ASTRO LS10, LS20 User Manual

(800-401-1441

LS10 and LS20 Series

Hot Melt Units

Manual Number: 19600-121

Revision: E

(800-401-1441

LS10 and LS20 Series

Hot Melt Units

Manual Number: 19600-121

Revision: D

Date: 02/17/10

(800-401-1441

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............................................................................................................................................ 5

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

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

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

3.3 Operating......................................................................................................................................... 6

3.4 Environmental................................................................................................................................. 6

3.5 Motor Speed, Adhesive Pressure, and Flow Rate ........................................................................ 7

3.6 Dimensions....................................................................................................................................... 7

4 Installation .............................................................................................................................................. 8

4.1 Setup................................................................................................................................................. 8

4.2 Component Installation.................................................................................................................. 9

4.2.1 Manual (Handgun) Systems....................................................................................................... 9

4.2.2 Automatic Systems .................................................................................................................... 9

4.3 Electrical Circuits and Wiring..................................................................................................... 10

4.3.1 Electrical Schematic................................................................................................................. 10

4.3.2 Power Requirements ................................................................................................................ 10

4.3.3 Electrical Connections ............................................................................................................. 10

4.3.4 Power-in Wiring....................................................................................................................... 11

4.3.5 Valve Group Control Circuits for Automatic Systems ............................................................ 11

4.3.6 VAC Valve Firing Voltage ...................................................................................................... 12

4.3.7 VDC Valve Firing Voltage ...................................................................................................... 12

4.3.8 Foot Switch Trigger for Semi-automatic Systems................................................................... 12

4.3.9 External Control of Pump Motor for Automatic Systems ....................................................... 13

5 Operation............................................................................................................................................... 14

5.1 Controls and Indicators................................................................................................................ 14

[1] System Power Switch/Circuit-Breaker and Indicator Light........................................................ 14

[2] Overtemperature Indicator Light................................................................................................. 14

[3] Tank Thermometer...................................................................................................................... 14

[4] Tank Heating Indicator Light...................................................................................................... 14

[5] Pump Motor ON/OFF Breaker Switch........................................................................................ 14

[6] Pump Warm-Up Thermostat (Not Shown) ................................................................................. 14

5.2 Start-up .......................................................................................................................................... 16

5.3 Adjustments................................................................................................................................... 17

5.3.1 Temperature Adjustments........................................................................................................ 17

5.3.2 Flow Adjustments .................................................................................................................... 18

6 Maintenance.......................................................................................................................................... 19

6.1 Preventive Maintenance ............................................................................................................... 20

7 Troubleshooting .................................................................................................................................... 21

8 Repair and Replacement....................................................................................................................... 23

8.1 Hose Replacement......................................................................................................................... 23

8.2 Hose Controller Replacement...................................................................................................... 25

8.3 Tank Heater Replacement ........................................................................................................... 26

8.4 Tank Controller Replacement ..................................................................................................... 27

8.5 Hose Manifold Filter Block Replacement or Cleaning.............................................................. 28

8.6 Pump Filter Installation, Servicing, and Replacement.............................................................. 29

8.7 Pump Motor and Pump Shaft Assembly Replacement ............................................................. 30

9 Parts List................................................................................................................................................ 32

9.1 Control Panel - Front View.......................................................................................................... 32

9.2 Electrical Enclosure and Chassis Base........................................................................................ 33

9.3 Motor Group and Pump Shaft Assembly ................................................................................... 34

9.4 Pump Warm-up and Tank Overtemperature Thermostats ..................................................... 35

9.5 V1 Pump, Flow Control Valve, and Hose Manifold Filter........................................................ 36

9.6 Accessories ..................................................................................................................................... 38

Appendix A: Component Resistance Tables ........................................................................................... 39

Table 1. Tank Heater Resistance....................................................................................................... 39

Table 2. Motor Resistance.................................................................................................................. 39

Table 3. RTD Sensor Resistance........................................................................................................ 40

Table 4. Potentiometer/Variable Resistor......................................................................................... 40

Table 5. Valve Coil Resistance........................................................................................................... 40

Table 6. Heater Resistance for Common Applicators ..................................................................... 41

Table 7. Heater Resistance for Common Hoses (in Ohms)............................................................. 42

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 Safety Goggles

Wear Heat-Resistant

Safety Gloves

Wear Protective Clothing

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.

