ASTRO D2-15 User manual

SAFETY PRECAUTIONS
SAFETY PRECAUTIONS
GENERAL CONSIDERATIONS
1. Read and follow these instructions. Failure to do
this could result in severe personal injury or death.
2. Additional safety instructions and/or symbols are
located throughout this manual. They serve to warn
maintenance personnel and operators about
potentially hazardous situations.
3. Inspect the machine for unsafe conditions daily
and replace all worn or defective parts.
4. Keep work area uncluttered and well lit.
5. All covers and guards must be in place before
operating this equipment.
For precautions and denitions of safety symbols,
refer to Safety Chapter of the service manual.
SERVICING EQUIPMENT
1. Only trained personnel are to operate and service
equipment.
2. Never service equipment while it is in motion.
3. Shut offthe equipment and lock out all input
power and air supply at their sources before
attempting any maintenance.
4. Follow the maintenance and service instructions in
the manual.
SIGNS
1. Read and obey all of the warning labels, signs and
caution statements on the equipment.
2. Do not remove or deface any of the warning labels,
signs, and caution statements on the equipment.
3. Replace any warning labels, signs, and caution
statements which have been removed or defaced.
Replacements are available.
ADDITIONAL CONSIDERATIONS
1. To ensure proper operation of the equipment, use
specied electrical and/or air supply sources.
2. Do not attempt to alter the design of the
equipment unless written approval is received from
our factory.
3. Keep all manuals readily accessible at all times and
refer to it often for the best performance from your
equipment.

TABLE OF CONTENTS
Chapter 1 Safety Precautions Chapter - Page #
Chapter 2 Description & Specications
Description ............................................................................................................................................
2 - 1
Features ...................................................................................................................................................
2 - 1
Specications .......................................................................................................................................
2 - 2
Motor Speed, Adhesive Pressure, and Flow Rate .....................................................................
2 - 2
Dimensions ............................................................................................................................................
2 - 3
Chapter 3 Installation & Start Up
Installation .............................................................................................................................................
3 - 1
Component Installation ....................................................................................................................
3 - 1
Start-Up ...................................................................................................................................................
3 - 3
Adding Adhesive .................................................................................................................................
3 - 3
Changing Adhesive Formula ...........................................................................................................
3 - 3
Adjusting the Flow Control Valve ..................................................................................................
3 - 4
Storage & Disposal of the Application System .........................................................................
3 - 5
Chapter 4 TC 500 Temperature Controller (K1 Software) Set-Up
Programming Temperature Set-points ........................................................................................
4 - 1
Set Offset Temperature .....................................................................................................................
4 - 2
Set Automatic Wakeup ......................................................................................................................
4 - 3
Set Clock Calendar ..............................................................................................................................
4 - 3
Save and Register Setting ................................................................................................................
4 - 4
Display/Set Audit Variables ..............................................................................................................
4 - 4
Performance Various Maintenance Tasks ....................................................................................
4 - 5
Performance Various System Tasks ...............................................................................................
4 - 7
Security Lock Level ..............................................................................................................................
4 - 8

Chapter 5 Preventive Maintenance
Maintenance .........................................................................................................................................
5 - 1
Preventive Maintenance ...................................................................................................................
5 - 1
Chapter 6 Troubleshooting
General Troubleshooting ..................................................................................................................
6 - 1
Tank does not heat ..............................................................................................................................
6 - 1
Zone Over-temperature ....................................................................................................................
6 - 1
Applicator and Hose Heat Slowly ..................................................................................................
6 - 1
Motor does not turn ...........................................................................................................................
6 - 2
Applicator and Hose Fail to Heat ...................................................................................................
6 - 2
Adhesive Output Levels ....................................................................................................................
6 - 2
Chapter 7 Repair & Replacement
Hose Replacement ..............................................................................................................................
7 - 1
Tank Heater Replacement ................................................................................................................
7 - 3
Tank RTD Sensor Replacement .......................................................................................................
7 - 4
Tank Over-temperature Thermostat Replacement .................................................................
7 - 5
Motor Replacement ............................................................................................................................
7 - 6
Pump Filter Installation & Replacement ......................................................................................
7 - 7
V4 Pump & Flow Control Block Replacement ............................................................................
7 - 8
V4 Pump Block Assembly Replacement ......................................................................................
7 - 9

