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ASTRO D2-15, Manual

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ASTRO D2-15 Manual Download Page 54

©Astro Packaging   Rev D

D2-15  Manual-19600-10-D215

8-11

Summary of Contents for D2-15

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Page 3: ...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...

Page 4: ... 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 Variou...

Page 5: ...t 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...

Page 6: ...nd 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 ...

Page 7: ...elow 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 article...

Page 8: ...eral Safety Symbols Specific 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 injur...

Page 9: ...y 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 reflect all details of these improvements Astro Packaging Rev D D2 15 Manual 19600 10 D215 1 3 ...

Page 10: ...elow 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 article...

Page 11: ...eral Safety Symbols Specific 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 injur...

Page 12: ...y 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 reflect all details of these improvements Astro Packaging Rev D D2 15 Manual 19600 10 D215 1 3 ...

Page 13: ...elt 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 ...

Page 14: ...0 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 ...

Page 15: ...Dimensions Astro Packaging Rev D D2 15 Manual 19600 10 D215 2 3 ...

Page 16: ...utomatic 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 separate...

Page 17: ...f 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 120 VAC L1 N 240 VAC L1 L2 Single phase service Single phase service Operation Astro Packaging Rev D...

Page 18: ...E 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...

Page 19: ...knob fully counterclockwise Gradually turn the knob clockwise until the desired pressure and flow 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 filter or drain valve to prevent accidental system pressurization or firing Do not touch hot surfaces Failure to follow these instructions may result ...

Page 20: ... 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...

Page 21: ...ses and then the guns Astro Packaging Rev D D2 15 Manual 19600 10 D215 4 1 Programming Temperature Set Points Press and release the following sequence Program Menu 1X Enter Press and release the Menu button until the desired Menu is displayed To choose between the following parameters press the left or right arrows Tank Tank Ready Delay 1 60 minutes Hose 1 Gun 1 Hose 2 Gun 2 To increase or decreas...

Page 22: ...Press and release the Menu button until the desired Menu is displayed To choose between the following parameters press the left or right arrows Motor Cut Off Tank Hose1 Gun 1 Hose2 Gun 2 Standby Tank Hose1 Gun 1 Hose2 Gun 2 Over temp Tank Hose1 Gun 1 Hose2 Gun 2 To increase or decrease values press the Up or Down arrows To exit press Program ...

Page 23: ... 1 14 Day Hour Minute On Off Event 1 2 Sunday Event 3 4 Monday Event 5 6 Tuesday Event 7 8 Wednesday Event 9 10 Thursday Event 11 12 Friday Event 13 14 Saturday Note that Event 1 must start on Sunday To increase or decrease values press the Up or Down arrows To exit press Program Set Clock Calendar Press and release the following sequence Program Menu 4X Enter Press and release the Menu button unti...

Page 24: ...Back Up Load Operating Variables from Factory Settings To increase or decrease values press Up or Down arrows To exit press Program Display Set Audit Variables Press and release the following sequence Program Menu 6X Enter Press and release the Menu button until the desired Menu is displayed This menu is for viewing only it can t be altered To choose between the following parameters press the left...

Page 25: ...parameters press the left or right arrows System Calibration Tank xxx xx Ω System Calibration Spare xxx xx Ω System Calibration Hose 1 xxx xx Ω System Calibration Gun 1 xxx xx Ω System Calibration Hose 2 xxx xx Ω System Calibration Gun 2 xxx xx Ω System Calibration 110 Ohms System Calibration 240 Ohms System Calibration Frequency 60 Hz System Calibration Voltage xxx x V Test LED Lamps LED Test Run...

Page 26: ...asks Continued Press and release the following sequence Program Menu 7X Enter Press and release the Menu button until the desired Menu is displayed LCD Back Light Intensity Current Level xxx Change Level 1 9 100 To increase or decrease values press Up or Down arrows To exit press Program ...

Page 27: ...F to C 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 7 is recommended Disable hose 1 Currently On Off Disable Gun 1 Currently On Off Disable hose 2 Currently On Off Disable Gun 2 Currently On Off Trigger 1 Safety enable Currently On Off Trigger 2 Safety enable Currently On Off ON for handguns Automatic On Off 7 day clock time...

Page 28: ...meter OFF LEVEL 1 LEVEL 2 LEVEL 3 Programming Temperature Setpoints Unlock Lock Unlock Not visible Offset Temperatures Unlock Lock Unlock Not visible Automatic Wakeup Unlock Unlock Unlock Not visible Set Clock Calendar Unlock Unlock Unlock Not visible Save and Register Settings N A N A N A Not visible Display Set Audit Variables N A N A N A N A Performance Various System Tasks Unlock Unlock Unlock ...

