VALCO MELTON MCP-4J User manual

MCP-4J Control Unit
w/Jam Detection
Manual Number: MC122
Revision Date: 9/2019
Software Version: C003.0002

© Valco Melton All Rights Reserved
This manual is provided with the MCP-4J Control Unit and may be used 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 Melton, 497 Circle Freeway Drive, Suite 490, Cincinnati, Ohio 45246.
http://www.valcomelton.com
Part Number: MC122
Written and printed in the USA.
Valco Cincinnati, Inc.
497 Circle Freeway Drive
Suite 490
Cincinnati, OH 45246
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Web: http://www.valcocincinnatiinc.com
Valco Cincinnati Limited
Hortonwood 32
Telford, TFI 7YN, England
Tel: [phone]
Fax: [phone]
Email: [e-mail]
Web: http://www.valco.co.uk
Valco Cincinnati GmbH
Bonnerstrasse 349
40589 Dusseldorf-Benrath, Germany
Tel: [phone]
Fax: [phone]
Melton S.L.U.
Pol. Industrial Agustinos
calle G, n. 34
31160 Orcoyen, Navarra, Spain
Tel: [phone]
Fax: [phone]
Valco Melton France
Technoparc des Hautes Faventines
32 Rue Jean Bertin
26000 Valence
Tel: [phone]
Fax: [phone]

Declaration of Conformity
(According to EN 45014)
The following declaration is issued under the sole responsibility of the manufacturer:
Manufacturer: Valco Melton
A division of Valco
Cincinnati, Incorporated
411 Circle Freeway Drive
Cincinnati, OH 45246
USA
Authorized Representatives in Europe: Valco Cincinnati, Ltd.
Unit 7-8
Hortonwood 32
Telford TF1 7YN England
Melton S.L.U.
Pol. Industrial
Agustinos
calle G, n. 34
31160 Orcoyen
Navarra, Spain
declares that the product:
Product Name: MCP-4J Control Unit
w/Jam Detection
complies with the following Council Directives:
Safety of Machinery: 2006/42/EC
Low Voltage Equipment: 2014/35/EU
EMC: 2014/30/EU
Reduction of Hazardous Substances (RoHS) 2011/65/EC
and conforms to the following standards:
Safety: EN60204-1:2006
EN13849-1
Risk: ISO12100:2010
EMC Emissions: EN61000-6-4:2007
EN61000-4-2
EMC Immunity: EN61000-6-2:2005
EN61000-4-3
EN61000-4-4
EN61000-4-5
EN61000-4-6
EN61000-4-8
EN61000-4-11
Place and Date: Cincinnati, Ohio USA
CE Mark first fixed 2006
Signature: Cincinnati, OH USA
David H. Swedes,
Vice President of
Engineering & Manufacturing
This Declaration of Conformity has been generated electronically and is legally binding without signature

MC122 - MCP-4J Control Unit Table of Contents
1
Table of Contents
Table of Contents ................................................................................................1
Section 1 - Introduction .......................................................................................1
System Description..................................................................................................................................................1
Features/Capabilities ...............................................................................................................................................1
Section 2 - Safety and Use ...................................................................................3
Read Thoroughly Before Handling Equipment.......................................................................................................3
Symbols ...................................................................................................................................................................3
Owner Responsibilities ............................................................................................................................................4
Limitations of Use ....................................................................................................................................................4
Installation/Startup/Use Safety Information.............................................................................................................5
Shut Down Safety Information ................................................................................................................................6
Hot-Melt-Specific, General Safety Information .......................................................................................................6
What to Do if Contact with Hot Adhesive Occurs ...................................................................................7
What to Do if Inhalation of Adhesive Fumes Occurs ..............................................................................7
What to Do if Adhesive-Related Fire or Explosion Occurs .....................................................................8
Hose Safety Information ..........................................................................................................................................9
Section 3 - Basic features ....................................................................................11
MCP-4J Control .......................................................................................................................................................11
Front Panel..............................................................................................................................................11
Back Panel ..............................................................................................................................................12
Pinouts, Standard .........................................................................................................................................13
Pinouts, Tri-Valve .........................................................................................................................................17
MCP-4J Control, Vertical; No EPC (074xx084)......................................................................................................20
Front Panel..............................................................................................................................................20
Bottom Panel...........................................................................................................................................20
MCP-4J Control, Vertical; with EPC (074xx085) ....................................................................................................21
Front Panel..............................................................................................................................................21
Bottom Panel...........................................................................................................................................21
MCP-4J Control, Vertical; 3NC Tipsealer (074xx086)............................................................................................22
Bottom Panel...........................................................................................................................................22
MCP-4J Control, Horizontal; with EPC (074xx087)................................................................................................23
Back Panel ..............................................................................................................................................23
MCP-4J Control, Horizontal; No EPC (074xx088) .................................................................................................24
Back Panel ..............................................................................................................................................24
MCP-4J Control, Horizontal; Folding Carton, Tipsealer (074xx089) .....................................................................25
Back Panel ..............................................................................................................................................25
MCP-4J Control, Horizontal; Dual External EPC (074xx090) ................................................................................26
Back Panel ..............................................................................................................................................26

