ASTRO KB Series Bedienungsanleitung

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

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.

For Sales and Service Centers in your area,

Call 1-800-642-7876 or

Visit our website at www.astropackaging.com

Table of Contents

1 Safety Precautions for Hot Melt Applicator Equipment ................................................1

1.1 Intended Use.................................................................................................................................... 1

1.2 Personal Safety................................................................................................................................ 1

1.3 Electrical Safety .............................................................................................................................. 2

1.4 Emergency Power Disconnect........................................................................................................ 2

1.5 Follow Directions ............................................................................................................................ 2

1.6 Safety Symbols and Signal Words................................................................................................. 2

2 Introduction ......................................................................................................................4

2.1 Description....................................................................................................................................... 4

2.2 Features............................................................................................................................................ 4

3 Specifications....................................................................................................................6

3.1 Electrical .......................................................................................................................................... 6

3.2 Physical ............................................................................................................................................ 6

3.3 Performance .................................................................................................................................... 6

3.4 Dimensions....................................................................................................................................... 7

3.5 Operating Pressure and Adhesive Flow........................................................................................8

3.6 Adhesive Flow Path......................................................................................................................... 8

3.7 Temperature Controller Options .................................................................................................. 9

4 Installation......................................................................................................................10

4.1 Shipping and Handling................................................................................................................. 10

4.2 Supporting the Melt Unit ............................................................................................................. 10

4.3 Component Installation................................................................................................................ 10

4.3.1 Hot Melt supply hoses - Important Points ............................................................................... 11

4.3.2 Supporting Applicator Heads................................................................................................... 12

4.4 Electrical Circuits and Wiring..................................................................................................... 13

4.4.1 Automatic Heads...................................................................................................................... 14

4.4.2 Head Control Circuit................................................................................................................ 14

4.4.3 Parent Machine Lockout Circuit.............................................................................................. 15

4.5 Customer Hookups ....................................................................................................................... 16

4.5.1 Valve groups (also known as Head groups) ............................................................................ 16

4.5.2 Other Hookups ......................................................................................................................... 17

5 Operation ........................................................................................................................18

5.1 Controls and Indicators................................................................................................................ 18

[1] System-Power-Switch/Circuit-Breaker and Indicator Light ....................................................... 18

[2] Pump motor On/OFF Switch and Indicator Light....................................................................... 18

[3] Tank Temperature Meter (Bimetallic only) ................................................................................ 18

[4] Tank Heating Indicator Light...................................................................................................... 18

[5] Overtemperature Indicator Light................................................................................................. 18

[6] Head Activate/Deactivate Test (HAT) Switch (user-added option only) ................................... 19

5.2 Startup ........................................................................................................................................... 20

5.3 Adjustments................................................................................................................................... 21

5.3.1 Temperature Adjustments - Bimetallic.................................................................................... 21

5.3.2 Flow Control Valve.................................................................................................................. 23

6 Maintenance ...................................................................................................................24

6.1 Preventive Maintenance ............................................................................................................... 24

6.2 General Maintenance.................................................................................................................... 24

6.2.1 Warning and Caution Notes..................................................................................................... 24

6.2.2 Heating of Parts........................................................................................................................ 25

6.2.3 Monthly Inspection Procedure................................................................................................. 25

7 Troubleshooting .............................................................................................................28

8 Repair and Replacement ................................................................................................40

8.1 Supply Hose Replacement............................................................................................................ 40

8.2 Hose Controller Replacement - Bimetallic ................................................................................. 41

8.3 Pump Motor Replacement ........................................................................................................... 41

8.4 V4 Pump (.450 and .675), Flow Control & Drive Shaft Replacement ..................................... 42

8.4.1 V4 Pump Replacement - .450 and .675 ................................................................................... 42

8.4.2 V4 and V3 Drive Shaft Assembly Replacement...................................................................... 43

9 Parts List .........................................................................................................................44

9.1 Pumps, V4 and Accessories.......................................................................................................... 44

9.2 Pumps, V2 and Accessories.......................................................................................................... 45

9.3 Pumps, V3 and Accessories.......................................................................................................... 46

9.4 Standard Melt Unit Switches ....................................................................................................... 47

9.5 HAT Switches................................................................................................................................ 48

9.6 Tank Heaters ................................................................................................................................. 49

9.7 Standard Fan-Cooled Motors ...................................................................................................... 50

9.8 Standard Fan-Cooled Motor Support......................................................................................... 51

9.9 Temperature Controllers ............................................................................................................. 52

9.10 Tank Level Sensors..................................................................................................................... 53

9.11 Weather-Resistant Housing ....................................................................................................... 53

9.12 Chassis Fans ................................................................................................................................ 53

9.13 Reverse Hose Mounting Kits...................................................................................................... 53

9.14 Adhesive Pressure Gauges ......................................................................................................... 54

ii KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009

9.15 Melt Unit Stand/Bracket ............................................................................................................ 54

9.16 Miscellaneous............................................................................................................................... 55

Appendix A: Component Resistance Tables ....................................................................56

Table 1. Hose/Applicator Fuse Size Specification............................................................................ 56

Table 2. RTD Sensor Resistance........................................................................................................ 56

Table 3. Heater Resistance ................................................................................................................. 56

Table 4. E100XT Automatic Applicator Resistance ........................................................................ 56

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iv KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009

1 Safety Precautions for Hot Melt Applicator Equipment

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.

1.1 Intended Use

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.

1.2 Personal Safety

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 system 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.

Wear Safety Goggles

Wear Heat-Resistant

Safety Gloves

Wear Protective Clothing

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 mm2(10 AWG) maximum and nominal

2.1 mm2(14 AWG) minimum.

1.4 Emergency Power Disconnect

In the event of a 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.

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.

DANGER: Indicates a hazard, which, if not

avoided, will result in serious injury, including

death, or equipment and property damage.

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