230VAC(074xx040) - Continued


38 Screw 784xx661 4 39 Split Lock Washer 798xx772 4 40 Screw 784xx985 3 41 Cable Assembly 033xx164 1 42 Cover Plate, no EPC 781xx298 1 44 Spacer 091xx599 4 45 Screw 784xx347 2 46 Mounting Foot 582xx848 2 47 Screw 784xx051 4 48 Cable Assy 029xx385 1 49 Cable Assy 029xx321 1 50 Terminal 091xx453 3 51 Hex Nut 798xx299 2 52 Conn 070xx055 1 53 Lock Washer 784xx308 7 54 Lock Washer 784xx375 2 55 Nut 793xx491 1 56 Wire Terminal, Ring 075xx075 4 57 Wire Terminal, Faston, Female 075xx078 4 58 Wire 540xx090 5 59 Ribbon Cable Clamp 067xx001 1 60 Label 782xx087 1 61 Installation Kit 091xx586 1 62 Lock Washer 784xx360 1 63 Flat Washer 784xx183 1 64 Marker Strip 070xx084 1 65 Screw 784xx491 2 66 Fuse 085xx017 2 68 Cable 029xx407 1 69 Software 119xx207 1 70 Wire Terminal 075xx073 4



MCP-4F Unit -115/230VAC(074xx039)

074xx039.DWG

CENTER LABEL ON SIDEOF POWER SUPPLYENCLOSURE.

DETAIL ESCALE 1 : 1

ATTACH MARKER STRIP LABEL & CONNECTWIRES FROM TRANSFORMER (ITEM #21).

#1 = BLUE WIRE #2 = YELLOW WIRE #4 = GREEN WIRE #5 = ORANGE WIRE

5 4 2 1

CONNECT INTERNAL EPC CABLE (FROM ITEM #20).

CONNECT EXTERNAL EPC CABLE (ITEM #48)

CONNECT PUMP CABLE (ITEM #49)


CONNECT DISPLAY RIBBON CABLE (ITEM #68)

ADJUST CONNECTOR PANEL SO THATIT IS FLUSH WITH GASKET SURFACEOF CONTROL COVER.

"X"


SECTION D-DSCALE 1 / 2

CONNECT TRANSFORMER (ITEM #21).

"W"

MUST COMPRESS GASKETTO ALIGN MOUNTING HOLES.

6.69 [169.8 mm]



MCP-4F Unit - 115/230VAC(074xx039) - Continued

074xx039.DWG

11.12 [282.4 mm] REF.

ATTACH GASKET (#14) TOBACKSIDE OF TOUCHSCREEN (#8)BEFORE ASSEMBLY.

ATTACH GASKET TO INSIDEOF ACCESS COVER #1BEFORE ASSEMBLY.

9.66 [245.4 mm]

.175 [4.45 mm]COMPRESSED

GASKET THICKNESS

"Z"

SECTION C-CSCALE 1 / 2

MAKE (4) GROUND CABLE ASSEMBLIESBY CUTTING THE WIRE INTO (4)SEPARATE PIECES AT THE FOLLOWINGLENGTHS: 3", 12", 16", & 20"

GROUND CABLE CONNECTION POINTS

3" GROUND STUD TO ON/OFF SWITCH "W" 12" GROUND STUD TO CONNECTOR PANEL LUG "X" 16" GROUND STUD TO TOUCH PANEL LUG "Y" 20" GROUND STUD TO ACCESS COVER LUG "Z"

SECTION G-GSCALE 1 : 1





1 Access Cover; MCP-4F 026xx185 1 2 Mounting Panel 026xx173 1 4 PCB Assy, MCP-4, w/ext EPC 151xx625 1 5 Cable Assy 029xx317 4 7 Flat Washer 784xx435 3 8 Overlay, MCP-4 Front Panel 782xx127 1 9 Display, LCD Yellow 137xx009 1

11 Stud, Ground 091xx519 1 12 Screw 784xx374 10 13 Grommet 092xx020 2 14 Gasket, Touchscreen 746xx145 1 15 Gasket, Power Supply Encl. 746xx149 1 16 Clip, Mounting 782xx079 2 19 Power Entry Module 086xx055 1 20 Manifold 753xx436 1 21 Transformer 550xx133 1 22 Screw 784xx180 1 23 Split Lock Washer 784xx600 3 25 Gasket, Enclosure Base 746xx150 1 26 Gasket, Access Cover 746xx147 1 27 Screw 784xx541 7 29 Screw 784xx575 4 30 Cover, MCP-4P Enclosure 026xx210 1 31 Baseplate, Mounting, MCP-4P 026xx183 1 32 Enclosure, Power Supply, MCP-4P 026xx184 1 33 Mounting Rail, MCP-4P 582xx849 1 35 Cable Assembly 029xx318 4 37 Hex Nut 798xx489 9





