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Instruction manual

for
Gear-pump
application systems

L tech GmbH
Industriestr. 7
40822 Mettmann
Deutschland
Tel. +49 (0)2104.912.330
Fax +49 (0)2104.912.331
www.ltech.de
info@ltech.de

System : Metering gear-pump application system

Order-No. : 200749012

System type : LT – 4080

Unit -No. : 01391

Chap. I Page - 1 -
ATTENTION!
The unit is only allowed to be used for what it is intended for.

While working on the unit or the applicators the power


supply has to be switched off.

The System, especially the cover of the reservoir, the area of


the adhesive container, the manifold and the application
guns will become very hot during operation.

DANGER: Contact with these areas may cause severe


injuries!
During all operations thermal protection gloves and
protective goggles should be worn.

Chap. I Page - 2 -
Safety Instructions
This instruction manual contains necessary information for the safe and correct installation,
operation, and maintenance of gear-pump application systems. Consequently, this manual must
be read carefully by the installer and the customer before installation and operation. It must be
available at the place of operation of the machine/equipment at all times.

Personnel Qualifications And Training


Operating, maintenance, inspection and installation/assembly personnel must possess the
proper qualifications for this work. The areas of responsibility, competence and supervision of
the personnel have to be laid down exactly be the customer. If the personnel are not in
possession of the knowledge they must be trained and instructed accordingly. Training and
instruction can be provided by the manufacturer/subcontractor on the customer’s behalf if
required. Furthermore the customer has to ensure that the contents of the instruction manual
are fully understood by the personnel.

Risks Arising From Non-observance Of The Safety Instruction


The non-observance of the safety instructions can result in danger to the personnel and the
environment as well as the machine/equipment. Moreover it can result in the loss of any claims
from damages.

Possible consequences from not following the safety instructions are as follows:

- Breakdown of important machine/equipment functions


- Danger to personnel from electricity, mechanical force and chemicals
- Danger to the environment from leakage of hazardous materials

Safety-conscious Operation
The safety instructions listed in this instruction manual, the national accident prevention
regulations currently in force and any internal working, operating and safety regulations issued
by the customer have to be strictly observed.

Safety Instructions For The Customer/Operator


If machine components are dangerously hot or cold, these parts must be guarded against
accidental contact.

It is strictly forbidden to remove any protection against contacting moving parts (e.g. couplings)
while the machine is in operation.

Any leakage of hazardous materials (explosive, toxic, hot) must be drained in a way to prevent
danger to personnel or to the environment. All legal regulations have to be observed.

Danger through electrical energy has to be ruled out (for details please consult the
specifications published by the VDE – the association of German Electrical Engineers – and the
local power company).

Safety Instructions For Maintenance, Inspection And Installation/Assembly


The customer has to ensure that all maintenance, inspection, installation and assembly work is
performed by authorized and qualified technical personnel who have closely studied the
instruction manual and are therefore suitably informed about the machine/equipment.

Chap. I Page - 3 -
Work on the machine may only be performed when the machine is shut down.

Tanks or their subassemblies contaminated with harmful media must be decontaminated.

All safety devices and guards must be reattached and enabled immediately after work is
completed.

Before reconnection the listed points mentioned in chapter “initial operation” have to be
observed.

Unauthorized Modifications And Production Of Spare Parts


Modifications or changes to the machine are only permissible after consultation with the
manufacturer. Original spare parts and accessories authorized by the manufacturer are to be
used to guarantee safety. The use of other parts may annul any liability for damages that may
occur.

Non-permissible Modes Of Operation


The operational safety of the delivered machine can only be guaranteed if the machine is used
for its intended purpose in accordance with the operation manual and with all other agreements
(e.g. order specifications). The limit values quoted in the technical data sheet (Dimension sheet
– see drawing set) must NOT be exceeded in any case.

Transport And Storage


Depending on size, construction, destination and mode of dispatch, the equipment was sent
either assembled completely or disassembled into several parts.

The shipment must be checked according to the packing list for completeness and for possible
transport damages in the presence of the carrier. If any faults or damages are discovered,
please contact L tech, Mettmann, or a sales representative immediately.

The complete unit must only be lifted under the base frame. It is strictly forbidden to lift the unit
only at the aggregates.

The unit has to be transported carefully and without impact or shocks.

Only lifting devices designed for the weight of the unit are to be used.

When storing the unit, the following points have to be observed:

- Storage area has to be dry and well ventilated.


- Storage has to be put on pallets or shelves, not directly on the ground.
- The unit has to be protected against damage, rain and direct solar irradiation.
- The unit has to be inspected visually every 4 weeks, in particular the onset of
corrosion has to be checked for.
- After 6 months the unit has to be inspected thoroughly and the corrosion protection
has to be renewed (if necessary).

