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[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

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LS10 and LS20 19600-121

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Copyright 2010 Astro Packaging

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Summary of Contents for LS10 Series

Page 1: ...LS10 and LS20 Series Hot Melt Units Manual Number 19600 121 Revision E 800 401 1441 800 401 1441 ...

Page 2: ... 800 401 1441 ...

Page 3: ...LS10 and LS20 Series Hot Melt Units Manual Number 19600 121 Revision D Date 02 17 10 Copyright 2010 Astro Packaging 800 401 1441 ...

Page 4: ... Copyright 2010 Astro Packaging 800 401 1441 ...

Page 5: ...llation 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...

Page 6: ...ng 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 Tan...

Page 7: ...t melt properly Refer to the Materials Safety Data Sheet MSDS of the hot melt for recommended disposal methods 1 2 Personal Safety Wear the following protection when working on or around this equipment Always wear heat resistant gloves rated to 205 C 400 F and allow all system temperatures to stabilize below 193 C 380 F before servicing Properly ventilate equipment according to MSDS of equipment T...

Page 8: ...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 wor...

Page 9: ...ect electrical power at external source Failure to do so can cause electrical shock DANGER High Voltage Can cause serious injury including death Disconnect electrical power at external source before servicing WARNING Hot Surface Can cause serious injury and burns Wear heat resistant clothing gloves and safety goggles PE On Tank Set Temp Tank Heater Off Heated Hose Standby Temp Alarm Ground Applica...

Page 10: ... 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 Sec...

Page 11: ...hermostat 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 pou...

Page 12: ...ity 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 ...

Page 13: ... standard requirements 3 6 Dimensions 317 5 mm 12 5 in 355 6 mm 14 in 342 9 mm 13 5 in 508 mm 20 in 269 7 mm 10 62 in 6 3 mm 0 25 in dia 0960149a LS10 Hot Melt Unit 355 6 mm 14 in 342 9 mm 13 5 in 698 5 mm 27 5 in 269 7 mm 10 62 in 317 5 mm 12 5 in 6 3 mm 0 25 in dia 0970014 LS20 Hot Melt Unit Frequency 50 60 Hz Motor Speed 44 min rpm 100 300 psi 689 48 2 068 43 kPa V4 675 Pump 6 89 20 68 bar 55 l...

Page 14: ...e 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...

Page 15: ...m 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 leak...

Page 16: ...se power An identification plate is attached to each melt unit on the outside rear door of the tank housing This plate specifies the exact voltage of the melt unit and frequency of the pump motor Pump motor voltage frequency and current are specified on the motor data plate located on the motor For safe and proper installation refer to the identification plate before applying electrical power to t...

Page 17: ...routing wires to electrical terminal blocks Holes in the chassis are provided for these installations 4 Close the front control panel after electrical hookup 4 3 5 Valve Group Control Circuits for Automatic Systems An automatic applicator or valve contains one or more adhesive valves which are activated by a solenoid A valve group is a number of valves powered by the same source which activate at ...

Page 18: ...power from an external power source 4 3 7 VDC Valve Firing Voltage Firing Voltage Source Trigger Signal Source Head Driver Required Pattern Control Jumpers DC Head Driver any 3 32 VDC trigger DC Head Driver not present 4 3 8 Foot Switch Trigger for Semi automatic Systems A manually operated foot switch allows operator to control adhesive deposition through automatic applicators while keeping hands...

Page 19: ...s extends pump life and provides added safety when the melt unit is used in conjunction with other machinery 1 Using melt unit electrical schematic locate parent machine interface jumper 2 Remove parent machine interface jumper 3 Wire contacts from external device to the melt unit main terminal block where the parent machine interface jumper was located Copyright 2010 Astro Packaging LS10 and LS20...

Page 20: ...perature of hot melt material in the melt tank The hose temperature adjustment located behind front panel indicates the set temperature of the material in the hose 4 Tank Heating Indicator Light Illuminates amber when tank heaters are powered and assists user in making temperature adjustments to tank temperature controller 5 Pump Motor ON OFF Breaker Switch Turns off pump motor during system warmu...

