Operations Manual. Manual Number: MC038

Transcription

1 Modular r Control System Operations Manual Manual Number: MC038 Issue Date: 2/2012

2 2012 Valco Cincinnati, Inc. All Rights Reserved. This manual is furnished with the Modular Control System Operations Manual and may be used or copied only in accordance with the terms of purchase. No part of this manual may be reproduced, stored in a retrieval system, or transmitted, in any form or by any means, electronic, mechanical, recording, or otherwise, without the prior written permission of Valco Cincinnati, Inc. The information in this manual is furnished for educational purposes only, is subject to change without notice, and should not be construed as a commitment by Valco Cincinnati, Inc. This manual written and designed at Valco Cincinnati, Inc., 411 Circle Freeway Drive, Cincinnati, Ohio Part Number: MC038 Printed in the USA To order parts, please contact your closest Valco office by mail, phone, or Valco Cincinnati, Inc. 411 Circle Freeway Drive Cincinnati, OH TEL: (513) FAX: (513) sales@valcomelton.com Web: Valco Cincinnati Limited Hortonwood 32 Telford, TFI 7YN, England TEL: (+44) FAX: (+44) sales@valco.co.uk Web: Valco Cincinnati GmbH Storkower Strasse 6 D Gallun, Germany TEL: (+49) FAX: (+49) info@valcogmbh.de Melton S.L.U. Pol. Industrial Agustinos calle G, n Orcoyen, Navarra, Spain TEL: (34) FAX: (34) Web:

3 Declaration of Conformity (According to EN 45014) Manufacturer: Authorized Representatives in Europe: declares that the product: Product Name: complies with the following Council Directives: Safety of Machinery: Low Voltage Equipment: EMC: and conforms to the following standards: Valco Melton A division of Valco Cincinnati, Incorporated 411 Circle Freeway Drive Cincinnati, OH USA Valco Cincinnati, Ltd. Unit 7-8 Hortonwood 32 Telford TF1 7YN England Modular Control System Operations Manual 2006/42/EC 2006/95/EC 2004/108/EC Melton S.L.U Pol. Industrial Agustinos calle G, n Orcoye Navarra, Spain Safety: Risk: EMC Emissions: EMC Immunity: Place and Date: Signature: EN :2006 EN EN :2007 EN :2007 EN EN :2005 EN EN EN EN EN EN Cincinnati, Ohio USA CE Mark first fixed 2006 David H. Swedes, Director of Engineering & Manufacturing This Declaration of Conformity has been generated electronically and is legally binding without signature

4 TABLE OF CONTENTS Section 1 - Introduction About this Manual Components of the Modular Control System Description of the Modular Control System System Layout Section 2 - Safety and Use Read Thoroughly Before Handling Equipment Symbols Owner Responsibilities Limitations of Use Installation/Startup/Use Safety Information Shut Down Safety Information Hot-Melt-Specific, General Safety Information What to Do if Contact with Hot Adhesive Occurs What to Do if Inhalation of Adhesive Fumes Occurs What to Do if Adhesive-Related Fire or Explosion Occurs Hose Safety Information Section 3 - General Wiring Diagrams Routing Low-Voltage Leads Connecting the Supply of Electrical Power Section 4 - Installation Introduction Mechanical Installation of the Modules Electrical Installation of the Modules Connecting the Main Power Supply Encoder Installation Mechanical Installation of Encoder Scanner, Valve, and Encoder Connections Using the Z Pulse Air-Line Installation Valco Cincinnati, Inc. TOC-1

5 Table of Contents MC038 - Modular Control System Operations Manual Section 5 - Control Panel Introduction Pattern Control Modules - PCM vs. PCM PCM Control Panel PCM2 Control Panel PCM2 Control-Panel Button Descriptions FCM Control Panel FCM Control-Panel Button Descriptions Section 6 - Parameter Setup PCM Parameter Setup PCM Functions PCM Parameter Storage First-Time Parameter Setup for Encoder-Based Function First-Time Parameter Setup for Timer-Based Functions First-Time Parameter Setup for Labeler-Based Function How to Adjust Parameters PCM2 Parameter Setup PCM2 Functions PCM2 Parameter Storage First-Time Parameter Setup for Encoder-Based Function Fine-Tuning First-Time Parameter Setup for Timer-Based Functions How to Adjust Parameters FCM Parameter Setup FCM Functions FCM Parameter Storage First-Time Parameter Setup for FCM Fine-Tuning the Parameters Head-Cleaning Feature Section 7 - Operation Introduction PCM Operation Entering Glue-Pattern Dimensions Entering Glue-Pattern Dimensions Performing Scanner Lockout Adjusting the Stitch-Line and Stitch-Gap Parameters Enabling Valves to Run Jobs Purging Valves from the Front Panel Displaying Product-Count Information Displaying Machine-Rate Information TOC-2 Valco Cincinnati, Inc.