The instruction manuals of the subcontractors have to be observed if necessary (see appendix).

Chap. I Page - 4 -
Technical Data
Model: LT - 4080 (details for maximum stage of expansion)

Tank capacity : 80l


Melting rate : 40 - 60kg/h (EVA based hot melts)
No. of metered outlets (max.) : 4
No. of AC-drives (max.) : 4
No. of supply hose connections (max.) : 4
No. of return hose connections (max.) : 4
Electrical service : 3 * 400 V + N + PE, 50-60 Hz or
230 VAC, 3phase delta, 50-60 Hz
(must be specified with order)
Power requirements : 10 KW
(basic system connection power)
Workplace-related A-weighted equivalent
continuous sound pressure level : < 70 dB(A)
Weight of the system : approx. 300 kg

Chap. I Page - 5 -
LT 4080

Marked arrows:

1. pressure sensor ( optional )


2. reservoir
3. upper grid
4. under grid
5. base tank
6. electric cabinet
7. level sensor ( optional )
8. level sensor ( optional )
9. level sensor ( optional )
10. locking bolt
11. hose connection manifold with safety valve
12. filter
13. inside guide rail

Chap. I Page - 6 -
ADHESIVE TANK DELIVERY SYSTEMS
The applicator is suitable for all applications in the hygiene, packing and paper converting
industry. Low- and high-viscosity hot melt adhesives can be used.

The application temperatures indicated by the adhesive manufacturers should be observed in


every case. The instructions and data from the EG Safety Data Sheets of the adhesive
manufacturer must be adhered to.

* The application temperature may NEVER be higher than the flash point or the maximum
permissible temperature according to the manufacturer's data.
* Therefore the adjustment of the application temperature has to be carried out very
precisely.
* The relevant notes in the OPERATING Instructions must be observed in every
case.

Attention:
The cover of the reservoir, the area of the adhesive container and the
application guns will become hot during operation. We are pointing out the
possible danger of injury if these parts are touched.

Model LT- 4080


The L tech LT-4080 tank unit consists of several aluminum castings to provide a total capacity
of 80 liters. The assembly contains four separate tank elements with cast heating elements.

The upper tank is used as a storage reservoir with a capacity of 40 l, and can absorb all
adhesives available on the market.

Below the storage reservoir, there is a powerful fin melting zone which provides a high melting
capacity. A retaining screen is installed directly below. The purposes of this screen are as
follows: Firstly it is a coarse filter to protect the pumps and prevent rough contamination from
entering the lower tank, and secondly to hold the solid adhesive in the melting zone until it has
been completely melted (this is especially important when a slat or pellet form of adhesive will
be used).

The lower tank casting is designed as a reservoir for molten adhesive and provides an
absorption for metering pumps and filter manifold assemblies.

The lower tank and the melting fin casting utilize reliable, high wattage cast-in heaters. Each
heating zones is controlled by a separate microprocessor. All electrical connections of the tank
assembly are protected against contact for safety reasons. Flexible cables are routed from the
tank to the electrical connection.

The total power rate without external connections is approximately 10 kW (3 heating zones).

Chap. I Page - 7 -
Corresponding to the attachment of two double metering gear pumps and two metering gear
pumps, four gearing motors can be fixed to the appliance.

The metering pump unit LT-4080 (tank capacity 80 l) is composed of a four-piece tank with cast-
in heaters, the possible use of which you can see in the following table:

tank unit 80l

4 single pumps
2 double pumps
1 single and 1 double pump
2 single and 1 double pump

Corresponding to the use one double pump and two single pumps with four outputs overall, four
filter manifold assemblies can be fixed to the appliance (one per metered output). Each filter
manifold contains a complete filter screw assembly, high pressure relief valve, return valves (if
required) with air connection, supply hose connection (maximum 2) and a return hose
connection (one).

According to the ordered quantity of hose connections, the standard delivery condition is that
each connection is equipped with connection nipple, fine filter, high pressure relief valves and
return nipples or return modules are provided on the back side of the unit.

In addition, the LT - 4080 tank system includes several features to provide more simple and
economical maintenance:
Chap. I Page - 8 -
1. Pump shut-off : Located in the tank at the attachment to the metering pump, the
system contains a shut-off mechanism which allows the removal
(maintenance) of the pump while the tank is hot and full. This is
shown in the open position (Picture 1.1) and in the closed / shut-off
position (Picture 1.2)

2. Filter screws: The filter screws are located outside the tank frame and arranged
in such a way to allow simple and operator friendly adhesive
drainage and filter changes over a suitable container. (Picture 1.3)

3. Tank insulation: The tank lid and the upper covers offer extensive protection, via
their double wall construction and additional insulation, against
burns through external contact.

