warning - Astro Packaging, Inc.
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1. Inoperative PCB 3 Replace PCB Tank does not heat but LED is Fuse 15 16 has tripped on 1 Replace fuses and observe ON PCB ASU If it blows again check for a short circuit in heater 2 Tank heater element is 2 Replace tank if element s inoperative resistance does not comply with resistance table Note remove lead wires from heater element when measure resistance 3 Disconnection in tank heater 3 Check and repair see wiring circuit diagram 4 Inoperative PCB 4 Replace PCB Tank does not heat and LED is Inoperative PCB 1 Replace PCB OFF A Hose or Head temperature 1 Loose plug connection on 1 Check connectors X12 X13 zone is not heating Hose or PCB X14 X15 and X17 and head LED on the PCB is ON restore connection 2 Heating element inoperative 2 Check resistance and compare to resistance table on page 7 4 a For head if heater cartridge is inoperative replace heater b For hose if heating element is inoperative replace hose Astro Packaging AP50 Manual 19600 09 AP50 76 A Hose amp Head temperature zone is not heating A Hose or Head temperature zone is not heating Hose or head LED on the PCB is OFF A hose or head temperature zone s actual temperature is much higher than set point Display for Hose or Head E01 Astro Packaging 1 Disconnection between ASU and Hose or between Hose and Head Hose or Head fuse on the PCB is inoperative S2. The standard AP50 AP100 ASU uses a brushless AC motor to drive a positive displacement gear pump This gear pump has an easily adjustable flow control The pressure can be adjusted from 75 PSI to a maximum of 900 PSI The ASU s Teflon coated tank accepts adhesive in all popular forms including pellets slugs and blocks The ASU can accommodate air actuated automatic applicators heads electric applicators hand held applicators and or special applicators Options available include pressure gauge a 40 mesh outlet filter 7 day scheduler and RS 232 interface Astro Packaging AP50 Manual 19600 09 AP50 2 1 Specifications Environmental Storage shipping teMPEsAatUre seccssecssccseeceesecsecessecseccseecseesneecseerseeseees 40 C to 70 C 40 F to 158 F 0 0 7 C to 50 C 20 F to 122 F Noise ErISSIOP Ice toit oie titan PAA AR KAG sasaqa 60 dbA at 1 meter Physical DIMENSIONS usus Q u h n d ampi d a pin pede dimensional layouts on following pages Number of heads hoses a up to 6 heads hoses Number 1 Number of 1 Gear pump 75 PSI to 900 PSI Enclosure styled durable metal and high temp plastic dust and splatter resistant Hose dera dope p dx ge i dias Electrical 12 pin Mechanical wrench secured fluid fittings 06 37 SAE
3. 2 Depressurize the system by activating the head until glue stops flowing 3 Using 9 16 hex wrench remove plus 1 from the end of the pump block 5 at the back of the unit Caution Hot Glue will leak out as the fitting is removed Using needle nose pliers remove plus the spring 2 thimble 3 and filter element 4 Temporarily replace plug to prevent hot melt drainage Clean filter element or replace as required Re install spring thimble and filter element as removed Re install plug Soe Pump Change Tool Astro Packaging AP50 Manual 19600 09 AP50 62 Hose Fittings All hose fittings should be checked for tightness after every three months of operation Fasteners After the first ten hours of operation check all set screws socket head and cap screws for tightness Thereafter re check all fasteners after every three months of operation Tank Screen Cleaning 1 Open tank lid and lift out tank screen with wire hook 2 Remove any debris and replace NOTE In high viscosity applications the tank filter assembly should be removed This filter is used to prevent damage to the pump in standard applications Astro Packaging AP50 Manual 19600 09 AP50 63 Summary of Preventive Maintenance Schedule Monthly Inspect output filter basket Replace as required Check for leaking adhesive under the base plate caused by a worn pump seal Replace as required Every Three Months Check all hose fittings fo
4. MOTOR ASSEMBLY Met BREAKER bay 5 e B N CAPACITOR 9p 0 S p MOTOR MOUNT n sil COUPLING PUMP SHAFT jn t SPIDER ASSEMBLY S COUPLING Astro Packaging AP50 Manual 19600 09 AP50 94 Chapter 10 SYSTEM SCHEMATICS amp ENGINEERING DRAWINGS System Schematics amp Engineering Drawings FUNCTION APPL HEATER APPL HEATER APPL SENSOR HOSE HEATER HOSE APPL SENSOR GROUND HOSE HEATER HOSE SENSOR SENSOR JUMPER SENSOR JUMPER SENSOR JUMPER Astro Packaging APPLICATOR END ASU END PLUG RECEPTACLE RTD SENSOR SCHEMATIC CHALLENGER HOSE WITH 120 OHM Ni SENSOR AP50 Manual 19600 09 AP50 10 1 System Schematics amp Engineering Drawings APPLICATOR PLUG GA RTD SENSOR SCHEMATIC CHALLENGER APPLICATOR WITH 120 OHM Ni SENSOR Astro Packaging AP50 Manual 19600 09 AP50 102 ONIHIM ON 1d H3MOd LONI ININ JAM OVAOOP OEZ HdE Ead cR d 540 07 1 913 LO e WIW d Dd P Pi X 3 9 0030 3508 14 v4 s OV3H 3SOH v1330g OVA0ES Hdt v133g 2vA0 HdE 1 IN jay N si dunr RRRRRR td 4d 93 Si NI ti HM MOTT3A 3AM 2VAOOV OtZ HdE EYSZLL Ng MOTA VITIO 2YAOC Hdi CPSZIL Nd I 3am 13100 OYAOCZ VITIO Hdt PST Nd 135 90d NOLLWYNSLINOD wamod 095211 Nd NOLLJO WIINO3HIS AVAL vv 5 32 Live xt 03 1 AP50 Manual 19600 09 AP50 Astro Packaging
5. To turn ON the temperature zone increase the set point When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature AP50 Manual 19600 09 AP50 52 Keypad Locking It is possible to lock or unlock the controller in order to restrict programming changes To change the code which is necessary to over ride or unlock the keypad lock see Service Functions Note the ASU is shipped with de activated keypad lock If the keypad lock must be used an access code must be programmed prior to locking the keypad Locking or Unlocking the Keypad Important Note the controller must be in the Temperature Display mode in order to allow locking or unlocking of the keypad Locking the Keypad Press the Down Scroll key then hold and press the 4 8 y p Service icon key You will see Loc to indicate that the Keypad Lock is active EN Unlocking the Keypad Press the Down Scroll key then hold and press the Ivi amp y p Service icon key You will see Cod to indicate that the access code is required Enter your access code by scrolling up or down L1 ab Confirm your code input by pressing Tank key Notes 1 Once the keypad lock is active unauthorized programming is not possible even after turning the ASU OFF then back ON again 2 Once the keypad lock is unlocked programming is possible until the ASU is turned OFF then back ON or
6. Adhesive VISCOSITY aao osten te dme UR NEGO Rio Reb eT Ue due 500 to 50 000 centipoise Warm Bp time f ll Cables omen S ons E dnte dinh KAG approximately 0 5 hour Adhesive delivery rate open line u a 2 91 Ibs min Adhesive melt rate depends on adhesives used 50 Ibs hr Adhesive press re maa ANAKAN up to 68 bar 1000 PSI maximum Maximum 170 rpm Temperature Controller Controller Boardi mmmmmmmmmmmmmmmmmmmmmmmmmmmmmmair 1 board modular construction Display type MR GANANG life long bright LED Temiperature control Zones nA toni ipic umb ag in a ua d cU rtu f aote xd NAGA 13 all fuses are size 5 mm 20 mm hose applicator head 6 3 amp fast open transformer 1 amp fast tank 10 amp fast Other Operator interface digital display with simplified all icon keypad SEVEN AC AY SCION EN iso oa oedo sci I a seca cde eet ect eed qi Died option END gt option Temperature standby uu u GA AGANG KNA GAAN a yes High amp low temperature tolerance yes Ready interlock contact NNI RS yes SES Ol OPS kalakal ANAN absences NAAN yes Astro Packaging AP50 Manual 19600 09 AP50 2 3 39 24 62 ES sss oro o eo eo 0 ol 14 l sa 44 12 L Cas 11 76 Astro Packaging AP50 Manual 19600 09 AP50 24 Chapter 3 INSTAL