6 MC038 - Modular Control System Operations Manual Table of Contents PCM2 Operation Entering Glue-Pattern Dimensions Performing Scanner Lockout Adjusting the Stitch-Line and Stitch-Gap Parameters Using the Auto Glue Mode (encoder-based) Using the Continuous Mode (encoder-based) Using the Timer Mode Programming Valve Driver Settings The Shut Down Message Restoring Factory Defaults (Clearing Flash Memory) Enabling Valves to Run Jobs Purging Valves from the Front Panel Displaying Product-Count Information Displaying Machine-Rate Information FCM Operation Entering the Purge Pressure and Pressure Setpoints Creating a Standard Curve Creating a Customized Curve Displaying Machine-Rate Information Fine-Tuning the Glue Pressure Section 8 - Troubleshooting Introduction Powerup Sequence - PCM/PCM Powerup Sequence - FCM Reference Figures for Troubleshooting Troubleshooting Procedures Section 9 - Specifications Power-Supply Module (PSM) Specifications Pattern-Control Module (PCM) Specifications Pattern-Control Module 2 (PCM2) Specifications Flow-Control Module (FCM) Specifications Section 10 - part number list How to Order Parts Modular-Control-System Parts List PSM Installation Kit (781xx360) PCM/PCM2 Installation Kit (781xx354) FCM Installation Kit - Imperial (781xx353) FCM Installation Kit - Metric (781xx434) Cables for Scanners and Pump Supply Valco Cincinnati, Inc. TOC-3

7 Table of Contents MC038 - Modular Control System Operations Manual Valve Cables Extension Cables Adapter Cables E Valve Cables Encoder Cables Extension Cables Encoders Standard Encoders Mini Encoders for Small Paper Folders Scanners Standard Scanners Fixed-Field Scanners Tubing Options Section 11 - Warranty Warranty Information Cold Glue Equipment and Electronic Controls Hot Melt Units, Hoses, Valves, Guns, and Related Equipment Section 12 - Service Appendix A - Valve Setup Parameters... A-1 Introduction...A-1 Programming Valve Driver Settings (PCM2 only)...a-2 Default Valve Settings for PCM2...A-3 Settings for A012 software... A-3 Settings for A011 software... A-4 Settings for A004 to A010 software... A-5 Settings for A003 software... A-6 Example: Changing the spike duration Sdr for the 400E Valve... A-7 Appendix B - Maintenance Procedures...B-1 Introduction...B-1 Daily Maintenance...B-1 Weekly Maintenance...B-2 Monthly Maintenance...B-3 6-Month Maintenance...B-4 12-Month Maintenance...B-5 Appendix C - Quick-Reference Installation Card... C-1 Introduction...C-1 TOC-4 Valco Cincinnati, Inc.

8 MC038 - Modular Control System Operations Manual Table of Contents Appendix D - Continuous-Gluing Option with FCM... D-1 Introduction...D-1 Installation...D-3 Setup...D-4 Setup...D-5 Operation...D-5 Head-Cleaning Feature...D-5 Troubleshooting...D-6 Valco Cincinnati, Inc. TOC-5

9 SECTION 1 - INTRODUCTION About this Manual Valco Cincinnati has prepared this manual as an aid for installing, operating, and servicing the Modular Control System. It also contains a list of part numbers for replacement parts. If you need more information, contact your Valco Cincinnati representative. Components of the Modular Control System The Modular Control System is a programmable, electronically controlled gluing system that contains a power-supply module and one or more function modules (Figure 1-1): Power-Supply Module (PSM) The PSM supplies the power to the Modular Control System. It can support up to four additional modules. Pattern-Control Module (PCM) The PCM selects and programs glue patterns. Each PCM includes two channels with up to six patterns per channel. Pattern-Control Module 2 (PCM2) The PCM2 selects and programs glue patterns. Each PCM2 includes two channels with up to eight patterns per channel. Flow-Control Module (FCM) The FCM ensures consistent glue-volume output regardless of changes in machine speed. A minimum system configuration requires both a PSM and a function module. additional function modules M C S X/MIN PSM PCM PCM2 FCM Figure 1-1. Function Modules of the Modular Control System ValcoMelton. 1-1

10 Section 1 - Introduction MC038 - Modular Control System Operations Manual Description of the Modular Control System The Modular Control System is a low-cost, modular, microprocessor-based control system that activates and controls various electro-mechanical devices, including hot and cold adhesive-dispensing valves in the paperconverting and packaging industries. System Layout M C S Scanner X/MIN PSM PCM2 PCM2 FCM Encoder Air Regulator Balancing Regulator Glue Pump Glue Valve Figure 1-2. Typical System Layout 1-2 ValcoMelton

11 SECTION 2 - SAFETY AND USE Read Thoroughly Before Handling Equipment Symbols Warning! Read and follow all safety precautions, warnings, cautions, and other recommendations in this manual. OTHERWISE, DEATH, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR. Read this entire section before handling the equipment. The following symbols may be used on the equipment and/or in this manual. This symbol represents a Caution or a Warning. Cautions draw special attention to anything that could damage equipment or cause the loss of data. Warnings draw special attention to anything that could injure or kill the reader. Both Cautions and Warnings are placed before the step they apply to. This symbol represents a Hot Surface. This symbol represents a Puncture Risk. It is usually used in regard to nozzle cleaning appliances and other sharp instruments that can cause puncture wounds and risk exposure to bloodborne pathogens and other debris. This symbol means that Working Gloves are required. This symbol means that Goggles are required. This symbol indicates a Shock Hazard. There is a presence of non-insulated dangerous voltage within the product s enclosure. This voltage may cause electrical shock or fire. Continued next page ValcoMelton 2-1

12 Section 2 - Safety Information MC038 - Modular Control System Operations Manual Symbols - Continued This symbol indicates the need to Unplug/Disconnect All Power Sources and to let them de-energize before attempting any type of work or maintenance. Remember that there can still be energy in equipment, cords, and wires even when unplugged/ disconnected. This symbol indicates the need to Lock Out All Power Sources and to let them de-energize before attempting any type of work or maintenance. If power is not locked out, the person working on the equipment may be injured or killed if someone unknowingly switches on the power to the equipment. This symbol indicates a Note. Notes point out something of special interest or importance to the reader. They give tips, hints, and information in addition to what is necessary for the step preceding it. 2-2 ValcoMelton

