H-2000H-3500_Operating_Manual
Contents
1. J mE CORPORATION Teamwork amp Communication Model H 2000 H 3500 Proportioning Unit Operating Manual 15942A 1 April 1 1999 Issue 2 GUSMER CORPORATION A Subsidiary of Gusmer Machinery Group Inc One Gusmer Drive Lakewood New Jersey USA 08701 8055 Toll Free 1 800 367 4767 USA amp Canada Phone 732 370 9000 Fax 732 905 8968 Copyright 1999 GUSMER CORPORATION http www gusmer com NOTICE This manual contains important information for your GUSMER equipment Read and retain for future reference CORPORATION Model H 2000 H 3500 Proportioning Unit NOTICE The equipment described in this technical manual must only be operated or serviced by properly trained individuals thoroughly familiar with the operating instructions and limitations of the equipment For technical service call your local distributor Call 1 800 FOR GSMR 1 800 367 4767 for the name and telephone number of your local distributor NOTICE All statements information and data given her2. 25 FIGURE 20 TERMINAL JUMPER STRIP uu 26 FIGURED T PRIMARY HEATER itoito ren rte EA 27 FIGURE 22 PRIMARY HEATER FUSES 28 FIGURE 23 PRIMARY HEATER asnashasqa qaqa ph h Qu e ene Desa Q atya 29 FIGURE 24 PROPORTIONING SYSTEM scccssscessceessecesncecesecesscecsecesaeecaeeeeaeecaeeseaeecsaeeesaes 30 FIGURE 25 HYDRAULIC MANIFOLD ise etri Oe e EXEAT au AE 33 FIGURE 26 CONTROL TRANSFORMER FUSE n 34 FIGURE 27 POWER asha ee ti ea ie apaku ed E one 35 FIGURE 28 PUMP LUBE SYSTEM 36 FIGURE 29 STRAINER aa AE 37 FIGURE 30 HYDRAULIC SYSTEM u anh n 38 FIGURE 31 THERMOCOUPLB a itte tede RR Dep a Pe eie t D E usya 4I M 1594214 1 Issue 2 4 1 99 Contents WARRANTY Gusmer Corporation Gusmer provides a limited warranty to the original purchaser Customer of Gusmer manufactured parts and equipment Product against any defects in material workmanship for a period of one year from the date of shipment from Gusmer facilities In the event Product is suspected to be defective in material or workmanship it must be returned to Gusmer freight prepai
3. 4 1 99 29 CORPORATION Model H 2000 H 3500 Proportioning Unit Proportioning System Figure 24 Proportioning System 1 A Pump Base 6 R Pump Base Not shown located on far side 2 A Discharge Ball Check Valve 7 R Discharge Ball Check Valve Not shown located on far side 3 A Inlet Ball Check Valve 8 R Inlet Ball Check Valve Not shown located on far side 4 R Over pressure Safety Switch 9 5 A Over pressure Safety Switch Rocker Arm Reversing Plate 24 Volt Pump Circuit Transformer Fuse A Material Supply Ball Valve R Material Supply Ball Valve Not shown located on far side WARNING BEFORE PERFORMING THESE TROUBLESHOOTING PROCEDURES DETERMINE THAT ALL CIRCUIT BREAKERS ARE OFF AND MAIN POWER IS DISCONNECTED AT THE SOURCE TO AVOID SEVERE BODILY INJURY FROM ELECTRIC SHOCK DO NOT ENTER THE ELECTRIC CONSOLE WITH THE POWER ON BEFORE OPENNING ANY HYDRAULIC CONNECTIONS OR SERVICING THE PUMP OR PUMP BASE THE OPERATOR MUST USE EXTREME CAUTION TO INSURE THAT THE PRESSURE IN BOTH THE SUPPLY AND DELIVERY SIDES OF THE PUMP HAS BEEN BLED OFF TO ZERO TO AVOID SERIOUS BODILY INJURY FROM FLUID INJECTION NEVER SERVICE COMPONENTS CONTAINING CHEMICALS WITHOUT WEARING PROPER PROTECTIVE EQUIPMENT 30 159421A 1 Issue 2 Troubleshooting Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all ci
4. 4 1 99 15 CORPORATION NOTE The hoses are Connected end to end during shipment to protect them from moisture intrusion Do not separate the hoses until they are ready to couple to the proportioning unit 16 Model H 2000 H 3500 Proportioning Unit 7 Connect the heated hose assemblies Important The importance of making proper hose connections cannot be overly emphasized The connection points are a potential source of chemical and air leaks and are the points most exposed to damage from scuffing and snagging on abrasive surfaces A liberal amount of duct tape can be used in this area to make the bundle as compact as possible Gusmer strongly recommends installing the optional scuff jacket to protect the hose insulation and TSU extension from damage A proper hose connection is shown in sequence on the following page The key areas of extra attention during installation are as follows a b 4 DO interchange the hoses Resin hoses are color coded BLUE Isocyanate hoses are color coded RED To assure a leak proof chemical connections take care not to cross thread the fitting and DO NOT over tighten Tape the electrical isolator securely in place between the hydraulic fittings failure to do so will cause a short circuit in the hose heating system To assure a secure electrical connection place the protective electrical isolator boot over each plug and tape togethe
5. 400159421 A 1 Issue 2 Operating Manual 4 1 99 Maintenance THERMOCOUPLE The thermocouple includes the compression nut and ferrule and once locked in place the ferrule becomes a permanent part of the thermocouple and cannot relocated or removed The location of the thermocouple 15 critical to the operation of the heater and requires proper positioning before tightening the compression nut Proper installation procedures are as follows 1 Determine that the body of the compression fitting is securely tightened into the heat exchanger tube to prevent any leakage Remember once the ferrule has been set the position of the body cannot be changed 2 Determine that the heat exchanger spring is not obstructing placement of the thermocouple Place the thermocouple into the body and continue to insert until it makes positive contact with the heating element 3 Firmly hold the thermocouple in place against the element while tightening the locknut Note the correct ferrule positioning Thermocouple Ferrule Compression Nut NL J Compression Fitting Body Q A ol Q A A g N 02 0 Wc X Eu NS L Z Heating Element Figure 31 Thermocouple 41 CORPORATION Model H 2000 H 3500 Proportioning Unit APPENDIX MAXIMUM OUTPUT OUTPUT S PRESSURE Ibs min
6. gpm strokes min OPERATING Chart based upon 208 Volts Formula This formula is useful for calculating the output of the proportioning unit Q Ibs min S strokes min x 31 S strokes x 31 Recommended Hydraulic fluid or equivalent 1 Mobil DTE 24 2 Mobil DTE 25 3 Cooks Albavis 10 The H 2000 and H 3500 interfaces with all the following Equipment e GX 7 High Pressure Spray Guns GX 7 Auto High Pressure Spray Gun TX 50 Automatic Shot Timer Counter GX 8 Spray Gun e GX10 Pour Head e AR C D High Pressure Pour Gun e Model D High Pressure Spray Gun aoo 15942141 Issue 2 Instruction Manual Discrepancy Report INSTRUCTION MANUAL DISCREPANCY REPORT Field Field Title Description Number 1 Date 2 Name 3 IM Number 4 Issue Number 5 Date of Issue 6 Page Number 7 Discrepancy Instructions Complete the above fields of the form by following the instructions listed on the reverse side of this sheet and mail to Gusmer Corporation One Gusmer Drive PO Box 2055 Lakewood N J 08701 4 1 99 43 44 Field Number 1 2 CORPORATION Field Title Date Name IM Number Issue Number Date of Issue Page Number Discrepancy Model H 2000 H 3500 Proportioning Unit Description Enter date report is submitted Enter name of person making report Enter the Part Number of the Instruction Manual from the title page Enter the I
7. o Figure 15 Directional Indicator Lights amp Reversing Switch Rocker Arm 12 The proportioning unit is now ready for operation Connect air to the gun Following instructions in the gun manual test spray Daily Shutdown Procedures 1 Set the pump switch to the RETRACT position 2 Trigger the gun off target until the Isocyanate proportioning pump stops in the retracted position and the proportioning pump pressures bleed off to a point where the spray pattern begins to diminish It is NOT a good practice to bleed the pressure to zero Some pressure is required to keep the packings operating normally and prevent weepage during shutdown 3 Switch OFF the motor control 4 Switch OFF the Hose Heater and Primary Heater Circuit Breakers 5 Switch OFF the main circuit breaker 6 Close both Inlet Supply Valves 7 SUPPLY shut down the supply system as required 8 GUN shut down and service the gun as stated in the gun service manual 22 159421A 1 Issue 2 Operating Manual Troubleshooting v TROUBLESHOOTING Introduction When properly maintained and operated Gusmer equipment will provide long and faithful service However occasional problems will arise which must be resolved before operation can continue This section of the manual is to provide operators with an explanation of some of the problems that may arise how to detect them and how to resolve them As when operating any piece of machin
8. OPERATION Daily Startup Procedures NOTE The daily start up procedures will describe normal operation and will assume that all calibrations have been properly executed and that the heating system is NOT up to required temperatures NOTE To prevent excessive pressure buildup in the dual heated hose always bring the hose up to temperature before the Hydraulic system is turned on The green pilot light on the hose heater controller will indicate that the liquid in the hose is up to temperature NOTE Primary heating is virtually instantaneous therefore do not turn on the primary heaters until required for operation It is also good practice to turn off the primary heaters during shutdowns exceeding one half hour NOTE The pump switch must be in the RETRACT or NORMAL position to adjust the hydraulic pressure 4 1 99 1 10 11 SERVICING check the condition of the hydraulic and pump lubrication systems and service as required Generally change the lubricating fluid when it shows signs of color change SUPPLY determine that the supply system is at the proper temperature as recommended by the system supplier the individual chemicals are properly mixed within their drums and the moisture protection system is properly set for operation Check the inlet screens and service as required Pressurize the transfer pumps and open both Chemical Supply Valves Switch ON the main circuit breaker The white pilot li
