Chapter 1 Safety Precautions
Contents
1. D2 15 Manual 19600 10 D215 1 2 Other Product Symbols O On Off Tank Heated Hose 4 7 4 Set Temp Standby Temp JH 0 Tank Heater Alarm Valve Group Manual Task Ground Applicator i Over temp Actual Temp Input 5 Protective Earth Pump Motor Adhesive Flow Source Power Y Output The manufacturer reserves the right to make design changes for product improvement This manual may not reflect all details of these improvements OAstro Packaging D2 15 Manual 19600 10 D215 Chapter 2 Description and Specifications 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 flow control valve for fluid pressure and flow regulation The melt unit has a 6 82 kg 15 Ib 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 fron2. 9 Tank heats slowly 1 Check 8 Amp tank fuses on power board 2 Check the status of components with a voltmeter system powered or an ohmmeter system powered down wires disconnected 3 Adjust the tank temperature Inadequate tank heat can affect performance 4 If problem still exists replace the tank heaters as specified under tank heater replacement section on page 7 3 Zone over temperature 1 Check the zone temperature when an over temp condition is present The temperature controller shuts off power to all zones if one zone reaches 20 over set point Applicator and hose heat slowly 1 Adjust the hose and applicator settings Inadequate low voltage heat levels can affect performance OAstro Packaging D2 15 Manual 19600 10 D215 6 1 mds S SA Motor does not turn 1 Check to see if applicator or hose is programmed on the TC500 See TC500 manual 2 Check to see if the green ready light on the TC500 is ON 3 Check to see if melt unit is up to temperature all zones 4 Check to see if pump circuit breaker switch is On 5 Check to verify there is no obstruction in pump 6 Check 5 Amp motor fuse on power board Applicator and hose fail to heat Check the incoming hose electrical connector to see if itis properly installed The connector wire pins may be misaligned or loose If there is no change disconnect the incoming hose electrical connector and check the hose heater resistance value
3. Start Up Date Date Received Astro Packaging 3845 E Miraloma Unit A Anaheim CA 92806 Start Up Date 714 572 1094 Serial No Order No Invoice No Serial No Order No Invoice No Serial No Order No Invoice No Serial No Order No Invoice No Serial No Order No Invoice No Serial No Order No Invoice No 800 642 7876 toll free 714 572 1943 fax
4. Do not turn the melt unit upside down 7 Support the hose to prevent excessive flexing Do not support the hose in a way which may add to its thermal insulating characteristics or overheating will result Failure to properly support the hose will result in premature failure Install the hose as follows 1 Loosely connect the hose JIC swivel fitting 1 to the fitting 2 on the flow control block or hose manifold 3 2 Fasten the hose support block 5 to the chassis 3 Tighten the JIC swivel fitting 1 4 Attach the hose electrical connector 4 5 Tuck the hose electrical connector 4 under the melt unit 6 Position and support the hose before using 7 After heating the hose tighten the JIC swivel fitting 1 OAstro Packaging D2 15 Manual 19600 10 D215 Tank Heater Replacement 1 Switch off the system power and disconnect electrical power from the external source 2 Remove the housing and retain the housing screws for reinstallation 3 Disconnect heater from power board 4 Pull the heater out of its bore 1 If the heater does not come out easily drive it out using a 6 35 mm 0 25 in diameter rod inserted into the knockout holes in the back of the tank base 5 Apply a coating of heat release and transfer agent to the new heater and slide it into the tank heater bore from the front 6 Route the heater lead wires through the electrical panel and reconnect the heater plug in their original locations See the electrical sc
5. expensive means of transport to customer or an authorized Sales and Service Center in the Continental United States only Payment for shipment to Astro Packaging or an authorized Sales or Service Center for evaluation repair or replacement is the responsibility if the customer H For service under this warranty contact Astro Packaging or the Authorized Representative which the product was purchased THIS WARRANTY IS IN LIEU OF ANY OTHER WARRANTY EXPRESSED OR IMPLIED INCLUDING THE WARRANTY OF MERCHANTABILITY AND FITNESS FOR THE PARTICULAR PURPOSE Astro Packaging 3845 E Miraloma Unit A Anaheim CA 92806 714 572 1094 800 642 7876 toll free 714 572 1943 fax PRET Equipment Record Record the information below on all equipment received and retain for your records Systems melt unit hose guns heads pattern controllers drivers etc Products were purchased from Product Model Description Product Part Number Astro Packaging Authorized Sales and Service Center Date Received Product Model Description Product Part Number Start Up Date Date Received Product Model Description Product Part Number Start Up Date Date Received Product Model Description Product Part Number Start Up Date Date Received Product Model Description Product Part Number Start Up Date Date Received Product Model Description Product Part Number