7. then the high alarm equals 210 degrees and the low alarm ready temp equals 190 degrees temperature zones An display of t 1 indicates the Tolerance xd Press the Service icon twice to select the Tolerances of your function has been selected Press the Tank button to display the Tolerance Use the scroll buttons to change the Tolerance range for all zones AJ Note your Tolerance range must be a value between 50 degrees r for Fahrenheit 27 degrees for Celsius iv When Tolerance programming is complete wait a few seconds and the controller will return to the ASU s actual temperature Turning Sequential Startup ON OFF The Sequential Startup feature programs the order in which the temperature zones will come on at startup A Sequential Startup of 5S1 On means the tank will begin heating first then when the hopper is ready the other zones will begin heating A Sequential Startup of SSO means Sequential Startup is Off and all zones will begin heating immediately x3 Press the Service icon three times to set Sequential Startup The display will flash either 551 sequential startup is ON or SSO sequential startup is OFF Scroll to choose between ON and OFF When programming is A complete wait a few seconds and the controller will return to or v the ASU s actual temperature Note Any time the ASU is switched ON you will briefly see SS1 or SSO displayed OAstro Packaging AP
8. Adding Adhesive WARNING HOT ADHESIVE Do not overfill the melt tank since adhesive generally expands as it melts and a full tank may overflow CAUTION Using adhesive with viscosity over 50 000 centipoise may cause the pump to stall The adhesive level should be maintained at 13 mm to 100 mm 1 2 to 4 from the top of the tank Where applications demand a high output volume of adhesive add small amounts of adhesive frequently ADDING LARGE AMOUNTS OF ADHESIVE TO AN ALMOST EMPTY TANK WILL LOWER THE TEMPERATURE OF THE ADHESIVE IN THE TANK AND MAY CAUSE THE ASU TO FALL BELOW ITS READY SET POINT Changing the Adhesive Formula If a different adhesive formulation from the one being currently used is needed the system will have to be flushed if the two formulations are incompatible See Chapter 6 of this manual for the proper flushing procedure When in doubt about adhesive compatibility flush your system Astro Packaging AP50 Manual 19600 09 AP50 3 3 Wattage Availability Chart ASU Voltage Max System Wattage Hopper Wattage Wattage Available for All Hoses and Heads 240 400 VAC Y 9600 240VAC 3000 240VAC 6600 240VAC or 240 VAC Delta Notes 1 Assume 33 Watts per foot of hose 6 hose at 240VAC 2 Assume 100 Watts per inch of head width at 240VAC 3 The power available for any one hose head combination is 1200 Watts at 240VAC 4 ATREDUCED VOLTAGE LESS WATTAGE IS AVAILABLE FOR EXAMPLE 240V EQUIPMENT OPERATED
9. Mesh 79064 Note Teflon O Rings are recommended for Polyamide Contact your Local distributor for Assistance il MOUNTING 1 o HARDWARE V2 PUMP BLOCK V2 PUMP V2 PUMP O RINGS V2 FILTER i 3 V2 FLOW CONTROL VALVE ASSEMBLY Astro Packaging AP50 Manual 19600 09 AP50 92 Standard Fan Cooled Motors 1 a meme m2 nm imma SS II IN SS sss SS mm me m pa mas gt ooo Kit Motor amp Capacitor 1 3 hp 170 RPM 200 230 VAC 60Hz 79414 01 Motor Group 1 3 hp 170RPM 200 230 VAC 60Hz 73278 98 Motor Assembly 1 3 hp 140 RPM 200 230 VAC 50Hz 73012 81 Motor Group 1 3 hp 140RPM 200 230 VAC 50Hz 73278 97 Note Motor Group includes motor assembly capacitor pump On Off breaker and motor mount Motor assembly is the basic motor intended for replacement of existing motor only k BREAKER NN Ng N B CAPACITOR p D N MOTOR MOUNT cj COUPLING PUMPSHAFT p SPIDER ASSEMBLY io gt COUPLING Astro Packaging AP50 Manual 19600 09 AP50 93 Standard Fan Cooled Motors Coupling 9 16 bore 1 8 keyway 2 jaw Coupling 5 8 bore 3 16 keyway 2 jaw Coupling 3 4 bore 3 16 keyway 2 jaw Coupling 5 8 bore 3 16 keyway 3 jaw Coupling 9 16 bore 1 8 keyway 3 jaw Coupling 3 4 bore 1 16 keyway 3 jaw Coupling 19mm bore 6mm keyway 3 jaw Common motor breakers Contact factory for system compatibility
10. ON 200 VOLTS WILL DEVELOP WATTAGE 31 LOWER THAN THE WATTAGE AVAILABLE AT 240 VOLTS Typical Start Up and Shut Down of the AP50 AP100 Application System Start Up Procedures 1 Fill the ASU s tank with clean hot melt adhesive as described on page 3 3 Close the tank lid immediately to prevent contaminants from falling in Cover your bulk supply of adhesive to prevent contaminants also 2 At the control panel turn ON the Main Power Switch The controller will perform its initial calibration cycle The display will read CAL Each of the 13 temperature zone s LEDs will flash as a lamp test 3 Program your adhesive set points see instructions on page 5 2 or use the factory settings listed below Allow adequate time approximately 20 30 min for the adhesive to melt and the temperatures of the temperature zones to stabilize Note When the ASU leaves Astro Packaging it is programmed with the following factory settings unless special factory settings were requested Tank 177 C 350 F Hose 177 C 350 F Applicator 177 C 350 F Sequential Startup OFF 4 Once the ASU has reached temperature the ASU will begin to pump adhesive NOTE A DELAY MAY BE PROGRAMMED AT CONTROLLER 5 Adjust the flow control with the provided 1 4 Allen wrench to desired pressure Shut Down Procedures 1 Turn OFF the Main Power Switch Astro Packaging AP50 Manual 19600 09 AP50 34 Storage and Disposal of the AP50 AP100 Application Syste
11. activated Standby is always OFF when the ASU is turned ON In standby mode the ready signal is OFF and the pump will stop Error Indication Messages A controller display of EO1 indicates that the selected zone ie a hose applicator or the tank has an open sensor A display of EO2 indicates a shorted sensor If either alarm occurs first verify that the following three connections are made correctly 1 The ASU to hose connection s located at the back of the ASU 2 The hose to applicator connection s 3 The RTD Input connections X4 X5 amp X6 located on the Control Printed Circuit Board If the problem is not with a connection check the sensor and replace if necessary Astro Packaging AP50 Manual 19600 09 AP50 42 Firmware Chip and Checksum The firmware chip is on the Control Printed Circuit Board see Ch 7 Inscribed on the controller s chip is information that is required if your controller needs service including the controller s checksum and software revision Chip example VX XX System Values That Are Permanently Programmed Minimum set point value 40 C 100 F Maximum set point value 218 C 425 F System Values as Programmed by the Factory Astro Packaging can set the controller s system values to customer s specs if provided If customer s specs are not provided the following values will be entered into the temperature controller at the factory They may be changed by reprogrammi
12. proper temperature and that selected adhesive is correct for your application Inspect hose for kinks internal plugs of debris or char degraded adhesive Clean or replace hoses as required Inspect heads for plugged nozzles proper air valve operation or plugged filters Clean or repair heads as needed Adjust flow control valve in for more pressure 79 Adhesive Leak at pump or 1 Bad O rings 1 Check O rings between tank manifold and pump manifold Check O rings between pump and pump manifold 2 Bad Pump Shaft Seals 2 Replace seals Replace pump Astro Packaging AP50 Manual 19600 09 AP50 7 10 Chapter 8 DISASSEMBLY amp RE ASSEMBLY PROCEDURES Disassembly Procedures Note Re read Chapter 1 Safety Precautions before performing any disassembly procedures All disassembly procedures must be performed by qualified trained technicians To Access the RTD SensorsTo Access the RTD Sensors Remove the pump and electronics cover Front Panel a RTD for ASU Each ASU has one RTD located between the 4 cartridge heaters This RTD slips into the tank and is easily plugged in electrically To Access the Electrical Components See illustrations on pages 10 3 amp 8 1 Remove the pump and electronics cover a Main On Off Switch Replacement Switch is located on the display panel 1 Free the old switch via two screws from the front 2 Remove the switch through the back 3 Disconnect two incom