Page 21: ...APPLICATOR TANK ON OFF PUMP POWER HEATING TEMPERATURE 5 1 2 3 4 0960130b OVERTEMP Copyright 2010 Astro Packaging LS10 and LS20 19600 121 15 ...

Page 22: ...lock or pump or when the motor is noisy a Loosen the screws holding the motor b Warm up melt unit and run the motor This causes the motor to center itself c With motor running tighten screws in a crisscross pattern 6 Set hose and tank temperature to desired settings Lower settings will increase the material pot life 7 Set the tank temperature as low as possible for each application Certain materia...

Page 23: ...ck in Maintenance section of the Tank Temperature Controller 1 To prevent hot melt degradation set melt tank temperature to the minimum temperature specified by the hot melt manufacturer 2 To raise melt tank temperature turn tank temperature controller adjustment shaft 1 in illustration below clockwise with screwdriver 3 To lower melt tank temperature turn adjustment shaft 1 counter clockwise with...

Page 24: ...re regulating device is mounted on the pump under the melt unit chassis See illustration below 1 Adjust flow control from the lower right side of melt unit using the hex wrench supplied with unit 2 To increase pressure turn hex wrench clockwise 3 To decrease pressure turn hex wrench counterclockwise 4 To achieve minimum pressure and lowest flow rate turn hex wrench fully counterclockwise 5 Gradual...

Page 25: ... hose fittings are disconnected and power is off CAUTION To prevent damage to components hose fittings 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 CAUTI...

Page 26: ...pported so it is not stressed during use Minimum bend radius is 8 in when hot Check temperatures Adjust temperature according to Hose Temperature Controller section On multi hose systems a temperature difference between hoses is quickly noted by touching outer insulation of each hose Verify system is not operating in overtemperature mode by observing Overtemperature Indicator Light Determine tank ...

Page 27: ... Check status of components with a voltmeter system powered or ohmmeter system unpowered wires disconnected 2 Adjust tank temperature controller Inadequate tank heat can affect performance 3 If problem still exists replace tank heaters as specified under Tank Heater Replacement Tank overtemperature 1 Check tank temperature when overtemp indicator is lit If too high turn tank controller countercloc...

Page 28: ...low control valve If no change remove nozzle and replace with a smaller orifice nozzle 2 Decrease hose temperature by 4 10 C 25 50 F If no change consult your hot melt material vendor regarding application Adhesive output too low 1 Increase system fluid pressure without stalling the motor by adjusting flow control valve If no change remove nozzle and replace with a larger orifice nozzle 2 Clean ap...

Page 29: ...warm or heat fitting with a hand held hot air gun 3 Switch system power off and disconnect melt unit electrical power from external source 4 Per illustration below disconnect hose electrical connector 2 by tilting melt unit back until underside is accessible Support the melt unit with block on back of housing so hot melt does not spill Do not turn melt unit upside down 5 Remove screws from hose mo...

Page 30: ...elt does not spill Do not turn melt unit upside down 5 Support hose to prevent excessive flexing Do not support 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 6 Install hose as follows a Loosely connect the hose JIC swivel fitting 5 to fitting 4 on the flow control block or hose ...

Page 31: ...low control valve 6 Remove thermostat bulb from hose end take care not to kink capillary tube 7 Open front control panel 8 Disconnect controller wires 9 Remove screws fastening controller to electrical panel 10 Install new controller a Insert thermostat bulb into hose end b Coil capillary tube so it hangs in a suitable position under chassis 11 Reconnect hose to JIC as specified in Section 4 2 Com...

Page 32: ...dix A for Component Resistance Tables 5 If heater requires replacement disconnect wires of defective heater 6 Pull heater out of bore using pliers If heater does not come out easily drive out using a 6 35 mm 0 25 in diameter rod inserted in knockout holes in back of tank base 7 Apply a coating of heat release and transfer agent to new heater and slide it into tank heater bore from the front 8 Rout...

