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KB30, KB50, KB100 Hot Melt Units Product Manual

1. 2000334 Bimetallic Temperature Control Solid State Temperature Control Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 19 5 2 Startup WARNING Fire explosion personal injury property and equipment damage can result if the materials used in or around any hot melt supply equipment do not meet the following requirements 1 Minimum flash point of the material to be 50 F 28 C above user s operating temperature 2 Liquid and vapor to be non toxic and non flammable at operating temperature of the hot melt equipment 3 The mixing of materials cleanout and adhesives or different brands of adhesives do not react violently to produce the following Heat or flames exothermic reaction b Atoxic gas as a by product of the reaction c Crosslinking or the disabling of the adhesive s ability to melt at its designed temperature 4 Material must not corrode or otherwise weaken hot melt equipment 5 Always read the manufacturer s recommended use of the material 6 Become familiar with controls by reading section 5 1 Controls and Indicators 7 Install the KB Series melt unit as specified in section 4 Fill tank with hot melt material 1 1 2 inches from the top 9 Turn the melt unit On and allow 30 minutes warm up time 10 Set hose and
2. n 6 K MA INIURIIS NE EU 6 33 Performance saa dresser delee analt Benene sida seede 6 JED 0 Ziagscesedcceiscuaesissativccanpdatubousacssssuosenendescussennbe2piagscegiseovbseusnssactesssibebstacensedeentbesbenseccenseewhiteses 7 3 5 Operating Pressure and Adhesive Flow sevessssveesnveennnveesnnvensnnvensnneensnneensnnesssnnesssnnessennensesnesseseeee 8 3 6 Adhesive Flow Pat these2sssccivececasecssavtes cinescelpucecessavescteusiestadssencseaseasess cavebucexeiaedecssvesanbusvonssseouencOesmueses 8 3 7 Temperature Controller Options esesvnvvevnnveeennveennnvnennnvensnnvennnnvennnnvennnneensnnnennnneensnneenennessnnneennnneee 9 4 Installation TI S 10 4 uinoPAIDBsEIDIT I pee 10 42 Suppor ne the Met Unit sci wsscvcsassseesvesancescanncsessensacusabesusebecnvess sosoo sioro sess roisses soies sorso esseet reos 10 4 3 erunt c0 10 4 3 1 Hot Melt supply hoses Important Points sessssssssseseeee ener 11 43 2 Supporting Applicator HeadShot inris tec ed ao ent ve soda toe rage tasa e t up dod 12 44 Electrical Circuits and WIrInp s ieceiete cette eo rentur ben Fato se kata se eoa So esas sese eee sees bv e vex vases Eva E VEU 13 24 T A tomatie Heads ad acr the rotes hod poi aie nobel aaa ed nnde ean 14 42 Head Control CAmrCUil sarin dials cak touts otal cca A tan Seals luni ie dat hPa ctna la Sct od alos SN 14 445 Parent Machine Lockout Crosse SAGN 15 4 5 Customer
3. KB100 KB50 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 3 Specifications 3 1 Electrical 3 2 Physical 3 3 Performance Input voltage 230 VAC single phase Frequency 50 60 Hz Power Required KB30 3000W Hoses not included KB50 4200W KB100 4700 W Additional System Wattage KB30 50 100 25 30 W ft per Hose KB30 50 100 200 600 W Applicator Circuit Breaker Rating KB30 30 A 230 VAC KB50 100 40 A 230 VAC Parent machine interface circuit System Type Bulk Tank Operating Air None Pump Type Positive Displacement Gear Pump Pump Drive Mechanism All Electric Motor Pump Pressure Regulation Pump Mounted Flow Control Valve Tank Capacity 30 Ib 13 6 kg 50 Ib 22 7 kg 100 Ib 45 4 kg Hose Capacity All 1 2 Handgun Hoses KB30 1 5 Automatic Head Hoses KB50 100 1 6 Automatic Head Hoses Weight full
4. KB30 95 Ib 43 1 kg KB50 110 Ib 50 kg EEE KB100 185 Ib 83 9 kg Warm up Time 30 45 minutes Maximum Melt Rate KB30 40 Ib hr 18 1 kg hr KB50 100 60 lb hr 27 2 kg hr Adhesive Viscosity Maximum 70 000 centipoise Maximum melt rates vary with different adhesive types 6 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 Copyright Astro Packaging 2009 imensions 3 4D 2 KB50 KB100 ALL 2000333 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 3 5 Operating Pressure and Adhesive Flow Pump and Motor Flow Rate at Typical Pressure Operating Pressure Range V4 450 Pump 250 psi 17 2 bar 100 350 psi 86 72 rpm 80 72 lb hr 36 3 32 7 kg hr 6 9 24 1 bar V4 675 Pump 250 psi 17 2 bar 100 300 psi 86 72 rpm 110 90 Ib hr 49 9 40 0 kg hr 6 9 20 7 bar V2 545 Pump 400 psi 27 6 bar 250 600 psi 86 72 rpm 95 83 Ib hr 43 1 37 6 kg hr 17 2 41 4 bar 170 140 rpm 197 164 lb hr 89 7 74 4 kg hr V3 675 Pump 250 psi 17 2 bar 300 800 psi 86 72 rpm 86 70 Ib hr 39 31 8 kg hr 20 7 55 2 bar 170 140 rpm 150 140 lb hr 68 63 5 kg hr NOTE Estimated flow rates are based on common EVA packaging grade adhesive For paired values left value is at 60 HZ right
5. Voltage Amps 100 4 115 4 200 4 230 4 Temperature Ohms 0 C 32 F 100 38 C 100 F 115 66 C 150 F 126 93 C 200 F 136 121 C 250 F 147 149 C 300 F 158 177 C 350 F 168 204 C 400 F 178 NOTE The tank and the hose have one RTD sensor each Tank Voltage Ohms 230 53 Motor Voltage Ohms 230 11 13 Table 4 EI00XT Automatic Applicator Resistance Voltage Ohms 115 50 65 230 216 264 56 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 Copyright Astro Packaging 2009 This page is intentionally left blank Warranty A Astro Packaging warrants its products when operated and maintained in accordance with Astro Packaging recommended procedures are free of defects in material and workmanship during the periods indicated below commencing with the date the product is placed in service Product Warranty Period 1 Tank heater including entire tank when 5 years or 10 000 hours of use heater is cast into tank whichever occurs first 2 Melt unit unless specified below pattern 1 year or 2000 hours of use controller head driver whichever occurs first 3 Stationary hose automatic electric head JR 1 year or 2 000 hours of use Series Hot Melt System or melt unit standard pail whichever occurs first unloader standard accessory purchased with a system 4 Manual hose handgun Mini Squirt IIl any butyl 6 mont
6. TANK RTD SENSOR TANK CONTROLLER Copyright Astro Packaging 2009 9 10 Tank Level Sensors Item Description Quantity Part Number Proximity Type KB30 one sensor 6 6 from tank bottom includes a modified tank 79233 07 Must be factory installed in melt tank at time of manufacture KB50 one sensor 9 from tank bottom includes modified tank 79233 03 KB50 one sensor 7 5 from tank bottom includes modified tank 79233 05 KB50 two sensor 3 and 7 from tank bottom includes modified 79233 06 tank KB100 one sensor 18 from tank bottom includes modified tank 79233 04 KB100 two sensor 6 and 17 from tank bottom includes modified 79233 02 tank Spares Kit Replacement 1 Sensor does not include amplifier or tank 79263 01 Kit Replacement 2 Sensors does not include amplifier or tank 79263 02 9 11 Weather Resistant Housing Item Description Quantity Part Number Kit Weather Resistant Housing 30 1b 79161 1 Kit Weather Resistant Housing 50 and 100 1b 79161 9 12 Chassis Fans Item Description Quantity Part Number Fan Kit chassis 230 VAC 79170 2 9 13 Reverse Hose Mounting Kits Item Description Quantity Part Number Reverse Hose Mounting Kit I hose 30 100 Ib unit RTD sensor 79188 01 Reverse Hose Mounting Kit 2 hose 30 100 Ib unit RTD sensor 79188 02 Reverse Hose Mounting Kit I hose 30
7. controller or relay On units with Standby make sure Standby switch is disengaged and in the Run position Refer to Solutions 1 through 6 If problem still exists replace the tank heaters On melt units with Standby make sure Standby switch is disengaged and in the Run position Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 29 Problem Solutions Tank overtemp condition OVERTEMPERATURE TH E RMOSTAT 2000285 Adjust the tank temperature controller according to section 5 3 of this manual Inadequate tank temperature can affect the performance of your hot melt system If the tank has reached an overtemperature condition try turning the controller down A failure of the solid state relay closed position can cause the tank to reach over temperature Check the relay s continuity failure of the relay is rare If problem persists replace the faulty component controller or relay On units with Standby make sure Standby switch is disengaged and in the Run position The Overtemperature O T switch is a safety device designed to prevent the melt tank from reaching a run away temperature condition Once the melt tank reaches an over temperature condition the O T switch controls the tank s temperature Check the melt tank s temperature when the O T indicator is lit If melt tank temperature is too high turn the tank temperature controller down cou
8. 2 of this manual If the F C V is inoperable replace or repair it as specified in section 8 4 Refer to section 9 for pump kit information Adjust the supply hose temperature controller according to section 5 3 in this manual Inadequate supply hose heat can affect the performance of your hot melt system If problem persists see Hose Controller Replacement section 8 2 and section 9 for hose temperature controller kits Adjust the tank temperature controller according to section 5 3 of this manual Inadequate tank temperature can affect the performance of your hot melt system If the tank has reached an overtemperature condition try turning the controller down A failure of the solid state relay closed position can cause the tank to reach over temperature Check the relay s continuity failure of the relay is rare If problem persists replace the faulty component controller or relay On units with Standby make sure Standby switch is disengaged and in the Run position The pump motor is normally the last item to check when troubleshooting All motors have internal thermal protection Switch Off pump motor switch and allow the motor to cool for approximately 20 minutes Turn pump switch back On If the motor still fails to operate continue troubleshooting Determine which pump motor is mounted in your melt unit Refer to the motor I D plate Consult factory for the properly rated pump motor for your specific appl
9. 9 5 HAT Switches ss sirene PRONUS EAE NN EVI LU tex a Sri 48 ER UM d dial iir pem 49 9 7 Standard Fan Cool d Motors eiae inea ees eb nna y eina rena ERROR EIUS A esa CE NEIN RES e ERA NR ME GR RU eee 50 9 8 Standard Fan Cooled Motor Support sersvesssvvesssnvennnvensnnvensnneessnnnensnnnennnnnennnnnennnnnennnnnennnnennneee S1 9 9 Temperatur Controllers cciscssseces sespocsvesdictacsergussesupsscctousssesosessssssdespucswoussacessoupiesoondssgessetpusstoukiece 52 9 TH Fank Wey el SO SOrs vicscssuctcapeasscosictsndcsedsdebsaancncbichcass EE E 53 9 11 W Gather Resistant Housing oii ssecsecsscenscensieceresvctsosderacdeensoceesseseendeseonssssesecdecsesasesassensssecosesonsncsne 53 9 12 Chassis Fasade Ge Nede 53 9 13 Reverse Hos Mounting ICIS scscsiscscacsaesed ceustescatssesedscuonsdsasssesubuundoussbusnsded soosis osseo resos seas tr saosi 53 9 14 Adhesive Pressure Gates aieo beer ee pube eae cea phe deba Een eiae saei oe oa Soo e eap ese saos eda bo bote eon b d bee eed enu ava pde 54 ii KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 9 15 Melt Unit Stand Bracket 90 16 Miscellamn e0US 2 7 ose eco iue tde eese eese sses d eee osse eise e Reo Te ae ed eee Pob aede eee soot uc sos ae LEDEDES sea Sessor adesse sais O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 iii This page intentionally left blank iv KB30 KB50 and