Page 29: ...D2 15 Manual 19600 10 D215 4 9 PARAMETER CHANNEL TEMPS NOTES Set Temperatures Tank Hose 1 Gun 1 Hose 2 Gun 2 Set Offset Temperatures Motor Cut OffTank Hose 1 Gun 1 Hose 2 Gun 2 StandbyTank Hose 1 Gun 1 Hose 2 Gun 2 Over temperatureTank Hose 1 Gun 1 Hose 2 Gun 2 ...

Page 30: ...11 Friday 12 Friday 13 Saturday 14 Saturday Performance Various System Tasks Astro Packaging Rev D D2 15 Manual 19600 10 D215 4 10 Notes Toggle Display Temperatures between C F Set Line Voltage Set Line Frequency Power Set Mode 7 is recommended Disable hose and gun 1 Disable hose and gun 2 Trigger Safety Enable ON for handguns Automatic On Off 7 Day clock Timer Security Lock Level 1 is recommended ...

Page 31: ... Astro Packaging Rev D D2 15 Manual 19600 10 D215 4 11 ...

Page 32: ...gs etc heat part s being serviced to 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 electric...

Page 33: ...l 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 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 Inadequat...

Page 34: ...temperature sensing device Do not touch applicator by hand to determine temperature 4 Check 6 3A fuse on power board Adhesive output is too high 1 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 2 Decrease the hose temperature by 4 10 C 25 50 F If there is no change consult Astro Packaging regar...

Page 35: ...onnect 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 Astro Packaging Rev D D2 15 Manual 19600 10 D215 7 1 CAUTION For safe and proper hose replacement verify that all material in melt tank has co...

Page 36: ...t does not spill 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 contro...

Page 37: ...r 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 schematic included with the melt unit 7 Reinstall the housing NOTE The ...

Page 38: ...re 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 Astro Packaging Rev D D2 15 Manua...

Page 39: ...pound 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 Astro Packaging Rev D D2 15 Manual 19600 10 D215 7 5 W...

Page 40: ... Refer to the following pages for the wiring configurations for each motor type 44 70 and 86 rpm 6 Open the control box cover and the control panel 7 Locate and remove the pump circuit breaker from the control panel 8 Install the new pump circuit breaker 9 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 ...

Page 41: ...ter 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 o ring 3 and replace it if it is damaged 10 Install ...

Page 42: ...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...

Page 43: ...he 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 grip sleeve 7 into the pump coupler 6 11 Coat the surface of the pump block 3 that contacts the base of the tank high temperature silicone grease provided Ensure that the o ring 2 is in place 12 Place the new pump block 3 assembly into the motor mount 8 A...

Page 44: ...ts Part Number Description Qty 12014 8B Fuse 8 amp 5 X 20mm 2 12014 5 Fuse 5 amp 5 X 20mm 2 939683 Fuse 6 5 amp 5 X 20mm 2 10760 50 Pump filter 1 D200109 Assembly Tank RTD 100 ohm 1 D200111 Assembly Over temp Thermostat 475 1 Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 1 ...

Page 45: ...nk D200109 1 3 Kit Tank Heater 120 V 750 W D212600 2 3 Kit Tank Heater 240 V 750 W D212600 2 2 4 Tank Seal 70020 1 5 Tank Lid Assembly 79283 15 1 6 D2 15 Tank Assembly 70827 60 1 7 D2 15 Melt Grid 70827 1 1 Knob 14517 99 1 Lid Outer Black 70586 462 1 Lid Inner Gold Zinc 70586 463 1 Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 2 ...

Page 46: ...3 Key Machine 1 8 in Square x 0 5 in Long 14475 1 1 4 Bushing Assembly 70827 71 1 5 Gear Grip w keyway 18425 9 16 1 6 Gear Grip Sleeve 18425 9C 1 7 Retainer 70601 1 8 Shaft Seal 10483 1 9 Socket Head Cap Screw 1 4 20 X 1 75 in 14431 GDO 2 To replace shaft only order items 2 7 8 Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 3 ...

Page 47: ... 14475 8 1 6 Coupler 5 8 in 86 rpm Motor 3 16 in key 18425 5 8 1 7 Circuit Breaker 86 rpm 2 5A 120 VAC 12055B 25 1 7 Circuit Breaker 86 rpm 1 5A 240 VAC 12055A 15 1 8 Spacer 86 5 8 in OD 3 4 in long 70827 84 2 4 9 Bolt Hex 3 8 16 X 1 5 in 86 rpm motor 14433 KAN 4 10 Lock Washer 25 in ID 14451 GA 4 11 Flat Washer 1 2 in 14456 GA 4 12 Nut 1 4 20 14441 GA 4 13 Screw Hex 1 4 20 X 1 in 14433 GAK 4 Capa...

Page 48: ... Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 5 ...

Page 49: ...tor Assemblies Item Description Part Number 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 Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 6 ...

Page 50: ... This page is intentionally left blank Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 7 ...