6. installation and service information OAstro Packaging 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 identification plate is attached to each melt unit on the outside rear panel of the tank housing This plate specifies the exact voltage of the melt unit and the frequency of the pump motor Pump motor voltage frequency and current are specified on the motor data plate located on the motor housing For safe and proper installation refer to the identification plate before applying electrical power to the melt unit Electrical Connections CAUTION Power conducting wires must be rated for intended current and 75 C 167 F 120 VAC L1 N 240 VAC L1 L2 Single phase service Single phase service Operation DANGER Disconnect power before opening front panel Hazardous voltage can shock burn or cause death OAstro Packaging D2 15 Manual 19600 10 D215 3 2 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 d
7. 4 675 0 675 CID Melt Grid nna dae Integral Performance Warm up TIM htm 30 45 minutes WIS COSILY satana 70 PaS 70 000 cps maximum MeltRat ci ooo eaten 6 8 kg hr 15 Ib hr Temperature Rath Qe visionaria 4 C 232 C 40 F 450 F Electrical Input Voltage rer 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 EU a ii 50 60 Hz Main Circuit Breaker Rating 120 VAC 20 A 240 VAC 20 A Motor Speed Adhesive Pressure and Flow Rate Adhesive Pressure V4 675 Pump 100 800 PSI Sample Flow Rates V4 675 Pump 60 Hz 86 rpm 50 kg hr 17 24 bar 110 Ib hr 250 psi These figures are based on standard packaging grade hot melt materials at 1 PaS 1 000 cps These figures vary with adhesive and tank temperature Consult your Astro Packaging representative for non standard material requirements OAstro Packaging D2 15 Manual 19600 10 D215 22 Dimensions ro 11 13 16 11 7 8 OAstro Packaging D2 15 Manual 19600 10 D215 23 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 Carefu
8. 7 2009 To exit press Program Performance Various Maintenance Tasks To exit press Program N A te desired Menus spa This menu is for viewing only it can t be OAstro Packaging D2 15 Manual 19600 10 D215 44 Performance Various System Tasks Press and release the following sequence Program Menu 8X Enter To choose between the following parameters press the left or right arrows Toggle Display Temperatures between C F C to F F toC Set Line Voltage 120V 240V Auto 120V Auto 240V Set Line Frequency 50 Hz 60 Hz Auto 50 Hz Auto 60 Hz Power Set Mode 1 7 Disable hose and gun 1 Currently On Off Disable hose and gun 2 Currently On Off Trigger Safety enable Currently On Off Automatic On Off 7 day clock timer On Off Security Lock Level Off 1 2 3 see next sheet To change values press the Up or Down arrows To exit press Program OAstro Packaging D2 15 Manual 19600 10 D215 45 SECURITY LOCK LEVEL Parameter OFF Programming Temperature Setpoints Offset Temperatures Automatic Wakeup Set Clock Calendar Save and Register Settings Record your settings on this sh Set Temperatures Tan po Hose tt o Gun tT ooo Hose 2 io i Set Offset Temperatures AAN Motor Cut Off L Standb L ____ Overtemperature Tank Hose tt y Gut pon o Hose _ _ po Gun OAstro Packaging D2 15 Manual 19600 10 D215 LE
9. 8 Align the pump coupling 6 with the motor coupling and slide the new assembly into place 13 Tighten the pump coupling 6 onto the new shaft 4 leaving 0 762 1 016 mm 0 030 0 040 in clearance between the coupling halves 14 Loosely insert the 4 bolts 11 and washers 12 through the motor mount 8 into the pump block 3 Ensure that the spacers 13 are in place between the motor mount 8 and the pump block 3 Do not tighten the bolts at this time 15 Insert the socket head cap screws 16 up through the pump block 3 into the tank bottom Tighten only finger tight 16 Ensure that the spacing between the coupling halves 6 and 17 is still between 0 762 1 016 mm 0 030 0 040 in 17 Tighten the 4 bolts 11 and washers 12 through the motor mount 8 and the 4 socket head cap screws 16 through the pump block 3 18 Reinstall the hoses and pressure gauge 19 Warm up the melt unit When the unit is hot retighten the screws mounted through the pump block 3 20 Return the melt unit to service OAstro Packaging D2 15 Manual 19600 10 D215 1 28 10 Chapter 8 Component Illustration and Bill of Materials Recommended Spare Parts 10760 50 Pump filter D200109 Assembly Tank RTD 100 ohm D200111 Assembly Over temp Thermostat 475 OAstro Packaging D2 15 Manual 19600 10 D215 8 1 Tank Components CO TR E E 1 28 10 OAstro Packaging D2 15 Manual 19600 10 D215 82 Bushing