13. the keypad is locked again 3 If the keypad must be unlocked permanently the access code must must be de activated in the Service Functions Astro Packaging AP50 Manual 19600 09 AP50 53 Service Functions After the basic programming of Temperature Set points is complete the programmer proceeds to programming of the Service Functions if desired The Service Functions are a continuous loop of programming steps functions which the programmer moves through by pressing the Service key These steps are described in this section of the chapter The Service Functions loop and basic programming is diagrammed below There are three ways to exit the Service Functions loop 1 Just wait approx 10 seconds and the controller will automatically return to the actual temperatures display 2 Press the Service key until you are back to the actual temperatures display or 3 Press any Hose or Head key and you will return to the actual temperatures screen Diagram of the Service Functions Loop to Actual Temperature Display Activate De activate Temperature Setback Change Setback Temperature Value wA Change Hi Lo Tolerance Value Activate De activate Sequential Startup Select Temperature Scale Change Ready Delay 4 Change Access Code Actual Temperature Display OAstro Packaging AP50 Manual 19600 09 AP50 54 Service Functions cont Standby Programming Standby is a temperatu
14. wc 09 Head Schematic all models Wiring Diagram Astro Packaging AP50 Manual 19600 09 AP50 Chapter 1 SAFETY PRECAUTIONS All operators and service personnel must read and understand this manual before servicing equipment All maintenance and service on this equipment must be performed by trained technicians Electrical Dangerous voltages exist at several points in this equipment To avoid personal injury do not 4 DANGER touch exposed connections and components HIGH VOLTAGE while input power is on Disconnect lockout and tag external electrical power before removing protective panels A secure connection to a reliable earth ground is essential for safe operation A disconnection switch with lockout capability must be provided in the line ahead of the unit Wiring used to supply electrical power should be installed by a qualified electrician High Temperatures Severe burns can occur if unprotected skin WARNING comes in contact with molten adhesive or hot HOT application system parts SURFACE Safety glasses gloves and long sleeved clothing must be worn whenever working with or around adhesive application systems High Pressure To avoid personal injury do not operate the WARNING equipment without all covers panels and safety Ven HIGH PRESSURE guards properly installed PRESSURE To prevent ser
15. 50 Manual 19600 09 AP50 56 Service Functions cont To Set Temperature Scale The Temperature Scale may be set to display temperature either in degrees Celsius or Fahrenheit Ng 4 A iv To Set Ready Delay Press the Service icon four times to set the Temperature XX Scale EO IL Scroll to choose between Celsius C or Fahrenheit F as indicated by the Temperature Scale LED When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature When the system is ready all temperature zones are within tolerance a ready delay may be programmed to delay the system s ready output signal Nps 45 Astro Packaging Press the Service icon five times to set a Ready Delay You will see d 1 to indicate you are in Ready Delay programming mode Press the Tank icon to display the Ready Delay To change a Ready Delay scroll up or down to the desired length in minutes of delay 0 Default no delay 99 minutes maximum length of delay When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature AP50 Manual 19600 09 AP50 57 Service Functions cont To Change Access Code De activate Keypad Locking To change the Access Code press the Service icon six times 2 You will see C 1 to indicate you are in Access Code programming mode Press the Tank icon to see the programmed A
16. Calllus at 800 642 7876 AP50 Manual 19600 09 AP50 EF a a ar ar E eN AnaheimyeAN92806 8005642 MSMO Alla 572 094 N SAFETY PRECAUTIONS GENERAL CONSIDERATIONS 1 Read and follow these instructions Failure to do this could result in severe personal injury or death 2 Additional safety instructions and or symbols are located throughout this manual They serve to warn maintenance personnel and operators about potentially hazardous situations 3 Inspect the machine for unsafe conditions daily and replace all worn or defective parts 4 Keep work area uncluttered and well lit 5 All covers and guards must be in place before operating this equipment For precautions and definitions of safety symbols refer to Safety Chapter of the service manual SERVICING EQUIPMENT 1 Only trained personnel are to operate and service equipment 2 Never service equipment while it is in motion 3 Shut off the equipment and lock out all input power and air supply at their sources before attempting any maintenance 4 Follow the maintenance and service instructions in the manual SIGNS 1 Read and obey all of the warning labels signs and caution statements on the equipment 2 Do not remove or deface any of the warning labels signs and caution statements on the equipment 3 Replace any warning labels signs and caution statements which have been removed or defa
17. LATION amp START UP Mounting the AP50 AP100 ASU The AP500 100 ASU can be mounted on most flat surfaces on either an open or a solid frame as shown below The main electrical power and the serial communication connections come in from below the unit and connect under the keypad Access to the underside of the ASU may be necessary and an open frame mount is generally best For installation dimensions see illustration on page 2 4 Lifting the ASU WARNING The unit must be lifted by two persons using proper lifting technique one person at either end Securely hold it under its base plate No belts or hooks should be used Never allow anyone to stand on the ASU Tank Lid Housing Controller Keypad Chassis Main On Off Switch Optional Stand PN 73121 9 Astro Packaging AP50 Manual 19600 09 AP50 3 1 Installation NOTE Re read Chapter 1 Safety Precautions before performing any installation procedures All installation procedures must be performed by qualified trained technicians After the AP50 AP100 ASU has been properly mounted the following general sequence should be followed for installation 1 Make sure that incoming line power to the ASU and the unit s main power switch are turned OFF DANGER HIGH VOLTAGE A lockable power disconnect switch with overload protection must be provided by the customer as part of the ASU installation The disconnect must isolate the ASU from its power so
18. OFF Press the Prog key once to end Repeat for Further Switching Commands Repeat the last three steps for programming of additional switching commands End Programming of Switching Commands Press the Time key once The display will show the current time Select Manual ON OFF Press the Manual Operation Selection key to select manual mode ON or OFF Manual mode ON manual mode OFF OAstro Packaging AP50 Manual 19600 09 AP50 541 Chapter 6 PREVENTATIVE MAINTENANCE Note Re read Chapter 1 Safety Precautions before performing any maintenance procedures All maintenance procedures must be performed by qualified trained technicians General Cleaning The AP50 AP100 ASU enclosure is finished with an extremely durable powder coating The enclosure may be cleaned with a variety of industrial cleaners following manufacturers directions To prevent discoloration or deterioration of the ASU s finish avoid prolonged contact with strong solvents Preventive Maintenance Schedule The AP50 AP100 ASU requires little maintenance The tank is fitted with a coarse screen to prevent large debris from entering the system Normally this screen does not require cleaning The ASU parts that require regular periodic maintenance are as follows Purging the Filter Manifold of Adhesive and Pressure As a safety precaution the ASU s system should be purged of pressure and adhesive before attempting to change the output filter or befo