13 MC038 - Modular Control System Operations Manual Section 2 - Safety Information Owner Responsibilities The owner of the equipment is under obligation to manage all safety information. Some examples include: Examine all safety materials and documents as well as jurisdictional laws and make certain all laws, recommendations, and other safety/hazard laws, certification requirements, training, and instructions are followed and kept current. Maintain all safety materials including tags, labels, documents, and MSDS information. Make certain they are distinct and can be read/understood. Replace any that are dirty, worn, or unreadable. Make sure all personnel who will handle, install, maintain, operate, fix, and work around the equipment have ready access to the safety information, training, and equipment according to jurisdictional authorities. The owner of the equipment is under obligation to make certain that all instructions, requirements, and jurisdictional laws are met. Some examples include: Make sure there are regular inspections of equipment and safety devices. Have regular safety drills and inspections supervised by the proper authorities. Provide all required safety items, first aid equipment, and training. The owner of the equipment is under obligation to make certain that all personnel who will handle, install, maintain, operate, fix, and work around the equipment are qualified, trained, and up-to-date with all information regarding the equipment. Some examples include: Make sure all personnel have the proper safety training, equipment, education, and abilities necessary for the job function according to safety instructions and all jurisdictional laws and regulations. It is strongly advised that personnel receive first-responder medical care training in case of burns, medical emergencies, or other injuries. Training should be kept up to date. Make sure all personnel understand and can follow safety policies and procedures for the organization as well as for the specific equipment. Make sure that all personnel are consistently trained, evaluated, free of alcohol and medications that may impair judgment and reflexes, and are tested for banned substances according to jurisdictional authorities. ValcoMelton 2-3

14 Section 2 - Safety Information MC038 - Modular Control System Operations Manual Limitations of Use Installation/ Startup/Use Safety Information Read this document and all information regarding the equipment before handling the equipment. The intended use of the equipment is stated in Section 1 of this manual. Do not use this equipment for anything other than its intended use. Do not modify, change, or alter the equipment in any way. If you are unsure of the intended use and the limitations of use for the equipment, contact your Valco Melton Representative before handling the equipment. Valco Melton hot melt units, cold glue units, controllers, inspection systems and all related accessories have the following universal safety precautions (this is not intended to be an exhaustive list; follow all instructions and safety precautions for the specific type of equipment involved): Warning! Only qualified personnel should install the equipment. Valco Melton strongly recommends that a Valco Melton Technician install all equipment. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR. Warning! Warning! Warning! Warning! Warning! The equipment should be installed so that it can be turned off at a location away from the equipment in case of injury, electrical problems, or malfunction. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. Properly route all electrical wires. Never tamper with equipment. Only use approved and correct voltage, type of current, fuses, and other power supplies. Replace worn cords, hoses, etc. immediately. FAILURE TO OBSERVE WARNING MAY RESULT IN DEATH, PERSONAL INJURY, AND/OR EQUIPMENT DAMAGE. Poor ventilation, smoking, and open flames can cause overheated hot melt to ignite. Adequate ventilation must be provided. Smoking should be prohibited in the immediate vicinity of the molten adhesive. Open flames must be kept away from the area around molten adhesive. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR. Never use any Valco Melton equipment in an explosive environment. Explosive environments include, but are not limited to, solvent-based cleaners or adhesives, explosive materials, radioactive materials, etc. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. Equipment will start automatically when remotely controlled by triggering devices. Be sure to disable all triggering devices, carefully release hydraulic pressure, and disconnect air pressure before servicing or working near guns, valves, and other triggered devices. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. 2-4 ValcoMelton

15 MC038 - Modular Control System Operations Manual Section 2 - Safety Information Shut Down Safety Information Valco Melton hot melt units, cold glue units, controllers, inspection systems and all related accessories have the following universal safety precautions (this is not intended to be an exhaustive list; follow all instructions and safety precautions for the specific type of equipment involved): Warning! Purge the fluid pressure and the air pressure from the system before disconnecting/disabling any part of the system. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. Warning! Disconnect and lock out all power before maintenance or other need to open the equipment. Only qualified personnel should open and service the control. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. Warning! Warning! Warning! Warning! Equipment may still be energized even if unplugged! When making adjustments or performing checkout procedures, stay clear of any moving mechanical parts and do not touch exposed electrical equipment or electrical connectors. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. Disconnect/disable all mechanical and/or electrical devices that send activation signals to the gun(s), valve(s), melter pump(s), etc. This includes pattern controls, timers, input/output signals, etc. Only qualified personnel should open and service the control. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. Disable all triggering devices, relieve all residual pressure (hydraulic and air) and allow adhesive to cool before attempting to disconnect guns, hoses, valves, etc. Only qualified personnel should open and service the control. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. Never point an adhesive dispensing gun, valve, hose, air hose, or anything else at yourself or another person. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. ValcoMelton 2-5

16 Section 2 - Safety Information MC038 - Modular Control System Operations Manual Hot-Melt- Specific, General Safety Information Valco Melton hot melt units have the following universal safety precautions in addition to all other universal precautions previously mentioned (this is not intended to be an exhaustive list; follow all instructions and safety precautions for the specific type of equipment involved): Warning! Never process any polyurethane reactive (PUR) hot melt or solvent-based material in a Valco Melton unit unless you are certain that the unit is compatible and is marked PUR! Read all instructions and MSDS sheets carefully, following manufacturer s instructions, especially regarding heat levels. If you have any question as to the compatibility of a Valco Melton unit for PUR hot melt, call your Valco Melton Representative before attempting to use the unit for PUR or solventbased materials. OTHERWISE, HAZARDOUS FUMES, EXPLOSION, DEATH, OR PERSONAL INJURY COULD OCCUR. Warning! Warning! Warning! Warning! Keep pump cover and electrical enclosures closed except during setup, service, and checkout procedures. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR. People with respiratory problems (e.g., asthma, bronchitis, etc.) should not work in the vicinity of molten adhesive. RESPIRATORY PROBLEMS MAY BE AGGRAVATED BY THE FUMES. Do not wear a face mask when working around molten adhesive. THE MASK MAY TRAP THE FUMES AND DEATH OR PERSONAL INJURY COULD OCCUR. Keep hot melt hoses away from walkways and the moving parts of hot melt systems. OTHERWISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR. Hot surfaces! Do not touch! Use extreme caution when refilling the unit by hand. OTHERWISE, PERSONAL INJURY COULD OCCUR. Warning! Wear protective gloves and goggles at all times around all machinery, especially hot melt. OTHERWISE, SERIOUS PERSONAL INJURY COULD OCCUR. Warning! Never use an open flame to heat hot melt components or adhesive. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR. 2-6 ValcoMelton