10. 9600 10 D215 OAstro Packaging Wd 98 AOPZ SI ZO SNN9 S3SOH Z YO H3TIOHINOO 330n1vu3dW31 00691 10080 siva 318V NO88IN ANNOYS ST BSSOZI Nid 289 5107120 Nid 182 MINVING LInOMIO Wiring Diagram 240V 93 D2 15 Manual 19600 10 D215 OAstro Packaging OAstro Packaging This page is intentionally left blank D2 15 Manual 19600 10 D215 94 P A Astro Packaging warrants its products when operated and maintained in accordance with Astro Packaging recommended procedures are free of defects in material and workmanship during the Warranty Product Warranty Period 1 Tank heater including entire tank when heater is cast 5 years or 10 000 hours of use whichever into tank occurs first 2 Melt unit unless specified below pattern controller 1 year or 2000 hours of use whichever head driver comes first 3 Stationary hose automatic electric head standard 1 year or 2000 hours of use whichever pail unloaded standard pail unloader standard comes first accessory purchased with a system 4 Manual hose handgun Astromini any butyl system 6 months of 1 000 hours of use whichever any PUR system including hose gun or head used with comes first PUR any spare or replacement components industrial heated hose nozzle nozzle bar 5 Rebuilt equipment 90
11. 9600 10 D215 7 8 V4 Pump Block Assembly Replacement 1 If the melt unit is cold allow the pump block 3 to warm to approximately 90 C 200 F If the melt unit is hot and full of adhesive either allow the melt unit to cool or drain the adhesive from the tank 2 If the system is hot relieve pressure by actuating the d applicator s several times 3 Turn off the melt unit and remove electrical power 4 Remove all hoses and pressure gauge if present from the flow control block 1 5 Carefully remove the plug 14 and o ring 15 from the bottom of the pump block 3 and drain the melted adhesive 6 Remove the long socket head cap screws 16 that hold the pump block 3 to the bottom of the tank 7 Remove the 4 bolts 11 washers 12 and spacers 13 that hold the pump block 3 to the motor mount 8 8 Once all 4 bolts and 4 screws 11 16 are removed move the pump block assembly to the rear of the chassis If the assembly resists loosen the 2 bolts 9 and washers 10 that hold the motor mount 8 to the chassis 9 On the replacement pump block 3 assembly loosen the pump coupling 6 Ensure that the key 5 is installed on the shaft 4 10 Insert the coupling spider 7 into the pump coupling 6 11 Coat the surface of the pump block 3 that contacts the base of the tank with heat sink compound Ensure that the o ring 2 is in place 12 Place the new pump block 3 assembly into the motor mount
12. Assembly Shaft Description Part PartNumber COM sn i CL femea pre ES I resse ven sareste ES pa pese Cc fumo 2 To replace shaft only order items 2 7 8 TI 5 5 9 px 4 1 8 gt S 3 2 Za Astro Packaging D2 15 Manual 19600 10 D215 83 Motor Group and Mounting Hardware E E E Capacitor 86 rpm motor not shown Astro Packaging D2 15 Manual 19600 10 D215 84 OAstro Packaging D2 15 Manual 19600 10 D215 85 Pump Motor Assemblies Ca CC Po V4 675 Pump with 86 rpm motor 120 VAC 50 60 Hz 79357 99 V4 675 Pump with 86 rpm motor 240 VAC 50 60 Hz 79357 100 2 18 10 OAstro Packaging D2 15 Manual 19600 10 D215 86 OAstro Packaging This page is intentionally left blank D2 15 Manual 19600 10 D215 Pump Group Parts included in V4 675 Pump Kit CI po 3 wemamem Pes NE ER OAstro Packaging D2 15 Manual 19600 10 D215 8 8 79361 SEE PAGE 8 3 Flow Control Group Cem pm o Cf pee o A seem Lou o CC own ES me fp o 17 90 Fitting No 6 JIC Straight Thread Long RE IL 3 2 90 Fitting No 6 JIC Straight Thread Long AS CS ISEE O ring Hi Temp Straight Thread BOSS No 6 Filters must be ordered separately OAstro Packaging D2 15 Manual 19600 10 D215 8 10 OAstro Packaging D2 15 Manual 19600 10 D215 8 11 TC500 Circuit Boards ren ito item ay Lo IA e 3 wewesse m CS A
13. Callus at 800 642 7876 D2 15 Manual 19600 10 D215 Rev A 2 24 10 ASTIROIPACKAGING ESMiralomalave Un AS Ananeim CA 8005642181011 4351421 FAX 57211943 wwwASTROPACKAGING com N 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 definitions 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 off the 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
