ASTRO KB Series Product Manual
  1. Manuals
  2. Brands
  3. ASTRO Manuals
  4. Melting Machines
  5. KB Series
  6. Product manual

ASTRO KB Series Product Manual

Hot melt units
Hide thumbs
Table of Contents

Advertisement

Quick Links

Download this manual
KB Series
KB30, KB50, KB100
Hot Melt Units
Product Manual
Manual Number: 19600-159
1-800-642-7876

Advertisement

Table of Contents
loading
Need help?

Need help?

Do you have a question about the KB Series and is the answer not in the manual?

Questions and answers

Related Manuals for ASTRO KB Series

Summary of Contents for ASTRO KB Series

  • Page 1 KB Series KB30, KB50, KB100 Hot Melt Units Product Manual Manual Number: 19600-159 1-800-642-7876...
  • Page 3 KB Series KB30, KB50, KB100 Hot Melt Units Product Manual Manual Number: 19600-159 Revision: A Date: 04/09/09  Copyright 2009 Astro Packaging...
  • Page 4 NOTE CONCERNING ILLUSTRATIONS: All illustrations within this product manual should be considered as general representations of the parts or assemblies depicted, and should not serve as mechanical drawings, nor be consulted for scope or scale. They are for reference only.  Copyright 2009 Astro Packaging...

  • Page 5: Table Of Contents

    5 Operation ........................18 5.1 Controls and Indicators........................ 18 [1] System-Power-Switch/Circuit-Breaker and Indicator Light ............18 [2] Pump motor On/OFF Switch and Indicator Light............... 18 © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 6 9.10 Tank Level Sensors ........................53 9.11 Weather-Resistant Housing ....................... 53 9.12 Chassis Fans ..........................53 9.13 Reverse Hose Mounting Kits...................... 53 9.14 Adhesive Pressure Gauges ......................54 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 7 Table 1. Hose/Applicator Fuse Size Specification................56 Table 2. RTD Sensor Resistance......................56 Table 3. Heater Resistance ......................... 56 Table 4. E100XT Automatic Applicator Resistance ................ 56 © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 8 This page intentionally left blank. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 9: Safety Precautions For Hot Melt Applicator Equipment

    Trained operators may perform only external equipment adjustments. Trained service technicians must perform internal Wear Protective Clothing adjustments and service. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 10: Electrical Safety

    CAUTION: Indicates a hazard, which, if not avoided, can result in minor injury, or equipment and property damage. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 11 Output The manufacturer reserves the right to make design changes for product improvement. This manual may not reflect all details of these improvements. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 12: Introduction

    Melt tank is also equipped with a pump warm-up switch, for the protection of the pump-drive mechanism. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 13 W HE AN UA SE RV R TO N LI T IC E M W HE AN UA N LI T 2000171a KB100 KB50 © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 14: Specifications

    Maximum Melt Rate*------------- KB30: 40 lb/hr (18.1 kg/hr) ---------------------------------------- KB50/100: 60 lb/hr (27.2 kg/hr) Adhesive Viscosity ---------------- Maximum 70,000 centipoise * Maximum melt rates vary with different adhesive types. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 15: Dimensions

    355.60 mm (29.00 in.) (14.00 in.) 63.50 mm (2.50 in.) 610.6 mm (24.04 in.) 12.70 mm (0.5 in.) 298.70 mm (11.76 in.) 2000333 © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 16: Operating Pressure And Adhesive Flow

    3.6 Adhesive Flow Path TANK BASE FILTER BLOCK MAIN ADHESIVE FLOW FILTER FLOW MANIFOLD PUMP FLOW CONTROL OUTPUT TO ADHESIVE BLOCK SUPPLY HOSES FLOW BYPASS 2000261 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 17: Temperature Controller Options

    7-day clock, remote standby NOTE: *A temperature zone is the heating element (heating circuit) in a tank, hose, or applicator head. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 18: Installation

    For safe and proper installation and to avoid accidental pressurization, make certain that all controls are in the Off position. Read section 5.1: Controls and Indicators before installing any components. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 19: Hot Melt Supply Hoses - Important Points

    Tuck capillary tubing and electrical connector underneath the unit. (Capillary controlled hoses only) g. Position and support hose as it is used in service. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 20: Supporting Applicator Heads

    (Refer to the supply hose manual for this procedure.) 4.3.2 Supporting Applicator Heads Applicator heads, such as the Astro Packaging E100, are mounted to appropriate brackets using supplied hardware. For the head to reach operating temperature, insulation spacers must be used...

  • Page 21: Electrical Circuits And Wiring

    (Also, refer to section 3 for further melt unit electrical specifications). N PE 0990047 230VAC, L1/N, 200-240VAC, L1/L2, Single Phase Service Single Phase Service © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 22: Automatic Heads

    Head control circuits must be isolated from the melt unit power when using Astro Packaging DC Head Drivers or damage will result to the timing device. These wiring configurations are illustrated in the electrical schematic that ships with the melt units.