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.

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.

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 cause 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

Tank

Set Temp

Tank Heater

Valve Group

Heated Hose

Standby Temp

Off

Alarm

Manual Task

Ground

Applicator

Overtemp

Actual Temp

Input

Protective Earth

Pump Motor

Adhesive Flow

Source Power

Output

The manufacturer reserves the right to make design changes for product improvement. This manual may not reflect all details of these improvements.

2 Introduction

2.1 Description

The Astro Packaging LS Series Hot Melt Unit is a light to medium

duty machine used for melting and pumping a variety of hot melt materials. The melt unit consists of a heated melt tank and a motordriven, positive displacement gear pump.

This all-electric melt unit accepts granular, pillow, pellet or block forms of adhesive. The LS Melt Unit is equipped with a flow control valve for fluid pressure and flow regulation. The melt unit is available in 10 and 20 lb tank capacities and supports 1 or 2 automatic or manual applicators and hoses.

The tank temperature ranges from ambient temperature to 205 °C (400 °F), adjustable by a bimetallic tank temperature controller. An internal melt grid transfers heat efficiently from the tank heaters to the hot melt material. The melt grid is standard on the 20 lb melt unit and an optional feature on the 10 lb tank.

Electrical power to the melt unit is controlled by a circuit breaker located on the front panel. The electrical panel contains a terminal block to make connections to the power-in supply circuit. See Section 4.3: Electrical Circuits and Wiring.

Melt Grid (Option on 10 lb)

Tank Heaters

Flow Control & Hose Manifold Block

Drive Motor

Melt Unit

Drive Shaft

Heated Tank Reservoir (Teflon Coated)

Positive Displacement Gear Pump

Heated Delivery Hose

AUTOMATIC APPLICATOR

0970000

Heated Delivery Hose

HANDGUN

2.2 Features

• System power circuit breaker protects the entire system from overload.

• A tank-mounted overtemperature thermostat turns the tank heaters off in the event of a tank controller failure.

• A circuit breaker protects the pump motor by turning the motor off should a stall or overload condition occur.

• A pump warmup thermostat protects the pump-drive mechanism by preventing motor/pump operation below 121 °C (250 °F).

• Head firing with LS automatic melt units can be from direct signal input or any AC or DC model of ET Series Pattern Controllers.

• An optional filter block is available for applications requiring adhesive filtering.

• AC power cords are supplied with 100 VAC and 115 VAC units only.

• A “Little Squirt” is a 10-pound one or two hose manual handgun configuration of the LS Series.

3 Specifications

3.1 Electrical

3.2 Physical

Voltage ------------------------------ 100, 115, 200 or 230 VAC (±10%)

single phase

Power Requirements -------------- LS10: 900 W (melt unit only: hoses/

---------------------------------------- LS20: 1400 W applicators not included) Frequency--------------------------- 50/60 Hz Main Circuit Breaker Rating----- All VAC: 15 A Pump Motor Circuit -------------- 200/230 VAC: 0.5 A Breaker Rating --------------------- 100/115 VAC: 1 A Tank Overtemperature Thermostat

---------------------------------------- 205 °C (400 °F) (standard, other ratings available)

Pump Warmup Thermostat------- 121 °C (250 °F) (standard, other ratings

---------------------------------------- available)

Tank Capacity---------------------- LS10: 4.5 kg (10 lb)

---------------------------------------- LS20: 9.1 kg (20 lb)

Hose Capacity---------------------- 2 manual hoses or 2 automatic hoses Shipping Weight ------------------- LS10: 29.1 kg (64 lb)

---------------------------------------- LS20: 35.4 kg (78 lb)

Storage Temperature -------------- 0–60 °C (32–140 °F) Pump Size -------------------------- V1-450: 7.4 CCD (0.450 CID)

---------------------------------------- V1-675: 11.1 CCD (0.675 CID)

Melt Grid --------------------------- LS10: optional

---------------------------------------- LS20: standard

3.3 Operating

Warmup Time---------------------- 30–45 minutes Viscosity ---------------------------- Maximum 25,000 centipoise (cps) Melt Rate --------------------------- LS10: 3.6 kg/hr (8 lb/hr) - without melt

grid

---------------------------------------- LS20: 9.1 kg/hr (20 lb/hr) - with melt grid

Temperature Range---------------- 38 °C – 232 °C (100 °F – 450 °F)