14. Es EN ER 1 A 2 2 3 3 4 ES Lamp Amber power and pump OAstro Packaging D2 15 Manual 19600 10 D215 8 12 TC500 Fuses Qty ast _ 7 Hose gun heater Power Board Fuse 6 3 Amp 4 Y Le NIY Z 5 Y V 77H WAV f An u n a la az NN A le o E o 00 o un 5 Yu TD o o o FEE S a a 3 l o a o o I Six c U e P N LL x E a v Q E 3 2 dh o a c lo 2 he Y n v a Motor Power Board Fuse 5 amp 8 13 D2 15 Manual 19600 10 D215 OAstro Packaging TC500 Connections em Gn Ba NS Tank Heater 1 Tank Over temp Motor Circuit Breaker trip signal Hose Head 2 Hose Head 1 Astro Packaging D2 15 Manual 19600 10 D215 8 14 Chapter 9 SYSTEM SCHEMATICS 8 ENGINEERING DRAWINGS Motor Wiring GREEN GREEN e SPLICE GREEN L1 WHITE WHITE L2 BLACK WHITE BROWN YELLOW RED 120 VAC GREEN PLICE GREEN 47 PUC GREEN 240 VAC TU 1 16 10 OAstro Packaging D2 15 Manual 19600 10 D215 9 1 Wiring Diagram 120V AOZL SI ZO SNNO SISOH Z YO L H3TIOHINOO 33n1vi3dW3l 00SDL aero anova saw EEN 318V NOggly 10020 ALAVA annous ST BSSOZI Nid 299 SLOZIZO Nid 189 VINVIUS LINOMIO 09YO9 YIMOd 100670 1uvd 3 LON 92 D2 15 Manual 1
15. VEL 1 LEVEL 2 LEVEL 3 pan es eet NOTES 46 Set Automatic stata Event Day Hour Minute On Off 1 Sunday 2 Sunday 3 Monday 4 Monday pe 5 Tuesday 6 Tuesday 7 _ Wednesday 8 Wednesday 9 Thursday __ 10 Thursday 11 Friday po 12 Friday __ 13 Saturday p 14 Saturday do Toggle Display Temperatures between C F Set Line Voltage Set Line Frequenc Power Set Mode Disable hose and gun 1 Disable hose and gun 2 Trigger Safety Enable Automatic On Off 7 Day clock Timer Security Lock Level OAstro Packaging Performance Various System Tasks D2 15 Manual 19600 10 D215 Notes Notes 47 Chapter 5 Preventive Maintenance Maintenance WARNING Hot melt materials can cause severe burns resulting in disfigurement or blindness Follow these precautions before beginning any maintenance Wear protective clothing safety goggles and safety gloves e Turn pump motor switch to the off position Depressurize applicator s by triggering e Unless stated otherwise always allow melt unit to cool before beginning any maintenance Disconnect hose electrical connector when hose fittings are disconnected and power is off CAUTION To prevent damage to components hose fittings etc heat part s being serviced to
16. actically safeguarded These exposed surfaces may be hot and take time to cool after the unit has been operating K 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 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 are required to meet standard IEC 309 Power conducting wires must be nominal 5 3 mm 10 AWG maximum and nominal 2 1 mm 14 AWG minimum OAstro Packaging D2 15 Manual 19600 10 D215 14 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 Follow Directions Re
17. ad 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 OAstro Packaging General Safety Symbols 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 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 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
18. approximately 121 C 250 F prior to dismantling assembling or adjusting Heat parts by applying power to the unit using a hand held hot air gun or placing parts on a hot plate Failure to do this will result in stripped threads and ruining both parts and tools CAUTION To avoid arcing of electrical contacts and possible failure of components do not connect electrical connectors when the hose power switch is on Preventive Maintenance CES I TS IS eem O O o pi x x Inspect hose s Verify hose s properly supported Minimum bend radius is 20 32 cm 8 in when hot Check temperatures Adjust temperatures according to Temperature Controller manual OAstro Packaging D2 15 Manual 19600 10 D215 51 Chapter 6 Troubleshooting L n ua SUS Does not power up 1 Check the main circuit breaker Refer to the wiring schematic 2 Inspired the power wires or power plug at the main power source Tank does not heat 1 Check 8 Amp tank fuses on power board 2 Check the temperature controller for Power On and Tank Temperature Set Refer to Chapter 4 TC500 Temperature Controller Guide 3 Inspect the power connections for proper fit 4 Check for any faulty wires 5 Check the supply voltage or system damage will occur 6 If problem still exists check each heater with an amperage probe system power on or an ohmmeter system power off wires disconnected Refer to the electrical schematics in Ch
19. been removed or defaced Replacements are available ADDITIONAL CONSIDERATIONS 1 To ensure proper operation of the equipment use specified 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 st Chapter 2 Description amp Specifications Description kes kid daso ta kak li alfa tk ok NE bk da Cd 2 1 Features A KATABA 2 1 Specifications a lira 2 2 Motor Speed Adhesive Pressure and Flow Rate sn 2 2 DIMENSIONS rina AAA abri ee Pepe 2 3 Chapter 3 Installation amp Start Up ld 3 1 Component Installation sienne 3 1 Srl Dr c ii 3 3 Adding AANI NA dde 3 3 Changing Adhesive Formada ns 3 3 Adjusting the Flow Control Valve adco rara 3 4 Storage amp Disposal of the Application System ee oo oo eee reeeeceneienionne 3 5 Chapter 4 TC 500 Temperature Controller Set Up Programming Temperature Set points sn 4 1 Set Offset Temperature rm 4 2 Set Automatic WakeUp n aee os DR LA i ano ones n kas son eversa e ds datos 4 2 Set Clock Calendar uaar 4 3 Save and Register Setting usati as RM oa did e Rota iUd te dea ed ek 4 3 Display Set Audit Variables garage 4 4 Performance Various System Tasks uni iii 4 5 Security Lock Level