10. HOOKUPS secsessascoscstesvnnatec conc caked bevaccencdincgnncsesdccsesuncgesesssscanastuda ods vusncndesandonesuauepeepscasnccen 16 4 5 1 Valve groups also known as Head groups cccccesssesseceseceseceeeeeeseecaeceeeseeecsaecneeseeeenseees 16 45 0thgr HoOEUpS ace dt oec tekqude paesi tes ted esconde SG opa d Mae ated oun nines 17 5 Operation ERE EDT 18 5 1 Controls and Indic datos iie te Eee seed decd n I pOP iae epa sees eee ia RD Ina eeu beue CIR Ue ene AP Ies 18 1 System Power Switch Circuit Breaker and Indicator Light esses 18 2 Pump motor On OFF Switch and Indicator Light sse 18 O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 3 Tank Temperature Meter Bimetallic only oororonrorrrrornrrnrrrrnrrrrrrrrrnrrnrrrrnrsrrrrresresnerrrssenseennee 18 4 Tank Heating Indicator EAglitu ases feasen ient ort Ra repleta fec s ilo tas cH eae ande 18 5 Overtemperature Indicator L vaas KNEGG 18 6 Head Activate Deactivate Test HAT Switch user added option only 19 Melius fc t 20 SI Adjustments NL 21 5 3 1 Temperature Adjustments Bimetallic iue etn D ee e et PA eee 21 3 9 2 PLOW CONE VE 23 GiMVIGINI ONAN CE rette DEDE eee 24 6 Preventive Maintenance mm 24 6 2 General Maintenant csssssscsssssssessesssssossssusosssoosssosisesossssssesssssr
11. If the motor still fails to operate continue troubleshooting Determine which pump motor is mounted in your melt unit Refer to the motor I D plate Remove foreign material from pump and tank Purge system with Strip N Clean if necessary Increase melt tank and supply hose Temperatures per section 5 3 1 If this does not improve performance consult the adhesive vendor concerning your applications Adhesive formulations tend to be a factor in each previously listed problems Refer to Startup Instructions section 5 2 for cautionary notes System should be purged if formulation is incorrect 34 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 Problem Solutions Pump motor breaker throws Incoming Voltage Determine exact voltage of the melt unit Insufficient voltage can be the cause of these problems Voltage drops are common Use a voltmeter to determine whether sufficient voltage is supplied to the melt unit Also the voltage of each melt unit component must be compatible to the melt unit or serious damage to the system will occur Refer to section 4 4 Electrical Circuits amp Wiring Refer to the electrical schematic and check the actual wire connections to ensure that the melt unit is wired properly If problem still exists check the status of specific components with a voltmeter system powered or with an ohmmeter system unpowered wire disco
12. KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 1 Safety Precautions for Hot Melt Applicator Equipment 1 1 Intended Use 1 2 Personal Safety Wear Heat Resistant Safety Gloves Wear Protective Clothing O Copyright Astro Packaging 2009 This manual contains important safety information and instructions Failure to comply with these instructions can result in death injury or permanent damage to this equipment and will void the warranty This equipment is designed for use with standard adhesive and sealant materials with flash points above 232 C 450 F Use of flammable material or material not compatible with the specifications of this equipment can cause injury to operator and damage to equipment The manufacturer has designed this equipment for safe operation Specified models are in compliance with EN 60204 1 1997 However heated thermoplastics and other hot melt materials are dangerous and care must be exercised to ensure operational safety Handling must be in accordance with hot melt manufacturer specifications Never exceed the maximum application temperature recommended by the adhesive manufacturer Dispose of hot melt properly Refer to the Materials Safety Data Sheet MSDS of the hot melt for recommended disposal methods Wear the following protection when working on or around this equipment Always wear heat resistant gloves rated to 205 C 400 F and allow all syste
13. machine that melt unit is at operating temperature Auto Standby 60B amp 61B Input from head driver input nominal 12 VDC to reset count down clock Standby to Run 60C amp 61C Requires a contact closure to change state Power On 60E amp 61E Output to light stack Indicator Standby to Run 60F amp 61F Check this against the other standby to run One of these should be run to standby Audible Alarm 60G amp 61G Low Level 78 amp 79 Dry contact closure to signal parent machine that hot melt Indicator level has dropped to predetermined setting Tachometer 34 amp 35 Terminal point to obtain multiple use of tachometer analog signal Run Ready 30A Light stack input Standby 30B Light stack input Alarm 30C Light stack input Low Level 30E Light stack input Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 5 Operation 5 1 Controls and Indicators NOTE Bimetallic only refer to temperature controller manual for solid state temperature controllers 1 System Power Switch Circuit Breaker and Indicator Light The system power switch is also a magnetic type breaker designed to open the circuit at currents exceeding 30 amps KB30 or 40 amps KB50 100 at 230 VAC or in response to a temperature based error with the appropriate controller The system power indicator light above the breaker illuminates when the system power switch is in t
14. value is at 50 Hz A 100 300 psi 6 9 20 7 bar V2 545 Pump is available 3 6 Adhesive Flow Path TANK BASE MAIN ADHESIVE FLOW FLOW MANIFOLD OUTPUT TO y SUPPLY HOSES KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 ADHESIVE FLOW BYPASS 2000261 O Copyright Astro Packaging 2009 3 7 Temperature Controller Options Name Type Capacity Accuracy Features Thermostat bimetallic tank only 10 F 8 C no readout capillary sensor 1 hose 15 F 8 C no readout T500 microprocessor 5 zones 1 F 1 C digital readout run ready each zone standby setting visual alarm auto standby auto shutoff T750 microprocessor 9 zones 1 F 1 C same as T500 T1000 microprocessor 15 zones F 1 C digital readout run ready each zone standby setting visual alarm auto standby auto shutoff 7 day clock remote standby NOTE A temperature zone is the heating element heating circuit in a tank hose or applicator head Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 4 Installation 4 1 Shipping and Handling 4 2 Supporting the Melt Un The KB melt units may be shipped with the supply hoses and the applicator heads or handguns already connected The melt units are either shipped in a corrugated box or bolted to a wooden pallet The supply hoses are coiled arou
15. 100 Ib unit capillary sensor 79188 11 Reverse Hose Mounting Kit 2 hose 30 100 Ib unit capillary sensor 79188 12 NOTE 1 One to two feet longer hose may be needed with reverse mounted hoses Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 2 Space does not permit more than two rear exit hoses on 50 and 100 Ib melt units 53 9 14 Adhesive Pressure Gauges Item Description Quantity Part Number Pressure Gauge Standard 1500 PSI 10 000 kPa 79227 02 Pressure Gauge Low Pressure 300 PSI 2000 kPa 79227 01 9 15 Melt Unit Stand Bracket CONTACT LOCAL DISTRIBUTOR FOR AVAILABLE STAND CONFIGURATIONS Fo 2000253 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 2000252 O Copyright Astro Packaging 2009 9 16 Miscellaneous Item Description Quantity Part Number Kit Gun Hanger 79023 Kit Front Mount Hose Electrical Connector 9 pin Standard hose 79311 04 Kit Front Mount Hose Electrical Connector 16 pin Standard hose 79311 03 Kit Front Mount Hose Electrical Connector 9 pin Washdown hose 79311 02 Kit Front Mount Hose Electrical Connector 16 pin Washdown hose 79311 01 Kit Remote Power on relay 79183 2 Kit Lexan Door T500 T750 T1000 79253 03 Kit Audible Alarm 60 db Standard 230 VAC 79189 02 Kit Audi
16. 4 30 50 100 79070 2 O Ring 070w x 614 I D high temp V4 10493 015 O Ring 070w x 1 864 LD high temp V4 10493 145 Flow Control Valve Block V4 450 79025 61 Flow Control Valve Block V4 675 79025 62 V4 Flow Control Valve Replacement 79287 07 Connection Piece V4 450 30 50 100 70488 1 Connection Piece V4 675 30 50 100 70488 2 O ring Connection Piece to tank 10415 O ring Connection Piece to block 10505 06 Hardware Kit V4 450 and V4 675 79042 1 Pump insulation kit V3 or V4 30 Ib melt units 79176 2 Pump insulation kit V3 or V4 50 100 Ib melt units 79176 1 Pump Filter Kit 50 Mesh 79064 Drain Purge Valve Kit KB 30 50 100 only 79057 1 Kit Knob Assembly FCV V2 V3 V4 79287 04 NOTE Teflon o rings are recommended for polyamide applications Contact your local distributor for assistance V4 PUMP BLOCK FLOW CONTROL VALVE REPLACEMENT DT i pes V4 HARDWARE KIT 44 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 9 2 Pumps V2 and Accessories Item Description Quantity Part Number V2 545 Pump Block amp FCV complete 79211 07 V2 545 Pump replacement for existing V2 79179 3 Flow Control Valve Kit V2 79082 7 Drain Valve Kit 79057 1 Tank Screen 73289 Kit Knob Assembly FCV V2 V3 Retrofit 79287 02 Pump Block O Ring Kit V2 79070 1 Kit V2 Pump Teflon o ring 30 50 100 Ib MU 79290 04 Pump Insulation K
17. 9 35 Problem Solutions Adhesive output too low 1 Adjusting the flow control valve F C V correctly will produce the desired pumping performance of your melt unit Refer to section 5 3 2 of this manual If the F C V is inoperable replace or repair it as specified in section 8 4 Refer to section 9 for pump kit information 2 Adjust the supply hose temperature controller according to section 5 3 in this manual Inadequate supply hose heat can affect the performance of your hot melt system If problem persists see Hose Controller Replacement section 8 2 and section 9 for Hose temperature controller kits 3 Adjust the tank temperature controller according to section 5 3 of this manual Inadequate tank temperature can affect the performance of your hot melt system If the tank has reached an overtemperature condition try turning the controller down A failure of the solid state relay closed position can cause the tank to reach over temperature Check the relay s continuity failure of the relay is rare If problem persists replace the faulty component controller or relay On units with Standby make sure Standby switch is disengaged and in the Run position 4 Remove foreign material from pump and tank Purge system with Strip N Clean if necessary 5 Determine which pump is mounted in your melt unit Refer to the melt unit I D plate The pumping performance listed in section 3 of this manual depends up