Chapter 8 Component Illustration and Bill of Materials
Recommended Spare Parts .............................................................................................................
8 - 1
Tank Components ...............................................................................................................................
8 - 2
Bushing and Assembly Shaft ..........................................................................................................
8 - 3
Motor Group & Mounting Hardware ............................................................................................
8 - 4
Pump/Motor Assemblies ..................................................................................................................
8 - 6
Pump Group ..........................................................................................................................................
8 - 8
Flow Control Group ............................................................................................................................
8 - 10
TC500 Circuit Board ............................................................................................................................
8 - 12
TC500 Fuses ...........................................................................................................................................
8 - 13
Exterior Panel and Controls .............................................................................................................
8 - 16
Chapter 9 Component Illustrations
Motor Wiring Diagram........................................................................................................................................
9 - 1
Wiring Diagram 120 V Unit ...............................................................................................................................
9 - 2
Wiring Diagram 240 V Unit ...............................................................................................................................
9 - 3

Chapter 1
Safety Precautions
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.
Intended Use
This equipment is designed for use with standard adhesive and sealant materials with ash points
above 232 °C (450 °F). Use of ammable material or material not compatible with the
specications of this equipment can cause injury to operator and damage to equipment.
The manufacturer has designed this equipment for safe operation. Specied 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 specications. 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.
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 Safety
Gloves, 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.
Electrical Safety
Determine voltage of this equipment before installation and conrm 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 are 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.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 1-1

Emergency Power Disconnect
In the event of a malfunction, turn offpower to the equipment at the power offswitch and
remove source power to the system at the nearest main disconnect.
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.
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.
General Safety Symbols
Specic Symbols and Signal Words
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 1-2
CAUTION:
Indicates a hazard, which, if not avoided, can result in
minor injury, or equipment and property damage.
WARNING:
Indicates a hazard, which if not avoided, can result in
serious 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.
DANGER:
High Voltage. Can cause serious injury, including death.
Disconnect electrical power at external source before
servicing.
WARNING:
Hot Surface. Can cause serious injury, including death.
Disconnect electrical power
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 OffGround Protective Earth
Tank Heated Hose Applicator Pump Motor
Set Temp Standby Temp Over-temp Adhesive Flow
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 reect all details of these improvements.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 1-3

Chapter 1
Safety Precautions
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.
Intended Use
This equipment is designed for use with standard adhesive and sealant materials with ash points
above 232 °C (450 °F). Use of ammable material or material not compatible with the
specications of this equipment can cause injury to operator and damage to equipment.
The manufacturer has designed this equipment for safe operation. Specied 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 specications. 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.
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 Safety
Gloves, 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.
Electrical Safety
Determine voltage of this equipment before installation and conrm 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 are 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.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 1-1

Emergency Power Disconnect
In the event of a malfunction, turn offpower to the equipment at the power offswitch and
remove source power to the system at the nearest main disconnect.
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.
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.
General Safety Symbols
Specic Symbols and Signal Words
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 1-2
CAUTION:
Indicates a hazard, which, if not avoided, can result in
minor injury, or equipment and property damage.
WARNING:
Indicates a hazard, which if not avoided, can result in
serious 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.
DANGER:
High Voltage. Can cause serious injury, including death.
Disconnect electrical power at external source before
servicing.
WARNING:
Hot Surface. Can cause serious injury, including death.
Disconnect electrical power
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 OffGround Protective Earth
Tank Heated Hose Applicator Pump Motor
Set Temp Standby Temp Over-temp Adhesive Flow
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 reect all details of these improvements.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 1-3