  • Page 23: Parent Machine Lockout Circuit

    • The second variation must be ordered as a kit from Astro Packaging. This variation locks out the parent machine until the melt unit has reached an acceptable operating temperature.

  • Page 24: Customer Hookups

    Valve Group Terminals 4 & 15A 4A & 15B 7 & 15C 7B & 15E 6 & 15F 6C & 15G KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 25: Other Hookups

    Terminal point to obtain multiple use of tachometer analog signal. Run-Ready Light stack input Standby Light stack input Alarm Light stack input Low Level Light stack input © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 26: Operation

    [5] Overtemperature Indicator Light This is a protection feature. All KB Series melt units are equipped with an overtemperature shutoff. If the melt tank's temperature exceeds the rating of the overtemperature thermostat, the...

  • Page 27: Head Activate/Deactivate Test (Hat) Switch (User-Added Option Only)

    OVERTEMP OVERTEMP REFER TO REFER TO SERVICE MANUAL SERVICE MANUAL WHEN LIT WHEN LIT APPLICATOR APPLICATOR 2000334 Solid-State Temperature Control Bimetallic Temperature Control © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 28: Startup

    6. Become familiar with controls by reading section 5.1: Controls and Indicators. 7. Install the KB Series melt unit as specified in section 4. 8. Fill tank with hot melt material, 1-1/2 inches from the top. 9. Turn the melt unit On and allow 30 minutes warm-up time.

  • Page 29: Adjustments

    30 minutes before making further adjustments. Refer to section 3.3, performance specifications, for temperature range of the melt tank. ELECTRICAL PANEL INTERIOR 2000335 © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 30 ELECTRICAL PANEL INTERIOR 2000336 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 31: Flow Control Valve

    CAUTION: For maximum performance and motor life, do not allow pump motor to stall. Prolonged stall conditions will cause motor to go into thermal overload. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 32: Maintenance

    * Extra maintenance required for continuous duty machines. 6.2 General Maintenance 6.2.1 Warning and Caution Notes KB Series melt units require monthly temperature checks per section 6.2.3. Should char buildup occur, or if the hot melt formulation is changed, the system should be purged with a flushing agent such as Astro Packaging "Strip-N-Clean".

  • Page 33: Heating Of Parts

    Heated Supply Hose manual. 1. Switch Off the pump motor switch. 2. Depressurize the system by activating the head until glue stops flowing. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 34 This filter is used to prevent damage to the pump in standard applications. (Refer to the melt unit parts list and assembly drawing in section 9.) KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 35 5. Temporarily replace plug to prevent hot melt drainage. 6. Clean filter element or replace as required. 7. Reinstall spring, thimble and filter element as removed. 8. Reinstall plug. 2000173a © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 36: Troubleshooting

    The O.T. switch THERMOSTAT 2000285 must be replaced in either case. (Refer to section 9 for switch kits.) KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 37 3. Refer to Solutions #1 through #6. If problem still exists, replace the tank heaters. On melt units with Standby, make sure Standby switch is disengaged and in the Run position. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 38 Refer to the appropriate applicator service manual. Determine exact voltage of the head heaters and the supply hose (found on the identification tags). KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 39 7. Determine if applicator is heating by using a surface temperature probe or a temperature-sensing device. Do not touch applicator by hand to determine temperature. Refer to the appropriate applicator service manual. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 40 Look into the melt tank for any foreign material plugging the inlet pump port. Pump gears can freeze up; in which case the pump may need replacement or repair. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 41 6. Adhesive formulations tend to be a factor in each previously listed problems. Refer to Startup instructions (section 5.2), for cautionary notes. System should be purged if formulation is incorrect. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 42 7. Adhesive formulations tend to be a factor in each previously listed problems. Refer to Startup Instructions (section 5.2), for cautionary notes. System should be purged if formulation is incorrect. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 43 Control Replacement and section 9 for pump kit information.) Tighten F.C.V. and pump mounting screws. If pump continues to leak, replace the o-ring, copper shim, and tank gasket. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 44 7. Increase melt tank and supply hose Temperatures per section 5.3.1. If this does not improve performance, consult the adhesive vendor concerning your applications. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 45 Determine which pump motor is mounted in your melt unit. (Refer to the motor I.D. plate.) Consult factory for the properly rated pump motor for your specific application. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 46 3. Adhesive formulations tend to be a factor in each previously listed problems. Refer to Startup Instructions (section 5.2), for cautionary notes. System should be purged if formulation is incorrect. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 47 If an external device such as timer or a DC Driver is being used the problem may lie with the external device. Refer to the external device's service manual. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 48: Repair And Replacement

    9. Install applicator head on the new supply hose. Switch On system power switch and supply hose power switch to determine if the applicator head and supply hose are operating properly. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 49: Hose Controller Replacement - Bimetallic

    NOTE: Motor must turn the pump shaft counterclockwise (looking down on the pump shaft). 8. Replace housing (for 170 rpm motor on KB30 melt units) and back panel. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 50: V4 Pump (.450 And .675), Flow Control & Drive Shaft Replacement

    12. Reconnect melt unit power, turn system power switch on, and allow unit to warm-up. KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 51: V4 And V3 Drive Shaft Assembly Replacement

    6. Clean all parts and inspect for wear, replace as required. 7. Replace the ball seal in the block. Apply small amount of high temperature lubricant, (Astro Packaging p.n. 30122-3) to the drive shaft in the area of the ball seal.