20. cce atte orsa od 4 6 Chapter 5 Preventive Maintenance MAINTENANCE asia A orali 5 1 Preventive Maintenance uuuccccccccscscscscessscscscssscsssssssssscsssesssssssssssssscscsssssssscscsssssssssesesescscssssesess 5 1 Chapter 6 Troubleshooting General Troubleshooting iia AA Tankdoes not Neat cion iaia a aa aaa Zone Over tempetat lte anakan ab di ola oo vi ie a ao e pd a ala ii l d pann Applicator and Hose Heat Slowly rene Motor does not turni ilaria Applicator and Hose Fail to Heat sen Adhesive Output Levels nn Chapter 7 Repair amp Replacement Hose Replacement us eiie rte annmedic Tank Heater Replacement een Tank RTD Sensor Replacement nee Tank Over temperature Thermostat Replacement sn Motor Replacement assiste dneennetindtethadendraniment Pump Filter Installation amp Replacement eese tentent trenes tenons V4 Pump amp Flow Control Block Replacement sens V4 Pump Block Assembly Replacement seen Chapter 8 Component Illustration and Bill of Materials Recommended Spare Parts inner Tank Components ec Bushing and Assembly Shaft asinti Motor Group 8 Mounting Hardware iria D e e ab UU Pump Motor Assemblies rene P MP Grou cote te aetatem od Flow Control Group y k sak RR T SO00 Circuit Board esa ia iaa TES OO FUSOS ii iii iii INA RATA Chapter 9 Component Illustrations Motor Wiring RB To f To opm Wiring Diagram 120 V Unit Wiring Diagram 240 V Unit erectione pte iaia Chap
21. days or 500 hours of use whichever comes first periods indicated below commencing with the date the product is placed in service B The sole liability of Astro Packaging and exclusive remedy extended to any Astro Packaging customer shall be limited to replacing or repairing at the option of Astro Packaging any product returned under the terms of this warranty Labor and related expenses incurred to install replacement or repaired parts are not covered by this warranty C Astro Packaging is not responsible for repair or replacement of any product that has been subject to abuse misuse alteration accident or negligent use nor for repairs made by an unauthorized person or with parts other than those provided by Astro Packaging D Astro Packaging assumes no responsibility for the performance of adhesives or other materials used with its products E The warranty for a product repaired or replaced under this warranty shall continue in effect for the remainder of the original warranty period or for ninety 90 days following the day of shipment by Astro Packaging of the repaired or replaced product whichever period is longer F No warranty is made with respect to custom products or products developed designed and manufactured to customer specifications except as specifically stated in writing by Astro Packaging G Astro Packaging is responsible only for payment of shipping charges for delivery of repaired or replaced product via the least
22. emove pressure before opening filter or drain valve to prevent accidental system pressurization or firing 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 An adjustable pressure regulating device is mounted on the pump under the melt unit chassis See the illustration below e Adjust the flow control by turning the provided 1 4 inch allen wrench 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 flow rate turn the knob fully counterclockwise Gradually turn the knob clockwise until the desired pressure and flow rate are achieved OAstro Packaging Fe D2 15 Manual 19600 10 D215 34 Storage and Disposal of the D2 15 Application System Temporary Storage of the Unit 1 Flush the adhesive application system with flushing fluid PN RB 5 following the instructions detailed in Chapter 6 of this manual Clean or replace both the output filter and the tank following instructions detailed in Chapter 6 Shut OFF all pressure and power sources Remove all residual adhesive and wipe components clean Remove all power supply cables Packthe unit in a corrosio