Chapter 2
Description and Specications
Description
The D215 Hot Melt Unit is a light-duty to medium-duty machine used for melting and pumping a
variety of materials. The melt unit consists of a heated melt tank and a motor-driven, positive
displacement V4 series gear pump. The melt unit is compatible with a variety of Astro Packaging
pattern generators and head drivers.
The D215 Hot Melt Unit is all-electric and accepts standard forms of adhesive. The unit is equipped
with a ow control valve for uid pressure and ow regulation. The melt unit has a 6.82 kg (15 lb.)
tank capacity, and supports 1 or 2 automatic or manual applicators and hoses.
All zone temperatures range from 4 °C (40 °F) to 232 °C (450 °F), adjustable by a TC500
Temperature Controller. An integral melt grid is standard.
Electrical power to the melt unit is controlled by a power-disconnect circuit breaker located on
the front end of the melt unit.
Features
• The solid-state Temperature Controller uses Resistance Temperature Detector (PT 100 RTD)
sensors to sample and regulate temperatures in the tank, hoses and applicators.
• Circuit breakers and fuses protect the entire system from overload.
• A tank-mounted over-temperature thermostat switches the system power offin the event of a
tank controller failure.
• A circuit breaker protects the pump motor by switching the motor offshould a stall or an
overload condition occur.
• TC500 Temperature Controller protects pump/motor from starting before the material in
system is Run-Ready.
• TC500 Temperature Controller provides a 7-Day Scheduler to Automatically turn the system On
and Offonce per day.
•TC500 Temperature Controller provides over-temperature protection to all zones and will shut
down the main circuit breaker if a temperature zone is over temperature.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 2-1

Specications
Environmental:
Storage/Shipping Temperature ............................................................................................. 0-60° C (32 - 140° F)
Ambient Air Temperature ......................................................................................................... 5 - 40° C (41-104° F)
Altitude .................................................................................................................. Sea level up to 2 km (1.24 miles)
Physical:
Dimension ............................................................................................. dimensional layouts on following pages
Tank Capacity ............................................................................................................................................ 6.8 kg (15 lb.)
Hose Capacity ........................................................................................................ 2 automatic or 2 manual hoses
Weight ....................................................................................................................................................... 35.4 kg (78 lb.)
Pump Size ........................................................................................................................................ V4-675: (0.675 CID)
Melt Grid ................................................................................................................................................................ Integral
Performance:
Warm-up Time ........................................................................................................................................ 30-45 minutes
Viscosity ..................................................................................................................... 70 PaS (70,000 cps) maximum
Melt Rate ......................................................................................................................................... 6.8 kg/hr (15 lb./hr)
Temperature Range ..................................................................................................... 4° C - 232° C (40° F - 450° F)
Electrical:
Input Voltage ................................................................................120 VAC single-phase, 240 VAC single-phase
Power Requirements ............................................. 120 VAC L1/N G, 20 A, 50/60 Hz,240 VAC L1, L2, G 20 A
Frequency ........................................................................................................................................................... 50/60 Hz
Main Circuit Breaker Rating ................................................................................... 120 VAC: 20 A, 240 VAC: 20 A
Motor Speed, Adhesive Pressure, and Flow Rate
Frequency
60 Hz
50 Hz
Motor Speed
86 rpm
70 rpm
Adhesive Pressure
Adhesive Pressure
Adhesive Pressure
V4-675 Pump
100-800 PSI
100-800 PSI
Sample Flow Rates*
V4-675 Pump
60 Hz, 86 rpm
50 kg/hr @ 17.24 bar
(110 lb./hr @ 250 psi)
*These gures are based on standard, packaging grade hot melt materials at 1 PaS (1,000
cps). These gures vary with adhesive and tank temperature. Consult your Astro
Packaging representative for non-standard material requirements.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 2-2

Dimensions
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 2-3

Chapter 3
Installation and Start-Up
Installation
Set-Up
1. Remove all packaging material from around the melt unit.
2. Carefully lift the melt unit out of the box.
3. Unpack the binder containing the product manuals, electrical schematics, and warranty
information. Retain the binder for future reference.
4. Unscrew the 4 screws from the plywood board base; remove and discard the plywood.
5. Carefully inspect all packing material for separately wrapped items.
6. Position the melt unit for easy access to the control panel and convenient servicing.
7. Using the base mounting holes, bolt the melt unit down to a durable mounting surface in
accordance with the dimensions listed in Section 3: Specications to prevent accidental
upset and possible injury.
8.Tighten all screws before startup and after the melt unit experiences excessive vibration.
Component Installation
Automatic Systems
Hoses
Hoses are normally installed on an automatic melt unit at the factory with no user
installation required. If they are not installed, see Hose Replacement. Refer to the
enclosed Heated Supply Hoses product manual (Astro Packaging P/N 19600-24) for
complete installation and service information.
Automatic Applicators
Automatic applicators may be attached to hoses or packaged separately. If they are not
installed, proceed as follows:
1. With the system power off, attach the hose output electrical connector to the
applicator. Heat the uid ttings on the applicator and the output end of the hose by
attaching the electrical connector and applying power for 3 – 5 minutes, or until the
hose tting will rotate.
2. Connect the output end of the hose to the adhesive input tting on the applicator.
3. When the system reaches operating temperature, retighten all the adhesive
connections. Pressurize and check for leaks.
Refer to the applicator product manual for installation and service information.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 3-1