  • Page 52: Parts List

    NOTE: Teflon o-rings are recommended for polyamide applications. Contact your local distributor for assistance. V4 PUMP BLOCK V4 PUMP KIT O-RING FLOW CONTROL VALVE BLOCK FLOW CONTROL VALVE REPLACEMENT V4 HARDWARE KIT 2000337 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 53: Pumps, V2 And Accessories

    NOTE: Teflon o-rings are recommended for polyamide. Contact your local distributor for assistance. MOUNTING HARDWARE V2 PUMP BLOCK V2 PUMP V2 PUMP O-RINGS V2 FILTER 2000264 V2 FLOW CONTROL VALVE ASSEMBLY © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 54: Pumps, V3 And Accessories

    NOTE: Teflon o-rings are recommended for polyamide. Contact your local distributor for assistance. V4 PUMP BLOCK FLOW CONTROL VALVE ASSEMBLY V3 PUMP ASSEMBLY WITH INTEGRATED FCV O-RING 2000338 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 55: Standard Melt Unit Switches

    Kit, Circuit Breaker 40 Amp(KB50/100) 79003-01 Control Relay 200/230 VAC, 40 amp 12040-92 Relay, SSR 25A, AC 12040-8 Relay, SSR 25A, DC 12041-6 © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 56: Hat Switches

    Off so no firing signal goes to the head coil(s), or in Test for manual testing firing of valve. Astro Packaging Pattern Generators and Head Drivers include a switch for test firing the valves. HAT Switches should not be installed on melt units with Head Drivers.

  • Page 57: Tank Heaters

    Band Heater Kit for tank, 200 or 230 VAC (KB50/100) 79088-100 TANK HEATER KIT KB30 2000281a BAND HEATER KIT BAND HEATER KIT KB100 KB50 TANK HEATER KIT KB50 and KB100 2000281 © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 58: Standard Fan-Cooled Motors

    Motor assembly is the basic motor, intended for replacement of existing motor only. MOTOR ASSEMBLY BREAKER CAPACITOR MOTOR MOUNT COUPLING PUMP SHAFT SPIDER ASSEMBLY COUPLING 2000339 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 59: Standard Fan-Cooled Motor Support

    79295-02 * Common motor breakers. Contact factory for system compatibility. MOTOR ASSEMBLY BREAKER CAPACITOR MOTOR MOUNT COUPLING PUMP SHAFT SPIDER ASSEMBLY COUPLING 2000339 © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 60: Temperature Controllers

    A1 plus remote Run to Standby switch and Run/Standby Indicator. Switch and Indicator light provided by customer RPM Monitor not available.) HOSE CONTROLLER 2000284 TANK RTD SENSOR TANK CONTROLLER KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...

  • Page 61: Tank Level Sensors

    NOTE: 1. One to two feet longer hose may be needed with reverse mounted hoses. 2. Space does not permit more than two rear exit hoses on 50 and 100 lb melt units. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...

  • Page 62: Adhesive Pressure Gauges

    Pressure Gauge, Standard, 1500 PSI/10,000 kPa 79227-02 Pressure Gauge, Low Pressure, 300 PSI/2000 kPa 79227-01 9.15 Melt Unit Stand/Bracket CONTACT LOCAL DISTRIBUTOR FOR AVAILABLE STAND CONFIGURATIONS. 2000253 2000252 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 63 PLC interface. Consult factory for assistance. © Copyright Astro Packaging 2009 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09...
  • Page 64 Tank Voltage Ohms Motor Voltage Ohms 11 - 13 Table 4. E100XT Automatic Applicator Resistance Voltage Ohms 50 - 65 216 - 264 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009...
  • Page 65 This page is intentionally left blank SLAUTTERBACK CORPORATION ❐ 5 Lower Ragsdale Drive, Monterey, CA 93940-5779, USA ❐ 831/658-6000 ❐ FAX: 831/658-6094 2 of 2 Rev C 70237-40; 5/99...
  • Page 66 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.
  • Page 67 Date Received____________ Start-Up Date____________ Invoice No.____________ Product Model/Description__________________________ Serial No._____________ Product Part Number______________________________ Order No._____________ Date Received_____________ Start-Up Date___________ Invoice No.____________ Astro Packaging 3845 E. Miraloma Ave, Unit A, Anaheim, Ca. 92806 (714)572-1094 (800)642-7876 toll free (714)572-1943 fax 2 of 2...

This manual is also suitable for:

Kb30Kb50Kb100

Table of Contents