18. KB Series KB30 KB50 KB100 Hot Melt Units Product Manual Manual Number 19600 159 1 800 642 7876 KB Series KB30 KB50 KB100 Hot Melt Units Product Manual Manual Number 19600 159 Revision A Date 04 09 09 O Copyright 2009 Astro Packaging For Sales and Service Centers in your area Call 1 800 642 7876 or Visit our website at www astropackaging com NOTE CONCERNING ILLUSTRATIONS All illustrations within this product manual should be considered as general representations of the parts or assemblies depicted and should not serve as mechanical drawings nor be consulted for scope or scale They are for reference only Copyright 2009 Astro Packaging Table of Contents 1 Safety Precautions for Hot Melt Applicator Equipment cccccsscccssssccesssscssecssccsscoees 1 LER Tin tem eth LETS Ded ones 1 12 Personal Safety e cT 1 13 l ctiical Safety saasTNA 2 L A Emergency Power DISCONMEC Es icccciaicccstcsccsssseckssteenussnccusssspassencedsousdsoogusessusasconsesnecesseusissoudedenessasestes 2 13 Follow Directions T 2 1 6 Safety Symbols and Signal Words messsseresssesessinssasnsssasersssnesennsnnnnnnssendebesnkesennknsenneeserneasednsaenksneden 2 P PCI ITE TIT BERE PP C 4 2L D VERY 0 1 17 2 TV ree ck 4 PATI ME 4 3 SPectfICallOHs iode e p lvcecoreetvea i blexdesue e Ry vNce eR Drei d Udvye eo UTE E RASEN era Vae a a Vw Ven ENDE de 6 3 L Lea eH
19. a Head Group to be in Run for normal automatic operation Off so no firing signal goes to the head coil s or in Test for manual testing firing of valve Astro Packaging Pattern Generators and Head Drivers include a switch for test firing the valves HAT Switches should not be installed on melt units with Head Drivers 48 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 9 6 Tank Heaters Item Description Quantity Part Number Tank Heater Kit 230 VAC 1000 Watt KB30 79088 30 Tank Heater Kit 230 VAC 1000 Watt KB50 100 79088 50 Tank Heater Kit 200 VAC 1000 Watt KB50 100 79088 51 Band Heater Kit for tank 200 or 230 VAC KB50 100 79088 100 TANK HEATER KIT KB30 20002812 BAND HEATER KIT BAND HEATER KIT KB50 KB100 e TANK HEATER KIT EE KB50 and KB100 2000281 O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 49 9 7 Standard Fan Cooled Motors Item Description Quantity Part Number Motor Assembly 86 72 RPM 200 230 VAC 60 50 Hz 73012 42 Motor Group 1 6 hp 86 RPM 200 230 VAC 60 Hz 73278 42 Motor Group 1 6 hp 72 RPM 200 220 VAC 50 Hz 73278 45 Motor Group 1 6 hp 72 RPM 220 240 VAC 50 Hz 73278 46 Kit Motor and Capacitor 1 3 hp 170 RPM 200 230 VAC 60Hz 79414 01 Motor Gr
20. a complete range of pattern control accessories The basic melt unit includes a melt grid and filter block assembly Pump filter must be ordered separately CJ All electric models operate from 230 VAC power source C No compressed air required o I to 2 hoses handguns 1 to 5 KB30 or 6 KB50 and KB100 hoses automatic applicators O Temperature control options range from thermostat to microprocessor CJ High torque high rpm motors for low maintenance and long life O Reliable smooth output gear pumps to handle a wide range of materials C Teflon lined melt tank reduces adhesive char and minimizes degradation buildup C Finned melt grid in tank bottom increases melt rate for fast warmup and continuous melting O High performance pump rates up to 395 lb hr 179 kg hr O Supported by high performance pattern controllers head drivers and automatic flow controllers O System power circuit breaker protects the entire system from overload O Tank mounted overtemperature switch backs up the tank thermostat in case of a tank thermostat failure CJ Circuit breaker protects the pump motor by opening the pump motor circuit during a stall or an overload condition O Melt tank is also equipped with a pump warm up switch for the protection of the pump drive mechanism 4 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 UK UL NN
21. acceptable or low tank temperature the O T switch is either faulty or rated at a low temperature The O T switch must be replaced in either case Refer to section 9 for switch kits 28 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 Problem Solutions Tank fails to heat Continued Refer to solutions 1 through 6 If problem still exists replace the tank heaters Refer to section 9 for part and kit numbers On melt units with Standby make sure Standby switch is disengaged and in the Run position Tank heats slowly Determine exact voltage of the melt unit Insufficient voltage can be the cause of these problems Voltage drops are common Use a voltmeter to determine whether sufficient voltage is supplied to the melt unit Also the voltage of each melt unit component must be compatible to the melt unit or serious damage to the system will occur Refer to section 4 4 Electrical Circuits amp Wiring Adjust the tank temperature controller according to section 5 3 of this manual Inadequate tank temperature can affect the performance of your hot melt system If the tank has reached an overtemperature condition try turning the controller down A failure of the solid state relay closed position can cause the tank to reach over temperature Check the relay s continuity failure of the relay is rare If problem persists replace the faulty component
22. akers Contact factory for system compatibility COUPLING PUMPSHAFT ASSEMBLY SPIDER COUPLING 2000339 O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 51 9 9 Temperature Controllers Item Description Quantity Part Number Kit Tank Controller adjustable 100 450 F 79006 Kit Hose Controller 100 200 F 79125 1 Kit Hose Controller 200 300 F 79125 2 Kit Hose Controller 300 400 F 79125 3 Kit Hose Controller 350 450 F 79125 4 RTD Sensor replacement for tank 79117 04 T500 Replacement Module includes on board power supply relays 79253 01 for two hoses and heads and all auxiliaries Kit T750 replacement module without power supply 79256 01 T1000 without power supply up to 6 hose units no Auxiliaries 79196 25 T1000 without power supply up to 6 hose units A1 Auxiliary 79198 25 Package Three basic auxiliary relays are installed Must have PB 12 with up to 12 relays and power supply T1000 without power supply up to 5 hose heads A3 Auxiliaries 79198 22 Must have PB12 and power supply A3 Auxiliaries include 3 standard A plus remote Run to Standby switch and Run Standby Indicator Switch and Indicator light provided by customer RPM Monitor not available 52 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 HOSE CONTROLLER 2000284
23. as specifically stated in writing by Astro Packaging G Astro Packaging is responsible only for payment of shipping charges for delivery of a repaired or replaced product via the least expensive means of transport to customer or an authorized Sales and service Center in the Continental United States only Payment for shipment to Astro Packaging or an authorized Sales and service Center for evaluation repair or replacement is the responsibility of the customer For service under this warranty contact the Factory Authorized Representative from which the product was purchased THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR IMPLIED INCLUDING THE WARRANTY OF MERCHANTABILITY AND FITNESS FOR THE PARTICULAR PURPOSE Complete Reverse Side and Retain for Your Records Astro Packaging 3845 E Miraloma Ave Unit A Anaheim Ca 92806 714 572 1094 800 642 7876 toll free 714 572 1943 fax Rev D 10f2 70237 40 Equipment Record Record the information below on all equipment received and retain for your records Systems melt units hoses guns heads pattern controllers drivers etc Products were purchased from Astro Packaging Authorized Sales and Service Center Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No P
24. at least 30 minutes before making further adjustments Refer to section 3 3 performance specifications for temperature range of the melt tank mA EN NESE EEE SNE EAS ELECTRICAL PANEL INTERIOR n x N N N N N Eg HEI SE 2 Q l Fr 1 2000335 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 21 Hose Temperature Controller 2 To raise the supply hose temperature turn adjustment shaft clockwise To lower hose temperature turn adjustment shaft counterclockwise Temperature graduations on hose controllers reflect the approximate hose temperature For precise readings measure the inside hose temperature with a pyrometer and bead probe The supply hose temperature should be set to the minimum temperature required for application to ensure maximum hose life and prevent degradation of the material in the supply hose ELECTRICAL PANEL INTERIOR 2000336 22 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 5 3 2 Flow Control Valve The flow control valve 1 is an adjustable pressure regulating device mounted to the pump underneath the melt unit chassis It is adjusted from the lower right side of the melt unit using the 1 4 inch hex key supplied with the unit Adjust for the following conditions 1 Maximum flow low viscosity materials from the full clockwise setting adjust 1 2 to one turn ba
25. ate tank temperature can affect the performance of your hot melt system If the tank has reached an overtemperature condition try turning the controller down A failure of the solid state relay closed position can cause the tank to reach over temperature Check the relay s continuity failure of the relay is rare If problem persists replace the faulty component controller or relay On units with Standby make sure Standby switch is disengaged and in the Run position Switch the pump motor On Off switch to the On position Allow sufficient time for the melt tank to reach operating temperature This will cause the pump warm up switch to close thus completing the pump motor circuit When the pump motor experiences overload conditions it will shut off or the pump motor breaker will trip or both This is usually caused by insufficient pump warm up time If this problem persists the pump switch breaker may need replacement Adjusting the flow control valve F C V correctly will produce the desired pumping performance of your melt unit Refer to section 5 3 2 of this manual If the F C V is inoperable replace or repair it as specified in section 8 4 Refer to section 9 for pump kit information The pump motor is normally the last item to check when troubleshooting All motors have internal thermal protection Switch Off pump motor switch and allow the motor to cool for approximately 20 minutes Turn pump switch back On