9. The temperature of the Primary Heater must cool down to within limits before you can reset the circuit breaker DO NOT attempt to reset the circuit breaker more than once You must determine the cause of the problem and correct it R Side Heater Fuses PRIMARY HEATER FUSE the primary heating circuit is protected by 5 two 30 Amp fuses With power OFF te remove the fuse s and check it for to continuity or simply replace it with one j de known to be good 1 s lt 2 L A Side Heater Fuses gt Figure 22 Primary Heater Fuses WARNING THE FUSE MUST BE REPLACED WITH ONE OF THE SAME RATING SUBSTITUTE MAY DAMAGE THE EQUIPMENT AND WOULD CREATE A POTENTIAL SOURCE OF INJURY TO THE OPERATOR PRIMARY HEATER SSR With Main Power OFF remove the lead from terminal 1 on the SSR Check for continuity across terminals 1 and 2 If continuity is present the SSR has shorted closed and needs replacing Refer to Figure 17 It is not possible to check for normal operation of the SSR without electric power Therefore if all other testing fails to determine the source of the problem assume the SSR is inoperative and replace it Important For the SSR to operate properly the heat generated by it must be passed off to the heat sink and dissipated DO NOT obstruct the heat sink with rags polyethylene or other protective covering or locate the unit in close proximity to a wall Always allow for as much a
10. 28 Ib min at 50 HZ 13 kg min H 3500 20 Ib min maximum 9 kg min 80 Mesh Standard Optional 60 40 Mesh 6000 Watts per heater at 220 Volts H 2000 A t 60 F 30 Ib min 14 Kg min 3500 A t 60 F 20 Ib min 9 Kg min 310 feet 94 5 meters maximum for heating purposes deal values obtained in laboratory testing and may not be duplicated under working conditions 12 159421A 1 Issue 2 Operating Manual Initial Machine Set Up 4 1 99 g INITIAL MACHINE SET UP DRUM __MAINAIR MAIN AIR _ ADAPTER AIRDRYER 2 SUPPLY SUPPLY OP 163 OP155 lt 2 1 TRANSFER _ PUMP 0 2320 i C AIRSUPPLY QP234H RSUPLY HOSE lt _ OP6157A 10 DRUM I EM X ADAPTER OP163 OP6157A A 1 0 A ISOLATION HOSE 14270 1 2 2 R ISOLATION 14270 1 2 1 FIRST SECTION HEATED HOSE 50 FT 1200 POWER LEAD SUPPLY HOSE 15585 LUBE RESERVIOR 15586 1 4 X 10 GUN HOSE 1250D ELECTRICAL ISOLATOR 5204 5 EXTENSION TEMPERATURE ADAPTER SENSING UNIT 20207 3 20206 SIZE ADDITIONAL HOSE SECTION Figure 2 Typical Installation 13 CORPORATION Model H 2000 H 3500 Proportioning Unit WARNING PROPER PROTECTIVE GEAR MUST BE WORN WHEN SERVICING OR OPERATING THI
11. HYDRAULIC CONNECTIONS OR SERVICING HYDRAULIC COMPONENTS USE EXTREME CAUTION TO INSURE THAT ALL PRESSURES HAVE BEEN BLED TO ZERO TO AVOID SERIOUS BODILY INJURY The hydraulic system should be checked annually for cleanliness as follows 1 Thoroughly clean the tank top the access cover plate and the components in the area of the cover plate This will insure that no foreign matter will enter the hydraulic reservoir when removing the cover plate 2 Remove the six 6 cover plate mounting screws Separate the hydraulic suction pipe from the fitting connecting the pipe to the hydraulic pump Figure 30 Hydraulic System Access Cover Plate 3 Remove the cover and pipe from the hydraulic reservoir 4 Inspect the bottom of the reservoir for sediment If sediment is present drain the hydraulic fluid thoroughly clean the tank and refill with new fluid The strainer on the suction pipe should be replaced with 200 mesh screening to insure free flow of hydraulic fluid to the pump 5 Replace the cover and the suction pipe connect and tighten the suction pipe to the fitting on the hydraulic pump and secure the cover in place with the mounting screws 6 Check to insure the hydraulic pump is full with hydraulic fluid 7 Proceed with normal operation 159421A 1 Issue 2 Maintenance Proportioning Pumps WARNING THE HYDRAULIC COMPONENTS ARE PRESSURIZED UP TO 3500PSI BEFORE OPENING ANY HYDRAU
12. LIST OF FIGURES FIGURE 1 DESCRIPTION OF CONTROLS FOR BOTH 2000 AND 3500 MODELS 8 FIGURE 2 TYPICAL INSTALLATION J an aaa un aa uu ayu 13 FIGURE 3 POWER CORD STRAIN RELIEF a 14 FIGURE 4 HYDRAULIC FLUID LEVEL 15 FIGURE RESERVOIR usaman uu ias 15 FIGURE ISOLATION HOSES u s a 15 FIGURE 7 HOSE CONNECTION STEP A 16 FIGURE 8 HOSE CONNECTION STEP B cesses eee enne enne entere nennen nnne 16 FIGURE 9 HOSE CONNECTION STEP 16 FIGURE 10 HOSE CONNECTION STEP D esses eene entere nenne enne 16 FIGURE 11 TEMPERATURE SENSING 17 FIGURE I2 BELE HOUSING iis stem HORE 17 FIGURE 13 SETTINGS SINGLE TRANSFORMER eese enne 19 FIGURE 14 SETTINGS DUAL TRANSFORMER 20 FIGURE 15 DIRECTIONAL INDICATOR LIGHTS amp REVERSING SWITCH ROCKER ARM 22 FIGURE 16 toda eee ePi 24 FIGURE TZ WIRE CONNECTION sal naa aqapana SERE UR au REA Re 25 FIGURE 18 SOLID STATE RELAY a aan 25 FIGURB TSU CONNECTION tei t eee t Hd ASPERIS
13. Once you have determined which chemical is missing the chemical pressure gauges on the problem side of the proportioning unit will tell you if the malfunction is due to a restriction at the gun or a lack of material produced by the pump To prevent misinterpretation the focus must be on the pressure gauge corresponding to the missing chemical Assume that the R component is not reaching the mixing chamber Spray off target and note the Resin pressure gauge If the Resin gauge is considerably higher than the Isocyanate gauge the problem is within the gun Refer to the gun manual to resolve the problem CAVITATION Cavitation is the formation of a partial vacuum or void created within the pump cylinder during the fill stroke It is actually a short fill since the fill chamber is not completely full when the pump reverses to start the discharge stroke This void occurs when the proportioning pump demands a greater volume of material during its fill stroke than the supply system can supply The most common causes of Cavitation are as follows a The transfer pump cannot handle the supply requirement or is malfunctioning The Gusmer 2 1 Transfer Pump is recommended for use with the H 2000 H 3500 Also recommended is a minimum of three quarter inch diameter supply hose as short as practical b The chemical is too viscous thick to pump properly Consult your Chemical Supplier for the recommended supply temperature c Inlet strainer screen
14. PARTICULAR PURPOSE CREDIT FOR OR REPLACEMENT OF PRODUCT DEFECTIVE IN MATERIAL OR WORKMANSHIP SHALL CONSTITUTE COMPLETE FULFILLMENT OF GUSMER OBLIGATIONS TO CUSTOMER NO OTHER WARRANTY EXPRESSED OR IMPLIED ON ANY PRODUCT IT MANUFACTURES AND OR SELLS WILL BE RECOGNIZED BY GUSMER UNLESS SAID WARRANTY IS IN WRITING AND APPROVED BY AN OFFICER OF GUSMER Under no circumstances shall Gusmer be liable for loss of prospective or speculative profits or special indirect incidental or consequential damages Further Gusmer shall have no liability for any expenses including but not limited to personal injury or property damage resulting from failure of performance of the product use of the product or application of the material dispensed through the product Any information provided by Gusmer that is based on data received from a third source or that pertains to product not manufactured by Gusmer while believed to be accurate and reliable is presented without guarantee warranty or responsibility of any kind expressed or implied Gusmer through the sale lease or rental of Product in no way expresses or implies a license for the use of nor encourages the infringement of any patents or licenses To insure proper validation of your warranty please complete the warranty card and return it to Gusmer within two weeks of receipt of equipment Revised 11 12 98 CORPORATION Model H 2000 H 3500 Proportioning Unit g GENERAL S
15. SERVICING HYDRAULIC COMPONENTS USE EXTREME CAUTUION TO INSURE THAT ALL PRESSURES HAVE BEEN BLED TO ZERO TO AVOID SERIOUS BODILY INJURY WARNING THERE IS HIGH TEMPERTATURE INSIDE THE PRIMARY HEATER COVER BOX BEFORE PERFORMING MAINTENANCE ALLOW HEATER TO COOL TO AVOID BODILY INJURY FROM HOT FLUID OR HOT METAL The sheath on the H 2000 and H 3500 heating rods are made from a special alloy designed to be resistant to corrosion and erosion However eventually the service life of the rod will be reached and if the sheath should fail fluid under pressure will leak into the heating element This may result in leakage through the potting at the junction end of the rod Therefore it is imperative that the unit NEVER be operated with the guard removed and furthermore you must never remove the guard for servicing without bleeding the material pressure in the heater to zero and disconnecting all electrical power Replacing the heating element does not require disassembly of the heater With the power OFF disconnect the lead wires and using an open end wrench loosen the heating element and remove it Since fluid surrounds each element be prepared to catch the residual fluid as the element is withdrawn Inspect the removed element it should be relatively smooth and shiny If there is crusted burnt ash like material adhered to the rod or the sheath shows pitting marks replace the heating elements Reinstall the heating element using a thread sealant
