7 Troubleshooting
Problem Solutions
Tank fails to heat 1. Main Breaker: Turn the system power switch to the
On position. If switch light fails to illuminate, the
switch may need replacement.
2. Power Cord: Inspect the power-in connections for
proper fit and check for faulty wires. Also, inspect
the connection of the power wires at the main power
supply source.
3. Incoming Voltage: Determine exact voltage of the
melt unit. Insufficient voltage can be the cause of
these problems. Voltage drops are common. Use a
voltmeter to determine whether sufficient voltage is
supplied to the melt unit. Also, the voltage of each
melt unit component must be compatible to the melt
unit or serious damage to the system will occur.
(Refer to section 4.4, Electrical Circuits & Wiring).
4. Refer to the electrical schematic and check the actual
wire connections to ensure that the melt unit is wired
properly. If problem still exists, check the status of
specific components with a voltmeter (system
powered), or with an ohmmeter (system unpowered,
wire disconnected).
5. Tank Controller: Adjust the tank temperature
controller according to section 5.3 of this manual.
Inadequate tank temperature can affect the
performance of your hot melt system. If the tank has
reached an overtemperature condition, try turning
the controller down. A failure of the solid state relay
(closed position) can cause the tank to reach over
temperature. Check the relay’s continuity – failure of
the relay is rare. If problem persists, replace the
faulty component (controller or relay). On units with
Standby, make sure Standby switch is disengaged
and in the Run position.
6. Overtemperature Switch: The Overtemperature
(O.T.) switch is a safety device designed to prevent
the melt tank from reaching a "run-away"
temperature condition. Once the melt tank reaches
an over-temperature condition, the O.T. switch
controls the tank's temperature. Check the melt
tank's temperature when the O.T. indicator is lit. If
melt tank temperature is too high, turn the tank
temperature controller down (counterclockwise per
section 5.3). If the O.T. light is On at an acceptable
or low tank temperature, the O.T. switch is either
faulty or rated at a low temperature. The O.T. switch
must be replaced in either case. (Refer to section 9
for switch kits.)
OVERTEMPERATURE
THERMOSTAT
2000285
28 KB30, KB50 and KB100 Series Hot Melt Units 19600-159 Rev. A 04/09/09 © Copyright Astro Packaging 2009
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