26. ble Alarm 100 db Optional 230 VAC 79217 01 Kit Audible Alarm 100 db Optional 115 VAC 79217 02 Kit Hose Mole for in place cleaning of hoses 79281 01 Kit Adapter FC1 with V3 Pump KB30 79305 04 Timer Adapter Kit 90 280 VAC in 48 280 VAC out 79060 Timer Adapter Kit 3 32 VDC in 48 280 VAC out 79060 24 KB30 melt unit using FC1 Flow Control must be equipped with this kit Timer Adapter is used with customer timer to switch 120 240 VAC output If output is 120 VAC 5 Amp 79060 will switch up to 20 Amps If timer output is 3 32 VDC use 79060 24 to switch up to 10 Amps Band Heater installed on 100 Ib Melt Unit additional I comes on ea 79088 101 KB100 Band Heater installed on 50 Ib Melt Unit additional 79088 102 Kit Stak Lite System 115 VAC 79285 02 Kit Light bulb spare Stak Lite System 115VAC 79310 01 For Stak Lite System to function your melt unit must be equipped with a T1000 with A3 auxilliary package a proximity type low level sensor remote power on relay kit and additional pole relays for PLC interface Consult factory for assistance O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 55 Appendix A Component Resistance Tables Table 1 Hose Applicator Fuse Size Specification Table 2 RTD Sensor Resistance Table 3 Heater Resistance
27. ck counterclockwise This will prevent pressure surges when system is valved open 2 Maximum flow high viscosity materials adjust so pump will start and run at normal speed when switched on with the system valved shut 3 Adjusting for lower flow rates adjust for desired flow rate when system is valved open WI WU Wl WK w __ AWWWW E d 4 g d NR WH WT WWW WK WOE 7 WW LE 2000172 CAUTION For maximum performance and motor life do not allow pump motor to stall Prolonged stall conditions will cause motor to go into thermal overload O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 23 6 Maintenance 6 1 Preventive Maintenance Procedure Daily Monthly AS Required Check for foreign material in tank X Wipe off excess adhesive from cover X Purge tank and hoses X X Clean tank screen X Clean replace pump filter X Clean applicator nozzle X Check for leaks X Extra maintenance required for continuous duty machines 6 2 General Maintenance 6 2 1 Warning and Caution Notes KB Series melt units require monthly temperature checks per section 6 2 3 Should char buildup occur or if the hot melt formulation is changed the system should be purged with a flushing agent such as Astro Packaging Strip N Clean Before attempting any maintenance procedure read the warning a
28. e in section 8 1 steps 1 through 7 4 Refer to section 9 for sequential parts breakdown Remove the four socket screws attaching the flow control valve and pump to the pump block Pull pump out and remove its o ring and pump block gasket Provide new replacement seals Refer to section 9 for appropriate pump kits Also remove flow control connection piece from the pump block if applicable Place o rings in the pump groove and on the flow control connection piece after lubricating with high temperature silicon based grease NOTE On units pumping heavy sealants it is necessary to slick both sides of the pump block gasket using some of the sealant itself to prevent air from being drawn into the pump 8 Install flow control and pump as an assembly with screws o ring and gasket in place Align pump shaft tab with drive shaft slot Take care not to cut o ring on the connection tube during assembly process Before tightening screws check pump o ring alignment by manually pressing the flow control valve against the pump CAUTION Be sure pump o ring is properly aligned in pump groove when replacing pump and or flow control valve A pinched or misaligned 10 11 12 o ring may result in pump leakage Replace the supply hose according to the procedure described in section 4 3 To properly align the pump with the motor turn flow control adjustment screw all the way out counterclockwise and loosen pump moun
29. e kit contains a thermostat that is mounted to the tank s base plate The two leads from the thermostat must be connected between two unused terminals on the terminal block The unused terminals should then be labeled by the user to TA 30 and TA 31 for reference The kit order number for a thermostat rated at 250 F is 79068 265 For other temperature options please contact an Astro Packaging sales representative KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 15 4 5 Customer Hookups 16 This list addresses most of the available options and configurations Always refer to the schematic that comes with your individual machine 4 5 1 Valve groups also known as Head groups Any melt unit can have up to 6 different valve groups See your schematic to determine how individual coil sets are wired within your machine Valve Group Terminals 1 4 amp 15A 2 4A amp 15B 3 7 amp 15C 4 7B amp 15E 5 6 amp 15F 6 6C amp 15G KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 4 5 2 Other Hookups As some of these terminations are optional they may not be present in your machine For additional hookups consult the appropriate accessory manual and wiring diagram that came with your machine Feature Option Terminals Notes Run Ready 60A amp 61A Dry contact closure to signal parent
30. ect incoming hose power connector and check hose heater resistance with an ohmmeter If the hose heater has failed it is necessary to replace the hose Refer to the appropriate supply hose service manual and section 8 1 Supply Hose Replacement Determine if applicator is heating by using a surface temperature probe or a temperature sensing device Do not touch applicator by hand to determine temperature Refer to the appropriate applicator service manual O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 31 Problem Solutions Applicator and supply hose overheat Determine exact voltage of the melt unit Insufficient voltage can be the cause of these problems Voltage drops are common Use a voltmeter to determine whether sufficient voltage is supplied to the melt unit Also the voltage of each melt unit component must be compatible to the melt unit or serious damage to the system will occur Refer to section 4 4 Electrical Circuits amp Wiring Adjust the supply hose temperature controller according to section 5 3 in this manual Inadequate supply hose heat can affect the performance of your hot melt system If problem persists see Hose Controller Replacement section 8 2 and section 9 for Hose temperature controller kits Determine if applicator is heating by using a surface temperature probe or a temperature sensing device Do not touch applicator by
31. es are adequate and no char is present in system l 2 Nu gd TA Switch Off the pump motor switch Depressurize the system by activating the head until glue stops flowing Using 9 16 hex wrench remove plug 1 from the end of the pump block 5 at the back of the unit AN CAUTION Hot glue will leak out as the fitting is removed 4 Using needle nose pliers remove the spring 2 thimble 3 and filter element 4 Temporarily replace plug to prevent hot melt drainage Clean filter element or replace as required Reinstall spring thimble and filter element as removed Reinstall plug 2000173a O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 27 7 Troubleshooting Problem Solutions Tank fails to heat OVERTEMPERATURE THERMOSTAT 2000285 Main Breaker Turn the system power switch to the On position If switch light fails to illuminate the switch may need replacement Power Cord Inspect the power in connections for proper fit and check for faulty wires Also inspect the connection of the power wires at the main power supply source Incoming Voltage Determine exact voltage of the melt unit Insufficient voltage can be the cause of these problems Voltage drops are common Use a voltmeter to determine whether sufficient voltage is supplied to the melt unit Also the voltage of each melt unit component must be compatible
32. for wear replace as required 7 Replace the bal seal in the block Apply small amount of high temperature lubricant Astro Packaging p n 30120 1 to the drive shaft in the area of the bal seal 8 Reassemble drive shaft assembly in reverse order 9 Refit drive shaft assembly to pump block replace gasket if required Do not fully tighten mounting screws 10 Switch on system power switch and allow tank heaters to warm up enough to permit turning of the pump drive shaft 1 Turn pump shaft and allow the drive shaft assembly to self align with the pump Tighten drive shaft assembly mounting screws and again rotate shaft by hand to see that it turns freely Realign if required 12 Replace motor mount assembly and coupling Do not fully tighten mounting bolts 13 Switch on pump motor switch and check misalignment of motor drive shaft Adjust motor mount position as required and tighten bolts Check again for misalignment and readjust motor mount position if required KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 43 9 Parts List 9 1 Pumps V4 and Accessories Item Description Quantity Part Number Pump kit V4 450 with Flow Control Valve amp block 79211 16 Pump kit V4 675 with Flow Control Valve amp block 79211 17 Pump Kit V4 450 all melt units 79290 1 Pump Kit V4 675 all melt units 79290 2 Pump Block O Ring Kit V
33. hand to determine temperature Refer to the appropriate applicator service manual Pump inoperative PUMP WARM UP THERMOSTAT V3 and V4 2000280 Main Breaker Turn the system power switch to the On position If switch light fails to illuminate the switch may need replacement System power switch and pump motor switch must both be in the On position for pump to operate Determine exact voltage of the melt unit Insufficient voltage can be the cause of these problems Voltage drops are common Use a voltmeter to determine whether sufficient voltage is supplied to the melt unit Also the voltage of each melt unit component must be compatible to the melt unit or serious damage to the system will occur Refer to section 4 4 Electrical Circuits amp Wiring Determine exact voltage and frequency of the pump motor marked on the motor data label located on the motor Switch the pump motor On OFF switch to the On position Allow sufficient time for the melt tank to reach operating temperature This will cause the pump warm up switch to close thus completing the pump motor circuit If warm up switch is faulty or rated at a higher temperature it must be replaced Refer to section 9 Determine which pump is mounted in your melt unit Refer to the melt unit I D plate The pumping performance listed in section 3 of this manual depends upon certain pump and pump motor combinations Refer to section 9 for pump kit infor