16. WARNING Do NOT FILL THE LUBE CYLINDER WITH PUMP LUBE THIS WOULD OVER SERVICE THE SYSTEM AND MAY CAUSE THE LUBE RESERVOIR TO BURST THE SYSTEM IS SELF PRIMING AND THE LUBE CYLINDER WILL FILL DURING NORMAL OPERATION OF THE MACHINE Inlet Strainer Screen NOTE More than 25 restriction of the screen can prevent proper filling of the pump during operation If more than 25 is blocked the screen should be replaced 4 1 99 A strainer screen in each proportioning pump filters out solid matter that could adversely effect the operation of the ball check valves in the pump base You will note that the Daily Start up procedure indicates these screens should be inspected daily For the first week or so of operation you should clean both pump screens on a daily basis The Isocyanate component can crystallize from either moisture contamination or from freezing Following proper storage transfer and operating procedures and if the chemicals you receive are clean you should have little problem with the Isocyanate screen In practice though it is good preventative maintenance to daily clean the Isocyanate screen NEVER clean the Isocyanate pump screen during the shutdown operation This is because the cleaning of the screen exposes it and its related parts to moisture and solvent which can cause the Isocyanate to crystallize Performing the cleaning operation during the start up procedure will minimize contamination problems because dispensing wi
17. as no further adjustments to this control will be required Reset the amperage will drop slightly and P not need readjusting temperature controller to the desired temperature setting NOTE 0 230V e 220 The default tap setting for the 0 transformer is 10V 220 0 220 0 220 AN AN Se LNB NES AB Y 51 52 53 54 55 ov 4 23V 14 77V 31 7V 71 9V 10 ai 1600 33 53 48 77 60 210 18 29M 64 00M 35 10 67M m 260 79 25 810 A 94 49M Figure 13 Tap Settings Single Transformer Hose Length ft Setting Voltage Ee A 3 58 47 1 A oom 58 1 6267 4 1 99 19 CORPORATION Model H 2000 H 3500 Proportioning Unit 200 to 240 Volts 6 0 200 to 240 Volts 0 0 0 i N J E N A ka A PUE 11 S 089 OV AN NN OV 4234 AN NN A HOSE B HOSE WW AA 52 s3 154 SB Figure 14 Tap Settings Dual Transformer Hose Length ft Seiting Voltage 0 1 584 14 f as s et EX 2 99 0 59289 222 o ss l r 20 159421A 1 Issue 2 Operating Manual g Operation
18. foot TSU extension harness at the hose connection If control is not restored change the TSU If control is restored make a systematic check of the TSU extension harness 8 MANUAL HOSE HEAT CONTROL The automatic hose heating system can be bypassed to allow manual control of the hose heater This feature allows for 3 ft TSU Extension Harness Figure 19 TSU Connection 25 CORPORATION 26 Model H 2000 H 3500 Proportioning Unit continued operation of the hose heating system in case of signal or SSR failure To convert to manual control proceed as follows a With power OFF remove the terminal jumper strip conveniently located on the heat sink and install it across terminals 1 and 2 on the hose heat SSR Terminal Jumper b Maintaining hose temperature now requires manual adjustment of the hose heater power set Adjust the control to maximum clockwise for initial warm up and then adjust as required to maintain the hose temperature SSR Figure 20 Terminal Jumper Strip WARNING THE TERMINAL JUMPER MUST NEVER BE USED ON EITHER PRIMARY HEATER SSR THIS WILL RESULT IN COMPLETE LOSS OF CONTROL AND CAUSE DAMAGE TO THE EQUIPMENT OR SERIOUS BODILY INJURY 10 11 The purpose of the hose heater is not to add heat but rather to maintain the temperature developed by the primary heater If conditions indicate that the hose heater is not maintaining temperature during flow Amber Hose
19. on a daily basis Change the pump lube before it becomes a gel or when its color becomes the same as the Isocyanate The gel formation is due to moisture absorption by the pump lube The time interval between changes due to gel formation depends entirely upon the environment in which the equipment is operating The enclosed pump lube system in the H 2000 H 3500 minimizes exposure to moisture but moisture contamination is still possible Discoloration of the pump lube is inevitable due to the continual weepage of Isocyanate during pump operation However if the packing within the Isocyanate pump is functioning properly pump lube replacement due to discoloration should not be more frequent than 3 or 4 week intervals To change the pump lube proceed as follows 1 Position the Isocyanate proportioning pump to the extreme right by jogging the pump switch with the gun or coupling block 2 Lift the lube reservoir out of the bracket and remove the cap from the container Holding the Cap over a suitable container remove the Check Valve and allow pump lube to drain Reattach the Check Valve to the inlet E Bracket hose N iu T 3 Now drain the reservoir flush it with pump lube and refill it with fresh pump WAS Check Valve lube Lube Bottle Figure 28 Pump Lube System 4 Screw the Lube Bottle back onto the Lube Cap and place in the Bracket 36 159421A 1 Issue 2 Maintenance
20. temperature Hose does not heat amber light on the Hose Heater Controller is ON 2 3 4 6 Hose does not heat red light on the Hose Heater Controller is ON 7 4 8 Hose does not cycle automatically red light on the Hose Heater 5 4 7 8 Controller is ON Hose heat circuit breaker trips 2 Hose temperature not maintained during flow 2 9 10 Hose or hoses adjacent to the unit are warm hoses downstream are 11 cold SOLUTIONS 1 HOSE LENGTH the H 2000 H 3500 hose heater operates with up to 310 feet of hose At 310 feet the hose temperature should rise approximately 120 F in 40 minutes Hose lengths in excess of 310 feet will reduce this capability 2 HOSE HEATER POWER SET Adjust the power set clockwise to achieve maximum amperage 3 HOSE HEAT FUSE with power OFF remove the inline fuse and check it for continuity Replace fuse as needed Figure 16 Wire Connection 24 159421A 1 Issue 2 Operating Manual 4 1 99 Troubleshooting WARNING THE FUSE MUST BE REPLACED WITH ONE OF THE SAME RATING SUBSTITUTE MAY DAMAGE THE EQUIPMENT AND WOULD CREATE A POTENTIAL SOURCE OF INJURY TO THE OPERATOR 4 HOSE HEAT CONTROL UNIT the 1 2 4 5 7 8 ZYTRON three heat control units on the w 230 vac N o H 2000 H 3500 are directly TYPE E 115 VAC DUM T C COM interchangeable with one another To determine if the control unit is operating correctly with power OFF swap the suspected control with one known to b
21. to operate Indicates when lighted that the R Primary Heater Circuit Breaker is on Controls and protects power to the A Primary Heater must be ON for the Primary Heater to operate Indicates when lighted that the A Primary Heater Circuit Breaker is on Push button daily to test Primary Heater Circuit Breakers Circuit Breaker must trip when this button is pushed Controls the temperature of the liquid maintained by the R primary heater set control selector dual scale Fahrenheit or Centigrade to the desired temperature From this point the temperature control is completely automatic Indicates when lighted that the temperature of the Resin component in the heater is within 5 F of dial set point Indicates when lighted that the temperature of the Resin component in the heater is more than 5 F cooler than dial set point Indicates when lighted that the temperature of the Resin component in the heater is more than 5 F warmer than dial set point Controls the temperature of the liquid maintained by the A Primary Heater Set Control Selector dual scale Fahrenheit or Centigrade to the desired temperature From this point the temperature control is completely automatic CORPORATION Green Controller Light Amber Controller Light Red Controller Light 11 HOSE HEATER CIRCUIT BREAKER Pilot light Amber 12 HOSE HEATER CONTROLLER Green Controller Light Amber Controller Light Red Contr
22. AFETY INFORMATION It is necessary to understand and follow the instructions in this manual to insure proper and safe operation of the equipment As with most mechanical equipment certain safety precautions must be taken when the equipment discussed in this manual is operated or serviced Severe bodily injury or damage to equipment and property may result if the instructions and precautions listed throughout this manual are not followed Needless to say sufficient guidelines cannot be developed to eliminate the need for good common sense in the use and servicing of this equipment and in the use and application of the products this equipment has been designed to process Users of this equipment must therefore make their own determination as to the suitability of the Information contained in this manual to their specific operation and requirements There should be no assumption made that the safety measures and instructions contained herein are all inclusive and that other safety measures may not be required for specific use or application The following safety guidelines are generally applicable to the safe and efficient use of the equipment Acceptable Equipment Uses The equipment is designed for the dispensing of polyurethane foams two component coating systems and some two component epoxy systems specifically polyureas Under no circumstances should any acid or corrosive chemicals be used in the unit Consult GUSMER if there is any