4. Tank wheel assemblies: The tank frame and electrical cabinet are equipped with large
diameter swivel/brake wheel assemblies to provide flexibility during
maintenance. (Picture 2)

Opened Closed

(Picture 1.1) (Picture 1.2)

(Picture 1.3) (Picture 2)

Chap. I Page - 9 -
Metering pumps applicator systems: Basic Units

Model Heating zones Main power Melting power


(Base system without additional
parts)
DTA-20 1 3500 W 10 kg/h
DTA-30 2 6700 W 20 kg/h
DTA-65 3 9700 W 40 kg/h
DTA-105 4-5 11,7 – 13,7 kW 60 - 80 kg/h
DTA-115 3-4 10,0 – 13,6 kW 60 - 80 kg/h
DTA-180 3-5 10,0 – 17,2 kW 80 - 100 kg/h
LT-4040 2 6700 W 20 kg/h
LT-4080 3 9700 W 40 kg/h
LT-4120 4-5 11,7 – 13,7 kW 60 - 80 kg/h
LT-4170 3-5 10,0 – 19,0 kW 80 - 100 kg/h
LT-5200 3-5 54 kW Approx 190 kg/h

Chap. I Page - 10 -
METERING PUMPS

The metering pumps are screwed onto the relevant manifolds. The adhesive is drawn out of the
tank and conveyed from the pressure opening of the pump to the appropriate filter.

These precision metering pumps are made of high quality special steels and undergo a
hardening treatment process afterwards. Consequently a very high resistance to wear and tear
is guaranteed.

The speed of the pumps should not exceed 80 rpm, otherwise the auto-lubrication cannot be
guaranteed and consequently components may be damaged.

Different pump sizes are available to meet the particular field of application and pump rate. The
rate of each pump is engraved on the front of the pump.

ORDER NO. DELIVERY/RPM MAXIMUM DELIVERY


PER HOUR
8.400.001.001 0,16 ccm 0,67 kg
8.400.003.001 0,3 ccm 1,47 kg
8.400.006.001 0,6 ccm 2,93 kg
8.400.012.001 1,2 ccm 6,27 kg
8.400.024.001 2,4 ccm 12,7 kg
8.400.045.001 4,5 ccm 21,6 kg
8.400.100.001 10,0 ccm 46,5 kg
8.400.200.001 20,0 ccm 92,9 kg
8.400.300.001 30,0 ccm 139,5 kg
8.400.400.001 40,0 ccm 185,9 kg

8.400.201.001 2x0,16 ccm 2 x 0,67 kg


8.400.203.001 2x0,3 ccm 2 x 1,47 kg
8.400.206.001 2x0,6 ccm 2 x 2,93 kg
8.400.212.001 2x1,2 ccm 2 x 6,27 kg
8.400.224.001 2x2,4 ccm 2 x 12,7 kg
8.400.248.001 2x4,8 ccm 2 x 21,6 kg
8.400.210.001 2x10,0 ccm 2 x 46,5 kg
8.400.220.001 2x20,0 ccm 2 x 92,9 kg

The metering pumps are driven by individual ac-gear motors. The regulating of the speed of
these ac-gear motors can be carried out manually or automatically in relation to the machine
speed. In the case of automatic regulation the processing machine has to be equipped with an
additional dc-tachogenerator, which emits an output signal of 0-10 V. This signal can, for
example, be taken from the electronic control unit ETI-204 or superior production controller.

Important!!!:
In case a high pump rate is required and in case the sum of the pump
rates exceeds the melt rate, a pre-melt installation will be needed to
provide the required melt rate!

Chap. I Page - 11 -
Pumping Rates

Pumping Rates

200

180

160

140

120
G (kg/h)

100

80

60

40

20

0
0 10 20 30 40 50 60 80
n (rev/min)
40 ccm/U 30 ccm/U 20 ccm/U 10 ccm/U

Diagram I

Chap. I Page - 12 -
Pumping Rates

50

45

40

35

30
G (kg/h)

25

20

15

10

0
0 10 20 30 40 50 60 80
n (rev/min)
10,0 ccm/U 4,50 ccm/U 2,40 ccm/U

Diagram II

Chap. I Page - 13 -
Pumping Rates

14

12

10

8
G (kg/h)

0
0 10 20 30 40 50 60 80
n (rev/min)
2,40 ccm/U 1,20 ccm/U 0,60 ccm/U
Diagram III

Chap. I Page - 14 -
Pumping Rates

3,5

2,5

2
G (kg/h)

1,5

0,5

0
0 10 20 30 40 50 60 80
n (rev/min)
0,60 ccm/U 0,30 ccm/U 0,16 ccm/U
Diagram IV

Chap. I Page - 15 -