19. aC apa acoso auque Md uM LA EE LE M MEDIE 22 5 kg 50 Ibs welded aluminum TFE Teflon coated pre and post pump filters 1 50 kg 100 Ibs Adhesive form 97 accepts most forms no water based adhesives Electrical Supply voltage u d atenta 240 400 VAC 3PH N 60 Hz Y WYE 240 VAC 3PH 60 Hz A DELTA 0 eesti Hand 240 VAC 1PH 60 Hz A DELTA Power Consumption system MAXIMUM 9600 watts Power Consumption tank 3000 Watts 4000 Optional Tank Heater Type qu ooi Nun abd a Du d buen nba tia a uuu replaceable cartridge style TeifipeFature Du i pn AGA micro controller Temperature SENSO sad ent op e S S RE BANA Ni120 standard Electrical connectors J durable latching connectors Nordson style Maximum current available for each hose head combination 5 amps OAstro Packaging AP50 Manual 19600 09 AP50 2 2 Performance Adhesive temperature control range 40 C to 218 C 100 F to 425 F Adhesive temperature control 1 C 1 F Over temperature cutoff for all zones 232 C 450 F Over temperature cutoff for tank thermostat 7 0 088080 224 C 435 F
20. absorbing surfaces such as cold floors or metal troughs These heat absorbing surfaces can alter adhesive flow and cause incorrect calibration Hoses should never be covered with materials that precent heat dissipation such as insulation or sheathing Read this manual before applying electrical power to the equipment Equipment may be damaged by incorrect electrical connections Do not use adhesive that is dirty or that may be chemically contaminated Doing so can cause system clogging and pump damage When adhesive hand help applicators or other movable applicators are used never point them a yourself or at any other person Never leave a hand held applicator s in use Do not operate the tank or other system components without adhesive for more than 15 minutes if the temperature is 150 degrees C 300 degrees F or more To do so will cause charring of the residual adhesive Never activate the heads hand held applicators and or other application devices until adhesive s temperature is within the operating range Severe damage could result to internal parts and seals Treatment for Burns From Hot Melt Adhesives Burns caused by hot melt adhesives must be treated at a burn center OAstro Packaging AP50 Manual 19600 09 AP50 12 Care should be used when working with hot melt adhesives in the molten state Because they rapidly solidify they present a unique hazards Even when first solidified they are still hot and can cause severe burns Whe
21. alarm signal if any zone has a critical situation This signal is available on a dry contact located at connector X10 on the Control printed circuit board CPU Module The central processing unit CPU of the microprocessor temperature control Temperature Controller The built in control system that controls monitors and displays all system temperature values of the adhesive application system Control PCB The printed circuit board PCB of the ASU It provides control signals to and monitoring signals from the tank hoses and applicators It features lighted LEDs to indicate that heater power is ON The ASU s fuses and power configuration plug are located on this board Keypad Locking The controller s keypad may be locked or unlocked to restrict or allow further programming Mechanical High Temperature Protection A mechanical redundant thermostat located on the hopper that will turn off the system above safe temperatures RTD Sensors The system uses 120 ohm Nickel resistance temperature detector RTD sensors for all temperature controls Ready Signal The controller provides a ready signal if all temperature zones are within a programmable tolerance and the system is ready for production This signal is available on a dry contact at connector X11 on the Control printed circuit board The ready signal also controls pump operation Astro Packaging AP50 Manual 19600 09 AP50 41 RS232 Remote I O Interface Bi directional data
22. ccess Code For example 999 To change the Access Code scroll up or down to the desired numeric value no Access Code Access code is de activated 1 999 possible Access Code values When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature Astro Packaging AP50 Manual 19600 09 AP50 58 Controller Features mI 2 System Ready Indicator Light When not in programming mode a flashing temperature scale light LED indicates that the ASU is not Ready for production This LED will cease to flash when all temperature zones are within the programmed temperature tolerance window qmm Error Indication Messages EO1 the temperature sensor is open no sensor attached or has high resistance mmi imi NR mm Rm is MN EN EO2 the temperature sensor is shorted or has low resistance EO3 or EO4 an internal error has occurred The printed circuit board or the ASU must be returned to Astro Packaging for re calibration CJ ER n mm o t over temperature on any zone Power to all heaters is switched OFF Recycle power re boot and check which zone has caused the fault alarm N To Copy and Paste Set points The Copy Paste feature of the controller copies the tank set point and pastes it as the set point of other temperature zones The paste will apply to only temperature zones t
23. ced Replacements are available ADDITIONAL CONSIDERATIONS 1 To ensure proper operation of the equipment use specified electrical and or air supply sources 2 Do not attempt to alter the design of the equipment unless written approval is received from our factory 3 Keep all manuals readily accessible at all times and refer to it often for the best performance from your equipment TABLE OF CONTENTS Chapter 1 Safety Precautions Chapter Page Chapter 2 Description amp Specifications 56 0 05 ay 2 1 Specifications s u s su u 2 2 DimensIonSu g u u D 2 3 Chapter 3 Installation amp Start Up 3 1 AKA i Fd E 3 2 Adding Adhesive nn 3 3 3 3 Changing Adhesive 3 4 Wattage Typical Start Up 8 Shut Down Procedures J 3 4 Storage amp Disposal of the Application System eren tentes 3 5 Chapter 4 Temperature Controller Set Up Temperature Control Functions in General 0 7 4 1 Defining Temperature Control Terms 4 1 Error Indication Message sah 4 2 Firmware Chip amp ChecksUm l a aa sa Sq a an aaa asas 4 3 System Values sace eq a RUNE pU AA qaa a a ua aa 4 3 Helpful ANTS TEE 4 4 Chapter 5 Programming of the Controller Controller 10 1 MM ccr 5 1 Programming e 5 2 SEIVICEFUNCLIONS ERR 5 4 Controller Feat les a Aka asa KA
24. e install electrical connectors onto the board refer to drawing on pg 7 2 if necessary Re install the ASU configuration plug onto the new PCB Remove mounting bracket screws 4 I Connector label For 230 VAC 3PH Delta use P N 112542 white plug with violet wire For 230 400 VAC 3PH WYE use P N 112543 white plug with yellow wire For 230 VAC 1 PH Delta use P N 112543 white plug with yellow wire On N LI ML LLL Configuration Plug 565 T Line Input Power Plug for 1 Jr each type of Power Supply 3PH 230VAC DELTA 1PH 230VAC DELTA 3PH 230 400VAC WYE LINE INPUT POWER PLUG WIRING OAstro Packaging AP50 Manual 19600 09 AP50 82 Re Assembly Procedures Unless noted the ASU s re assembly is simply the reverse sequence of the disassembly procedures However the following cautions should be followed whenever they apply for proper re assembly CAUTION In general all O RINGS AND SEALS should be replaced whenever hot melt equipment is re assembled All new o rings should be lubricated with o ring lube PN N07588 CAUTION TAPERED PIPE THREADS are found on air line fittings used with the pump air supply and on the outlet filter manifold Apply thread sealant PN N02892 whenever tapered pipe threaded parts are re assembled CAUTION SOME FITTINGS used for adhesive on the ASU have straight threads and o ring seals Use of thread sealant is n