23. ED WITH EQUIPMENT THAT HAS HYDRAULIC COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI TO AVOID SERIOUS BODILY INJURY FROM HYDRAULIC INJECTION OF FLUID NEVER OPEN ANY HYDRAULIC CONNECTIONS OR SERVICE HYDRAULIC COMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO WARNING TO AVOID SERIOUS BODILY INJURY PROPER PROTECTIVE GEAR MUST BE WORN WHEN OPERATING SERVICING OR BEING PRESENT IN THE OPERATIONAL ZONE OF THIS EQUIPMENT THIS INCLUDES BUT IS NOT LIMITED TO EYE AND FACE PROTECTION GLOVES SAFETY SHOES AND RESPIRATORY EQUIPMENT AS REQUIRED WARNING THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HIGH TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES TO PREVENT SERIOUS BODILY INJURY FROM HOT FLUID OR HOT METAL NEVER ATTEMPT TO SERVICE THE EQUIPMENT BEFORE ALLOWING IT TO COOL WARNING FAILURE TO READ AND FOLLOW THIS SAFETY INFORMATION MAY RESULT IN PERSONAL INJURY AND OR DAMAGE TO THE EQUIPMENT FROM ONE OR MORE OF THE ABOVE LISTED HAZARDS CORPORATION Model H 2000 H 3500 Proportioning Unit DESCRIPTION R H arER 07 C ie e V 2000 e zm N 1 X N Figure 1 Description Of Controls for both 2000 3500 Models 8 159421A 1 Issue 2 10 4 1 99 MAIN CIRCUIT BREAKER Pilot light White MOTOR CONTROL Pilot l
24. EMPERATURE INSIDE THE PRIMARY HEATER COVER BOX NEVER OPERATE THE HEATER WITH THE COVER BOX REMOVED COOL THE FLUID IN THE HEATER BY PUMPING UNHEATER FLUID THROUGH THE HEATER WITH THE HEATER OFF TO AVOID BODILY INJURY FROM HOT FLUID AND HOT METAL Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and controls are properly set and wiring is correct before assuming there is a problem Problems Solutions Primary Heater circuit breaker trips 1 Primary Heater does not heat amber light on the Primary Heater 2 4 3 6 Controller is ON Primary Heater does not heat red light on the Primary Heater 5 4 Controller is ON Primary Heater heats but red light on the Primary Heater Controller is 3 4 6 ON continuously Primary Heater partially heats but amber light on the Primary Heater 6 7 8 Controller is ON continuously When flow starts the red light on the Primary Heater Controller comes 6 on and stays ON for 30 seconds or more 4 1 99 27 28 CORPORATION Model H 2000 H 3500 Proportioning Unit SOLUTIONS 1 A completely independent over temperature safety circuit has been provided and consists of four 4 thermal limit safety switches attached to the heating tube s When the surface temperature of the tube s exceeds 230 F the thermal limit safety switch will automatically trip the primary heater circuit breaker to OFF
25. G THE WORK ON THE EQUIPMENT IS QUALIFIED TO DO SO THIS INDIVIDUAL MUST HAVE A WORKING KNOWLEDGE OF BASIC HYDRAULICS MUST FOLLOW ALL GENERALLY ACCEPTED SAFETY PRECAUTIONS USED WHEN WORKING WITH HYDRAULIC AND ELECTRICAL EQUIPMENT MUST HAVE READ AND UNDERSTOOD THE APPLICABLE SECTIONS OF THIS MANUAL AND MUST WEAR PERSONAL PROTECTION APPROPRIATE TO THE TASK BEING UNDERTAKEN WARNING ALL ELECTRICAL TROUBLESHOOTING DESCRIBED IN THIS MANUAL MUST BE DONE WITH POWER OFF TO AVOID SERIOUS BODILY INJURY FROM ELECTRIC SHOCK THIS MEANS THAT IN ADDITION TO ALL CIRCUIT BREAKERS OFF THE MAIN POWER MUST BE DISCONNECTED AT THE SOURCE ANY ELECTRICAL TROUBLESHOOTING REQUIRED BEYOND THE SCOPE OF THIS MANUAL MUST BE DONE BY A QUALIFIED ELECTRICIAN THOROUGHLY FAMILIAR WITH THE OPERATION OF GUSMER EQUIPMENT 4 1 99 23 CORPORATION Model H 2000 H 3500 Proportioning Unit Hose Heat WARNING BEFORE PERFORMING THESE TROUBLESHOOTING PROCEDURES DETERMINE THAT ALL CIRCUIT BREAKERS ARE OFF AND THE MAIN POWER IS DISCONNECTED AT THE SOURCE TO AVOID SEVERE BODILY INJURY FROM ELECTRIC SHOCK DO NOT ENTER THE ELECTRIC CONSOLE WITH POWER ON Try the recommended solutions in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and controls are properly set before assuming there is a problem Problems Solutions Hose warms but does not reach temperature or takes too long to reach 1 2 10
26. Heat Controller light on the console stays lit continuously check that the primary heater and hose heater controllers are set for the same temperature or reduce the output The hose heater operates at 220 Volts Low line voltage will significantly reduce power available and the heater will not perform to its full capability When checking for improper electrical isolation remember that the electrical connection of the low voltage hoses is in series and that the hose fittings make the electrical connection between hoses Thus If the Resin fittings contact the Isocyanate fittings all hoses from the point of contact out to the gun will be cold while those hoses back to the proportioning unit will be heated This can occur if there was no electrical isolator installed between them or if the isolator has slipped out of position If this occurs it is a matter of finding where the fittings are in contact and isolating them 159421A 1 Issue 2 Troubleshooting Primary Heater Thermocouple Figure 21 Primary Heater WARNING BEFORE PERFORMING THESE TROUBLESHOOTING PROCEDURES DETERMINE THAT ALL CIRCUIT BREAKERS ARE OFF AND MAIN POWER IS DISCONNECTED AT THE SOURCE TO AVOID SEVERE BODILY INJURY FROM ELECTRIC SHOCK DO NOT ENTER THE ELECTRIC CONSOLE WITH POWER ON WARNING THERE IS HIGH VOLTAGE INSIDE THE PRIMARY HEATER COVER BOX DO NOT REMOVE THE COVER BOX WITH THE POWER ON WARNING THERE IS HIGH T
27. LIC CONNECTIONS OR SERVICING HYDRAULIC COMPONENTS USE EXTREME CAUTUION TO INSURE THAT ALL PRESSURES HAVE BEEN BLED TO ZERO TO AVOID SERIOUS BODILY INJURY Disassemble and clean both proportioning pumps annually Inspect the pistons and cylinder for mars or scratches which may cause leakage or damage to packings Gusmer also recommends replacing the piston and cylinder packings expanders and packing springs on an annual basis as a preventative maintenance precaution Refer to the Proportioning Pump Assembly section of the Parts I D for reference WARNING TO AVOID SERIOUS BODILY INJURY BOTH PROPORTIONING PUMPS OPERATE UNDER HIGH PRESSURE IT IS IMPERATIVE THAT THE PUMP TIE RODS BE PRECISELY TORQUED AFTER SERVICING 2000 TORQUE TO 17 FT LBS 3500 TORQUE TO 30 FT LBS Pump Bases WARNING BOTH PUMP BASES OPERATE UNDER HIGH PRESSURE TO AVOID SERIOUS BODILY INJURY BEFORE SERVICING THE PUMP BASE ASSEMBLY USE EXTREME CAUTION TO INSURE ALL PRESSURE FROM BOTH THE SUPPLY AND DELIVERY SIDE OF THE PUMP BASE HAVE BEEN BLED TO ZERO Disassembled and clean both Pump Bases annually To do so follow these steps Refer to the Pump Base Assembly section of the Parts I D for reference 1 De pressurize the system 2 Remove the valve cover bracket and the ball guides A groove in the ball guide will facilitate removal by use of a screwdriver If the ball guide is particularly difficult to remove use a wrench to turn the guide back and fort
28. S EQUIPMENT WHICH INCLUDES BUT IS NOT LIMITED TO GLOVES EYE PROTECTION AND RESPIRATORY PROTECTION AS REQUIRED An Accessory Package is included with the unit and contains the following parts that are required for setup a Isolation hose Blue Resin Red Isocyanate b TSU extension adapter c Electrical isolator d 1 roll electrical tape e Fittings Adapters Screws Refer to Figure 2 for additional parts required for set up WARNING THE ELECTRIC SERVICE MUST BE DONE BY A QUALIFIED ELECTRICIAN NOTE 1 The power source must be capable of meeting the electrical requirements specified on the nameplate of the proportioning unit and an accessible quick disconnect provided NOTE 2 The material supply valves are loosely assembled to the unit so that they may be oriented in the position that best suits the setup 3 14 Connect the main power cord not supplied to the electric console Open the electric control console Feed the power cord through the strain relief Strain Relief Figure 3 Power Cord Strain Relief Set up the supply and moisture control systems as required Refer to the individual instruction manuals for the proper procedures Fill the hydraulic reservoir through the vented filler neck with approximately 16 gallons of hydraulic fluid Refer to the listing in Appendix B for the recommended types of fluid Important DO NOT overfill Check that the filler neck is approximately 1 2 fill
29. SHOOTING 23 INTRODUCTION hapa a a e a A cen 23 CR CIE 24 iS OLULI ONS ios tete Nene Rq UL ayasa Eee 24 PRIMARY HEATER aayqa an ha ene 27 SOHO Su cisco 28 PROPORTIONING 5 5 44000 30 SOLUTIONS ote Toe E ua 31 HYDRAULIC DRIVE 34 a ne ee A een ERE REIN 35 MAINTENANE o Y 36 nie s ka EE en ub dixe 36 INLET STRAINER SCREEN ier ae hehehe nenne nenne rere nennen rene n iiie 37 HYDRAULIG SYSTEM Revue be usai 38 PROPORTIONING PUMPS ccccccceceseeeseseceseseseseseseseseseseseseseseseeeseseceseseseseseseceseseseeeeecess 39 PUMBBASESQX ie m n I NE 39 PRIMARY 85 4 4 6 40 uyasha uva EU 42 INSTRUCTION MANUAL DISCREPANCY REPORT A 43 4 1 99 3 CORPORATION Model H 2000 H 3500 Proportioning Unit