Page 33: ... Remove wires connected to thermostat Tank thermostat controller is the elongated thermostat mounted horizontally on the tank base plate 5 Remove screws holding tank thermostat to tank 6 Apply even coating of heat sink compound to base of the new thermostat 7 Attach replacement thermostat to the tank assembly using the mounting clip and screws Reconnect wires 8 Replace tank access plate 9 Close fr...

Page 34: ...spill Do not turn melt unit upside down 5 Per illustration below loosen JIC fittings 5 and remove hose s from fitting s 6 on hose manifold 3 6 Remove screws 4 from hose manifold filter block 3 7 Ease hose manifold 3 from flow control block 1 Two screws remain 3 for reverse mounting holding flow control block 1 and pump to tank base plate 8 Clean hose manifold 3 thoroughly especially flow control b...

Page 35: ... all pressure in the system 4 Place a disposable container below filter access area to catch all adhesive spillage or run off 5 Slowly remove plug 1 with o ring 2 to release any residual pressure trapped in hose manifold filter block 6 A 9 16 in hex wrench is required 6 Remove spring 3 spring retainer 4 and filter 5 Clean all parts 7 Carefully switch pump motor on for approximately 1 to 2 seconds ...

Page 36: ... 13 9 Install new pump motor on motor mounting plate 10 Check pump shaft alignment on pump in tank 11 Align motor coupling 3 with pump shaft in tank and lower onto shaft 12 Align motor mounting plate to melt unit with mounting screws 4 13 Verify that pump shaft seats properly with pump and verify that coupler clearance 14 of 0 8 mm 0 3 mm 0 030 in 0 010 in exists 14 Replace liquidtite fitting and ...

Page 37: ...14 13 10 6 1 4 3 2 5 7 8 11 12 9 4 0950178 Copyright 2010 Astro Packaging LS10 and LS20 19600 121 31 ...

Page 38: ...rtemperature indicator 12030 1 3 Thermometer 11029 4 Thermometer spring 14488 1 5 Lamp round amber tank heating indicator 12030 10 6 Circuit breaker switch pump motor 1 A 100 115 VAC unit 12055 1 6 Circuit breaker switch pump motor 0 5 A 200 230 VAC unit 12055 3 APPLICATOR TANK ON OFF PUMP POWER HEATING TEMPERATURE 6 1 2 3 4 5 0960130c OVERTEMP 32 LS10 and LS20 19600 121 Copyright 2010 Astro Packa...

Page 39: ...rs for 20 lb unit 79044 1 1 Tank heater kit 100 VAC 600 W 2 heaters for 20 lb unit 79044 2 1 Tank heater kit 200 VAC 600 W 2 heaters for 20 lb unit 79044 3 2 Tank controller kit 38 232 C 100 450 F 79006 3 Panel access 70350 1 4 Connector 9 pin for solid capillary controlled melt units 12115 9 5 Flange 9 pin connector panel mount 12115 10 6 Female electrical pins 12116 7 Hose controller kit 38 93 C...

Page 40: ...ket head cap 10 32 x 1 75 LG 14431 FDO 10 Screw set flat point 1 4 28 x 3 16 14401 HDB 11 Pump shaft assembly 10 lb melt unit 73726 21 11 Pump shaft assembly 20 lb melt unit 73726 22 12 Washer rat trap 14528 4 13 Retaining ring 14502 12 14 Shaft pump with keyway 10 lb melt unit 70461 3 14 Shaft pump with keyway 20 lb melt unit 70461 4 15 Retaining spring pump shaft 70028 Retainer seal for pump sha...

Page 41: ... F 79068 300 1 176 67 C 350 F 79068 350 LS10 Overtemperature Thermostat Kit 2 65 56 C 150 F 79126 150 2 93 33 C 200 F 79126 200 2 148 89 C 300 F 79126 300 2 204 44 C 400 F 79126 400 2 232 22 C 450 F 79126 450 LS20 Overtemperature Thermostat Kit 2 65 56 C 150 F 79127 150 2 93 33 C 200 F 79127 200 2 148 89 C 300 F 79127 300 2 204 44 C 400 F 79127 400 2 232 22 C 450 F 79127 450 2 2 1 1 0960370 Copyri...