40 Screw 784xx985 3 41 Ribbon Cable 033xx164 1 44 Spacer 091xx599 4 45 Screw 784xx347 2 46 Mounting Foot 582xx848 2 47 Screw 784xx051 4 48 Cable Assy, EPC 029xx385 1 49 Cable Assy, Pump 029xx321 1 50 Terminal 091xx453 3 51 Hex Nut 798xx299 2 52 Connector, Plug 070xx055 1 53 Lock Washer 784xx308 7 54 Lock Washer 784xx375 2 55 Nut 793xx491 1 56 Wire Terminal, Ring 075xx075 4 57 Wire Terminal, Faston 075xx078 4 58 Wire, Green/Yellow 540xx090 5 59 Ribbon Cable Clamp 067xx001 1 60 Label, Caution 782xx087 1 61 Installation Kit Assy 091xx586 1 62 Lock Washer 784xx360 1 63 Flat Washer 784xx183 1 64 Marker Strip 070xx084 1 65 Screw 784xx491 2 66 Fuse, 2AMP 085xx017 2 68 Cable 029xx407 1 69 Software 119xx207 1 70 Wire Terminal 075xx073 4



Glue SystemLayout withMCP-4

D73

9-01



Core Winding System with MCP-4

C08

0-14

6


SECTION 9 - WARRANTYSECTION 9 - WARRANTYSECTION 9 - WARRANTYSECTION 9 - WARRANTYSECTION 9 - WARRANTY

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

All components are warranted for a period of six (6) months from the date ofshipment by Valco Cincinnati, Inc.

Liability of the company is limited to repair of the product, or replacement ofany part shown to be defective, and does not extend to defects caused byaccidents, misuse, abuse, neglect, tampering or deterioration by corrosion.This warranty does not cover those items determined by Valco Cincinnati,Inc. to be normal wear items such as seals, O-rings, diaphragms, springs,etc.

Reconditioned equipment, unless specified otherwise at the time ofpurchase, will be warranted as described above for a period of ninety (90)days from the date of shipment by Valco Cincinnati, Inc.

Components purchased by Valco Cincinnati, Inc. from others for inclusion inits products are warranted only to the extent of the original manufacturer’swarranty. In no event shall Valco Cincinnati, Inc. be liable for indirect orconsequential damages arising out of the use of Valco products.

This warranty is conditioned upon the prepaid return of the equipmentclaimed to be defective to Valco Cincinnati, Inc. for examination andverification. If claimed defect is verified, repairs or replacements will bemade F.O.B. Cincinnati, Ohio, U.S.A. If the inspection of the equipment doesnotnotnotnotnot disclose any defect of workmanship or material, any necessary repairswill be made at a reasonable charge and return transportation will becharged.

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

Hoses, Valves,and RelatedEquipment


SECTION 10 - SERVICESECTION 10 - SERVICESECTION 10 - SERVICESECTION 10 - SERVICESECTION 10 - SERVICE

If a problem with your system persists, contact a Valco Cincinnati TechnicalSupport representative. If your need is urgent, we encourage you to contactour corporate office in Cincinnati, Ohio, U.S.A. at (513) 874-6550. If theproblem cannot be resolved, Valco Cincinnati will promptly arrange to havea technical representative visit your facility. Any charges for a service callwill be quoted at that time. Any part that fails during the warranty period shallbe returned prepaid to Valco Cincinnati, Inc. by the customer for disposition.

Upon request, Valco personnel areavailable to repair or replace such partsat the customer’s facility. Charges forthis service include travel time andexpenses.

If an equipment problem is the result of customer abuse, improperinstallation or operation, all travel time, labor, parts, and expenses will becharged to the customer.

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

A-1Valco Cincinnati, Inc.

APPENDIX A - JOB CHARTSAPPENDIX A - JOB CHARTSAPPENDIX A - JOB CHARTSAPPENDIX A - JOB CHARTSAPPENDIX A - JOB CHARTS

Use the following tables to record saved jobs for quick reference and to prevent duplication/erasure ofimportant job information. The tables may be copied for use.

Job Number Job Name Description

A-2 Valco Cincinnati, Inc.

Appendix A - Job Charts MC075 - MCP-4 Control Unit

Job Number Job Name Description

MC075

Documents

safe operating

industrial

touch panel

compressed

external enable

single digit

4p enclosure

power supply