Table of Contents MC122 - MCP-4J Control Unit
2
MCP-4J Valve Driver Instructions ...........................................................................................................................27
Wiring Configurations for Triggering the Valves..................................................................................... 27
Wiring the Scanner Cable ............................................................................................................................27
Encoder Installation .................................................................................................................................................29
Mechanical Installation of Encoder......................................................................................................... 29
Wheel-Driven Encoder .................................................................................................................................29
Gear-Driven Encoder ...................................................................................................................................29
Section 4 - Programming ..................................................................................... 31
Mounting ..................................................................................................................................................................31
Using the Operator Interface ...................................................................................................................................31
The Operator Interface Buttons.............................................................................................................. 31
The Main Menu Buttons ......................................................................................................................... 32
The Valve Buttons .................................................................................................................................. 32
The Navigation Buttons .......................................................................................................................... 32
Flash Memory Storage .................................................................................................................................33
The Edit Buttons ..................................................................................................................................... 34
Open a Highlighted Menu with the OK Button.............................................................................................34
Thumbwheel vs. Single Digit Edit ................................................................................................................35
The Status LEDs .................................................................................................................................... 35
Screen Contrast Adjustment................................................................................................................... 36
First Use Setup (Wizard) .........................................................................................................................................36
Language................................................................................................................................................ 36
Application .............................................................................................................................................. 37
Measurement Mode................................................................................................................................ 38
Encoder .................................................................................................................................................. 39
Valve Type.............................................................................................................................................. 39
Jog Mode ................................................................................................................................................ 40
Finish Configuration................................................................................................................................ 40
Additional Setup Button Parameters.......................................................................................................................41
Language................................................................................................................................................ 41
Pattern Entry Mode................................................................................................................................. 42
Jog Mode ................................................................................................................................................ 42
Batch Counter......................................................................................................................................... 42
Jam Prevention....................................................................................................................................... 42
Purge Signal ........................................................................................................................................... 43
External Enable Signal ........................................................................................................................... 43
Output Configuration .............................................................................................................................. 43
Menu Configuration ................................................................................................................................ 44
Tipsealer Enable..................................................................................................................................... 44
COM Interface Option............................................................................................................................. 45
Enable the Interface .....................................................................................................................................45
Scanner Menu ........................................................................................................................................ 46
Scanner X Setup ..........................................................................................................................................46
Enter Password .......................................................................................................................................................47
Password Levels .................................................................................................................................... 48
Level 2 Password Options...................................................................................................................... 48
Protected Level Mode ..................................................................................................................................48
Change the Level 2 Default Password ........................................................................................................50
Configure the Valve/Channel Settings....................................................................................................................52
Compensation Time ............................................................................................................................... 52
Speed Settings ....................................................................................................................................... 53
Valve Type.............................................................................................................................................. 53