25. e the automatic operation clock icon at upper right on display re appears For additional information on the scheduler see the Appendix in this manual Schedular Display Scheduler Display Automatic Operation Indication Switching State Indication Manual Operation Indication Days of the Week Clock Display Time Enter Day Hour Minute Manual Automatic Enter Switching Operation Selection Times Time and Day Programming Press the Time key and hold throughout the following procedure Set the day of the week with the Day key 1 Monday 2 Tuesday 7 Sunday Set the desired hour with the h key Set the desired minutes with the m key Release the Time Key The colon will now flash Astro Packaging AP50 Manual 19600 09 AP50 5 10 Setting the Switching Commands The programmer must set the desired days of the week switching times and switching state Select the Free Memory Spaces Press the Prog key as necessary until the digits 1 thru 7 are visible Release the Prog key Select the Desired Days of the Week Press the Day key to select any single day or any combination of days Monday 1 Tuesday 2 Sunday 3 Select the Desired Switching Times Press the h key to select the hours Press the m key to select the minutes Select the Desired Switching State Press the Manual Operation Selection key to toggle the switching state The symbol will indicate the state Symbol ON
26. equential heat up may be inactive Inoperative PCB Inoperative Hose or Head triac on PCB corresponding PCB LED is OFF Inoperative Hose or Head temperature sensor corresponding PCB IED is ON No Hose or Head is connected Disconnection between ASU and Hose or between Head and Hose 3 Disconnection at X4 X5 or X6 on PCB 4 Hose or Head sensor is inoperative AP50 Manual 19600 09 AP50 1 Check plug connections 2 Insert new fuse If fuse blows again check for a short circuit in heater Note there are two fuses for each hose head combination 1 Check controller display at start up Re program if necessary 2 Replace PCB 1 Replace PCB 2 Check resistance and compare to resistance table a For head if sensor is inoperative replace sensor b For hose if sensor is inoperative replace hose 1 Connect Hose or Head if needed If not needed ignore display 2 Check plug connection 3 Make proper connection 4 Check resistance and compare to resistance table a For head if sensor is inoperative replace sensor b For hose if sensor is inoperative replace hose 77 Display for Hose or Head 1 Hose or Head sensor short 1 Check resistance and E02 circuit compare to resistance table a For head if sensor is inoperative replace sensor b For hose if sensor is inoperative replace hose 2 Short circuit in plug 2 Make prope
27. g AP50 AP100 adhesive supply unit ASU is a computer controlled hot melt supply unit designed on metric standards Its easy to use all icon control panel is internationally operator friendly The AP50 AP100 is available for either 240V 400V service The AP50 100 uses a microprocessor temperature control to closely control the temperature of hot melt adhesive for up to six hoses and six heads Temperature set points are operator selected for up to thirteen zones and the system automatically provides warnings and alarms for operator errors and system malfunctions The system provides accurate proportionate temperature control for the tank hoses and applicators Sequential start up delays may be programmed for turn on of the hoses and heads A standby temperature may be programmed so that the temperature zones can be maintained at a lower temperature when the ASU is not in active use enabling rapid return to normal operation The temperature control can interlock the parent machine with preselected adhesive temperatures so that production automatically begins when adhesive temperatures are correct for the application All system temperature values can easily and quickly be programmed With these flexible temperature programming features the system increases adhesive life by eliminating prolonged high adhesive temperatures It reduces energy consumption and brings the system up to normal operating temperatures in the shortest possible time
28. hat are switched ON Set your Tank set point as described earlier in this chapter o o amp o Push and hold the Tank icon While holding press the 1 Hose icon Release then Push and hold the Tank icon again While holding press the 1 Head icon Release i s The manually programmed set point has now been pasted in to all turned on hose and head zones When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature Astro Packaging AP50 Manual 19600 09 AP50 Programming of Optional Features Seven Day Scheduler The Seven Day Scheduler allows the operator to program main power ON and OFF times which coincide with his daily production schedule throughout the work week Up to 20 switching times may be scheduled A switching time is a specific day time and state An ASU which has an active seven day scheduler should be turned ON at the main power switch It should never be turned off by the main power switch while the scheduler is active To turn the ASU OFF temporarily overriding the scheduler use the seven day scheduler s manual operation key If the scheduler switches the ASU OFF the controller s main display will say OFF To re activate the ASU over ride the scheduler press the scheduler s manual operation icon at the lower right on the scheduler display once or twice Later to return the scheduler to active press the manual operation icon again until th
29. ing and two outgoing power leads from the old switch and connect them to new switch b Fuse Replacement Note Use fuses as specified on page 7 2 i Fuses on PC Board see also detailed illustration on page 7 2 for sizes and locations of fuses Note on PCB fuses each Hose Head pair ie Hose 2 Head 2 is fused with two fuses either one of which can blow causing the zone to not heat ii Fuses on Hopper Hopper is fused with two resettable circuit breakers Push the knob to re set c Optional 7 Day Scheduler Battery Replacement Optional Scheduler s battery is located on the back of its Optional 7 Day Scheduler amp Battery display which is located on the display panel AA Battery Astro Packaging AP50 Manual 19600 09 AP50 8 1 d Printed Circuit Board Replacement CAUTION Reference the manual section entitled Handling Printed Circuit Boards on page 1 before proceeding For a detailed diagram of electrical components see Chapter 10 1 2 Disconnect all electrical connections to the board Remove the four mounting bracket screws 3 Lift the old PCB and mounting bracket heat sink assembly from the ASU ONAUSA Note Do not attempt to separate the PCB from its mounting bracket heat sink It is all one assembly Remove the ASU configuration plug from the old PCB Place the new PCB and mounting bracket heat sink assembly in the ASU Re install the four mounting bracket screws R
30. ious injury from molten adhesive under pressure when servicing the equipment disengage the pumps and relieve the adhesive under pressure e g trigger the heads hand held applicators and or other application devices into a waste container before opening any hydraulic fittings can connections Protective Covers Keep all guards in place WARNING To avoid personal injury do not operate the DO NOT OPERATE application system without all covers panels WITHOUT GUARDS and safety guards properly installed IN PLACE Astro Packaging AP50 Manual 19600 09 AP50 1 1 Eye Protection amp Protective Clothing WARNING It is very important that you PROTECT YOUR EYES when working around hot melt adhesive equipment EYE PROTECTION Wear glasses with side shields which conform REQUIRED to ANSI Z87 1 or EN166 Failure to wear safety glasses could result in severe eye injury y PROTECTIVE CLOTHING potential burns when working around hot It is important to protect yourself from melt adhesive equipment REQUIRED Always wear steel reinforced safety shoes Wear protective gloves and long sleeved protective clothing to prevent burns that could result from contact with hot material or hot components Safe Installation and Operation To avoid possible failure of hoses make sure all hoses are routed to avoid kinking tight radius turns 8 or less and abrasive contact Hot melt hoses should not have prolonged contact with heat