17 MC038 - Modular Control System Operations Manual Section 2 - Safety Information What to Do if Contact with Hot Adhesive Occurs If hot adhesive comes in contact with the skin, do the following: Warning! Do not attempt to remove heated hot melt adhesive from the skin. OTHERWISE, SEVERE PERSONAL INJURY AND DEATH COULD OCCUR. 1. Immediately immerse the contacted area in clean, cold water. It is strongly recommended that a source of clean, cold water be provided near the hot melt work area. 2. Cover the affected area with a clean, wet compress and call the emergency medical response system (such as 911) immediately. 3. Watch for and treat the subject for signs of shock while waiting for professional help to arrive. What to Do if Inhalation of Adhesive Fumes Occurs 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 the emergency medical response system (such as 911) immediately. ValcoMelton 2-7

18 Section 2 - Safety Information MC038 - Modular Control System Operations Manual What to Do if Adhesive-Related Fire or Explosion Occurs During the heating and melting process, the surface of the adhesive will be exposed to air. The mixture of polymer fumes and air can catch fire if the hot melt is overheated. Warning! Poor ventilation, smoking, and open flames can cause overheated hot melt to ignite. Adequate ventilation must be provided. Smoking should be prohibited in the immediate vicinity of the molten adhesive. Open flames must be kept away from the area around molten adhesive. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR. Warning! Warning! Exposed arcing may ignite the fume/air mixture. Shield all electrical equipment from melt fumes to avoid exposed arcing. OTHERWISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR. Do not use a water extinguisher to extinguish the fire! OTHERWISE, PERSONAL INJURY OR EQUIPMENT DAMAGE 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. Leave the area immediately if conditions are unsafe. If you feel you can fight the fire safely, do one of the following: - Smother the fire with a fire blanket. - Aim a CO 2 fire extinguisher at the base of the flames. - Aim a dry-powder fire extinguisher at the base of the flames. 2-8 ValcoMelton

19 MC038 - Modular Control System Operations Manual Section 2 - Safety Information Hose Safety Information Do not use bindings, wire ties, or unapproved fasteners around the hoses. Do use approved wrapping (P/N KAP0434), making sure the wrapping is slightly snug but not tight. Do not place hoses close together. Do allow at least 2 inches (5.1 cm) between hoses for proper ventilation. Do not bend hoses sharply. Do not allow kinks or indentations in the hoses. Do use a minimum bend radius of 10 inches for a 20-inch diameter coil hose. Do not use unapproved hooks to hang hoses. Do not wrap hoses over or around objects. Do use a hose hanging kit (P/N 781xx827). Do not use the one handed/one wrench technique to attach or remove hoses. Do not wrench on any surface other than the large hexagon swivel nuts. Do use two hands and two wrenches to tighten or loosen connections on hoses. Do wrench only on large hexagon swivel nuts. ValcoMelton 2-9

20 Section 2 - Safety Information MC038 - Modular Control System Operations Manual Hose Safety Information - Continued Do not allow hoses to rub against objects or to come into contact with sharp edges or points. Do wrap the hoses in approved padding (P/N 795xx549) if the hoses must be installed where they will come into contact with objects. Do not use worn, damaged, or bent hoses. Do inspect all hoses regularly for damage and/or wear and replace damaged or worn hoses immediately ValcoMelton

21 SECTION 3 - GENERAL WIRING GUIDELINES Routing Low- Voltage Leads Warning! Electrical installation should be accomplished only by experienced service personnel! Otherwise, death, personal injury, or damage to equipment could occur. When routing low-voltage leads, follow these guidelines: Do not route low-voltage cables (scanner cables, encoder cables, etc.) in the same conduit as high-voltage wires (AC power, etc.). Do not route low-voltage leads adjacent to, or across wires carrying a high-current load. If low-voltage leads must cross or run parallel to wires carrying high current, keep the leads at least 6" (152 mm) from high-current wires. Do not splice or solder wires together. Trim leads to the required length. Leads should be only as long as necessary for installation. All wiring should be in conduits or wireways. Connecting the Supply of Electrical Power Warning! Electrical connections should be made only by experienced service personnel! Otherwise, death, personal injury, or damage to equipment could occur. The control must be connected to a clean supply of electrical power. Use a dedicated circuit if possible if a dedicated circuit is not available, do not connect the control to a circuit that supplies high-amperage equipment. Use another circuit such as a fluorescent or incandescent lighting circuit. ValcoMelton. 3-1