Page 51: ...ng 11604 12 1 7 Socket Head Cap Screw 3 8 16 x 5 in 14431 KDKX 4 8 Pump Block Assembly 70827 65 1 9 O ring Viton 1 114 ID X 070 W 10424 1 9 O ring Teflon 1 114 ID X 070 W 10493 024 1 10 Gasket Pump to Tank 70118 1 11 O ring Viton 675 Pump 10545 1 11 O ring Teflon 675 Pump 10493 145 1 12 O ring Viton 0 614 in ID X 0 070 in W 10417 1 12 O ring Teflon 0 614 in ID X 0 070 in W 10493 024 1 13 Pump Filt...

Page 52: ... Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 9 ...

Page 53: ...ton 10412 2 7 Collar 14445 01 1 8 FCV Adjustable Shaft 70038 3 1 9 1 10 Plug Parker Hol Hex 6 Steel 11604 6 1 11 90 Fitting No 6 JIC Straight Thread Long 11447 01 2 12 13 14 Fitting Filter Retainer Purge Valve 74456 2 15 Filter 50 Mesh Standard 10760 50 1 16 O ring Hi Temp No 8 10505 08 1 Cap No 6 JIC Long 11421 6B 3 Plastic Knob 14517 13 1 Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 10 1 4...

Page 54: ... Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 11 ...

Page 55: ...1A TC500 Control Board D250014 1 2 Main Circuit Breaker 120 V D212015 1 2 Main Circuit Breaker 240 V 12010 5 1 3 Pump Circuit Breaker 120 V 12055 B 25 1 3 Pump Circuit Breaker 240 V 12055A 15 1 4 Lamp Amber power and pump 12030 10 2 Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 12 ...

Page 56: ...er Qty TC500 Power board D250015 1 F1 F2 Tank Heater Power board fuse 8 amp 12014 8B 2 F3 Motor Power Board Fuse 5 amp 12014 5B 1 F4 F5 Hose gun heater Power Board Fuse 6 3 Amp 939683 2 Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 13 ...

Page 57: ... 15 Manual 19600 10 D215 8 14 Item Connection Descriptions J1 Control Ribbon Cable J3 J4 24 vdc Solenoid s J5 Power Supply J6 Tank Heater 2 J7 Tank Heater 1 J8 Tank Over temp J9 Motor Circuit Breaker trip signal J10 Hose Head 2 J11 Hose Head 1 ...

Page 58: ... This page is intentionally left blank Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 15 ...

Page 59: ...70586 467 Chassis Base 1 2 70586 465 Electrical Panel 1 3 70586 471 Housing 1 4 70586 472 Front Door 1 5 70586 466 Power Pump Panel 1 6 70586 468 Lid with Hinge 1 7 70586 4681 Inner Lid 2 Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 16 8 70586 473 Access Cover Plate 2 ...

Page 60: ...Component Illustration Exterior Panel and Controls Parts List Astro Packaging Rev D D2 15 Manual 19600 10 D215 8 17 ...

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Page 62: ...nit Model Motor Part RPM Hz Voltage Ohms D2 15 120V D279424 86 50 60 100 120 7 9 D2 15 240V D279424 2 86 50 60 200 250 15 17 RTD Sensor Resistance Valve Coil Resistance Temperature Ohms 0 C 32 F 100 38 C 100 F 115 66 C 150 F 126 93 C 200 F 136 121 C 250 F 147 149 C 300 F 158 177 C 350 F 168 204 C 400 F 178 Astro Packaging Rev D D2 15 Manual 19600 10 D215 9 1 E100XT Style Coil E100XT Style Coil E90...

Page 63: ...tomatic Hoses RTD Sensor HC Style Automatic Hoses RTD Sensor HC Style Automatic Hoses RTD Sensor HC Style Automatic Hoses RTD Sensor HC Style Automatic Hoses RTD Sensor HC Style Automatic Hoses RTD Sensor HC Style Automatic Hoses RTD Sensor Part VAC 4 ft 6 ft 8 ft 10 ft 12 ft 14 ft 16 ft 26701 115 VAC 127 140 86 96 66 72 53 58 44 49 39 41 33 37 26703 240 VAC 510 563 347 384 264 291 212 235 178 196...

Page 64: ...Motor Wiring Astro Packaging Rev D D2 15 Manual 19600 10 D215 9 3 ...

Page 65: ...Wiring Diagram 120V Astro Packaging Rev D D2 15 Manual 19600 10 D215 9 4 D200113 ...

Page 66: ...Wiring Diagram 240V Astro Packaging Rev D D2 15 Manual 19600 10 D215 9 5 D200113 ...

Page 67: ... This page is intentionally left blank Astro Packaging Rev D D2 15 Manual 19600 10 D215 9 6 ...

Page 68: ...tions 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 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...

Page 69: ...___ Serial No ______________ Product Part Number _____________________________________Order No ______________ Date Received ________________ Start Up Date ______________ Invoice No _____________ Product Model Description________________________________ Serial No ______________ Product Part Number _____________________________________Order No ______________ Date Received ________________ Start Up D...

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