23. ent verify that all material in melt tank has completely solidified CAUTION The illustration above is for reference only DO NOT TURN THE MELT UNIT UPSIDE DOWN Failure to comply with this caution can result in injury and or damage to the equipment Removal of an Existing Hose 1 Switch the system power off and allow the hot melt in the tank to completely solidify 2 Switch the system on for 5 minutes to allow the fittings to warm or heat the fittings with a handheld hot air gun 3 Switch the system power off and disconnect the melt unit electrical power from the external source 4 Disconnect the hose electrical connector 4 5 Remove the screws from the hose mounting block 5 6 Loosen the hose JIC fitting 1 and remove the hose from the fitting 2 on the flow control block 3 OAstro Packaging D2 15 Manual 19600 10 D215 7 1 Installation of a New Hose 1 Never flex a hose when it is cold Hoses have a minimum bend radius of 20 32 cm 8 in when hot 2 Further flexing will cause permanent damage 3 Switch off the system power and disconnect the melt unit electrical power from the external source 4 Heat the hose JIC fittings 1 before adjusting or damage may result New or clean hose fittings may not require heating 5 Install the hoses onto the melt unit by tilting the unit back until the underside is accessible 6 Support the melt unit with a block on the back of the housing so that hot melt does not spill
24. esired 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 flow control valve counterclockwise to minimize pressure and lower flow rate NOTE the pump motor will not run until the TC500 has green ready LED Adding Adhesive WARNING HOT ADHESIVE Do not overfill the melt tank since adhesive generally expands as it melts and a full tank may overflow CAUTION Using adhesive with viscosity over 50 000 centipoise may cause the pump to stall 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 flushed if the two formulations are incompatible See Chapter 6 of this manual for the proper flushing procedure When in doubt about adhesive compatibility flush your system OAstro Packaging D2 15 Manual 19600 10 D215 33 Flow Adjustments Flow Control Valve WARNING Contents at high temperature and pressure R
25. g down on the motor the motor shaft should turn counterclockwise The cooling fan may spin in the opposing direction so it is important to judge the correct rotation by the motor shaft Astro Packaging D2 15 Manual 19600 10 D215 7 6 Pump Filter Installation and Replacement The pump filter is installed in the flow control block Refer to the figure below for installation and replacement of the filter element WARNING Contents at high temperature and pressure Remove pressure before opening filter or drain valve to prevent accidental discharge of system pressure Do not touch hot surfaces Failure to follow these instructions may result in severe burns 1 Bring the melt unit to operating temperature 2 Switch off the pump motor 3 Actuate the applicator several times to relieve all pressure in the system 4 Place a disposable container below the filter access area to catch all the adhesive spillage or run off 5 Slowly remove the cap 1 fitting 2 and o ring 3 to release any residual pressure trapped in the flow control block 5 6 Remove the filter 4 It is recommended that the filter be replaced and not cleaned for reuse 7 Carefully switch the pump motor on for approximately 1 2 seconds to cause a small amount of adhesive to flush the filter chamber Clean the filter chamber of all foreign material Repeat if necessary 8 Insert the new filter 4 into the flow control block 5 9 Inspect the
26. hematic included with the melt unit 7 Reinstall the housing NOTE The tank heater connections at the power board are J6 and J7 and are fused by F1 and F2 Astro Packaging D2 15 Manual 19600 10 D215 Tank RTD Sensor Replacement 1 Switch off the system power and disconnect electrical power from the external source 2 Remove the housing and retain the housing screws for reinstallation 3 Locate the RTD sensor 2 in its bore on the tank base 4 Remove the failed sensor from the bore located at the tank base Note the wire routing for installation NOTE The sensor plugs into the CPU board at J2 5 Coat the RTD sensor lightly with heat sink compound 6 Slide the new RTD sensor 2 into its bore 7 Route the RTD lead wires in their original locations as noted in Step 4 8 Reinstall the housing OAstro Packaging D2 15 Manual 19600 10 D215 74 Tank Over temperature Thermostat Replacement WARNING The over temperature thermostat is a necessary safety device for preventing runaway heating on all melt units Do not bypass this protection Runaway heating of the tank can cause hot melt materials to burst into flames 1 Disconnect the melt unit electrical power at the external source 2 Remove the housing and retain the housing screws for reinstallation 3 Locate the over temperature thermostat 3 4 Remove and retain the mounting screws and wire connectors from the over temperature thermostat 5 Remove the