22 SECTION 4 - INSTALLATION Introduction Mechanical Installation of the Modules This section contains procedures for installing the Modular Control System. Modules should be installed on the operator s side of the parent machine in a location free of vibrations. The modules should require less than 25 feet (8 m) of wiring to reach the dispensing valves, sensors, and encoder. If needed, longer wiring is available upon request. To install the modules, follow these steps. 1. Cut and mount the DIN rail: a. Cut the DIN rail to a length equal to the combined width of all the modules to be installed. Each module is 2.5" (57 mm) wide. If you anticipate future installation of additional modules, leave the DIN rail long enough to accommodate the modules. b. Use the supplied screws to mount the DIN rail on the wall. c. Use a level to ensure that the rail is horizontal. If the wall can be tapped, use a 0.203" (13/64" or 5mm) diameter pilot drill and 1/4-20 (M6 x 1) tap. If the wall is too thin, use a 0.281" (9/32" or 8mm) diameter clearance drill and the supplied screws, lockwashers, and nuts. 2. Hang and secure the modules - Basic wall installation: a. Remove the bottom-cover-plate screw and the bottom cover of the module (Figure 4-1). b. Disconnect any cables connecting board to cover. c. Use the hook mounted to the rear of the module housing to hang the module on the DIN rail. ValcoMelton. 4-1

23 Section 4 - Installation MC038 - Modular Control System Operations Manual Mechanical Installation of the Modules - Continued d. Use the supplied screw to secure the module by screwing the lower foot of the module into the wall. e. Repeat steps a through d for each module. Mounting-plate assembly installation (optional): a. Use the screws provided to bolt the module directly to the mounting plate. These screws will thread into the pretapped plate holes. b. Mount the plate to a bracket located on the parent machine. external-devices connector (bottom cap) system-bus connector power connector Figure 4-1. Bottom View of PCM (With Cover Removed) 3. Interconnect the modules: CAUTION! Power cable must be aligned properly. OTHERWISE, DAMAGE TO ALL MODULES IN SYSTEM COULD OCCUR. 4-2 ValcoMelton

24 MC038 - Modular Control System Operations Manual Section 4 - Installation Mechanical Installation of the Modules - Continued a. Connect the power cable from the power-supply module (PSM) to the corresponding connector in the first function module (PCM, PCM2, FCM, etc.). b. If there are two or more function modules, connect both the power cable and the system-bus-ribbon cable from each function module into the corresponding connectors on the previous module (Figure 4-2). The ribbon cable and the power cable together form the dual-module interconnect cable kit. One interconnect cable kit is required for each module added to the system. Figure 4-2 shows two interconnect cable kits. ribbon cable power cable Figure 4-2. Example of Interconnected System (With Bottom Caps Removed) ValcoMelton 4-3

25 Section 4 - Installation MC038 - Modular Control System Operations Manual Mechanical Installation of the Modules - Continued c. Use a knife to cut down groove #1 (Figure 4-3). d. Use a knife to cut down groove #2. e. Use pliers to break away the wire-access areas by bending /snapping them outward. f. Reconnect any cables from the modules to the boards in their respective bottom covers. g. Reinstall the bottom covers, ensuring that the power and system ribbon cables are routed in the wireaccess area. (Be careful not to pinch the ribbon cables or air lines.) h. Use the captive cover-plate screws to secure the bottom covers. wire-access areas before removing cutouts #1 #2 wire-access areas after removing cutouts Figure 4-3. Wire-Access Areas 4-4 ValcoMelton

26 MC038 - Modular Control System Operations Manual Section 4 - Installation Electrical Installation of the Modules Connecting the Main Power Supply The main power supply must be either 115/230 VAC, 50/60 Hz or 100/200 VAC, 50/60 Hz. The appropriate range is field-selectable. The power-entry module (Figure 4-4) accepts a standard IEC line cord, which is supplied. To connect the main power supply to the Modular Control System, follow these steps: 1. Select the voltage: a. Turn off the power switch on the power-entry module (Figure 4-4). b. If the power cord is attached to the power-entry module, remove the power cord. c. Use a small screwdriver to open the hinged door of the fuse holder. The fuse holder on the bottom cover of the PSM contains the fuse drawer, which allows for either 100/115 or 200/ 230 VAC operation (Figure 4-5). d. Remove the fuse drawer, ensuring that the fuse(s) in the holder remain in place. fuse drawer e. If the control is to be connected to 100 or 115VAC, rotate the drawer so that 115V shows through the door opening. If the control is to be connected to 200 or 230VAC, rotate the drawer to 230V. on/off power switch on/off power switch power-cord connector pump-supply connector 115V/230V power -entry module power-cordclamp screws shorting clip (or second fuse) fuse drawer Figure 4-4. Bottom View of PSM Figure V/230V Power-Entry Module ValcoMelton 4-5

27 Section 4 - Installation MC038 - Modular Control System Operations Manual Connecting the Main Power Supply - Continued Warning! The PSM uses a 2A, 250V, SLO-BLO standard fuse for 115V operation and a 1A, 250V, SLO-BLO standard fuse for 230V operation. No other type of fuse should be used. OTHERWISE, DAMAGE TO EQUIPMENT COULD OCCUR. The setup in step 1f may vary, depending on the country in which the system is being installed. It is the purchaser s responsibility to ensure that all local, county, state, and national codes, regulations, rules, and laws relating to safety and safe operating conditions are met and followed. OTHERWISE, DEATH, PERSONAL INJURY, OR DAMAGE TO EQUIPMENT COULD OCCUR. f. For line-to-neutral operation, use either the shorting clip and one fuse or two fuses. (The shorting clip must be on the left side of the drawer when rotated to the correct voltage position, as shown in Figure 4-5.) For line-to-line use, discard the shorting clip and use two fuses. g. Replace the drawer in the fuseholder in the correct voltage position and close the fuseholder door. h. Ensure that the correct operating voltage shows through the window in the fuse drawer. For 100/200VAC installation, perform steps 1i-1l as well: i. Remove the screw holding the top cover of the PSM in place. j. Remove the top cover. k. In the top panel of the PSM, there is a rocker switch with two positions 100/200 and 115/230. Place the switch in the appropriate position. l. Replace the top cover of the PSM and secure the cover with the captive screw. 2. Connect the power cord (Figure 4-5): a. Insert the power cord into the power-entry module. b. Attach the power-cord clamp to the bottom surface of the PSM using the two screws on either side of the power-entry module. 4-6 ValcoMelton