34. he On position 2 Pump motor On OFF Switch and Indicator Light This switch allows the user to switch Off the pump motor during system warm up or system maintenance A circuit breaker pump warmup switch in the pump motor circuit protects the motor during a stall or an overload condition The pump motor indicator light above the switch will illuminate indicating the pump warmup switch has closed and the melt unit is ready for operation 3 Tank Temperature Meter Bimetallic only The tank temperature meter indicates the operating temperature of the melt tank It does not indicate the temperature of the supply hose The hose temperature adjustment located behind the front panel indicates the temperature of the supply hose 4 Tank Heating Indicator Light This light illuminates when tank heaters are powered It also assists the user when making temperature adjustments to the tank temperature controller 5 Overtemperature Indicator Light This is a protection feature All KB Series melt units are equipped with an overtemperature shutoff If the melt tank s temperature exceeds the rating of the overtemperature thermostat the overtemperature indicator light will illuminate and the overtemperature thermostat will regulate the melt unit s temperature The temperature rating of the overtemperature thermostat is below the failure temperature of the Viton o rings in the melt unit and the Teflon lining in the supply hoses Should an over
35. hs or 1 000 hours of use system any PUR system including hose gun whichever occurs first or head used with PUR any spare or replacement component pneumatic head industrial heated hose T100 Temperature Controller nozzle nozzle bar 5 Rebuilt equipment 90 days or 500 hours of use whichever occurs first The sole liability of Astro Packaging and exclusive remedy extended to any Astro Packaging customer shall be limited to replacing or repairing at the option of Astro Packaging any product returned under the terms of this warranty Labor and related expenses incurred to install replacement or repaired parts are not covered by this warranty Astro Packaging is not responsible for repair or replacement of any product that has been subject to abuse misuse alteration accident or negligent use nor for repairs made by an unauthorized person or with parts other than those provided by Astro Packaging Astro Packaging assumes no responsibility for the performance of adhesives or other materials used with its products The warranty for a product repaired or replaced under this warranty shall continue in effect for the remainder of the original warranty period or for ninety 90 days following the day of shipment by Astro Packaging of the repaired or replaced product whichever period is longer No warranty is made with respect to custom products or products developed designed and manufactured to customer specifications except
36. ication O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 37 Problem Solutions Excessive smoking from tank and 1 Adjust the tank temperature controller according to gun section 5 3 of this manual Inadequate tank temperature can affect the performance of your hot melt system If the tank has reached an overtemperature condition try turning the controller down A failure of the solid state relay closed position can cause the tank to reach over temperature Check the relay s continuity failure of the relay is rare If problem persists replace the faulty component controller or relay On units with Standby make sure Standby switch is disengaged and in the Run position 2 Adjust the supply hose temperature controller according to section 5 3 in this manual Inadequate supply hose heat can affect the performance of your hot melt system If problem persists see Hose Controller Replacement section 8 2 and section 9 for hose temperature controller kits 3 Adhesive formulations tend to be a factor in each previously listed problems Refer to Startup Instructions section 5 2 for cautionary notes System should be purged if formulation is incorrect KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 Problem Solutions Valving heads won t fire Main Breaker Turn the system power switch t
37. igured so that the three HAT switches control different combinations of the five or six heads The HAT switches are wired in two different modes Internally wired HAT switches utilize the melt unit s voltage as a power source externally wired HAT switches use a separate power source for systems that use external control devices Head control circuits must be isolated from the melt unit power when using Astro Packaging DC Head Drivers or damage will result to the timing device These wiring configurations are illustrated in the electrical schematic that ships with the melt units 14 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 O Copyright Astro Packaging 2009 4 4 3 Parent Machine Lockout Circuit Two variations of the parent machine lockout circuit are available for the KB melt units e The first variation allows the parent machine to lock out the melt unit by controlling the melt unit s pump motor A pair of contacts furnished by the parent machine is connected into the melt unit between terminal block locations TA 9 and TA 9a Jumper 3 must be removed After the contacts have been connected and the jumper removed the melt unit s pump motor is only operational when the parent machine is in use e The second variation must be ordered as a kit from Astro Packaging This variation locks out the parent machine until the melt unit has reached an acceptable operating temperature Th
38. ion 5 3 NOTE On multihose systems a temperature imbalance between hoses can be quickly found by feeling the outside insulation of each hose Supply hose Temperature Check A supply hose temperature check should only be done if there is reasonable doubt that the supply hose is not heating properly To do a supply hose temperature check it is necessary to probe one end of the supply hose The supply hose must remain electrically connected to the melt unit This means extreme caution and protection should be used because the supply hose is physically hot Removing the applicator head from the supply hose or removing the supply hose from the melt unit are two methods for doing a supply hose temperature check The procedure for removing the applicator head from the supply hose is described below The method for removing the supply hose from the unit is described in the Heated Supply Hose manual 1 Switch Off the pump motor switch 2 Depressurize the system by activating the head until glue stops flowing O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 25 3 Disconnect the applicator head s electrical connector from the matching supply hose connector Loosen 76 JIC fitting on the applicator head enough to allow molten glue to leak past the fitting Once the glue stops flowing and all pressure is relieved remove the supply hose from the head Securely position the output end of the su
39. it V2 30 Ib melt units 79176 4 Pump Insulation Kit V2 50 100 Ib melt units 79176 3 Pump Filter Kit 50 Mesh 79064 NOTE Teflon o rings are recommended for polyamide Contact your local distributor for assistance MOUNTING HARDWARE V2 PUMP BLOCK V2 PUMP V2 PUMP O RINGS V2 FILTER 2000264 V2 FLOW CONTROL VALVE ASSEMBLY O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 45 9 3 Pumps V3 and Accessories Item Description Quantity Part Number V3 450 Pump Assembly with integrated FCV 79204 6 V3 675 Pump Assembly with integrated FCV 79204 8 V3 450 Pump complete filter block amp FCV 79211 10 V3 675 Pump complete filter block amp FCV 79211 11 V3 Flow Control Repair Kit 79082 8 Kit Knob Assembly FCV V2 V3 Retrofit 79287 02 Kit V3 Pump Teflon o ring 30 50 100 Ib MU 79290 06 Pump insulation kit V3 or V4 30 Ib melt units 79176 2 Pump insulation kit V3 or V4 50 100 Ib melt units 79176 1 Pump Filter Kit 50 Mesh 79064 Drain Purge Valve Kit KB 30 50 100 only 79057 1 Kit Mounting FC1 KB50 100 79385 02 Kit Mounting FC1 KB30 79385 04 NOTE Teflon o rings are recommended for polyamide Contact your local distributor for assistance 46 V4 PUMP BLOCK V3 PUMP ASSEMBLY FLOW CONTROL VALVE ASSEMBLY WITH INTEGRATED FCV N en LITT 2000338 KB30 KB50 and KB100 Series Hot Melt Uni
40. m temperatures to stabilize below 193 C 380 F before servicing Properly ventilate equipment according to MSDS of equipment Trained operators and service technicians should be aware of exposed surfaces of the unit that cannot be practically safeguarded These exposed surfaces may be hot and take time to cool after the unit has been operating Keep parts of the body away from rotating parts Do not wear loose articles of clothing when operating or servicing units with rotating parts Remove wristwatches rings necklaces or other jewelry and cover or pin up long hair before performing any work on or with the unit Trained operators may perform only external equipment adjustments Trained service technicians must perform internal adjustments and service KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 1 3 Electrical Safety Determine voltage of this equipment before installation and confirm compatibility with available power Equipment must be connected to a properly grounded circuit and installed in accordance with all applicable electrical codes Ground fault protection must be provided in supply circuitry at site installation Models designed to EN60204 1 1997 require power cords be approved to a harmonized HAR standard and rated for 70 C 158 F A HAR approved Type B plug and strain relief for power cord is required to meet standard IEC 309 Power conducting wires must be nominal 5 3 mm 10 AWG ma
41. mation Look into the melt tank for any foreign material plugging the inlet pump port Pump gears can freeze up in which case the pump may need replacement or repair 32 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 Problem Solutions Pump inoperative Continued The pump motor is normally the last item to check when troubleshooting All motors have internal thermal protection Switch Off pump motor switch and allow the motor to cool for approximately 20 minutes Turn pump switch back On If the motor still fails to operate continue troubleshooting Determine which pump motor is mounted in your melt unit Refer to the motor I D plate Look into the melt tank for any foreign material plugging the inlet pump port Pump gears can freeze up in which case the pump may need replacement or repair Remove foreign material from pump and tank Purge system with Strip N Clean if necessary Pump motor stalls Adjust the tank temperature controller according to section 5 3 of this manual Inadequate tank temperature can affect the performance of your hot melt system If the tank has reached an overtemperature condition try turning the controller down A failure of the solid state relay closed position can cause the tank to reach over temperature Check the relay s continuity failure of the relay is rare If problem persists replace the faulty component c