30. al valve for service OVER PRESSURE PROTECTION Each proportioning pump contains a pressure switch set to 2200 psi 3700 psi On reaching this pressure the switch will automatically remove power from the directional valve causing the pumps to stall When the power is removed both directional indicator lights will go off which is the 33 CORPORATION 34 Model H 2000 H 3500 Proportioning Unit indication to the operator of over pressure This is not a lockout type of system and when the pressure bleeds off below approximately 2200 psi 3700 psi the system will be restored to normal operation however the cause of the over pressure should be determined and corrected The three most likely causes are a restriction in the gun b Cavitation of the opposite pump c Hydraulic pressure set too high 6 CONTROL TRANSFORMER FUSE with power OFF remove the transformer fuse and check it for continuity or simply replace it with one known to be good Control Transformer Fuse Figure 26 Control Transformer Fuse WARNING THE FUSE MUST BE REPLACED WITH ONE OF THE SAME RATING A SUBSTITUTE MAY DAMAGE THE EQUIPMENT Hydraulic Drive System WARNING BEFORE PERFORMING THESE TROUBLESHOOTING PROCEDURES DETERMINE THAT ALL CIRCUIT BREAKERS ARE OFF AND MAIN POWER IS DISCONNECTED AT THE SOURCE TO AVOID SEVERE BODILY INJURY FROM ELECTRIC SHOCK DO NOT ENTER ELECTRIC CONSOLE WITH POWER ON Try the recommended solutio
31. amount of power delivered to the hose heater Indicates the amount of heating power delivered to the hose heater Controls the hydraulic pressure available to the hydraulic drive system Turns off the hydraulic drive system when the Resin proportioning pump exceeds the safe pressure limitation Indicates the pressure in the Resin proportioning system Indicates the pressure in the Isocyanate proportioning system Indicates the pressure in the hydraulic drive system Turns off the hydraulic drive system when the Isocyanate proportioning pump exceeds the safe pressure limitation 159421A 1 Issue 2 g ENVIRONMENT RECOMMENDED USE SAFETY EQUIPMENT APPLICATION AIR 4 1 99 Specifications SPECIFICATIONS The equipment is not of explosion proof design and should never be used in an atmosphere requiring this design The equipment is designed for use with standard spray pour and froth pour urethane foams and approved coating systems Other use of the equipment or any part thereof constitutes misuse without expressed written approval from Gusmer Some plural component systems available for use with this equipment contain abrasives Although the equipment is abrasion resistant it is not abrasion proof and those parts damaged from using abrasive materials will not be covered under warranty Ware sufficient protective clothing when servicing or operating this equipment to preve
32. ash danger to the operator a b The Gusmer 2 1 Transfer Pump has a ground lug Ground this pump in accordance with the Instructions provided with the pump Ground the proportioning unit at the main electrical source In the event that the unit is being powered by a generator the generator must also be grounded directly to a suitable electrical electrode such as an underground water system the metal frame of a building or a driven pipe Electrodes of pipe or conduit shall not be smaller than 34 inch diameter galvanized for corrosion protection and driven below the moisture level For additional information consult the National Electric Code Connect the material supply system to the inlet of the proportioning unit Exercise caution to ensure connecting chemicals to the appropriate proportioning pumps We now have the proportioning unit heated hose and material supply system set up Before the equipment is ready for use it is necessary to purge the entire system of air and mineral oil that left over from the functional testing of the equipment conducted at the factory 16 To purge the machine proceed as follows a b 4 f g h i Pressurize the transfer pumps and open the material supply valves It is a good practice at this point to check for hydraulic leaks Determine that the hydraulic pressure control is full decrease counter clockwise Switch ON the main circuit breaker and motor contro
33. ction of rotation Perform steps 10 11 12 13 Remove the Bell Housing Safety Plug to allow you to see the shaft coupling Turn the hydraulic pressure control counter clockwise to the end Make sure the pump switch is in the OFF position Determine that all circuit breakers on the main console are OFF Switch the main circuit breaker to ON Rotation Direction Arrow While observing shaft coupling cycle the motor ON and OFF The rotation of the coupling must agree with the directional indicator If the rotation does not agree turn off all circuit breakers and disconnect the main power at the source Open the electric console and switch any two of the three power leads Recheck the rotation Figure 12 Bell Housing Replace the plug in the motor bell housing 17 CORPORATION NOTE Disposal of waste chemicals must be in accordance with local state and federal codes NOTE These procedures are not required be executed periodically as part of 18 on a daily basis but may have to the daily start up routine Model H 2000 H 3500 Proportioning Unit 14 Connect the coupling block to the gun hose and determine that the manual valves are closed 15 Properly ground all equipment The high velocity flow of fluid can create static sparking which may cause fire or explosion Certain solvents which are commonly in use with this equipment are flammable and may present a fl
34. d If Product is found to be defective in material or workmanship as determined solely by Gusmer Gusmer will issue full credit to Customer for the freight charges incurred in returning the defective Product and either credit will be issued for the replacement cost of the Product or a replacement part will be forwarded no charge freight prepaid to Customer This warranty shall not apply to Product Gusmer finds to be defective resulting from installation use maintenance or procedures not accomplished in accordance with our instructions normal wear accident negligence alterations not authorized in writing by Gusmer use of look alike parts not manufactured or supplied by Gusmer or Product used in conjunction with any other manufacturer s pumping or proportioning equipment Further the terms and conditions of this warranty shall not apply to services or repairs made to Product by any third party not authorized in writing by Gusmer For such Product a written estimate will be submitted to Customer at a nominal service charge itemizing the cost for repair Disposition of Product will be done in accordance with the terms stated on the written estimate The warranty provisions applied to product that are not manufactured by Gusmer will be solely in accordance with the warranty provided by the original manufacturer of the product GUSMER MAKES NO WARRANTY WHATSOEVER AS TO THE MERCHANTABILITY OF OR SUITABILITY FOR ITS PRODUCT TO PERFORM ANY
35. doubt about the compatibility of the chemical system to be used in this equipment Any use of this equipment other than as indicated above constitutes misuse unless express written approval is obtained from GUSMER 6 159421A 1 Issue 2 Operating Manual General Safety Information Operational Safety Procedures Solvents and Chemicals P High Voltage High Pressure Personal Protective Equipment High Temperature Warning 4 1 99 This safety information will not be repeated in the text of this manual The symbols pertaining to this information will appear where appropriate to alert the operator to potential hazards WARNING THE SOVENTS AND CHEMICAL USED WITH THIS EQUIPMENT EXPOSE THE OPERATOR TO CERTAIN HAZARDS ADEQUATE PERSONAL PROTECTIVE MEASURES MUST BETAKEN SO AS TO AVOID EXCEEDING THE THRESHOLD LIMIT VALUE TLV OF THE PRODUCTS BEING USED AS ESTABLISHED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION OSHA OR OTHER QUALIFIED AGENCY INFORMATION CONCERNING PERSONAL PROTECTION AND PROPER HANDLING FROM THE SUPPLIER OF SUCH CHEMICALS WARNING TO PREVENT SERIOUS BODILY INJURY FROM ELECTRICAL SHOCK NEVER OPEN THE ELECTRIC CONSOLES OR OTHERWISE SERVICE THIS EQUIPMENT AND OR EQUIPMENT USED WITH IT BEFORE SWITCHING OFF THE MAIN POWER DISCONNECT AND INTERRUPTING SUPPLY VOLTAGE AT THE SOURCE THE ELECTRICAL SERVICE MUST BE INSTALLED AND MAINTAINED BY A QUALIFIED ELECTRICIAN WARNING THIS EQUIPMENT HAS OR IS US
36. e good 12 814 56 78 gggg RED VIOLET BLACK RED Figure 17 Wire Connection 5 HOSE HEAT SOLID STATE RELAY SSR Important For the SSR to gt operate properly the heat generated must be passed off to the heat sink DO NOT obstruct the heat sink with rags or other coverings or locate the unit in close proximity to a wall Always allow for as much air circulation as possible since the effectiveness of the heat sink is dependent upon unobstructed airflow gt gt E With power OFF remove the lead fae from terminal 1 on the SSR Check Heater SSR for continuity across terminals 1 and 2 If continuity is present then the Figure 18 Solid State Relay SSR is shorted closed and must be replaced 6 HOSE HEATING ELEMENT first check to see that the screw terminals on the isolation hoses are secure If these connections are secure then with the power OFF check for continuity across terminals 1 and 2 on the hose heater SSR If continuity is not present make a systematic search for the failed hose or connection 7 TEMPERATURE SENSOR two conditions must be satisfied for proper operation the sensor must be functional and the signal must travel uninterrupted from the sensor to the control unit Unplug the TSU extension at the gun hose Without undoing any hydraulic connections transport the gun hose to the proportioning unit and plug the TSU directly into the 3