MC122 - MCP-4J Control Unit Table of Contents
3
Scanner Settings.....................................................................................................................................53
Encoder Settings.....................................................................................................................................54
Valve - Voltage Settings..........................................................................................................................54
Valve - Timing Settings ...........................................................................................................................54
Check Other Valves/Channels................................................................................................................................55
Memory ....................................................................................................................................................................55
Backup ....................................................................................................................................................56
USB...............................................................................................................................................................56
SD .................................................................................................................................................................56
Restore....................................................................................................................................................57
USB...............................................................................................................................................................57
SD .................................................................................................................................................................58
Initialize Settings .....................................................................................................................................58
Jam Detection ..........................................................................................................................................................59
Jam Alarm Message ...............................................................................................................................59
Jam Setup Menus ...................................................................................................................................60
Encoder Menu Screen.............................................................................................................................................62
Ratio Compensation................................................................................................................................62
Speed Calculation ...................................................................................................................................63
Direction Detection..................................................................................................................................63
Prescale Factor .......................................................................................................................................63
Status Bar ...............................................................................................................................................64
Section 5 - Operation...........................................................................................65
Set the Pattern Menu Information ...........................................................................................................................65
Scrolling Through Valve Numbers with the Pattern Button.....................................................................65
Gluing Mode............................................................................................................................................66
Scanner Lockout .....................................................................................................................................67
Valve to Scanner Distance......................................................................................................................67
Scanner Number/Z Pulse.............................................................................................................................68
Jog Mode Parameter...............................................................................................................................68
Batch Counter .........................................................................................................................................69
Input Values/Gluing Mode.......................................................................................................................69
Glue Mode Screen Information....................................................................................................................70
Pattern Mode ................................................................................................................................................70
Stitch Mode ...................................................................................................................................................73
Stitch Mode Menus.......................................................................................................................................74
Auto Glue Mode............................................................................................................................................74
Auto Glue Mode Menus ...............................................................................................................................74
Continuous Glue Mode.................................................................................................................................75
Continuous Glue Mode Menus ....................................................................................................................75
Glue Pattern Length Range .........................................................................................................................75
Jam Detection ..........................................................................................................................................................76
Jam Alarm Message ...............................................................................................................................76
Jam Channel Configuration Menus.........................................................................................................76
Set the Pressures ....................................................................................................................................................77
Pressure Offset Value.............................................................................................................................77
Minimum Speed/Pressure.......................................................................................................................77
Pressure Point 1 (PT1).................................................................................................................................78
Pressure Point 2 (PT2).................................................................................................................................78
Speed/Pressure Graphs - Examples ...........................................................................................................78
Purge Pressure .......................................................................................................................................79

Table of Contents MC122 - MCP-4J Control Unit
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Set Purge Pressure......................................................................................................................................79
Purge Pressure % ........................................................................................................................................79
Helpful Hints about Pressures................................................................................................................80
Diagnostic Button.....................................................................................................................................................80
Total Products/Products per Hour..........................................................................................................80
Valve Status............................................................................................................................................81
Scanner and Trigger Status....................................................................................................................81
Version Information ................................................................................................................................81
Control Information.................................................................................................................................81
Event History ..........................................................................................................................................82
Job Button................................................................................................................................................................82
Load a Job..............................................................................................................................................82
Save a Job..............................................................................................................................................83
Section 6 - Maintenance ......................................................................................85
Purging the Adhesive ..............................................................................................................................................85
Performing Downtime Maintenance........................................................................................................................85
Flushing the Glue System.......................................................................................................................................86
Lubricating the System............................................................................................................................................86
Reprogramming with a USB Flash Drive................................................................................................................87
Replacing Micro-SD Card........................................................................................................................................88
Section 7 - Specifications ....................................................................................91
Max Valve Chart......................................................................................................................................................91
Section 8 - Part Number List................................................................................93
How to Order Parts..................................................................................................................................................93
MCP-4J, Vertical with EPC (074xx084)..................................................................................................................94
MCP-4J, Vertical w/o EPC (074xx085)...................................................................................................................97
MCP-4J, Vertical 3NC Tipsealer (074xx086)..........................................................................................................100
MCP-4J, Horizontal, with EPC (074xx087).............................................................................................................103
MCP-4J, Horizontal, w/o EPC (074xx088) .............................................................................................................106
MCP-4J, Horizontal, Folding Carton Tipsealer (074xx089) ...................................................................................109
MCP-4J, Horizontal, Dual External EPC (074xx090).............................................................................................112
Glue System Layouts with the MCP-4J..................................................................................................................115
Layout using FC Tipsealer Unit 074xx089 .............................................................................................115
Layout using 3NC Tipsealer Unit 074xx086...........................................................................................116
General Layout with one Valve and Scanner, using the Vertical w/EPC Unit 074xx084,
or Horizontal w/EPC Unit 074xx087.......................................................................................................117
Layout for a Contact Boardrunner Setup using the Vertical w/EPC Unit 074xx084...............................118
Layout where an External EPC is used on the External EPC Unit 074xx090........................................119
Section 9 - Warranty............................................................................................ 121
Warranty Information...............................................................................................................................................121
Cold Glue Equipment and Electronic Controls.......................................................................................121
Hot Melt Units, Hoses, Valves, Guns, and Related Equipment .............................................................121