31. kn LANA 5 9 5 10 Astro Packaging AP50 Manual 19600 09 AP50 Chapter 6 Preventive Maintenance NAG e 6 1 Purging Manifold of Adhesive and Pressure tentent tents 6 1 qua aaa anqa ER AA qa anata 6 2 QUEUE 6 3 97 7 8 Hose Fittings and Fasteners 6 3 Tank 56706 LS Summary of Preventative Maintenance a 6 4 Chapter 7 Troubleshooting 7 1 Handling 7 1 Control Printed Circuit Boards 0 7 7 2 7 3 Tank OVer Urrenttu a a 7 3 Ready Contact to Parent Machine tiis dist o d lO RUD UU dL ER AR od 7 3 Temperature Zones Not Heating u ee 7 3 Location of PCB Circuit Breaker Over temp Thermostat Re set amp RTD Sensor 7 2 Resistance Tables irren KANA GA AnG GNG AUG NRW un 7 4 Troubleshooting Guide 0 asaqasasssaa ss 7 5 Piston Pump Troubleshooting Guide 0 9 7 9 Chapter 8 Disassembly amp Re assembly Procedures Access Electrical 0 15 8 1 Printed Circuit Board Replacement u cscssscssscssscssecssesssescsecssscsssscenscensecssecssecsnecsncesseeesseesseeses 8 2 Re assembly Procedures amp Cautions 7 9 8 3 Chapter 9 Component Illustrations amp Bills of Material 9 2 015 055 00 amp 2 P rrips 9 3 2 2 Astro Packaging AP50 Manual 19600 09 AP50 Chapter 10 Component Illustrations Hose Schematic all models
32. m Temporary Storage of the Unit 1 Flush the adhesive application system with flushing fluid PN RB 5 following the instructions detailed in Chapter 6 of this manual Clean or replace both the output filter and the tank following instructions detailed in Chapter 6 Shut OFF all pressure and power sources Remove all residual adhesive and wipe components clean Remove all power supply cables Pack the unit in a corrosion proof manner Store the unit in such a way that it is protected from damage Disposal of the Unit 1 2 3 4 5 Shut OFF all pressure and power sources Remove all residual adhesive Remove all adhesive supply hoses and all power supply cables Dismantle all components and sort into mechanical and electrical components Arrange for all components to be recycled Astro Packaging AP50 Manual 19600 09 AP50 3 5 Chapter 4 TEMPERATURE CONTROLLER SET UP Temperature Control Functions in General The AP50 AP100 temperature controller provides accurate temperature control for the hopper hoses and applicators Set points are programmed at the user friendly all icon keypad The controller will display an error message any time an open or shorted sensor condition occurs Defining Temperature Control Terms Adhesive Temperature Control Range The temperature limits within which the ASU hoses and applicators may be programmed and maintained Alarm Signal The controller provides an
33. n does not move with the applicator and hose the problem is probably in the ASU Controller set points are not adjustable All channels display error message or wrong actual temperatures System is not working display is dark Actual tank temperature is higher than set point over temp Astro Packaging 1 Main Power switch OFF 2 Control PCB inoperative 3 Keypad is locked 4 7 Day Scheduler active Control PCB in operative 1 Ribbon connector X6 or harness X7 is disconnected 2 Board fuse F1 or F2 on the PCB is inoperative 1 Tank sensor not fully inserted 2 Tank sensor inoperative 3 Inoperative PCB AP50 Manual 19600 09 AP50 1 Switch ON 2 Replace PCB 3 Unlock Keypad see ch 5 programming 4 See Ch 5 to override scheduler Replace Control PCB 1 Check connection 2 Insert new fuse if it blows the Control PCB is inoperative 1 Check tank sensor 2 Replace tank sensors if resistance does not comply with resistance table 3 Replace PCB 75 Display for Tank E01 1 Plug connection X6 1 amp 2 on 1 Restore connection PCB is loose 2 Temperature sensor 2 Replace sensor if resistance inoperative does not comply with resistance table Display for Tank E02 Tank sensor short circuit 1 Replace sensor if resistance does not comply with resistance table Short circuit at plug 2 Check and eliminate short connection X6 on Control circuit PCB
34. n working near a hot melt application system always wear safety gloves safety glasses and long sleeved protective clothing Always have first aid information and supplies available Call physician and or an emergency medical technician immediately Service Refer all servicing to qualified personnel only Explosion Fire Hazard Never operate this unit in an explosive environment Use cleaning compounds recommended by Astro Packaging Flash points of cleaning compounds vary according to their composition so consult with your supplier to determine the maximum heating temperatures and safety precautions Lockout Tag out Follow OSHA 1910 147 Lockout Tag out Regulation for equipment s lockout procedures and other important lockout tag out guidelines Be familiar with all lockout sources on the equipment Even after the equipment has been locked out there may be stored energy in the application system particularly capacitors within the panel box To ensure that all stored energy is relieved wait at least one minute before servicing electrical capacitors In This Manual WARNINGS and CAUTIONS are found throughout the manual WARNINGS mean that failure to observe the specific instructions may cause injury to personnel CAUTIONS mean that failure to observe the specific instructions may damage the equipment Astro Packaging AP50 Manual 19600 09 AP50 13 Chapter 2 DESCRIPTION AND SPECIFICATIONS Description The Astro Packagin
35. ng through the keypad Temperature Scale displayed in degrees Fahrenheit Applicator head and hose set points OFF e Tank Set point 177 C 350 F All zones are switched off except for the tank Access Code not active All programmable time delays set to zero 0 Tolerance range for high amp low temperature limits 27 C 50 F OAstro Packaging AP50 Manual 19600 09 AP50 43 Helpful Tips for the User When the ASU is turned on all temperature set points and other operating parameters will be exactly where they were when the ASU was turned off When the ASU is turned on all system heaters go on unless they have previously been set below 40 C 100 F ie switched OFF When the ASU is turned on the controller checks all RTDs If a zone does not have a valid RTD this zone will be switched off WHEN THE ASU IS TURNED ON AND THE PUMP SWITCH IS TURNED ON THE PUMP WILL AUTOMATICALLY RUN WHEN ALL SET POINTS ARE REACHED Astro Packaging AP50 Manual 19600 09 AP50 44 Chapter 5 CONTROLLER PROGRAMMING INSTRUCTIONS Controller Keypad Temperature Display Temperature Scale amp LED Hose 1 Temp Zone Icon amp LED T Head 1 Temp Zone amp LED NS Hose 2 Temp Zone Icon amp LED 2 Ti Head 2 Temp Zone i amp LED dq Hose 3 Temp Zone Icon amp LED and Head 3 Temp Zone Icon amp LED Scroll Keys increase value reduce value Service Hopper Temp Ho
36. ot necessary with these parts but the o ring seals should be clean and lubricated Tighten straight threaded parts and fittings until their shoulders are firmly seated against the pump body or other surface Excessive torque may damage straight threaded parts and the use of power wrenches is not recommended CAUTION HOT MELT RESIDUE should be cleaned from parts before they are re assembled particularly from threaded parts As a precaution against adhesive residue preventing proper re assembly threaded parts should always be re tightened at operating temperature Astro Packaging AP50 Manual 19600 09 AP50 83 Chapter 9 COMPONENT ILLUSTRATIONS amp BILL OF MATERIALS WARNING U All parts must be periodically inspected and replaced if worn or broken Failure to do this can affect equipment s operation and can result in personal injury Chapter Format This chapter contains the component illustrations exploded view drawings for each assembly of the AP50 AP100 ASU These drawings are useful for finding part numbers as well as for use when maintaining or repairing the unit Astro Packaging AP50 Manual 19600 09 AP50 9 1 Pumps V2 amp Accessories item Description Quantity Part Number EM V2 545 Pump Block amp FCV complete 79211 07 V2 545 Pump Replacement for Existing V2 pm gt qme Re 6 x aa memo a qmm ar quee 000 qme mm me p Pump Filter Kit 50