27. lly 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 Specifications 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 fluid fittings 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 fitting will rotate 2 Connect the output end of the hose to the adhesive input fitting 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
28. n proof manner Store the unit in such a way that it is protected from damage Disposal of the Unit 1 2 3 4 Shut OFF all pressure and power sources Remove all residual adhesive Remove all adhesive supply hoses and all power supply cables Dismantle all components and sort into mechanical and electrical components 5 Arrange for all components to be recycled OAstro Packaging D2 15 Manual 19600 10 D215 35 Chapter 4 TC 500 Temperature Controller TEMPERATURE CONTRLLER O Standby Ready O Program Tank Error Q Hose 1 Error O Gun 1 Error O Hose 2 Error O Gun 2 Error PRELIMINARY Programming Temperature Setpoints To choose between the following parameters press the left or right arrows Press and release the following sequence Program Menu 1X Enter ee To increase or decrease values press Up or Down arrows CA JD To exit press Program Astro Packaging D2 15 Manual 19600 10 D215 4 1 To choose between the following parameters press the left or right arrows Motor Cut Off Standby Over temp Tank Tank Tank Hose Hose Hose Gun 1 Gun 1 Gun 1 Set Offset Temperatures Press and release the following sequence Program Menu 2X Enter l lls Hose2 Hose2 Hose2 Gun 2 Gun 2 Gun 2 To increase or decrease values press the Up or Down arrows To exit press Program Set Automatic Wakeup To choose between the following parameters press the left or right arr
29. o ring 3 and replace it if it is damaged 10 Install the fitting 2 o ring 3 and cap 1 securely into the flow control block 5 OAstro Packaging D2 15 Manual 19600 10 D215 7 7 V4 Pump and Flow Control Block Replacement WARNING Contents at high temperature and pressure Remove pressure before opening touch hot surfaces Failure to follow these instructions may result in severe burns er filter or drain valve to prevent accidental discharge of system pressure Do not V If melt unit is cold allow to heat for approximately 5 minutes Depressurize the system by manually actuating the applicator s Remove electrical power from the system at the main circuit breaker and at the external source Disconnect the hose fluid connection s from the flow control block 5 Disconnect the hose electrical connection s from the bottom of the control box Set the hose s aside Remove the 4 screws flat washers and lock washers 2 3 4 holding the flow control block 5 6 Remove the flow control block 5 and set it aside Do not lay the flow control block flat on any surface it may glue itself to the surface 7 Remove and discard the existing pump 10 gasket 11 wear plate 8 and pump o ring 9 8 Reassemble the pump as follows NOTE V4 pump is shipped with bolts and nuts 15 holding pump 10 and wear plate 8 together a Remove and discard the bolts and nuts 15 holding the new pump 10 and wear
30. ows Press and release the following sequence Program Menu 3X Enter Next Previous 1 14 Event 1 8 2 Sunday ngan Event 3 8 4 Monday Event 5 8 6 Tuesday Event 7 8 8 Wednesday Event 9 amp 10 Thursday Event 4 13 amp 14 Saturda To increase or decrease values press the Up or Down arrows To exit press Program OAstro Packaging D2 15 Manual 19600 10 D215 42 Set Clock Calendar Press and release the following sequence Program Menu 4X Enter Save and Register Settings Press and release the following sequence Program Menu 5X Enter To choose between the following parameters press the left or right arrows Year Month Date Day Hours Minutes To increase or decrease values press the Up or Down arrows To exit press Program To choose between the following parameters press the left or right arrows Save Operating Variables as backup Load Operating Variables from Back Up Load Operating Variables from Factory Settings To increase or decrease values press Up or Down arrows To exit press Program OAstro Packaging D2 15 Manual 19600 10 D215 43 To choose between the following parameters press the left or right arrows Display Set Audit Variables Press and release the following sequence Program Menu 6X Enter System run time counter Year 0000 Day 0000 Hour 0000 Software revision H1 and the date it was revised Jan 1
