Astro Kb series User manual

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

This page intentionally left blank.

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.

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

Specific Symbols and Signal Words

Other Product Symbols

The manufacturer reserves the right to make design changes for

product improvement. This manual may not reflect all details of

these improvements.

WARNING: High Pressure. System contents

under pressure. Can cause serious injury and burns

or equipment and property damage. Relieve

pressure before servicing.

WARNING: Disconnect electrical power at

external source. Failure to do so can cause

electrical shock.

DANGER: High Voltage. Can cause serious

injury, including death. Disconnect electrical

power at external source before servicing

WARNING: Hot Surface. Can cause serious

injury and burns. Wear heat resistant clothing,

gloves and safety goggles.

Tank

Set Temp

Tank Heater

Off

Heated Hose

Standby Temp

Alarm

Ground

Applicator

Overtemp

Actual Temp

Protective Earth

Pump Motor

Adhesive Flow

Source Power

Valve Group Manual Task Input Output

2 Introduction

2.1 Description

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 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.

2.2 Features

All-electric models operate from 230 VAC power source.

No compressed air required.

1 to 2 hoses – handguns. 1 to 5 (KB30) or 6 (KB50 and

KB100) hoses – automatic applicators.

Temperature control options range from thermostat to

microprocessor.

High torque, high rpm motors for low maintenance and long

life.

Reliable, smooth output gear pumps to handle a wide range of

materials.

Teflon-lined melt tank reduces adhesive char and minimizes

degradation buildup.

Finned melt grid in tank bottom increases melt rate for fast

warmup and continuous melting.

High performance pump rates up to 395 lb/hr (179 kg/hr).

Supported by high performance pattern controllers, head

drivers, and automatic flow controllers.

System power circuit breaker protects the entire system from

overload.

Tank-mounted overtemperature switch backs up the tank

thermostat in case of a tank thermostat failure.

Circuit breaker protects the pump motor by opening the pump

motor circuit during a stall or an overload condition.

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 © Copyright Astro Packaging 2009

POWER

OFF

HEATING

OVERTEMP

REFERTO

SERVICEMANUAL

WHENLIT

PUMPTANKTEMPERATURE

POWER

OFF

TANK

HEATING

OVERTEMP

REFERTO

SERVICEMANUAL

WHENLIT

PUMPTANKTEMPERATURE

2000171a

TANKH

OSEHEADHOSEHEAD

RUN

STANDBY

SCAN

ALARM

T500

Temperature Controller

SETA

CTUAL

350349

WARNING

POWER

OFF

TANKHEATING

OVERTEMP

HEADGROUPS

REFERTO

SERVICEMANUAL

WHENLIT

PUMP

TANKHOSEHEADHOSEHEAD

RUN

STANDBY

SCAN

ALARM

T500

Temperature Controller

SETACTUAL

350349

WARNING

KB30

KB50 KB100

3 Specifications

3.1 Electrical

Input voltage ----------------------- 230 VAC single phase

Frequency--------------------------- 50/60 Hz

Power Required -------------------- KB30: 3000 W

(Hoses not included) -------------- KB50: 4200 W

---------------------------------------- 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

3.2 Physical

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 lb (13.6 kg)

---------------------------------------- 50 lb (22.7 kg)

---------------------------------------- 100 lb (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)------------------------ KB30: 95 lb (43.1 kg)

---------------------------------------- KB50: 110 lb (50 kg)

---------------------------------------- KB100: 185 lb (83.9 kg)

3.3 Performance

Warm-up Time--------------------- 30–45 minutes

Maximum Melt Rate*------------- KB30: 40 lb/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

3.4 Dimensions

KB30

KB100

355.60 mm

(14.00 in.)

298.70 mm

(11.76 in.)

12.70 mm

(0.5 in.)

736.60 mm

(29.00 in.)

622.30 mm

(24.50 in.)

355.60 mm

(14.00 in.)

736.60 mm

(29.00 in.)

622.30 mm

(24.50 in.)

610.6 mm

(24.04 in.)

63.50 mm

(2.50 in.)

2000333

304.80 mm

(12.00 in.)

666.496 mm

(26.24 in.)

622.30 mm

(24.50 in.)

KB50

ALL

3.5 Operating Pressure and Adhesive Flow

Pump and Motor Flow Rate at Typical Pressure Operating

Pressure Range

V4-450 Pump

86/72 rpm

250 psi (17.2 bar)

80/72* lb/hr (36.3/32.7 kg/hr)

100–350 psi

(6.9–24.1 bar)

V4-675 Pump

86/72 rpm

250 psi (17.2 bar)

110/90 lb/hr (49.9/40.0 kg/hr)

100–300 psi

(6.9–20.7 bar)

V2-545 Pump

86/72 rpm

170/140 rpm

400 psi (27.6 bar)

95/83 lb/hr (43.1/37.6 kg/hr)

197/164 lb/hr (89.7/74.4 kg/hr)

250–600 psi**

(17.2–41.4 bar)

V3-675 Pump

86/72 rpm

170/140 rpm

250 psi (17.2 bar)

86/70 lb/hr (39/31.8 kg/hr)

150/140 lb/hr (68/63.5 kg/hr)

300–800 psi

(20.7–55.2 bar)

NOTE: Estimated flow rates are based on common EVA packaging grade

adhesive. *For paired values: left value is at 60 HZ/right 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

FLOW MANIFOLD

PUMP

FILTER

FILTER BLOCK

MAIN ADHESIVE

FLOW

OUTPUT TO

SUPPLY HOSES

ADHESIVE

FLOW BYPASS

FLOW CONTROL

BLOCK

2000261

3.7 Temperature Controller Options

Name Type Capacity* Accuracy Features

Thermostat bimetallic

capillary sensor

tank only

1 hose

±10 °F (8 °C)

±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 ±1 °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.

4 Installation

4.1 Shipping and Handling

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 around 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.

4.2 Supporting the Melt Unit

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.

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 backwards 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. 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)

b. 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)

c. Fasten hose support block [3] to chassis.

d. Tighten JIC swivel fittings.

e. Plug in hose electrical connector(s) [2].

f. Tuck capillary tubing and electrical connector underneath

the unit. (Capillary controlled hoses only)

g. Position and support hose as it is used in service.

0980678a

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 hose. 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

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

Applicator heads, such as the Astro Packaging E100, are mounted to

This manual suits for next models

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