42. nd caution notes that follow WARNING Hot melt materials can cause severe burns resulting in disfigurement or blindness Take the following precautions before beginning any maintenance e Wear eye protection goggles gloves and protective clothing Switch pump motor On Off Switch to the Off position Make sure the head is positioned over some type of disposal receptacle Depressurize the supply hoses and valving heads Always disconnect the supply hose electrical connector before hose fittings are disconnected 24 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 CAUTION To prevent damage to components hose fittings etc the system specifically the part being serviced should be heated to approximately 250 F prior to dismantling assembly or adjustment Failure to do this will result in stripping of threads and ruining both parts and tools To avoid arcing of electrical contacts and possible failure of components do not connect hose or head electrical connectors when the power switch is ON 6 2 2 Heating of Parts Heating parts may be accomplished by e Applying power to the melt unit e Using a hand held hot air gun 6 2 3 Monthly Inspection Procedure Hose Inspection 1 Verify that the hose is being properly supported so it is not over stressed during use Minimum bend radius is 8 inches when hot 2 Check temperatures and adjust as explained in sect
43. nd the melt unit and the applicator heads or handguns wrapped in packaging envelopes A 1 4 inch hex wrench for the flow control valve and a binder containing system manuals and warranty information are shipped with the units it Position the melt unit so that servicing is convenient and the control panel is easily accessible Using the base mounting holes bolt the melt unit down to the mounting surface The mounting surface must be level and flat to prevent warping of the melt unit and misalignment of the pump and motor shaft The melt unit must be properly bolted down to prevent accidental upset and possible injury 4 3 Component Installation For safe and proper installation and to avoid accidental pressurization make certain that all controls are in the Off position Read section 5 1 Controls and Indicators before installing any components 10 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 4 3 1 Hot Melt supply hoses Important Points 1 To prevent damage to the hot melt supply hose the hose should not be flexed when cold These hoses have a minimum bend radius of eight inches when hot Further flexure will cause permanent damage 2 Hot melt fittings must be heated before loosening or tightening or damage may result New and clean supply hose fittings do not need to be heated 3 To install the supply hoses on the melt unit raise or tilt the unit far enough backward
44. nnected Switch the pump motor On Off switch to the On position Allow sufficient time for the melt tank to reach operating temperature This will cause the pump warm up switch to close thus completing the pump motor circuit Replace pump breaker Adjusting the flow control valve F C V correctly will produce the desired pumping performance of your melt unit Refer to section 5 3 2 of this manual If the F C V is inoperable replace or repair it as specified in section 8 4 Refer to section 9 for pump kit information The pump motor is normally the last item to check when troubleshooting All motors have internal thermal protection Switch Off pump motor switch and allow the motor to cool for approximately 20 minutes Turn pump switch back On If the motor still fails to operate continue troubleshooting Determine which pump motor is mounted in your melt unit Refer to the motor I D plate Pump leaks Determine which pump is mounted in your melt unit Refer to the melt unit I D plate The pumping performance listed in section 3 of this manual depends upon certain pump and pump motor combinations Refer to section 8 4 Pump Flow Control Replacement and section 9 for pump kit information Tighten F C V and pump mounting screws If pump continues to leak replace the o ring copper shim and tank gasket O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 0
45. nterclockwise per section 5 3 If the O T light is On at an acceptable or low tank temperature the O T switch is either faulty or rated at a low temperature The O T switch must be replaced in either case Refer to section 9 for switch kits Applicator and supply hose heat slowly Determine exact voltage of the melt unit Insufficient voltage can be the cause of these problems Voltage drops are common Use a voltmeter to determine whether sufficient voltage is supplied to the melt unit Also the voltage of each melt unit component must be compatible to the melt unit or serious damage to the system will occur Refer to section 4 4 Electrical Circuits amp Wiring Adjust the supply hose temperature controller according to section 5 3 in this manual Inadequate supply hose heat can affect the performance of your hot melt system If problem persists see Hose Controller Replacement section 8 2 and section 9 for Hose temperature controller kits Determine if applicator is heating by using a surface temperature probe or a temperature sensing device Do not touch applicator by hand to determine temperature Refer to the appropriate applicator service manual Determine exact voltage of the head heaters and the supply hose found on the identification tags 30 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 Problem Solutions heat Applicator and su
46. o the On position If switch light fails to illuminate the switch may need replacement System power switch should be in the On position and the HAT switch must be in the Run position Incoming Voltage Determine exact voltage of the melt unit Insufficient voltage can be the cause of these problems Voltage drops are common Use a voltmeter to determine whether sufficient voltage is supplied to the melt unit Also the voltage of each melt unit component must be compatible to the melt unit or serious damage to the system will occur Refer to section 4 4 Electrical Circuits amp Wiring Determine coil voltage of the applicator head I D plate and check incoming control voltage to terminal blocks Refer to electrical schematic that came with the melt unit Refer to the electrical schematic that came with the melt unit and check the actual wire connections to ensure that the melt unit is wired properly If problem still exists check the status of specific components with a voltmeter system powered or with an ohmmeter system unpowered wire disconnected Adjust the supply hose temperature controller according to section 5 3 in this manual Inadequate supply hose heat can affect the performance of your hot melt system If problem persists see Hose Controller Replacement section 8 2 and section 9 for hose temperature controller kits Determine if applicator is heating by using a surface temperature probe or a temperature sen
47. on certain pump and pump motor combinations Refer to section 9 for pump kit information Consult factory for the proper pump combination needed for specific application 6 The pump motor is normally the last item to check when troubleshooting All motors have internal thermal protection Switch Off pump motor switch and allow the motor to cool for approximately 20 minutes Turn pump switch back On If the motor still fails to operate continue troubleshooting Determine which pump motor is mounted in your melt unit Refer to the motor I D plate Consult factory for the properly rated pump motor for your specific application 7 Increase melt tank and supply hose Temperatures per section 5 3 1 If this does not improve performance consult the adhesive vendor concerning your applications 36 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 Problem Solutions Adhesive output too low Continued Adhesive formulations tend to be a factor in each previously listed problems Refer to Startup Instructions section 5 2 for cautionary notes System should be purged if formulation is incorrect Clean applicator nozzle or change to larger nozzle Refer to section 9 Maintenance Tools Adhesive output too high Adjusting the flow control valve F C V correctly will produce the desired pumping performance of your melt unit Refer to section 5 3
48. ontroller or relay On units with Standby make sure Standby switch is disengaged and in the Run position Adjusting the flow control valve F C V correctly will produce the desired pumping performance of your melt unit Refer to section 5 3 2 of this manual If the F C V is inoperable replace or repair it Refer to section 9 for pump kit information The pump motor is normally the last item to check when troubleshooting All motors have internal thermal protection Switch Off pump motor switch and allow the motor to cool for approximately 20 minutes Turn pump switch back On If the motor still fails to operate continue troubleshooting Determine which pump motor is mounted in your melt unit Refer to the motor I D plate Remove foreign material from pump and tank Purge system with Strip N Clean if necessary Increase melt tank and supply hose temperatures per section 5 3 1 If this does not improve performance consult the adhesive vendor concerning your applications Adhesive formulations tend to be a factor in each previously listed problems Refer to Startup instructions section 5 2 for cautionary notes System should be purged if formulation is incorrect O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 33 Problem Solutions Pump motor overload Adjust the tank temperature controller according to section 5 3 of this manual Inadequ
49. oup 1 3 hp 170 RPM 200 230 VAC 60 Hz 73278 98 Motor Assembly 1 3 hp 140 RPM 200 230 VAC 50 Hz 73012 81 Motor Group 1 3 hp 140 RPM 200 230 VAC 50 Hz 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 MOTOR ASSEMBLY gt 1s BREAKER COUPLING PUMPSHAFT SPIDER ASSEMBLY COUPLING 2000339 50 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 Copyright Astro Packaging 2009 9 8 Standard Fan Cooled Motor Support Item Description Quantity Part Number Wire nuts medium low temperature 12277 2 Spider bronze 2 jaw 18425 7B Coupling 9 16 bore 1 8 keyway 2 jaw 18425 6G Coupling 5 8 bore 3 16 keyway 2 jaw 18425 6H Coupling 3 4 bore 3 16 keyway 2 jaw 18425 6J Spider bronze 3 jaw 18425 7C Coupling 5 8 bore 3 16 keyway 3 jaw 18425 3 Coupling 9 16 bore 1 8 keyway 3 jaw 18425 4G Coupling 3 4 bore 1 16 keyway 3 jaw 18425 4J Coupling 19 mm bore 6 mm keyway 3 jaw 18425 4K Breaker motor 2 9 Amp 115 VAC Fast Trip 12055A 29 Breaker motor 1 5 Amp 230V Fast Trip 12055A 15 Breaker motor 2 0 Amp 12055 2 Breaker motor 2 5 Amp 520 Trip 12055B 25 Pump Shaft Assembly 73726 Kit Gearbox Repair 86 72 RPM Motor 79295 02 Common motor bre