MC122 - MCP-4J Control Unit Table of Contents
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Section 10 - Service.............................................................................................123
Appendix A - Job Charts ......................................................................................125
Appendix B - System Connectivity (Clearvision) ...................................................127
MCP-8 ......................................................................................................................................................................127
MCP-4 ......................................................................................................................................................................128
Plugging the Control Gluer System in the BC7 Cabinet .........................................................................129
Gluer Connection Setup with 1 Network Card ........................................................................................129
Gluer Connection Setup with 2 Network Cards......................................................................................................131
Hardware Installation ..............................................................................................................................131
Windows Configuration ...........................................................................................................................132
Adding the Gluer Tab in BC7 system......................................................................................................134
Appendix C - Instruction Sheets for the MCP-4J ...................................................135

Table of Contents MC122 - MCP-4J Control Unit
6

MC122 - MCP-4J Control Unit Section 1 - Introduction
1
Section 1 - Introduction
System Description
This manual has been prepared by Valco Cincinnati, Inc. to provide assistance in the installation, operation, and
servicing of your MCP-4J Control Unit.
The MCP-4J Control Unit from Valco provides operators with a full-featured affordable solution to adhesive system
pattern control. The control features 4-channel operation, multiple glue patterns, and an optional flow control
capability. The unit allows program changes and adjustments, so you can get desired results immediately. The control
has a compact design and features “plug-and-run” connectors for easy installation and quick start up.
Features/Capabilities
The MCP-4J Control Unit works with a variety of Valco’s cold-glue or hot melt adhesive dispensing valves.
Features/Capabilities of the MCP-4J Unit include:
•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
•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
•Jam Detection
•USB Software Updates
•USB and Micro-SD Backup & Restore
•Automatic Input Voltage Selection
All hardware must be up-to-date for all new functions to
work. Please see the Parts List for a compatibility chart.

Section 1 Introduction MC122 - MCP-4J Control Unit
2

MC122 - MCP-4J Control Unit Section 2 - Safety and Use
3
Section 2 - Safety and Use
Read Thoroughly Before Handling Equipment
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.
Symbols
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.
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.

Section 2 - Safety and Use MC122 - MCP-4J Control Unit
4
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.
Limitations of Use
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.

MC122 - MCP-4J Control Unit Section 2 - Safety and Use
5
Installation/Startup/Use 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! 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! 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.
WARNING! 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.
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! 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.
WARNING! 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.

Section 2 - Safety and Use MC122 - MCP-4J Control Unit
6
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! 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.
WARNING! 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.
WARNING! 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.
WARNING! 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.
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 solvent-based materials. OTHERWISE, HAZARDOUS FUMES, EXPLOSION,
DEATH, OR PERSONAL INJURY COULD OCCUR.
WARNING! Keep pump cover and electrical enclosures closed except during setup, service, and
checkout procedures. OTHERWISE, DEATH OR PERSONAL INJURY COULD OCCUR.

MC122 - MCP-4J Control Unit Section 2 - Safety and Use
7
WARNING! 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.
WARNING! Keep hot melt hoses away from walkways and the moving parts of hot melt systems.
OTHERWISE, PERSONAL INJURY OR EQUIPMENT DAMAGE COULD OCCUR.
WARNING! 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.
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.

Section 2 - Safety and Use MC122 - MCP-4J Control Unit
8
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! 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.
WARNING! 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 CO2fire extinguisher at the base of the flames.
•Aim a dry-powder fire extinguisher at the base of the flames.

MC122 - MCP-4J Control Unit Section 2 - Safety and Use
9
Hose Safety Information
DO NOT DO
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.
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.

Section 2 - Safety and Use MC122 - MCP-4J Control Unit
10