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GUSMER H-20/35 Operating Manual

Vr series proportioning unit
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"Success through Unity"
H-20/35 VR Series
Proportioning
Unit
Operating Manual
42942-VR-1
December 19, 2002
Issue 1
®
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 & Canada)
Phone: (732) 370-9000
Fax: (732) 905-8968
®
Copyright 2002, GUSMER CORPORATION
http://www.gusmer.com
NOTICE: This manual contains important information about your GUSMER equipment. Read and retain for future reference.

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  • Page 1 One Gusmer Drive Lakewood, New Jersey, USA 08701-8055 Toll Free 1-800-367-4767 (USA & Canada) Phone: (732) 370-9000 Fax: (732) 905-8968 ® Copyright 2002, GUSMER CORPORATION http://www.gusmer.com NOTICE: This manual contains important information about your GUSMER equipment. Read and retain for future reference.
  • Page 2 All statements, information and data given herein 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.

  • Page 3: Table Of Contents

    Operating Manual Contents CONTENTS LIST OF FIGURES ......................4 WARRANTY ........................5 GENERAL SAFETY INFORMATION................6 ..................6 CCEPTABLE QUIPMENT ................7 PERATIONAL AFETY ROCEDURES DESCRIPTION.........................8 SPECIFICATIONS......................16 INITIAL MACHINE SET-UP..................17 RATIO ADJUSTMENT....................25 ................25 ATIO DJUSTMENT ROCEDURES OPERATION ........................27 ..................27 AILY TART ROCEDURES .................28 AILY DOWN ROCEDURES TROUBLESHOOTING ....................29 ....................29...

  • Page 4: List Of Figures

    H-20/35 VR Series Proportioning Unit LIST OF FIGURES 1. M ..................8 IGURE AJOR OMPONENTS 2. T ......12 IGURE RANSFORMER OMPARTMENT LECTRICAL OMPONENTS 3. E ..............14 IGURE LECTRICAL ONSOLE OMPONENTS 4. T ...................17 IGURE YPICAL NSTALLATION 5. M ................18 IGURE OWER ONNECTION 6.

  • Page 5: Warranty

    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.

  • Page 6: General Safety Information

    Under no circumstances should any acid or corrosive chemicals be used in the unit. Consult GUSMER if there is any doubt about the compatibility of the chemical system to be used in this equipment.

  • Page 7: Operational Safety Procedures

    Operating Manual General Safety Information Operational Safety Procedures 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: T HE SOLVENTS AND CHEMICALS USED WITH THIS EQUIPMENT EXPOSE THE OPERATOR TO CERTAIN HAZARDS DEQUATE PERSONAL PROTECTIVE MEASURES MUST BE...

  • Page 8: Description

    H-20/35 VR Series Proportioning Unit DESCRIPTION Figure 1. Major Components 42942-VR-1, Issue 1...
  • Page 9 Operating Manual Description MAIN POWER DISCONNECT- Controls power to all circuits. Must be ON for any function of the proportioning unit to operate. The disconnect can be locked in the OFF position for OSHA required lockout/tagout during machine maintenance. MAIN POWER LIGHT (WHITE)- Lights up when the Main Disconnect Switch is in the ON position and the control power transformer is operational.
  • Page 10 H-20/35 VR Series Proportioning Unit 11. ACTIVATOR PLATE – Works with the reversing switches to change pump direction. 12. HYDRAULIC PUMP (ISOCYANATE) – Hydraulic pump that supplies the pressure and flow rate to the hydraulic drive system that attaches to the Isocyanate proportioning pump.
  • Page 11 Operating Manual Description 24. POLYOL PRIMARY HEATER SWITCH- Energizes the Polyol Primary Heater system circuit. In the ON position, the green light within the switch lights up. 25. POLYOL PRIMARY HEATER TEMPERATURE CONTROLLER- Digital display of controller will be energized when Control Power Switch is activated. Controller will display set point temperature.

  • Page 12: Figure 2. Transformer Compartment Electrical Components

    H-20/35 VR Series Proportioning Unit 41. HYDRAULIC PRESSURE GAUGE- Indicates the pressure in the Hydraulic Drive System for the Polyol pump. 42. HYDRAULIC TANK LEVEL GAUGE- Shows the level of oil in the tank. 43. LUBE PUMP SYSTEM (Iso side only)- Continuously circulates Pump Lube to prevent the crystallization of Isocyanate on the pump shaft.
  • Page 13 Operating Manual Description 12/19/02...