50. pply hose fail to Main Breaker Turn the system power switch to the On position If switch light fails to illuminate the switch may need replacement System power switch and supply hose power switch must both be in the On position for hoses and heads to heat Power Cord Inspect the power in connections for proper fit and check for faulty wires Also inspect the connection of the power wires at the main power supply source Inspect the 9 pin hose electrical connector for proper fit Incoming Voltage Determine exact voltage of the melt unit Insufficient voltage can be the cause of these problems Voltage drops are common Use a voltmeter to determine whether sufficient voltage is supplied to the melt unit Also the voltage of each melt unit component must be compatible to the melt unit or serious damage to the system will occur Refer to section 4 4 Electrical Circuits amp Wiring Adjust the supply hose temperature controller according to section 5 3 in this manual Inadequate supply hose heat can affect the performance of your hot melt system If problem persists see Hose Controller Replacement section 8 2 and section 9 for Hose temperature controller kits Check the incoming hose power connector 9 pin underneath the melt unit to see if it is properly installed Connector wire pins may be misaligned or loose If the melt unit has a supply hose power switch make sure it is the On position If problem remains disconn
51. pply hose over a disposal receptacle so that it will not fall and pull the supply hose away Do not point the end of supply hose towards face or any other part of the body 4 When the supply hose has reached operating temperature insert a pyrometer bead probe approximately 2 ft into output end of the supply hose If the supply hose temperature is verified to be in error it should be adjusted to the desired operating temperature as instructed in section 5 3 1 After adjusting the temperature allow the supply hose temperature to stabilize before checking temperature and removing the bead probe 5 Switch Off the system power switch and reconnect the applicator head to the supply hose Tank Temperature Check 1 Verify the system is not operating in overtemperature mode Refer to section 5 1 5 Overtemperature Indicator Light 2 Check the tank temperature meter and adjust tank temperature as explained per section 5 3 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 Refer to the melt unit parts list and assembly drawing in section 9 26 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 Pump Block Filter Cleaning NOTE This procedure need not be done if flow rat
52. roduct Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Product Model Description Serial No Product Part Number Order No Date Received Start Up Date Invoice No Astro Packaging 3845 E Miraloma Ave Unit A Anaheim Ca 92806 714 572 1094 800 642 7876 toll free 714 572 1943 fax Rev D 2 of 2
53. s so that the bottom is accessible but not as far so adhesive spills out of the melt tank Do not turn melt unit upside down a monno Insert thermostat bulb entirely into brass tube of hose 1 Take care not to kink the capillary tube 4 or not to bend the hose at a sharp angle Capillary controlled hoses only Loosely connect JIC swivel fitting 6 on hose to the right angle fitting 5 on the hose connection flow control 7 or manifold 8 Make sure the brass tube with thermostat bulb is oriented at either three or nine o clock for optimal temperature control Capillary controlled hoses only Fasten hose support block 3 to chassis Tighten JIC swivel fittings Plug in hose electrical connector s 2 Tuck capillary tubing and electrical connector underneath the unit Capillary controlled hoses only Position and support hose as it is used in service O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 11 4 Failure to properly support the supply hose will result in premature failure Support the supply hose to prevent excessive flexure Do not support the supply hose in a way that may add to the thermal insulation or overheating will result Do not add to the hose support block 5 Always check the calibration of the supply hose s temperature after installing a new or different ho
54. se Hoses can vary and each supply hose can produce different temperature results Refer to the supply hose manual for this procedure 4 3 2 Supporting Applicator Heads Applicator heads such as the Astro Packaging E100 are mounted to appropriate brackets using supplied hardware For the head to reach operating temperature insulation spacers must be used between the applicator head and the mounting bracket and between the mounting bracket and mounting bolt see illustration below The applicator head should be mounted as close as possible to the application surface Refer to the applicator head manual for detailed mounting and operating instructions 2000191 12 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 4 4 Electrical Circuits and Wiring O Copyright Astro Packaging 2009 The KB melt units use standard single phase 230 volt power sources each with earth ground for safety An identification plate is attached to each melt unit on the outside of the rear door of the tank housing This plate specifies the exact voltage and maximum current of the melt unit and the frequency of the pump motor Pump motor voltage frequency and current are specified on the motor data plate located on the motor For safe and proper installation it is important to refer to the identification plate before applying electrical power to the melt unit Also refer to section 3 for further mel
55. se serious injury and burns Wear heat resistant clothing gloves and safety goggles WARNING Disconnect electrical power at external source Failure to do so can cause electrical shock WARNING High Pressure System contents under pressure Can cause serious injury and burns or equipment and property damage Relieve pressure before servicing Other Product Symbols On Off Ground Protective Earth Tank Heated Hose Applicator Pump Motor w 4d 7 4d T Set Temp Standby Temp Overtemp Adhesive Flow Jet I O Tank Heater Alarm Actual Temp Source Power Valve Group Manual Task Input Output The manufacturer reserves the right to make design changes for product improvement This manual may not reflect all details of these improvements O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 2 Introduction 2 1 Description 2 2 Features The KB30 KB50 and KB100 Series of heavy duty melt units supplies hot melt adhesive in a wide range of applications The tank capacity of these melt units is 30 50 and 100 pounds A wide range of options affords choice of pump and motor size thermostat or solid state temperature controllers and head firing or gun hose configuration All units operate on single phase AC power with models available for 230 VAC power sources These units operate up to five KB30 or six KB50 and KB100 automatic or two manual applicators and are supported by
56. sing device Do not touch applicator by hand to determine temperature Refer to the appropriate applicator service manual Clean applicator nozzle Refer to section 9 Maintenance Tools Make sure the HAT switch is in Run position This allows valving signals to reach the applicator heads To check if applicator heads are functioning properly place the HAT switch in the Test position This will test fire the heads only if an external device such as a Timer or a DC Driver is not used If no external device is used and the head does not test fire in the Test position it is possible the head coil could have failed If an external device such as timer or a DC Driver is being used the problem may lie with the external device Refer to the external device s service manual O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 39 8 Repair and Replacement Refer to Parts List in section 9 for all replacement parts listed in this section Repair and replacement procedures not found here are on the instruction sheets that come with spares kits listed in section 9 8 1 Supply Hose Replacement 1 Switch Off system power switch and allow the hot melt material in the melt tank to cool CAUTION Liquified hot melt adhesive can cause difficulty in maintaining your unit Be certain that all material in the tank has cooled before continuing with maintenance 2 Switch On system power
57. ssesusss sodsos oos sss usssssso sste ssosrss sissoo 24 6 2 1 Warme and Ca tion N S Lae 24 6 2 HP ER 25 6 2 3 Monthly Inspection Procedure uiua baie samedskengmadentGemaean apie 25 7 Troubleshooting m ds eden 28 8 Repair and Replacement sasscischivecacadacdivecaiss sspancssistsstasastsneshisoceusisebouastieascesveabivavesusesbecasus 40 8 1 Supply Hose Replacement dme m ener sees eee eee ses s een es sees sneen eee 40 8 2 Hose Controller Replacement Bimetallic 1 enes enes seen tna nen eee 41 8 3 Pump Motor Replacement sissisescsisscsecceveucsedscsiisssseouvasdsadtssndsssossecscoensgecsssabaes soonseecoosssoadessosusassunbece 41 8 4 V4 Pump 450 and 675 Flow Control amp Drive Shaft Replacement eee 42 8 4 1 V4 Pump Replacement 450 and 675 adsense dan seen 42 8 4 2 V4 and V3 Drive Shaft Assembly Replacemeht eie tei teu en ate eq bet SN es 43 9 Parts Liss 44 9 1 Pumps V4 and Accessories siddende sees ses es o oet ee ceto we peace tk e oobd eei duo sue eee bue p es 44 9 2 Pumps V2 and ACCOSSOFIGS a drieceessceten tebesise e kubese soe ee sense Uo Tees eo bet bo et eU noc dn ss uve ve bx sees eders ses sens 45 9 3 Pumps V3 and Accessories acier eite ep on ee ode a REF ET ep PR e Fee a CERE Te e REEF e e sisoas AER d o ERR e EE NURSE ERR TN ERE PR EREEHI 46 9 4 Standard Melt Unit Switches inei oriente reni en peei Ipae eol eee Ia PE trees na eee eee sees CIAR eee enes dan 47
58. switch and supply hose power switch for 5 minutes to allow fittings to warm up Switch Off system power switch after the 5 minutes has elapsed Disconnect power and tilt unit backward Disconnect the supply hose electrical connector Remove screws from hose mounting block ON eno cbe O9 Loosen hose JIC fitting and remove hose from 90 degree fitting on the flow control valve 7 Disconnect the applicator head s electrical connector and remove the old supply hose from the 6 JIC fitting on the applicator head 8 Install new supply hose on the melt unit as specified in section 4 3 Component Installation 9 Install applicator head on the new supply hose Switch On system power switch and supply hose power switch to determine if the applicator head and supply hose are operating properly 40 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 8 2 Hose Controller Replacement Bimetallic 1 Follow section 8 1 steps 1 7 for hose replacement 2 Disconnect melt unit power and open front control panel 3 Disconnect controller wires 4 Remove the two 6 32 screws fastening the controller to the electrical mounting panel CA Attach hose to the JIC fitting as specified in section 4 3 6 Reconnect melt unit power switch hose power switch On and adjust controller as indicated in section 5 3 1 8 3 Pump Motor Replacement 1 Switch Off system power switch and disconnect mel