37. ed with liquid 159421A 1 Issue 2 Initial Machine Set Up 90 Elbow 7 4 Check the hydraulic pump to insure that it is full with hydraulic fluid Remove the 90 elbow fitting from the top of the pump and determine that the fluid level is to the top of the threaded hole Add fluid as required and reattach fitting Figure 4 Hydraulic Fluid Level Lube Reservoir 5 Install the pump lube reservoir and bracket Thread it onto the reservoir cap assembly and place it into the bracket No priming of the system is required Figure 5 Lube Reservoir 6 Connect the isolation hoses to their respective primary heaters Important Every precaution has been taken to prevent the inadvertent connection of a hose to the wrong chemical source The Resin hoses are color coded blue and the Isocyanate hoses are color coded red for easy identification In addition the Resin and Isocyanate hose fittings thread sizes are different making it virtually impossible to improperly connect the hoses The Resin thread is 9 16 18 whereas the Isocyanate thread is 15 20 Connect the hose heater wire leads to each isolation hose Take care to make the connection tight It is recommended that electrical tape be applied to the connection to prevent loosening from vibration Resin Blue RN TSU Harness Connection AN Hose Heater Wire Leads Iso _ Red Tape Figure 6 Isolation Hoses
38. ein are believed to be accurate and reliable but are presented without guarantee warranty or responsibility of any kind expressed or implied Statements or suggestions concerning possible use of GUSMER equipment are made without representation or warranty that any such use is free of patent infringement and are not recommendations to infringe any patent The user should not assume that all safety measures are indicated or that other measures may not be required 2 15942A 1 Issue 2 Operating Manual Contents g CONTENTS EIST OE FIGURES L auqa tentes a w a ee u Sa kasu au Qa 4 WARRANTY cei ssiiscciiscssscsicccssesdescescsscocadssevessscbicteadessevssusecssesiee sesnseedsadevieassevsacs nsedioeaeceseoss s 5 GENERAL SAFETY INFORMATION 6 ACCEPTABLE EQUIPMENT USES L a N 6 OPERATIONAL SAFETY 2 2 6 0 7 DESCRIPTION E R 8 SPECIFICATIQONS S 1 desees ua R a UE en EE Oe UY 11 INITIAL MACHINE SET UBP 13 OPERATION 21 DAILY STARTUP PROCEDURES ccccccscceeeeeseseseseseseseseseseseseseseseseceseseceseseseseseseseeeeeeens 21 DAILY SHUTDOWN 5 44400 22 TROUBLE
39. ery it is imperative to know what is normal operation before one will be able detect abnormal operation Perhaps the best way to acquire knowledge of what is normal performance of Gusmer equipment is through experience in operating it according to the book After obtaining this experience one can readily detect equipment malfunctions After acquiring the ability to recognize a malfunction and before being able to fix the problem knowledge of how the equipment operates is mandatory This manual is written to give the operator an overview of the operation of the equipment therefore it is imperative that before any troubleshooting process begins the operators have read and understood the applicable portions of this manual To further develop the necessary knowledge of the proper operation maintenance and troubleshooting of Gusmer equipment training schools are held on a regular basis throughout the country These schools give concentrated training on our equipment and help to develop an operator into a competent Foam Mechanic Information on these schools is available from our sales office Important Gusmer maintains a competent staff of technical representatives and authorized distributors who can resolve almost any problems you may encounter with Gusmer equipment Feel free to call on these people for assistance when you need it WARNING THE TROUBLESHOOTING SECTION OF THIS MANUAL IS BASED ON THE ASSUMPTION THAT THE INDIVIDUAL PERFORMIN
40. ght should be on Switch ON the Hose Heater Circuit Breaker and set the temperature controller as required The amber pilot light should be on as well as the amber controller light When the liquid in the hose reaches the temperature selected the green controller light will light and the ammeter will begin to cycle Switch on the Primary Heater Circuit Breakers and set the temperature controllers as required The amber pilot light should be on as well as the amber controller lights Switch ON the Motor control and set the hydraulic pressure as required The amber pilot light should be on Set the pump switch to the NORMAL position One of the amber directional Indicator lamps will light and the proportioning pumps should move a short distance and pressurize Check the pressure of each proportioning pump After setting the pump switch to NORMAL observe both pressure gauges The Resin and Isocyanate pressures should be approximately equal and the pressures must remain fixed Observe the directional indicator lights and manually depress the reversing switch rocker arm which corresponds to the light which is off Observe the pressures again they must remain fixed If the pressure bleeds off on either stroke consult the Trouble Shooting Procedures before continuing 21 CORPORATION Model H 2000 H 3500 Proportioning Unit Directional Indicator Lights Reversing Switch Rocker Arm
41. h while applying upward leverage with a screwdriver 3 Check the chamfer around the cavity to insure that there are no sharp edges which could damage the o ring and prevent proper seal Inspect the ball guide o ring and replace as required It is a good practice to liberally coat the o ring with grease prior to inserting the ball guide back into the pump base cavity 4 1 99 39 CORPORATION Model H 2000 H 3500 Proportioning Unit 4 Using the ball seat removal tool 5 8 hex stock unthread and remove the ball seat e Clean the gasket seating surfaces on the underside of the seat and inside the pump base cavity e Inspect the seat gasket and replace as required e Inspect the ball seat for nicks or scratches Replace as required e Thoroughly clean the thread on the seat before replacement It is also a good practice to coat the threads with a liberal amount of lubricant e Install the seat with gasket by threading the seat into the base by hand until the gasket bottoms inside the pump base Use a 6 adjustable wrench to snug the seat approximately 1 4 turn e DO NOT OVERTIGHTEN It may be necessary to periodically retighten the seat throughout the life of the gasket 5 Wipe the valve ball clean and inspect for nicks Replace as required and complete the Pump Base Assembly Primary Heaters WARNING THE HYDRAULIC COMPONENTS ARE PRESSURIZED UP 2000 3 500 51 BEFORE OPENING ANY HYDRAULIC CONNECTIONS OR
42. ied electrician must perform all electrical servicing to the unit Electrical service must meet federal and local codes WARNING DAMAGE TO THE EQUIPMENT COULD RESULT IF THE UNIT IS OPERATED AT OTHER THAN THE NAME PLATE VOLTAGE The Model H 2000 H 3500 is hydraulically driven There are no air requirements for the proportioning unit itself 11 CORPORATION MATERIAL SUPPLY CHEMICAL VISCOSITY HYDRAULIC SERVICING WEIGHT DIMENSIONS OPERATING PRESSURE SUPPLY PRESSURE OUTPUT INLET FILTER PRIMARY HEATER HOSE LENGTH Model H 2000 H 3500 Proportioning Unit The temperature of the chemical supply must be as specified by your chemical supplier Protect the chemical supply from moisture in the atmosphere with a blanket of dry nitrogen or desiccated air Resin Inlet 3 4 NPT FE swivel Isocyanate Inlet 1 2 NPT FE swivel There is no established maximum limitation and assuming adequate supply viscosity s of 5 000 cps or more may be possible 16 gallons 62 Liters Recommended operating temperature 120 F 48 C Maximum operating temperature 160 F 71 C Empty 385 pounds 175 kilograms Serviced 482 pounds 219 kilograms Height 47 inches 119 centimeters Width 40 inches 102 centimeters Depth 22 inches 56 centimeters H 2000 2000 psi maximum 136 Bars H 3500 3500 psi maximum 238 Bars 400 psi maximum 27 Bars 2000 30 Ib min maximum 14 kg min
43. ight Amber PUMP SWITCH OFF NORMAL RETRACT PUMP DIRECTIONAL INDICATOR LIGHTS Amber COUNTER R PRIMARY HEATER CIRCUIT BREAKER Pilot light Amber A PRIMARY HEATER CIRCUIT BREAKER Pilot light Amber PUSH TO TEST BUTTON R PRIMARY HEATER CONTROLLER Green Controller Light Amber Controller Light Red Controller Light A PRIMARY HEATER CONTROLLER Description Controls and protects power to all circuits must be ON for any function of the proportioning unit to operate Indicates when lighted that the main circuit breaker is on Controls power to the electric motor must be ON for the hydraulic drive system to operate Indicates when lighted that the electric motor is on controls operation of the hydraulic drive system Hydraulic Directional Drive System is off and cannot generate hydraulic pressure in this position Must be in this position for the proportioning pumps to operate This position should be used for shutdown and will stop the Hydraulic Drive System with the A proportioning pump in the retracted position Indicates the direction of proportioning pump travel both lights will be off when the pump switch is OFF or when either proportioning pump exceeds its safe operating pressure limitation Records the cycle count of the proportioning pumps one cycle equals two 2 strokes one in each direction Controls and protects power to the R primary heater must be ON for the primary heater