Electrical Circuits and Wiring
Power Requirements
The D215 melt unit 120 VAC is wired for 2-wire, single-phase power, and comes with a
power-cord and 20 Amp plug. The 240 VAC unit comes with the power cord but the end
user must supply the power plug for their power outlet. An identication plate is
attached to each melt unit on the outside, rear panel of the tank housing.
This plate species the exact voltage of the melt unit, and the frequency of the
pump motor. Pump motor voltage, frequency and current are specied on the motor
data plate located on the motor housing. For safe and proper installation, refer to the
identication plate before applying electrical power to the melt unit.
Electrical Connections
120 VAC L1/N 240 VAC L1, L2
Single-phase service Single-phase service
Operation
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 3-2
DANGER:
Disconnect power before opening front panel.
Hazardous voltage can shock, burn, or cause death.
CAUTION:
Power conducting wires must be rated for intended
current and 75° C (167° F).

Start-Up
1. Become familiar with the temperature controller information in the D2-15 manual.
2. Install the melt unit.
3. Fill the tank with hot melt material to 38 mm (1.5 in.) from the top.
4. Turn the unit on, and allow for 30 minutes of warm-up time.
5. Set the tank, hose and applicator temperatures to the desired settings. Lower settings will
increase the material pot life.
6. Set the tank temperature as low as possible for each application. Certain materials degrade
over time due to oxidation.
7. To prevent stalling the motor, adjust the ow control valve counterclockwise to minimize
pressure and lower ow rate.
*NOTE: the pump motor will not run until the TC500 has green ready LED.
Adding Adhesive
The adhesive level should be maintained at 13 mm to 100 mm (1/2”to 4”) from the top of the tank. Where
applications demand a high output volume of adhesive, add small amounts of adhesive frequently.
ADDING LARGE AMOUNTS OF ADHESIVE TO AN ALMOST EMPTY TANK WILL LOWER THE TEMPERATURE OF
THE ADHESIVE IN THE TANK AND MAY CAUSE THE MELT UNIT TO FALL BELOW ITS READY SET-POINT.
Changing the Adhesive Formula
If a different adhesive formulation from the one being currently used is needed, the system will have to be
ushed if the two formulations are incompatible. See Chapter 6 of this manual for the proper ushing
procedure. When in doubt about adhesive compatibility, ush your system.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 3-3

Flow Adjustments
Flow Control Valve
An adjustable, pressure-regulating device is mounted on the pump under the melt unit chassis.
See the illustration below.
• Adjust the ow control by turning the black knob on the left side of the melt unit.
•To increase the pressure, turn clockwise.
•To decrease the pressure, turn counterclockwise.
•To achieve the minimum pressure and the lowest ow rate, turn the knob fully
counterclockwise. Gradually turn the knob clockwise until the desired pressure and
ow rate are achieved.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 3-4
WARNING:
Contents at high temperature and pressure. Remove
pressure before opening lter or drain valve to prevent
accidental system pressurization or ring. Do not touch hot
surfaces. Failure to follow these instructions may result in
severe burns.
CAUTION:
For maximum performance and motor life, do not allow
the pump motor to stall. A prolonged stall condition
will call condition will cause the motor go into thermal
overload.

Storage and Disposal of the D2-15 Application System
Temporary Storage of the Unit
1. Flush the adhesive application system with ushing uid (PN RB-5), following the instructions detailed
in Chapter 6 of this manual.
2. Clean or replace both the output lter and the tank, following instructions detailed in Chapter 6.
3. Shut OFF all pressure and power sources.
4. Remove all residual adhesive and wipe components clean.
5. Remove all power supply cables.
6. Pack the unit in a corrosion-proof manner.
7. Store the unit in such a way that it is protected from damage.
Disposal of the Unit
1. Shut OFF all pressure and power sources.
2. Remove all residual adhesive.
3. Remove all adhesive supply hoses and all power supply cables.
4. Dismantle all components and sort into mechanical and electrical components.
5. Arrange for all components to be recycled.
©Astro Packaging Rev D D2-15 Manual-19600-10-D215 3-5