59. t unit power 2 Remove back panel and housing for 170 rpm motor on KB30 melt units 3 Disconnect motor electrical connector and remove fast on connectors from capacitor 4 Remove motor with mounting bracket as a whole assembly from the melt unit 5 Remove motor shaft coupling Remove motor from mounting bracket 6 Reassemble melt unit with new motor 7 Turn motor On system warmed up and observe motor and drive shaft coupling for misalignment Loosen and retighten motor mounting bracket to realign as necessary NOTE Motor must turn the pump shaft counterclockwise looking down on the pump shaft 8 Replace housing for 170 rpm motor on K B30 melt units and back panel O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 41 8 4 V4 Pump 450 and 675 Flow Control amp Drive Shaft Replacement 8 4 1 V4 Pump Replacement 450 and 675 42 l If it is possible and can be done safely pump out all the hot melt material in the melt unit then switch off the system power switch and allow the melt unit to cool down completely Otherwise switch off system power switch and allow adhesive in tank to completely solidify Switch on system power switch for 10 minutes to allow pump and flow control valve to warm up Switch off system power switch disconnect melt unit power remove the back panel and tilt unit forward Remove the supply hose according to the procedur
60. t unit electrical specifications L L1 N L1 L2 TI IT 230VAC L1 N 200 240VAG L1 L2 Single Phase Service Single Phase Service S ED S FE S 0990047 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 13 AN CAUTION Always check the wiring configuration in the electrical panel terminal blocks before and after making electrical connections Verify that the jumpers are in their correct locations to avoid possible damage to the system 4 4 1 Automatic Heads The appropriate power in head program wires and jumpers must be configured or installed in the terminal block provided A detailed electrical schematic is shipped with the melt units Astro Packaging recommends the use of 3 8 liquid tight conduit and fittings when routing wires to the electrical terminal blocks 7 8 diameter holes in the chassis are provided for these installations Close the front panel after completing electrical wiring 4 4 2 Head Control Circuit The head control circuit allows electrical valving signals to be channeled to the correct applicator head s This circuit is enabled and disabled by the HAT switches user added option only located on the front panel A KB30 with the maximum five head hose combinations or KB50 KB100 with the maximum six head hose combinations and three HAT switches can be conf
61. tank temperatures to desired settings Lower settings will increase the material s pot life NOTE Certain product assembly materials will degrade over time due to oxidation It is best not to put more material in the tank than are used in one day Set the tank temperature as low as feasible for each specific application To prevent stalling of the motor adjust the flow control valve so the pump is partially bypassed 20 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 5 3 Adjustments O Copyright Astro Packaging 2009 5 3 1 Temperature Adjustments Bimetallic NOTE Refer to temperature controller manual for solid state temperature controllers Tank Temperature Controller 1 To prevent degradation of the hot melt material the melt tank temperature should be set to the minimum temperature specified by the hot melt manufacturer Melt tank temperature is controlled by a 30 amp KB30 or 40 amp KB50 100 230 VAC solid state relay on the electrical panel The relay is in turn controlled by the melt tank temperature controller To raise melt tank temperature turn the melt tank temperature controller s adjustment shaft clockwise To lower temperature turn the adjustment shaft counterclockwise Use the tank temperature meter to verify temperature The tank temperature can also be verified by inserting a pyrometer into the tank calibration hole Allow melt tank temperature to stabilize
62. temperature condition occur the tank temperature controller should be replaced if it has failed 18 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 6 Head Activate Deactivate Test HAT Switch user added option only The head activate deactivate test switch HAT controls the valving signals to the automatic heads The HAT switch is located on the melt unit s front panel and can be identified by the three positions on the switch body Off to disable the head control circuit TEST allows the heads to be test fired independently and RUN enables the head control circuit and allows head valving signals from timers drivers limit switches or photoeyes to actuate the heads KB30 KB50 and KB100 melt units can have a maximum of three HAT switches to control up to three independent valving head signals The HAT switches can be connected in a variety of combinations since each melt unit can support up to six automatic heads WARNING During system warm up and when adjusting system hoses or valving heads each HAT switch must be in the Off center position to prevent accidental head firing 1 2 4 4 POWER PuUv TANK TEMPERATURE TANK TEMPERA JRE HEATING HEATING ov E X 3 EA o 9 D OVERTEMP OVERTEMP DVERTENP ml 5 O O
63. ting screws one half turn each Reconnect melt unit power turn system power switch on and allow unit to warm up KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 Copyright Astro Packaging 2009 O Copyright Astro Packaging 2009 13 Turn pump motor switch on and carefully tighten pump mounting screws while pump is turning This will align the pump with the drive shaft assembly 14 Observe motor and drive shaft coupling Check for misalignment If necessary loosen and retighten motor mounting bracket to realign Replace rear panel 8 4 2 V4 and V3 Drive Shaft Assembly Replacement 1 Ifitis possible and can be safely done pump out all of the hot melt material in the melt unit then switch off the system power switch and allow the melt unit to completely cool down Otherwise switch off system power switch and allow hot melt material in tank to completely solidify 2 Switch on system power switch for about 10 minutes to allow melt unit to warm up enough to permit removal of drive shaft assembly 3 Remove back panel and remove motor mounting assembly and motor coupling 4 Remove the two socket head cap screws that hold the drive shaft block to the pump block Pull the drive shaft assembly off the pump block 5 Dismantle drive shaft assembly by pressing the motor side of the shaft through the block Support the block so the bal seal is free to come out with the drive shaft 6 Clean all parts and inspect
64. to the melt unit or serious damage to the system will occur Refer to section 4 4 Electrical Circuits amp Wiring Refer to the electrical schematic and check the actual wire connections to ensure that the melt unit is wired properly If problem still exists check the status of specific components with a voltmeter system powered or with an ohmmeter system unpowered wire disconnected Tank Controller Adjust the tank temperature controller according to section 5 3 of this manual Inadequate tank temperature can affect the performance of your hot melt system If the tank has reached an overtemperature condition try turning the controller down A failure of the solid state relay closed position can cause the tank to reach over temperature Check the relay s continuity failure of the relay is rare If problem persists replace the faulty component controller or relay On units with Standby make sure Standby switch is disengaged and in the Run position Overtemperature Switch The Overtemperature O T switch is a safety device designed to prevent the melt tank from reaching a run away temperature condition Once the melt tank reaches an over temperature condition the O T switch controls the tank s temperature Check the melt tank s temperature when the O T indicator is lit If melt tank temperature is too high turn the tank temperature controller down counterclockwise per section 5 3 If the O T light is On at an
65. ts 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 9 4 Standard Melt Unit Switches Item Description Quantity Part Number Kit Tank Overtemp Thermostat 150 F 79127 150 Kit Tank Overtemp Thermostat 200 F 79127 200 Kit Tank Overtemp Thermostat 300 F 79127 300 Kit Tank Overtemp Thermostat 400 F 79127 400 Kit Tank Overtemp Thermostat 450 F 79127 450 Pump Warm up Thermostat 100 F 79068 100 Pump Warm up Thermostat 200 F 79068 200 Pump Warm up Thermostat 225 F 79068 225 Pump Warm up Thermostat 250 F 79068 265 Pump Warm up Thermostat 300 F 79068 300 Pump Warm up Thermostat 350 F 79068 350 Circuit Breaker 230 V 30 Amp KB30 12015 12 Circuit Breaker 230 VAC 40 Amp TXXX with Aux KB50 100 12015 19 Handle Kit 2 Pole Breaker 12015 12A Kit Circuit Breaker 40 Amp KB50 100 79003 01 Control Relay 200 230 VAC 40 amp 12040 92 Relay SSR 25A AC 12040 8 Relay SSR 25A DC 12041 6 O Copyright Astro Packaging 2009 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 47 9 5 HAT Switches Item Description Quantity Part Number Kit HAT Switch AC Head Group 1 79128 101 Kit HAT Switch AC Head Group 2 79128 102 Kit HAT Switch DC Head Group 1 79128 103 Kit HAT Switch DC Head Group 2 79128 104 HAT Switches end user to install Definition A HAT Switch is a 3 position switch that allows
66. ximum and nominal 2 1 mm 14 AWG minimum 1 4 Emergency Power Disconnect In the event of malfunction turn off power to the equipment at the power off switch and remove source power to the system at the nearest main disconnect 1 5 Follow Directions Read the product manual thoroughly before installation operation or maintenance Failure to do so can result in a serious accident or equipment malfunction The manufacturer will not be held liable for injuries or damage caused by misuse of this equipment 1 6 Safety Symbols and Signal Words The following safety symbols and signal words are used throughout the manual and on the product to alert the reader and operator to personal safety hazards or to identify conditions that may result in equipment or property damage DANGER Indicates a hazard which if not avoided will result in serious injury including death or equipment and property damage WARNING Indicates a hazard which if not avoided can result in serious injury or equipment and property damage CAUTION Indicates a hazard which if not avoided can result in minor injury or equipment and property damage 2 KB30 KB50 and KB100 Series Hot Melt Units 19600 159 Rev A 04 09 09 O Copyright Astro Packaging 2009 Specific Symbols and Signal Words DANGER High Voltage Can cause serious injury including death Disconnect electrical power at external source before servicing WARNING Hot Surface Can cau

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