28 MC038 - Modular Control System Operations Manual Section 4 - Installation Connecting the Main Power Supply - Continued c. Tighten the power-cord clamp to prevent the cord from working its way out of the module and providing strain relief for the line cord. The power cord supplied can either be directly wired to a branch circuit or, with the proper plug type, plugged into an outlet. The wire colors of the supplied power cord are as follows: Wire Function International Power-Cord Color North-American Power-Cord Color Line Voltage Brown Black Neutral Blue White Protective Earth Green/Yellow Green Encoder Installation Mechanical Installation of Encoder An encoder must be installed in order for the control to determine the speed of the parent machine. CAUTION! For best results, pulses per inch (25.4 mm) of product travel should be supplied to the Modular Control System PULSES PER INCH (25.4 mm) MAY CAUSE PATTERN-PLACEMENT ERRORS. LESS THAN 50 PULSES PER INCH (25.4 mm) MAY CAUSE PATTERN FAILURES. MORE THAN 110 PULSES PER INCH WILL INCREASE ACCURACY BUT WILL REQUIRE A DECREASE IN OVERALL SPEED. There are two primary types of encoder setup: Wheel-driven encoder setup Gear-driven encoder setup ValcoMelton 4-7

29 Section 4 - Installation MC038 - Modular Control System Operations Manual Wheel-Driven-Encoder Setup If you use a wheel-driven encoder setup (Figure 4-6), a VDD-1000 encoder with a 10-inch measuring wheel is recommended. To install a wheel-driven encoder, follow these steps: 1. Mount the encoder s bracket to the frame of the parent machine. 2. Make sure the wheel of the encoder rides securely against the belt and does not slip. The encoder assembly should be installed on the main drive belt if possible. Try not to use a belt that is driven by friction. This could cause slippage and erratic glue patterns. Figure 4-6. Example of a Wheel-Driven Encoder Setup 4-8 ValcoMelton

30 MC038 - Modular Control System Operations Manual Section 4 - Installation Gear-Driven-Encoder Setup The following formula can be used to determine the correct combination of gear teeth and encoder for approximately 100 pulse per inch: Teeth-S x Counts = Pulses per inch of travel Teeth-E Travel Teeth-S = Number of teeth on the line-shaft driver gear. Teeth-E = Number of teeth on the encoder-driven gear. Counts = Number of encoder pulses per one revolution (100, 500, etc.). Travel = Product travel in inches (or millimeters divided by 25.4) per revolution of the drive shaft. All ratio compensation values are calculated using pulses per inch! Example: Using a 92-tooth split line-shaft gear, a 24-tooth encoder-driven gear, a 500- pulse encoder, and 18 inches (or 457 millimeters divided by 25.4) of product travel per drive shaft revolution, the formula is: 92 x 500 = Therefore, the ratio compensation setting should be The gear selection should be done to achieve as close to 100 pulses per inch as possible. To install a gear-driven encoder (Figure 4-7), follow these steps: 1. Install the drive gear on the line shaft. Tighten the set screws. 2. Position and install the encoder so that it is square with the drive gear. 3. Raise or lower the encoder to tighten the belt against the drive gear. (Ensure that the two sides of the belt are not pressed together under the wheel.) Due to the low torque required, the belt should not be extremely tight. At least 7-9 teeth should engage in the line shaft drive gear. It may be necessary to fabricate an adjustable bracket to connect the encoder base to the parent machine frame. ValcoMelton 4-9

31 Section 4 - Installation MC038 - Modular Control System Operations Manual Gear-Driven-Encoder Setup - Continued line shaft (drive) drive gear minimum 7-9 teeth shaft encoder machine base encoder gear Adjustable mounting (supplied by customer) 11 (279 mm) machine base Figure 4-7. Typical Installation of a Gear-Driven Encoder Scanner, Valve, and Encoder Connections The following cables need to be connected to the Modular Control System (Figure 4-8): Scanner and pump-supply cables The cables for connecting these and most other devices to the Modular Control System have M12 normal-keyed, 5-pin connectors with yellow molded trim. The cables are available in 1-, 2-, 4, 8-, 10-, 15-, and 20-meter lengths (see Section 10 Part Number List). These cables connect to the scanner inputs or pump output connections and the device feeding the signal back to the control. Valve cables The cables for connecting glue valves or air valves to the Modular Control System have M12 reversekeyed, 5-pin connectors identified by blue molded trim. The cables are available in 1-, 2-, 4-, 8-, 10-, 15-, and 20-meter lengths (see Section 10 Part Number List). These cables connect to the valve output connectors and run to the valve directly, or by using an adapter to individual valves. Encoder cables The cables for connecting an encoder to the Modular Control System have DIN 8-pin connectors with a black plastic backshell. The cables are available in 2-, 4-, 8-, 16-, and 32-meter lengths (see Section 10 Part Number List). These cables connect the DIN connector on the PCM/ PCM2 to the VDD encoder ValcoMelton

32 MC038 - Modular Control System Operations Manual Section 4 - Installation Scanner, Valve, and Encoder Connections - Continued PSM PCM/PCM2 encoder connector valve 1 output valve 2 output pump-supply connector scanner 1 input scanner 2 input Figure 4-8. Bottom View of PSM and PCM/PCM2 ValcoMelton 4-11