44. ir circulation as possible since the effectiveness of the heat sink is dependent upon unobstructed airflow PRIMARY HEATER CONTROL UNIT the three heat controller units on the H 2000 H 3500 are directly interchangeable with one another To determine if a control unit is operating correctly with the power OFF replace the suspected controller with one known to be good THERMOCOUPLE the design of the temperature controller units includes a fail safe feature which prevents the heating system from operating in the event that there is no signal from the thermocouple In this case the thermocouple requires replacing Refer to the Maintenance section of this manual for the proper procedures HEATING ELEMENTS the heater contains four 1500 Watt 32 ohm heating elements wired in parallel To check operation of the elements proceed as follows 159421A 1 Issue 2 Troubleshooting Resin Heater Circuit Breaker 2 uem O T W X lel le I Isoctanate Heater Circuit Breaker Terminal 41 _ Terminal 2 Isocyanate SSR Figure 23 Primary Heater Fuses a With Main Power OFF read the resistance across terminal 1 on the Resin SSR and terminal P1B on the Resin heater circuit breaker b Read the resistance across terminal 2 on the Isocyanate SSR and terminal on the Isocyanate heater circuit breaker The resistance should be 8
45. is restricted Service as described in the Maintenance section of this manual 159421A 1 Issue 2 4 1 99 Troubleshooting d An inlet valve ball and or a leaking seat gasket that does not properly seat will permit some of the proportioned material to flow back towards the supply drum When this happens the proportioning pump will not pump the proper volume of material during the discharged stroke and an off ratio condition will result This malfunction will evidence itself identically to Cavitation perhaps somewhat less severe however REVERSING MALFUNCTION For the proportioning pumps to change direction or reverse the Activator plate must contact the rocker arm to activate the reversing switch Failure of the activator plate to make proper contact is usually caused by something physical such as a bent or loose activator plate Should the above not be the cause the problem is likely to be a result of the pump piston packing retaining bolt having loosened This would cause the piston to contact the inner face of the pump inlet flange before the activator plate contacts the rocker arm To resolve this shut down the unit and disassemble the appropriate pump for repair When the directional valve fails to shift the activator plate will have passed the rocker arm and not reversed When this happens the first thing to do is to relocate the activator plate so that it is situated between the arms of the rocke
46. l With the Coupling Block Ports held over separate containers open both manual valves Switch the pump switch to the NORMAL Position Allow material to flow out of the coupling block until all spitting of air stops and all traces of residual material have disappeared Switch the pump switch to OFF Close both manual valves and flush any residual material from the outside of the coupling block Mount the gun to the coupling block Important During the initial start up slowly increase the hydraulic pressure and check all fittings for signs of hydraulic and chemical leakage Tighten as required HOSE HEATER The hose heater transformer tap settings must match the length of hose in use Therefore this procedure will have to be executed during the initial installation and when changing the hose length according to the figure below a Loosen the shaft lock on the hose heater power set control and adjust to zero full counter clockwise 159421A 1 Issue 2 Operating Manual Initial Machine Set Up b Switch ON both the main and hose heater circuit breakers The white and amber pilot lights respectively should be on The hose heater ammeter should be zero c Adjust the hose temperature controller for maximum temperature The amber pilot light on the hose heater controller should be on NOTE d Adjust the power set control clockwise to maximum setting Tighten the shaft As the Nester warms the lock nut
47. ll immediately flush out any Isocyanate residue Removal and cleaning of the strainer screen is accomplished as follows 1 Close the material supply valve at the inlet of the appropriate proportioning pump This prevents material being pumped when the strainer screw is removed 2 Place a container beneath the strainer base to catch the drain off of chemical when removing the strainer screw _ Material Supply Valve 3 Remove the screen from the strainer base Thoroughly flush the screen with gun cleaner and shake it dry Inspect the screen to insure that no more than 25 Strainer of the mesh is restricted Screen Inspect the strainer screw gasket and replace as required Strainer Screw Figure 29 Strainer 4 Install the strainer screw with the strainer in place and tighten Important Take care not to over tighten let the gasket make the seal 5 Open the material supply valve insure there are no leaks and wipe the equipment 37 CORPORATION Model H 2000 H 3500 Proportioning Unit clean 6 Proceed with operation Hydraulic System NOTE Upon starting the motor the hydraulic pump may make a screeching noise for a short time upon initial start up Should this 38 noise continue for more than 30 seconds switch off the motor control and refer to the troubleshooting section of this manual WARNING THE HYDRAULIC COMPONENTS ARE PRESSURIZED UP TO 3500PSI BEFORE OPENING ANY
48. ns in the order given for each problem to avoid unnecessary repairs Also determine that all circuit breakers switches and controls are properly set before assuming there is a problem Problems Solution Electric motor will not start or stops during operation 1 Hydraulic pump does not develop pressure 2 Low or zero pressure with screeching noises 2 3 159421A 1 Issue 2 Troubleshooting SOLUTIONS Power Contactor Figure 27 Power Contactor 1 POWER CONTACTOR A power contactor set to trip when the motor draws too much current protects the electric motor To restore the motor to operation allow it to cool and with power OFF depress the reset button It is also important to determine the cause of the trip Improper low line voltage can also cause harm to the motor due to overheating which will cause the power contactor to trip 2 ZERO OR LOW PRESSURE Remember when the motor or pump switch in the off position hydraulic pressure cannot be generated Assuming the pump is in proper working order and the pump switch is set to NORMAL the major factors which can cause it not to produce pressure are that the pump is either not primed or loses its prime To assure a positive prime check the following a Hydraulic reservoir serviced to the proper level including a check that the cartridge strainer and hydraulic fluid are clean b Pump case is full with Hydraulic fluid c Inlet fitting is full
49. nt skin and eye contact with the chemicals or solvents used in or with this equipment Ware approved safety glasses or goggles when servicing or operating this equipment Respiratory protection capable of providing sufficient filtration to prevent inhalation of toxic vapors emitted from the chemical system being used must be worn by any and all persons in the vicinity of any operation where GUSMER Equipment is operated In poorly ventilated areas Gusmer recommends using a fresh air type of respirator system Due to the potential fire hazard of exposed urethane foam follow all procedural and safety directives for the storage handling and application of the chemicals used with this equipment WARNING INFORMATION CONCERNING PERSONAL PROTECTION AND PROPER HANDLING AND APPLICATION PROCEDURES OF THE CHEMICALS AND SOLVENTS USED WITH THIS EQUIPMENT MUST BE OBTAINED FROM THE SUPPLIERS OF SUCH CHEMICALS AND SOLVENTS Electric Requirements are as follows SHP 220 Volts AC current 60 103 AMPS at 220 Volts AC current HZ Single Phase 23 KVA 18 4 kw peak power at 220 Volts 5 220 Volts AC current 50 60 45 AMPS at 220 Volts AC current HZ 3 Phase 17 KVA 13 6 kw peak power at 220 Volts SHP 3 x 380 50 HZ AC current 38 AMPS at 3 x 380 50 HZ AC current 25 20 kw peak power at 380 Volts A terminal block is located in the main electric console for easy connection of the main power cord not supplied A certif
50. ohms A higher resistance indicates that one or more heating elements are inoperative If this is the case disconnect the heating elements and measure the resistance of each element Each heating element should measure 32 ohms If not replace the damaged element or elements The positioning of the thermocouple in the outlet heat exchanger is critical to the proper operation of the primary heater Therefore two conditions must be satisfied a The thermocouple must make positive contact with the heating element b The heating element must be functioning properly If either of these conditions is not satisfied it could cause erratic temperature control and possibly overheating The thermocouple is properly positioned and mechanically locked in place at the factory However during maintenance or changing of the thermocouple the positioning may have changed Refer to the Maintenance section of the manual for proper thermocouple positioning Check the resistance of the heating element it should be 32 ohms 7 primary heater rating is 6000 Watts at a voltage of 220 Volts Low line voltage will significantly reduce the power available and the primary heater will not perform to its full capability 8 The H 2000 H 3500 s very efficient primary heater design maximizes the heat transfer from the power available However under certain conditions the heater will not be able to reach the required temperature and will require a reduction in flow