Page 42: ...ter block kit 2 hose for rear exit only optional 79133 02 16 Plug 3 8 NPTF steel 11603 6A 17 Fitting male 1 4 in NPT to No 6 JIC straight 11408 64A 18 Screw socket head cap 1 4 20 x 2 50 in both pumps 14431 GDR 19 Screw socket head cap 1 4 20 x 3 75 in for V1 450 14431 GDV 19 Screw socket head cap 1 4 20 x 4 25 in for V1 675 14431 GDY 20 Hose manifold filter block 70122 21 O ring viton 0 86 in ID ...

Page 43: ... Copyright 2010 Astro Packaging LS10 and LS20 19600 121 37 ...

Page 44: ...use with pump Filter Block Assembly 79064 Kit Reverse 1 Hose Mounting Filter Block Assembly not included 79135 10 Kit Reverse 2 Hose Mounting Filter Block Assembly not included 79135 11 Kit Knob Assembly FCV V1 Retrofit to existing units 79287 01 Power Cord Assembly 115 VAC 73712 12 Kit Hose Mole use for in place cleaning of hoses 79281 01 Kit Tank Thermometer 79014 1 2 3 4 5 5 Hose Boom Balancer ...

Page 45: ...5 6 SS10G Mark II 73714 24 73714 24 38 31 50 60 200 230 16 LS SQ10 20 73795 01 73714 20 44 36 50 60 100 115 25 28 LS SQ10 20 73795 02 73714 21 44 36 50 60 200 230 102 105 KS10 20 73795 01 73714 25 44 36 50 60 100 115 25 28 KS10 20 73795 02 73714 26 44 36 50 60 200 230 102 105 KB FS10 20 73794 01 73714 41 43 86 72 50 60 100 115 6 9 73794 02 73714 42 44 86 72 50 60 200 230 16 20 73794 06 73714 45 46...

Page 46: ...300 F 158 177 C 350 F 168 204 C 400 F 178 Same RTD sensor is used in tank hose and applicator Table 5 Valve Coil Resistance E100XT Style Coil E900 Style Coil Voltage Ohms Voltage Ohms 100 39 42 100 64 75 115 45 48 115 77 89 200 156 157 200 239 281 230 172 201 230 285 335 40 LS10 and LS20 19600 121 Copyright 2010 Astro Packaging ...

Page 47: ...01 230 1 150 150 369 399 E902 230 2 150 300 182 211 E904 230 2 150 300 182 211 M101 230 2 150 300 182 211 M102 230 4 150 600 91 106 M104 230 4 150 600 91 106 Manual Applicators L4 SW4 230 1 80 80 664 720 L1 115 1 50 50 247 314 L4 SW4 115 1 80 80 170 190 For applicators with more than 1 heater resistance shown is for heaters in parallel Copyright 2010 Astro Packaging LS10 and LS20 19600 121 41 ...

Page 48: ...12 235 178 196 153 169 134 148 Handgun Hoses Part No VAC 8 ft 12 ft 16 ft L1 Hose Capillary Sensor 26257 115 VAC 80 83 54 56 41 42 26276 230 VAC 293 305 199 207 150 156 L1 Hose RTD Sensor 26499 115 VAC 73 80 49 54 36 40 26500 230 VAC 298 306 199 204 149 L4 Hose Capillary Sensor 21260 115 VAC 71 74 48 50 36 38 21262 230 VAC 283 294 192 200 145 152 L4 Hose RTD Sensor 21285 115VAC 75 79 45 52 37 39 2...

Page 49: ...IED INCLUDING THE purchased H For service under this warranty contact the Factory Authorized Representative from which the product was Center for evaluation repair or replacement is the responsibility of the customer via the least expensive means of transport to customer or an authorized Sales and Service Center in the F No warranty is made with respect to custom products or products developed des...

Page 50: ...____ Product Part Number______________________________ Order No _____________ Product Model Description__________________________ Serial No _____________ Date Received____________ Start Up Date____________ Invoice No ____________ Product Part Number______________________________ Order No _____________ Product Model Description__________________________ Serial No _____________ Date Received________...

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