Warner Electric MCS-638-4 User Manual
MCS-638-3 and MCS-638-4 Series
MCS-149
Power Supply
MCS-638
Knife or
Heat Seal
Color Mark
P-241-135
819-0468
MCS-638-3 Part Number 7135-448-011
MCS-638-4 Part Number 7135-448-012
Installation & Operating Instructions
Print Registration/Color Mark/Contrast Sensors
The MCS-638 sensor evaluates the brightness difference
between a target color and a background color.
Sometimes the color difference can be very slight, in
these cases the MCS-638 with its variable color LED light
source is beneficial. The color of the light source is
important, and the appropriate choice of color for the light
source, or using the MCS-638 with it’s automatic light
source color selection allows the detection of very slight
contrasts. For example, a green color LED light source is
more likely to detect a contrast between red and blue
than a contrast between green and blue.
A common application for contrast sensors is a
converting operation. A web of printed media may need
to be cut into individual sheets, and registration marks are
printed in certain locations to signal the machine controller
to cut the media. For example, a continuous sheet of
margarine wrappers is cut into individual wrappers with
the printing centered on each individual sheet. Another
common application is on bag making machinery where
the sensor detects the registration mark and signals the
machine to stop and cut or heat seal a bag.
Features:
Typical Application
• Static mode teach allows one automatic
teach step for the target and one automatic
teach mode for the background.
• Remote teach input allows setup to be
programmed remotely.
• Dual lens position
• Automatic selection of best color light
source (Green, Red, Blue).
• Light Operate (Normally Off) / Dark Operate
(Normally On) Operate Modes.
• Quick Disconnect (2 Meter Cable included
with Sensor).
• LED indication of Output status.
• Output - Push-Pull (NPN/PNP)
Warner Electric • 800-825-9050 P-241-135 • 819-0468
Teach In
LED
Yellow: Output Status
Yellow: (flashing): Contrast not found
from programmed values
Teach Push Button
19
(.75)
16.5
(.649)
M5x8
Screw Depth 5
*Interchangeable
60.8
(2.4)
Cover*
4
(.16)
19
Lens*
38.6
(1.52)
23.5
(.925)
28
(1.1)
M12x1
47.9
(1.88)
28
(1.1)
19
(.75)
28
(1.1)
21 (.827)
33
(1.3)
4
(.16)
85.6
(3.4)
19
(.75)
1.5
(.06)
Specifications Electrical
43
2
1
Black
Blue
Brown
Gray
Load
(-)
(+)
White
(no connection)
Optional Customer Supplied
Pushbutton for Remote Teach
Male Receptacle End View
NPN OUTPUT WIRING
43
2
1
Black
Blue
Brown
Gray
(-)
(+)
White
(no connection)
Optional Customer Supplied
Pushbutton for Remote Teach
Male Receptacle End View
PNP OUTPUT WIRING
5
5
Load
Model Number MCS-638-3 MCS-638-4
Part Number 7135-448-011 7135-448-012
Sensing Range 9.5 mm ± 3 mm 25 mm ± 6 mm
Sensitivity Adj. Yes (Push-Button Teach)
Output 1 Push-Pull (NPN/PNP)
Load Current 200 mA Max
Voltage Drop ≤ 2.5VDC
Short Ciruit and
Overload YES
Protection
Reverse Polarity
YES
Protection
Supply Voltage 10-30 VDC
Voltage Ripple 10%
LED Indicator YES
Current
70 mA
≤
Consumption
Operating Mode Light on/Dark on
Response Time 30 µs
Switching
16.5 kHz
Frequency
Protection(IEC) IP 67
Light Spot Size 1 mm x 4 mm 2 mm x 8.5 mm
and Orientation Parallel to Housing
Light Source Green, Red, or Blue LED
Wiring
Mechanical Data
Housing Material Makrolon
Lens Material Glass
Weight 7.1 oz
Connection
Quick Disconnect
(2 Meter Cable Included)
Programming
1. Connect the supply
voltage to the wires noted
in the wiring diagram.
P-241-135 819-0468 8/11 Printed in USA
Warner Electric
31 Industrial Park Road
815-389-3771
• Fax: 815-389-2582
www.warnerelectric.com
2. Aim the light spot at the
target mark. For glossy or
reflective surfaces, the
sensor should be angled
at 10° to 15° off the perpendicular axis from the target.
3. Press the Teach push button on the sensor or apply V+
to the Teach Input for a minimum of 50 milliseconds. The
LED should flash slowly (at a rate of approximatel 1 Hz).
4. Aim the light spot at the background.
5. Press the Teach push button on the sensor or apply V+
to the Teach Input for a minimum of 50 milliseconds. The
LED will now turn on when the target mark is present
and off when it is absent after a successful teach. If the
teach was not successful or the contrast was not
sufficient, the LED flashes quickly (at a rate of
approximately 4 Hz). Programming the MCS-638 as
indicated above sets the switching threshold exactly in
the middle of the target and background values. The
above procedure is for Light Operate mode. For Dark
Operate mode, reverse steps 2 and 4.
• New Hartford, CT 06057
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