  • Page 14: Figure 3. Electrical Console Components

    H-20/35 VR Series Proportioning Unit Figure 3. Electrical Console Components 42942-VR-1, Issue 1...
  • Page 15 Operating Manual Description 55. CONTROL MAIN TERMINAL BLOCK- Termination/distribution point for control system component wires. 56. CONTROL TRANSFORMER SECONDARY CIRCUIT BREAKER- Provides over-current protection for the control transformer secondary 120-volt AC output. 57. MASTER RELAY- Controls distribution of 120 volt AC to control power system. The Control Power Switch energizes the relay.

  • Page 16: Specifications

    H-20/35 VR Series Proportioning Unit SPECIFICATIONS The Model H-20/35 VR is hydraulically driven. There are no air requirements for the AIR: proportioning unit itself. MATERIAL SUPPLY: The temperature of the chemical supply must be as specified by your chemical supplier.

  • Page 17: Initial Machine Set-Up

    Operating Manual Initial Machine Set-up INITIAL MACHINE SET-UP Figure 4. Typical Installation * Consult Gusmer Sales for the correct hose sizes for your application 12/19/02...

  • Page 18: Figure 5. Main Power Connection

    H-20/35 VR Series Proportioning Unit WARNING: P ROPER PROTECTIVE GEAR MUST BE WORN WHEN SERVICING OR OPERATING THIS EQUIPMENT WHICH INCLUDES BUT IS NOT LIMITED TO GLOVES EYE PROTECTION RESPIRATORY PROTECTION AS REQUIRED The Accessory Package included with the unit contains the following parts required for set-up: •...

  • Page 19: Figure 7. Hydraulic Fluid Level

    Prepare the Lube System for use as follows: a) Fill the Lube Reservoir. NOTE: Figure 7. Hydraulic Fluid Level Use only Gusmer Pump Lube (P/N 0960-1-GAL) b) Thread the reservoir onto the Reservoir Cap Assembly and place it into the bracket.

  • Page 20: Figure 10. Heated Hose Assembly Connections

    A liberal amount of duct proportioning unit. 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 Harness from damage.

  • Page 21: Figure 11. Temperature Sensing Unit (Tsu)

    Operating Manual Initial Machine Set-up b) Insert the Temperature Probe into the Isocyanate Hose and connect the TSU to the Hose Whip, taking care not to cross-thread or over-tighten the fittings, thereby assuring a leak-proof chemical connection. c) Connect the ground wire on the gun hose to the Ground Point on the TSU. d) Connect the Heated Hose Assemblies to the TSU, taking care not to cross- thread or over-tighten the fittings, thereby assuring a leak-proof chemical connection.
  • Page 22 H-20/35 VR Series Proportioning Unit 11. Properly ground all auxiliary equipment. The high velocity flow of fluid can create static sparking, which may cause fire or explosion. Certain solvents that are commonly in use with this equipment are flammable and may present a flash danger to the operator.

  • Page 23: Figure 12. Temperature Controller

    14. Attach harnesses to gun and machine. 15. Temperature Controller Set-up: The H-20/35 has separate Temperature Controllers that automatically control the temperature for the Hose Heater and each of the Primary Heaters. To enter the set point, proceed as follows:...

  • Page 24: Figure 13. Tap Settings

    The Temperature Controller should begin to cycle toward the new will not need readjusting. set point. If all steps have been followed and no problems have been encountered, the H-20/35 VR should now be ready for ratio adjustment. 42942-VR-1, Issue 1...

  • Page 25: Ratio Adjustment

    Operating Manual Initial Machine Set-up RATIO ADJUSTMENT Ratio Adjustment Procedures NOTE: Determine that the supply system is at the proper temperature as recommended by the The output of each chemical pump chemical system supplier, the individual chemicals are properly mixed within their is controlled by the output of the drums/day tanks, and the moisture protection system is properly set for operation.
  • Page 26 15. Tighten lock nut on Hydraulic Pump Flow Control Adjustments and replace caps. Both the locking nut and caps contain o-ring seals. 16. Close the Recirculating Ball Valves. If all steps have been followed and no problems have been encountered, the H-20/35 VR should now be ready for operation. 42942-VR-1, Issue 1...

  • Page 27: Operation

    Operating Manual Operation OPERATION Daily Start-up Procedures NOTE: Check the condition of the Hydraulic and Lube System and service as required. The Daily Start-up Procedures Change the Pump Lube when it shows signs of color change. describe normal operation and assume that all calibrations have Determine that the supply system is at the proper temperature as recommended by the been properly executed.

  • Page 28: Daily Shut-Down Procedures

    H-20/35 VR Series Proportioning Unit NOTE: 15. Verify the Pump Switch is set to RUN. The Hydraulic Drive System will not cycle back and forth without 16. With the Recirculating Ball Valves closed, turn the Pump Switch to Service. the gun being triggered.