37. ound lug are at the bottom left of the PCB X1 Conduit fitting or cable grip not supplied Jumpers 8 us Line Input Power Plug for 1 L each type of Power Supply 3PH 230VAC DELTA 1PH 230VAC DELTA 3PH 230 400VAC WYE LINE INPUT POWER PLUG WIRING OAstro Packaging AP50 Manual 19600 09 AP50 32 4 The adhesive hoses are connected under the unit You must make both an electrical and an adhesive flow connection The electrical hose connections are at the six numbered rectangular receptacles on the front end panel The hose adhesive ports are located to the at the bottom of the unit There are six ports fittings for the use of up to six hoses They may be routed out the front back or down from the unit When making hose connections follow the number guide label on the ASU above the hose socket i e when using one hose make your hookup to electrical connection 1 and adhesive port 1 When using two heads hoses connect hose head 1 to electrical connection 1 and adhesive port 1 then hookup hose head 2 to electrical connection 2 and adhesive port 2 In a similar manner connect the remainder of your hose s head s Route hoses so that there is at least an eight inch radius at any bend Do not hang hoses without proper support Do not crimp clamp squeeze or tie hoses Refer to the hose and applicator manuals for further details on these items
38. r connection connection between ASU and Hose or between Hose and Head Inoperative PCB 3 Replace PCB Astro Packaging AP50 Manual 19600 09 AP50 78 Piston Pump Troubleshooting Guide WARNING HOT SURFACE amp ADHESIVE Some if the procedures in the following Troubleshooting Guide require working near hot adhesive Be sure to wear protective gloves safety glasses and clothing and use proper tools for handling hot melt components For pump disassembly instructions see page 8 5 Pump will not operate Low or Inconsistent Adhesive Output Astro Packaging on temperature control is on steady Pump motor switch on front panel is OFF Check for output from X18 on power PCB No pump warm up t stat is open and tank is hot Motor is bad Output filter clogged Adhesive used is too VISCOUS Blocked hose Blocked Applicator Heads 5 Flow control valve needs adjusting AP50 Manual 19600 09 AP50 Check to see that F C light 1 If blinking one or more temperature zones are cold Switch to ON Check fuse F3 amp F4 If there is no 230V output and fuses are good replace Power PCB Replace Pump warm up T stat Check 230V at 3 pin motor plug If 230V is present replace motor Remove and inspect filter screen Clean or replace as necessary See Chapter 6 Preventative Maintenance for procedure Verify that system components are at
39. r tightness Check all fasteners for tightness Inspect Tank Screen Clean or replace as required Astro Packaging AP50 Manual 19600 09 AP50 64 Chapter 7 TROUBLESHOOTING General Troubleshooting Notes Note Re read Chapter 1 Safety Precautions before performing any troubleshooting or repair procedures All troubleshooting or repair must be performed by qualified trained technicians Handling Printed Circuit Boards PCBs DANGER WARNING HIGH VOLTAGE HOT SURFACE The AP50 AP100 uses electrical power that can be life threatening and hot melt adhesives that can cause serious burns Only qualified persons should perform service on the ASU DANGER HIGH VOLTAGE Before unplugging connectors from the Control PCB ground yourself to the ASU by touching any available unpainted cool metal surface mounting screws etc This will avoid electrical discharge to the PCB assembly when you are removing and replacing connectors CAUTION Printed circuit boards PCB should be handled using the following procedures 1 Wear a wrist grounding strap If a grounding strap is not available frequently touch a bare metal part of the ASU unpainted frame mounting screw etc to safely discharge any electrostatic buildup on your body 2 Handle a PCB by its edges only Don t grip a PCB across its surface 3 When removed from the ASU the PCB must be packaged inside a metallized static drain envelope Do not place the removed PCB on a
40. re removing any of the hoses or applicators from their manifold port Refer to the illustration on page 6 2 while following these instructions WARNING HIGH PRESSURE During the purging procedure hot adhesives can come out of the manifold under high pressure Wear a face shield gloves and protective clothing Stand clear of the ASU until all pressure is relieved HOT ADHESIVE Avoid splashing hot adhesive Position a heat resistant container under the manifold s purge drain before proceeding The ASU should be at operating temperature Turn the ASU s motor OFF 1 Locate the bleed valve on the output filter manifold 2 With a hex key screwdriver allen wrench slowly loosen the purge screw do not attempt to remove it which is in the bleed valve s port Allow the adhesive and pressure to escape outof the manifold The adhesive will flow into the heat resistant container positioned below the manifold Astro Packaging AP50 Manual 19600 09 AP50 6 1 Output Filter The output pump filter should be replaced monthly during the first few months of operation After you gain experience with your system you can determine how often you need to replace it The output filter is located on the pump manifold on the hose connection panel of the ASU Use the following procedure to replace the output filter Note This procedure need not be done if flow rates are adequate and no char is present in system 1 Switch OFF the pump motor switch
41. re value by which all temperature zones will lower when Standby mode is activated For example if your temperature set points are all 300 degrees and you program a 100 degree Standby then the Standby temperature of all zones will be 200 degrees Similarly if your temperature zones set points vary and you program a 100 degrees Standby each zone s Standby temperature will be 100 degrees lower than its set point Press Service icon to enter Service Functions You will see either S 1 standby is On or S 0 5 standby is Off or Press the Tank icon to activate de activate Standby A If desired you may set the Standby temperature by scrolling up or down to desired temperature v When programming is complete wait a few seconds and the controller will return to the ASU s actual temperature Note When Standby is active the display will alternate between the ASU s actual temperature and S 1 Astro Packaging AP50 Manual 19600 09 AP50 55 Service Functions cont To Set Tolerance Hi amp Low Temperature Limits The Tolerance high low alarm set point is a range and the zone s temperature set point between which your ASU can safely operate It s lower temperature represents the ASU s ready temperature It s upper value represents the over temperature point Setting the Tolerance range for example if the temperature set point is 200 degrees and the Tolerance set point is 10 degrees