33 Section 4 - Installation MC038 - Modular Control System Operations Manual Using the Z Pulse If a scanner is not used because the system is going to use the encoder Z pulse, this mode is enabled inside the bottom cap of the PCM. To use the Z pulse, follow these steps: 1. Remove the bottom cap from the PCM. 2. Move the jumper from the SCANNER position and place it in the Z-PULSE position (Figure 4-9). 3. Replace the bottom cap on the PCM. The LED of the scanner mapped to the Z pulse should appear active (on) at all times. 2-pin jumper Figure 4-9. Inside View of PCM Bottom Cap The encoder Z pulse is softwareselectable with the PCM2 module ValcoMelton

34 MC038 - Modular Control System Operations Manual Section 4 - Installation Air-Line Installation If your system includes a Flow-Control Module (FCM), follow these steps to install the air line: 1. Screw the push-in fittings tightly into the brass port fittings. The push-in fittings are supplied with the module. 2. Using 1/4" (6 mm) O.D. poly tubing, connect the air-regulator/ drier output port to the FCM air-input port (Figure 4-9) by pushing the tubing into the push-in fitting. 3. Using 1/4" (6 mm) O.D. poly tubing, connect the FCM regulatedair output port (Figure 4-10) to the glue-regulator air-input port by pushing the tubing into the push-in fitting. If the control was ordered with the imperial installation kit, the 1/4" tubing must be used. If the control was ordered with the metric installation kit, only the 6 mm tubing will fit. air-input port regulated- air output port exhaust port dump valve output +12V air MAC scanner connector encoder connector Figure Bottom View of FCM ValcoMelton 4-13

35 SECTION 5 - CONTROL PANEL Introduction Pattern Control Modules - PCM vs. PCM2 This section describes the PCM operator panel (Figure 5-1), PCM2 operator panel (Figure 5-2), and the FCM operator panel (Figure 5-3). Depending on manufacturing date, your MCS system may have either first generation (PCM) or second generation (PCM2) pattern control modules. The PCM2 module is a replacement for the PCM. All PCM2 modules can be identified by the PCM2 PCM2 label appearing at the bottom of the unit. Additionally, PCM2 modules have a different Valco part number (084xx521). PCM modules carry the Valco part number (084xx501). The PCM2 replaces the PCM module, however, the two versions of pattern control modules are compatible. When compared to the original PCM module, the PCM2 offers the following added features: Up to eight patterns per channel Auto Glue function Batch counting Web detection Programmable jogging mode (system will apply a stitched glue pattern at a programmed speed until he minimum speed setting is reached) Box length maximum up to 200 inches This Modular Control System (MCS) operations manual contains information specific to both versions of pattern control modules. For general information about the PCM module, refer to pages 5-2 to 5-4 of this section of the manual. For general information about the PCM2 module, refer to pages 5-5 to 5-7. If you are setting up parameters for the first time on a PCM module, follow the instructions contained on pages 6-1 to 6-13 in Section 6 Parameter Setup. If you are setting up parameters for the first time on a PCM2 unit, follow the instructions contained on pages 6-14 to Operating instructions for the PCM module are contained on pages 7-1 to 7-4 in Section 7 Operation. Operating instructions for the PCM2 are contained on pages 7-5 to 7-9. ValcoMelton. 1-1

36 Section 5 - Control Panel MC038 - Modular Control System Operations Manual PCM Control Panel pattern/mode window clear-display button pattern/mode button start-dimension window and thousands product counter start-dimension symbol start-dimension increase button start-dimension decrease button length-dimension window and units product counter length-dimension symbol length-dimension increase button length-dimension decrease button pattern-select button line pattern indicator stitch pattern indicator above minimum speed indicator below minimum speed indicator channel 1 data button channel 1 data indicator channel 2 data button channel 2 data indicator valve 1 enable button valve 1 enabled indicator valve 2 enable button valve 2 enabled indicator valve 1 purge button valve 1 on indicator valve 2 purge button valve 2 on indicator scanner 1 indicator scanner 2 indicator Figure 5-1. Pattern-Control Module (PCM) Control Panel 5-2 ValcoMelton

37 MC038 - Modular Control System Operations Manual Section 5 - Control Panel PCM Control-Panel Button Descriptions Clear-Display Button The clear-display button allows you to quickly clear a pattern selection, counter, or setup parameter to a value of zero or to a factory-set minimum value. Pattern/Mode Button The pattern/mode button allows you to display information for patterns (1-6), product counts (C), machine rate (r), and setup parameters (P). Repeatedly pressing the pattern/mode key displays this information. Start-Dimension Symbol Start-Increase Button Start-Decrease Button When the pattern/mode window indicates numerals 1 through 6, the start-increase and start-decrease buttons allow you to adjust the start dimension for up to six patterns on each of two channels. The start-dimension window uses four numeric digits to indicate the start dimension, which is the distance from the leading edge of the product to the point where the glue line will start. Only one pattern is available in the Labeler function. When the Labeler function is selected, L replaces 1 through 6 in the pattern/mode display. Length-Dimension Symbol Length-Increase Button Length-Decrease Button > X < X Encoder Symbol and Indicators ValcoMelton When the pattern/mode window displays numerals 1 through 6, the length-increase and length- decrease buttons allow you to adjust the length dimension for up to six patterns on each of two channels. The length-dimension window uses four numeric digits to indicate the length dimension, which is the length of the desired glue line. When the pattern/mode window displays a P, the parameter setup mode is active, and the length-increase and the length-decrease buttons allow you to adjust the setting of a parameter. The startdimension window indicates which parameter is being set. The lengthdimension window displays the parameter s value. The two indicators next to the encoder symbol denote if product travel is above the minimum gluing speed, below the minimum gluing speed, or stopped. When the parent machine is running faster than the minimum speed setting of the PCM, the above minimum speed indicator ( > X ) illuminates. When the parent machine is running slower than the minimum speed setting of the PCM, the below minimum speed indicator ( < X ) illuminates. When the parent machine is stopped, neither indicator illuminates. When either the Timer 1 or the Labeler mode is selected, the pattern-control module will always be above minimum speed. In the Timer 2 mode, the PCM will be above minimum speed only while product is under the scanner. 5-3