51. oller Light 13 POWER SET 14 HOSE HEATER AMMETER 15 HYDRAULIC PRESSURE CONTROL 16 RESIN OVER PRESSURE SAFETY SWITCH 17 RESIN PRESSURE GAUGE 18 ISOCYANATE PRESSURE GAUGE 19 R INLET SUPPLY BALL VALVE 20 A INLET SUPPLY BALL VALVE 21 HYDRAULIC PRESSURE GAUGE 22 ISOCYANATE OVER PRESSURE SAFETY SWITCH 10 Model H 2000 H 3500 Proportioning Unit Indicates when lighted that the temperature of the Isocyanate component in the heater is within 5 F of dial set point Indicates when lighted that the temperature of the Isocyanate component in the heater is more than 5 F cooler than dial set point Indicates when lighted that the temperature of the Isocyanate component in the heater is more than 5 F warmer than dial set point Protects hose heater circuit must be ON for the hose heater to operate Indicates when lighted that the Hose Heater Circuit Breaker is on Controls the temperature of the liquid maintained by the Hose Heater Set control selector dual scale to the desired temperature From this point the temperature control is completely automatic Indicates when lighted that the temperature of the hose heater is within 5 F of dial set point Indicates when lighted that the temperature of the hose heater is more than 5 F cooler than dial set point Indicates when lighted that the temperature of the hose heater is more than 5 F warmer than dial set point Controls the
52. r Figure 10 Hose Connection Step d Repeat Step 7 for adding additional hoses 159421A 1 Issue 2 Power lead L3 is not used for single phase installation Connect the ground wire to the ground lug Close the electric control console 4 1 99 Initial Machine Set Up Install the Temperature Sensing Unit TSU onto the gun hose Pull out and carefully straighten the LOOSE END of the temperature probe from the TSU Insert the temperature probe into the Isocyanate hose Connect the ground wire on the gun hose to the ground lug on the TSU lt Temperature Sensing Unit s Ground Point Figure 11 Temperature Sensing Unit WARNING THE TEMPERATURE SENSOR EXTENDS APPROXIMATELY 8 INCHES INTO THE ISOCYANATE HOSE AND ALTHOUGH IT IS A RUGGEDLY BUILT ASSEMBLY IT WILL NOT WITHSTAND REPEATED ABUSE CARE MUST BE TAKEN NOT TO CRUSH THE HOSE OR SUBJECT IT TO SEVERE BENDING IN THE AREA WHERE THE SENSOR IS LOCATED TAKE CARE NOT TO COIL THE HOSE TIGHTER THAN THE RECOMMENDED 3 FT MINIMUM BEND RADIUS 9 10 11 12 13 Connect the TSU extension harness to the proportioning unit using the adapter furnished in the provided package Connect the main air source to the heated hose Important for 3 phase units only At this point it is necessary to check the rotation of the electric motor An arrow located on the Hydraulic Pump and on the Bell Housing indicates a correct dire
53. r arm as follows a Determine in which direction the plate must move this is predicated upon which stroke is overrun b Go to the hydraulic manifold and locate the manual operator centered in the end of the housing of the coil on the same side of the machine toward which the activator plate must go For example If the plate over ran to E the left and requires moving to the T EE right toward the Resin pump go to Manual Operator coil on the Resin side Figure 25 Hydraulic Manifold With the gun or coupling block open the main circuit breaker and motor control ON and the pump switch OFF push in the manual operator a 3 16 Allen wrench is ideal for this and hold it in until the activator plate is approximately centered Release it and close the gun or coupling block If the spool seemed to move freely when pushed the cause of the overrun was probably an electrical problem Turn off the motor and place the pump switch in the NORMAL position Push in each end of the rocker arm listen for the shifting of the spool and note the direction indicators light as appropriate If the spool does not shift or if the lights do not light there is an electrical problem with the reversing switch directional valve coil or pump switch Should the spool hang up or be hard to push it is likely that there is a mechanical problem within the directional valve which will necessitate shutting down the unit and disassembling the direction
54. rcuit breakers switches and controls and controls are properly set before assuming there is a problem Problems Solutions Proportioning pump does not hold pressure when stalled 1 Pressure unbalance between pumps 2 3 1 Cavitation in the proportioning pumps 3 2 1 Failure of the pump to reverse 4 Pumps do not move and both directional indicator lights are out 6 5 4 Pump movement is erratic 5 SOLUTIONS 1 LEAKING BALL CHECK VALVE a Determine which pump is losing pressure by observing the gauges b Determine in which direction the pump has stalled by observing which directional indicator light is ON Refer to the Figure below to isolate the problem Lighted Lighted io a 6 I 2 7 xu R Discharge Ball Check Valve or R Pump Inlet Ball Check Valve or components fouling components fouling A Inlet Ball Check Valve or A Pump Discharge Ball Check Valve or components fouling components fouling To service perform the following procedure a Shut off all electrical switches breakers and the main power supply b Close the appropriate Inlet Material Supply Valve and disconnect the air supply to the transfer pump WARNING ALLOW THE HOSE S AND PRIMARY HEATER S TO COOL PRIOR TO SERVICING THE UNIT c Bleed off chemical until the pressure gauge s read zero 4 1 99 31 32 CORPORATION Model H 2000 H 3500 Proportioning Unit d Remove the approp
55. riate ball guide Inspect the ball seat gasket and replace as required Flush and wipe clean the valve ball and ball seat of all residual material Using the ball seat removal tool check the seat for proper seat compression Snug the seat up to a turn maximum The gasket should extend beyond the seat by approximately 1 16 of an inch If this does not resolve the problem remove the seat inspect the gasket and replace as required In most cases the cause of a leaking valve is a particle of foreign material preventing the ball from seating properly If cleaning the valve ball and seat does not resolve the problem replace these parts along with the gasket PRESSURE UNBALANCE The success of the troubleshooting procedure for this problem will depend on the determination of two points a Which chemical did not reach the mixing chamber b Why did the chemical fail to get there Which chemical is missing can usually be determined by observing the color of the pattern as it exits the gun Foam systems are usually a combination of light and dark material Therefore by observing the color of the liquid exiting the gun you can determine which material is not reaching the mixing chamber The determination as to why the chemical did not reach the mixing chamber may be more difficult to resolve A restriction at the gun or the proportioning pump not properly pumping its designed volume is the usual cause for a lack of material at the mixing chamber
56. ssue number of the Instruction Manual from the title page If there is no issue number enter NONE Enter the date of Issue of the Instruction Manual from the title page If there is no issue date enter NONE Enter the page number containing the discrepancy Provide a brief description of NOTE You may send a marked copy of the page as an attachment to your submittal 159421A 1 Issue 2
57. y tight to insure no air is leaking into the pump case 3 SCREECHING the screeching noise is a characteristic of Cavitation and is normal at initial start up for a maximum of 30 seconds If the screeching continues for more than 30 seconds check that the inlet fittings are tight and that the pump has not lost its prime A second cause of screeching can be excessive hydraulic oil temperature Determine that the reservoir is properly serviced and if necessary provide better ventilation to permit the reservoir to dissipate heat more efficiently 4 1 99 35 CORPORATION Model H 2000 H 3500 Proportioning Unit MAINTENANCE To realize full productivity from the Model H 2000 H 3500 it is necessary to perform certain maintenance procedures daily or periodically WARNING WHENEVER WORKING WITH THE EQUIPMENT INSURE THAT EYE PROTECTION IS WORN AND THAT SKIN IS PROTECTED AGAINST EXPOSURE TO CHEMICALS AND SOLVENTS BEING USED WORK SHOULD ALWAYS BE DONE IN A WELL VENTILATED AREA TO PREVENT HARMFUL FUMES AND VAPORS INFORMATION CONCERNING THE TOXICITY AND PROPER HANDLING PROCEDURES OF YOUR CHEMICALS IS AVAILABLE FROM YOUR SUPPLIER WARNING UNLESS SPECIFIED OTHERWISE ALL CIRCUIT BREAKERS SHOULD BE OFF AND THE MAIN POWER DISCONNECTED AT THE SOURCE TO AVOID SEVERE BODILY INJURY FROM ELECTRICAL SHOCK DO NOT ENTER ELECTRICAL CONSOLE WITH POWER ON Pump Lube System To insure that the pump lube will do its job check its condition
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