42. se 4 Temp Zone Icon amp LED Zone Icon and Head 4 Temp Zone Icon amp LED amp LED Hose 5 Temp Zone Icon amp LED and Head 5 Temp Zone Icon amp LED oS 7 Day Scheduler Head 6 Temp Zone Icon amp LED Display option Hose 6 Temp Zone Icon amp LED Astro Packaging AP50 Manual 19600 09 AP50 5 1 Programming Turn Controller ON O On Off Turn ON the main power switch System will go through its self diagnostics CAL Controller will display CAL Temperature zone LEDs will flash Controller will display SS 1 On or SS 0 Off to indicate status of the Sequential Startup feature see info on Sequential Startup later in the chapter Controller will display firmware version ie VX XX Programming Temperature Set points o o o lt gt for a shortcut method of setting set points see To Copy amp Paste Set points on pg 5 9 Choose a temperature zone When flashing the zone s set point is displayed and it can be programmed In order to program the temperature set point scroll up to increase value or down to reduce value After two seconds the display will read the actual temperature The set point is stored Turning Temperature Zones ON OFF Z o 4 o lt 4 Astro Packaging Choose a temperature zone Scroll to reduce value until the temperature set point shows This temperature zone is now turned OFF
43. table counter etc until it has first been placed in or on a static drain envelope 4 When handing a PCB to another person touch the hand or wrist of that person to eliminate any electrostatic charge before you hand the PCB to him 5 When unwrapping a PCB from its static drain envelope place the envelope on a grounded nonmetallic surface 6 To cushion a PCB for shipment use only static drain bubble pack Do not use foam peanuts or bubble pack not known to be static draining Astro Packaging AP50 Manual 19600 09 AP50 74 Control Printed Circuit Board Notes 1 The green LEDs cycle on and off as each heater outputs 2 The Power Configuration Plug user installed must be correct for your application or serious ASU damage will result See Installation Chapter 3 for details CAUTION Using the incorrect power configuration plug may cause serious damage to the unit 3 Fuses sizes are as shown in diagram below The pump s is fused together with Head Hose 6 fuses Software V Connect to RTDs Firmware 1 amp 2 Tank Chip 3 amp 4 Hose 1 5 amp 6 Head 1 788 Hose 2 Connect to Alarm Ready 9 amp 10 Head 2 Keypad AUX NOCOMNC NOCOMNC JUMPER eos IED2 Connect to Connect to RTDs RTO Selection REMOVED O Head Hose 1 1 amp 2 Head 3 HON HEY Connect to 384 Hose 3 Head Hose 2 586 Head 4 7 amp 8 Hose 4 Connect to 87654321 10987654321 H H Connect to RTDs ead Hose 3 182 Head 5
44. transfer to a remote computer is available for the controller via the RS232 option The ASU s RS232 serial port connection allows remote interface up to 50 meters from the AP50 AP100 controller Sequential Startup This feature allows the temperature zones to come on in sequence tank followed by hoses and heads When activated and the ASU is turned ON from a cold start the tank heats first When the tank is within its set point tolerances the hoses and heads begin to heat Set point A programmable temperature that has been selected for tank hoses and applicators Set point Limitation This is a universal maximum temperature for all zones 218 C 425 F The programmer cannot program a temperature set point higher than the set point limitation Seven Day Scheduler This option enables the controller to provide scheduling of ON and OFF operating modes for the ASU s system at the keypad It therefore allows the operator to program ON and OFF heating cycles which coincide with his production schedule throughout the work week The scheduler helps conserve electricity usage and functions also as an additional safety feature Standby Setback During breaks or delays in production it is possible to reduce the temperature of all zones by a specified amount through programming of a standby The programmed standby also referred to as setback is the difference in temperature by which all zones will reduce below their set points when standby is
45. urce DANGER HIGH VOLTAGE Disconnect and lockout input power to the application system before start ing any installation procedures Make sure there is no electrical power on the leads you will be connecting 2 Your power supply should be rated for 30 Amp service and should include an earth ground conductor CAUTION Grounding conductors never carry electrical current The use of a neutral conducting wire as earth ground is incorrect and may cause damage to the controller 3 Make two connections to the printed circuit board Loosen the 3 button head screws on the top Front door will open forward a Select proper power configuration plug for your system two plugs are shipped with the unit You must install one of these CAUTION Using the incorrect power configuration plug may cause serious damage to the unit for 230 VAC 3PH Delta use PN 112542 white plug with violet wire for 230 400 VAC 3PH WYE use PN 112543 white plug with yellow wire NES power for 230 VAC 1 PH Delta use PN 112543 Tw f Wapa os white plug with yellow wire w Line input you will need to add jumpers see below power plug b Insert proper power configuration plug into socket J1 at bottom center of control printed circuit board located within the control enclosure see illustration of PCB in Chapter 7 for location c Wire main power into Line Input Power Plug and the ground lug Main power connections amp the gr
46. ure Resistance in Nominal 240 V F CC Ohms 32 120 0 Meters Feet 50 127 2 68 134 5 86 142 1 149 8 157 7 165 9 174 2 Nominal Hose Heater Resistance for Challenger Hoses Resistance in Ohms Nominal 240 V ao 200 269 9 Nominal Head Heater Resistance Nominal Resistance in Voltage Ohms 182 8 191 6 200 6 209 8 219 3 229 0 238 8 249 0 280 8 292 0 315 3 Tank Heater Resistance 303 5 327 5 Temperature Sensor Resistance for Ni120 RTD Note Resistance is measured at ambient temperature 20 C 68 F Astro Packaging AP50 Manual 19600 09 AP50 74 Troubleshooting Guide Preliminary Checks Verify the following before proceeding 1 The ASU is switched on 2 The ASU is supplied with power 3 Electrical connections including the power configuration plug are correct 4 Adhesive is in the hopper and it has had time to melt Error Messages see also Chapter 4 EO1 temperature zone has an open sensor EO2 temperature zone has a shorted sensor EO3 or E04 internal error ASU or pcb must be returned to Astro Packaging o t Over temperature check for faulty zone Hose Applicator Troubleshooting Tip Hose or applicator problems can be isolated by electrically connecting the applicator and hose to an alternate socket on the ASU If the malfunction goes with the applicator and hose the problem will usually be in the applicator or hose that was moved If the malfunctio
47. x Connect to 384 Hose 5 z lt Head Hose 4 5 amp 6 Head 6 788 Hose 6 5 Connect to Head Hose 5 Connect to Overtemp Thermostat Head amp Hose Fuses 6 6 3 A Fast Connect to Head Hose 6 Head amp Hose Fuses 1 3A Connect to Connect to Pump Solenoid Main Power Switch lt Connect to Tank Heater Controller Fuses 2 1 1A Fast Blow Circuit Breakers 2 Power Configuration Plug user installed Must be Correct for your power supply Connect to Main Power Supply Astro Packaging AP50 Manual 19600 09 AP50 72 Over temp Thermostat The over temp thermostat cuts off power to all temperature zones if the tank temperature exceeds 224 C 435 F The over temp thermostat will reset automatically when the tank temperature drops Ready Contact to Parent Machine A ready contact from the controller to the parent machine can enable the parent machine if it is connected on the control printed circuit board Temperature Zones Not Heating If two temperature zones simultaneously cool down the problem could be a bad fuse on the main PCB as these fuses relate to hose head combinations If only one temperature zone cools the problem could be a bad heater or a PCB problem such as a PCB connection TANK HEATER 4 P N 12600 C TANK OVERTEMP THERMOSTAT FRONT P N 13029 450 OF O TANK C OAstro Packaging AP50 Manual 19600 09 AP50 73 Resistance Tables Hose Length Resistance in Ohms Temperat
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