31. plate 8 together b Place the 4 screws flat washers and lock washers 2 3 4 into the flow control block 5 c Cover the new pump o ring 9 with silicone grease and place it into the groove in the pump body d Coat and insert the wear plate o ring 7 into the groove in the pump wear plate 8 Place the pump body 10 onto the wear plate 8 ensuring not to pinch the o ring 7 e Place the new pump 10 and wear plate 8 into the flow control block 5 Align the assembly with the screws flat washers and lock washers 2 3 4 so that the bushing assembly 14 faces away from you and the flow control valve faces to the right f Place new gasket 11 on pump 10 No sealants needed 9 Align the pump shaft slot on the end of the shaft 13 with the tab atop the pump 10 10 Slide the pump assembly into the pump block 12 and tighten the screws flat washers and lock washers 2 3 4 in a crisscross fashion DO WN a Un 11 Reconnect hose s fluid and electrical connections and reapply electrical power to the melt unit 12 With the pump switch off allow the melt unit to heat to operating temperature 13 Retighten pump screws to 5 65 8 47 N m 50 75 Ibs in 14 Adjust the adhesive pressure by turning the flow control knob 1 Refer to Section 4 2 Adjustments 15 Test the melt unit adjust the pressure and check for leaks 16 Return the melt unit to service OAstro Packaging D2 15 Manual 1
32. t 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 Atank mounted over temperature thermostat switches the system power off in the event of a tank controller failure A circuit breaker protects the pump motor by switching the motor off should 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 Off once 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 OAstro Packaging D2 15 Manual 19600 10 D215 2 1 Specifications Environmental Storage Shipping Temperature sense 0 60 C 32 140 F Ambient Air Temperature users 5 40 C 41 104 F Suis Sea level up to 2 km 1 24 miles Physical DIMENSION pe M dimensional layouts on following pages TANKICA PIN Y ss M 6 8 kg 15 Ib Hose Capacity sess 2 automatic or 2 manual hoses Weight seen 35 4 kg 78 Ib Pump SIZE NS V
33. ter 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 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 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 pr
34. thermostat and clean the mounting surface 6 Apply a small amount of heat sink compound on the back side of the replacement over temperature thermostat 7 Position the thermostat in the appropriate location on the tank base and attach it using the original mounting screws 8 Reconnect the over temperature thermostat wire connectors and reinstall the housing NOTE The over temperature thermostat plugs into the power board at J8 OAstro Packaging D2 15 Manual 19600 10 D215 7 5 Motor Replacement 1 w OND 9 Remove electrical power from the system at the main circuit breaker and at the external source Locate and remove the electrical cord 2 that connects the motor 1 with the control box Remove and retain the 4 screws 3 at the base plate of the motor 1 Pull the motor 1 slightly out then down and away from the motor mount 5 The motor shaft coupler 4 will clear the motor mount hole as shown Install the new motor by following steps 2 4 in reverse order Refer to the following pages for the wiring configurations for each motor type 44 70 and 86 rpm Open the control box cover and the control panel Locate and remove the pump circuit breaker from the control panel Install the new pump circuit breaker Close the control panel and cover 10 Restore electrical power to the melt unit 11 Allow the melt unit to heat to operating temperature 12 Test the motor for correct rotation While lookin
35. with an ohmmeter If the hose heater fails replace the hose See Heated Hose Manual Determine if the applicator is heating by using a pyrometer or temperature sensing device Do not touch applicator by hand to determine temperature Check 6 3A fuse on power board Adhesive output is too high Decrease the system fluid pressure with the flow control valve 6 2 If there is no change remove the nozzle and replace it with a smaller orifice nozzle Decrease the hose temperature by 4 10 C 25 50 F If there is no change consult Astro Packaging regarding application Adhesive output is too low Increase the system fluid pressure taking great care not to stall the motor by adjusting the flow control valve If there is no change remove the nozzle and replace it with a larger orifice nozzle Clean applicator nozzle Clean replace pump filter Purge the system Hot melt formulations tend to be a factor in previously listed problems Refer to Ch 3 for start up cautions 6 Increase the hose temperature by 4 10 C 25 50 F If there is no change consult Astro Packaging regarding the application Contact Astro Packaging Technical Services department for assistance at 800 642 7876 OAstro Packaging D2 15 Manual 19600 10 D215 62 Chapter 7 Repair 8 Replacement Refer to Parts List in Chapter 8 for all replacement parts listed in this section Hose Replacement CAUTION For safe and proper hose replacem
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