38 Section 5 - Control Panel MC038 - Modular Control System Operations Manual Pattern-Select Button and Indicators The pattern-select button allows each channel to dispense either line patterns or stitch patterns independently. A line pattern is a pattern that consists of an unbroken line. A stitch pattern is a pattern that is broken into small segments or dots. The two indicators next to the pattern-select button indicate whether the selected channel is dispensing a stitch glue pattern or a line glue pattern. Channel 1 Data Button and Indicator Channel 2 Data Button and Indicator Pressing the channel 1 data button causes the start-dimension display and the length-dimension display to indicate pattern information for valve 1. Pressing the channel 2 data button causes the start-dimension display and the length-dimension display to indicate pattern information for valve 2. The indicator next to the appropriate data button illuminates to indicate which valve s pattern information is being displayed in the startdimension and length-dimension windows. Valve 1 Enable Button and Indicator Valve 2 Enable Button and Indicator Pressing the valve 1 enable button until its indicator illuminates allows valve 1 to be fired using valve 1 pattern information. Pressing the valve 1 enable button again disables valve 1. Pressing the valve 2 enable button until its indicator illuminates allows valve 2 to be fired using valve 2 pattern information. Pressing the valve 2 enable button again disables valve 2. Valve 1 Purge Button and Indicator Valve 2 Purge Button and Indicator Pressing the valve 1 purge button manually energizes valve 1 for as long as the button is pressed. The indicator next to the valve 1 purge button will illuminate to indicate that valve 1 is being purged. Pressing the valve 2 purge button manually energizes valve 2 for as long as the button is pressed. The indicator next to the valve 2 purge button will illuminate to indicate that valve 2 is being purged. The indicators next to the valve purge buttons will also illuminate whenever the respective valve is energized due to its programmed pattern data. Scanners 1 and 2 Indicator The scanner 1 indicator illuminates when the sensor signal for valve 1 is active. The scanner 2 indicator illuminates when the sensor signal for valve 2 is active.these indicators stay illuminated until the product is no longer sensed by the corresponding scanner. 5-4 ValcoMelton

39 MC038 - Modular Control System Operations Manual Section 5 - Control Panel PCM2 Control Panel pattern/mode window clear-display button pattern/mode button start-dimension window and thousands product counter start-dimension increase button start-dimension decrease button start-dimension or start delay symbol length-dimension window and units product counter length-dimension or end gap symbol length-dimension increase button length-dimension decrease button pattern-select button line pattern indicator stitch pattern indicator above minimum speed indicator below minimum speed indicator channel 1 data button channel 1 data indicator channel 2 data button channel 2 data indicator valve 1 enable button valve 1 enabled indicator valve 2 enable button valve 2 enabled indicator valve 1 purge button valve 1 on indicator valve 2 purge button valve 2 on indicator scanner 1 indicator scanner 2 indicator Figure 5-2. Pattern-Control Module 2 (PCM2) Operator Panel ValcoMelton 5-5

40 Section 5 - Control Panel MC038 - Modular Control System Operations Manual PCM2 Control-Panel Button Descriptions Clear-Display Button The clear-display button allows you to quickly clear a pattern selection, counter, or setup parameter to a value of zero, or to a factory-set minimum value. Pattern/Mode Button The pattern/mode button allows you to display information for patterns (1-8), product counts (C), machine rate (r), and setup parameters (P). Repeatedly pressing the pattern/mode key displays this information. Start-Dimension Symbol Start-Increase Button Start-Decrease Button When the pattern/mode window indicates numerals 1 through 8, the start-increase and start-decrease buttons allow you to adjust the start dimension (delay) for up to eight patterns on each of two channels. The start-dimension window uses four numeric digits to indicate the start dimension or delay, which is the distance from the leading edge of the product to the point where the glue line will start. Unlike the PCM, the PCM2 does not have a dedicated labeler function. Labeler functionality can be programmed using the Timer Mode and setting the delay to Length-Dimension Symbol Length-Increase Button Length-Decrease Button > X < X Encoder Symbol and Indicators When the pattern/mode window displays numerals 1 through 8, the length-increase and length- decrease buttons allow you to adjust the length dimension and end gap for up to eight patterns on each of two channels. The length-dimension window uses four numeric digits to indicate the length dimension, which is the length of the desired glue line. When the pattern/mode window displays a P, the parameter setup mode is active, and the length-increase and the length-decrease buttons allow you to adjust the setting of a parameter. The startdimension window indicates which parameter is being set. The lengthdimension window displays the parameter s value. The two indicators next to the encoder symbol denote whether product travel is above minimum gluing speed, below minimum gluing speed, or stopped. When the parent machine is running faster than the minimum speed setting of the PCM2, the above minimum speed indicator ( > X ) illuminates. When the parent machine is running slower than the minimum speed setting of the PCM2, the below minimum speed indicator ( < X ) illuminates. When the parent machine is stopped, neither indicator is illuminated. When either the Timer 1 mode is selected, the PCM2 module will always be above minimum speed. In the Timer 2 mode, the PCM2 will be above minimum speed only while product is under the scanner. 5-6 ValcoMelton