3.4 Environmental

Ambient Air Temperature -------- 5–40 °C (41–104 °F) Altitude------------------------------ Sea level up to 2 km (1.24 miles) Humidity ---------------------------- 30–95 R.H. (%)

3.5 Motor Speed, Adhesive Pressure, and Flow Rate

Frequency 50-60 Hz Motor Speed 44/min (rpm)

Recommended Adhesive Pressure Range*

V4-675 Pump 6.89–20.68 bar

689.48–2,068.43 kPa

100–300 psi

Maximum Flow Rate*

V1-675 Pump 25 kg/hr 21 kg/hr

55 lb/hr 45 lb/hr

3.6 Dimensions

*Based on standard, packaging grade hot melts at 1000 cps. Varies with adhesive and tank temperature. Consult factory representative for nonstandard requirements.

508 mm

(20 in.)

269.7 mm

355.6 mm (14 in.)

LS10 Hot Melt Unit

698.5 mm (27.5 in.)

342.9 mm (13.5 in.)

(10.62 in.)

269.7 mm (10.62 in.)

6.3 mm (0.25 in.) dia.

317.5 mm (12.5 in.)

6.3 mm (0.25 in.) dia.

0960149a

0970014

355.6 mm 14 in.)

342.9 mm 13.5 in.)

317.5 mm (12.5 in.)

LS20 Hot Melt Unit

4 Installation

4.1 Setup

1. Remove all packaging material around melt unit.

2. Carefully lift melt unit out of box.

3. Unpack the binder containing product manuals, electrical schematic, warranty information and flow control valve hex wrench. Retain binder for future reference.

4. Unscrew 4 screws from plywood board base; remove and discard plywood.

5. Carefully uncoil hoses from around melt unit and remove protective wrap from applicators. Inspect all packing material for separately wrapped items.

6. Position melt unit for easy access to control panel and convenient servicing.

7. Level mounting surface to prevent warping of melt unit and to avoid misalignment of the pump and motor shaft.

8. Using the base mounting holes, bolt melt unit down to a durable mounting surface in accordance with dimensions in illustrations in Section 3.6 to prevent accidental upset and possible injury.

9. Tighten all screws before startup and after melt unit experiences excessive vibration.

4.2 Component Installation

4.2.1 Manual (Handgun) Systems

All standard components are normally installed on the melt unit at the factory with no user installation required. If not installed, refer to Hose Replacement. Refer to handgun product manual for complete information on installation and service of the handgun/hose assembly.

4.2.2 Automatic Systems

Hoses

Hoses are normally installed on an automatic melt unit at the factory with no user installation required. If not installed, refer to Hose Replacement. Refer to heated supply hoses product manual for complete installation and service information.

Automatic Applicators (Heads)

Automatic applicators may be attached to hoses or packaged separately. If not installed, proceed as follows:

1. With system power off, attach hose output electrical connector to applicator. Heat fluid fittings on applicator and output end of hose by attaching the electrical connector and applying power for 3–5 minutes or until hose fitting will rotate.

2. Connect output end of the hose to adhesive input fitting on the applicator.

3. When system reaches operating temperature, retighten all adhesive connections. Check for leaks.

Refer to applicator product manual for installation and service information.

Pattern Controllers, Head Drivers and Optional External Components

Pattern controllers, head drivers and other external components normally need to be connected to melt unit during installation. Refer to electrical schematic, located in manual binder or back of melt unit, for appropriate wire connections to the melt unit. Refer to individual component product manual for complete installation and service information.

+ 35 hidden pages

ASTRO LS10, LS20 User Manual

Specifications and Main Features

Frequently Asked Questions

User Manual

1 Safety Precautions for Hot Melt Applicator Equipment

1.1 Intended Use

1.2 Personal Safety

1.3 Electrical Safety

1.4 Emergency Power Disconnect

1.5 Follow Directions

1.6 Safety Symbols and Signal Words

2 Introduction

2.1 Description

2.2 Features

3 Specifications

3.1 Electrical

3.2 Physical

3.3 Operating

3.4 Environmental

3.5 Motor Speed, Adhesive Pressure, and Flow Rate

3.6 Dimensions

4 Installation

4.1 Setup

4.2 Component Installation

4.2.1 Manual (Handgun) Systems

4.2.2 Automatic Systems