  • Page 29: Troubleshooting

    GUSMER equipment. These schools give concentrated training on the equipment and help to develop an operator into a competent Certified Gusmer Technician. Obtain information on these schools from our sales office. GUSMER maintains a competent staff of Technical Representatives and authorized Distributors who can resolve almost any problem you may encounter with GUSMER equipment.

  • Page 30: Hose Heat System

    OLUTIONS HOSE LENGTH- The design of the H-20/35 VR Hose Heat System allows it to operate with up to 310 feet of hose. Hose lengths greater than this require the use of an auxiliary hose heat system (Call Gusmer Sales for details). In addition, if chemical or ambient temperature is too cold, the hose circuit may not have enough power to bring the chemical up to temperature.

  • Page 31: Figure 15. Hose Heat Circuit Breaker

    (See Figure 15) Figure 15. Hose Heat Circuit Breaker HOSE HEAT CONTROL UNIT- The three Temperature Controllers on the H-20/35 VR are directly interchangeable with one another. To determine if the control unit is operating correctly, turn OFF the red Main Disconnect and swap the suspected controller with one known to be good.

  • Page 32: Figure 16. Terminal Jumper Strip Installation

    H-20/35 VR Series Proportioning Unit b) Turn ON power to the Hose Heat System and adjust the Hose Heat Power Set (clockwise) to between 45 and 50 Amps; If hose heat is restored, then the fault is within the Gun Whip.

  • Page 33: Primary Heaters

    Operating Manual Troubleshooting c) Maintaining hose temperature now requires manual adjustment of the Hose Heat Power Set. (See Figure 14) Adjust the control clockwise for initial warm up and then adjust as required to maintain the hose temperature. (Do Not exceed 50 Amps.) WARNING: T HE TEMPERATURE MUST BE CLOSELY MONITORED DURING MANUAL CONTROL OF THE...

  • Page 34: Solutions

    PRIMARY HEATER CONTROL UNIT- The three Temperature Controllers on the H-20/35 VR are directly interchangeable with one another. To determine if a controller is operating correctly, turn OFF the red Main Disconnect and replace the suspect controller with one known to be good.

  • Page 35: Proportioning System

    The efficient Primary Heater design of the H-20/35 VR 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 or the use of an auxiliary hose heat system.

  • Page 36: Solutions

    H-20/35 VR Series Proportioning Unit Try the recommended solutions in the order given for each problem to avoid unnecessary repairs. Also, determine that all circuit breakers, switches, and controls and controls are properly set before assuming there is a problem.
  • Page 37 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-20/35 VR. Also recommended is a minimum of three-quarter-inch-diameter supply hose, as short as practical.

  • Page 38: Figure 20. Hydraulic Manifold

    H-20/35 VR Series Proportioning Unit 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 stopped.

  • Page 39: Hydraulic Drive System

    AUDIBLE ALARM - Audible alarm can only be reset if the high- or low-pressure condition is removed. PUMPS DON’T OPERATE WHEN GUN IS TRIGGERED – the H-20/35 VR requires a special dispensing gun that will electrically start and stop the pump circuit of the system.

  • Page 40: Solutions

    H-20/35 VR Series Proportioning Unit OLUTIONS MOTOR CIRCUIT PROTECTOR- The Motor Circuit Protector is set to trip when the electric motor draws too much current. To restore the motor to operation, allow it to cool and, with power OFF, reset the ON/OFF Switch to ON.

  • Page 41: Maintenance

    ALLOW HEATER TO COOL TO AVOID BODILY INJURY FROM HOT FLUID OR HOT METAL The sheaths on the H-20/35 VR Heating Rods are made from a special alloy designed to be resistant to corrosion and erosion. However, the maximum service life of the rod will eventually be reached and if the sheath should fail, fluid under pressure will leak into the heating element.

  • Page 42: Thermocouple Replacement

    SERIOUS BODILY INJURY Disassemble and clean the 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.

  • Page 43: Pump Bases

    Operating Manual Maintenance ASES WARNING: B OTH PUMP BASES OPERATE UNDER HIGH PRESSURE O AVOID SERIOUS BODILY INJURY USE EXTREME CAUTION TO ENSURE ALL PRESSURE FROM BOTH THE SUPPLY AND DELIVERY SIDE OF THE PUMP BASE HAVE BEEN BLED TO ZERO BEFORE SERVICING THE PUMP BASE ASSEMBLY Disassemble and clean both Pump Bases annually as follows: (Refer to the Pump Base Assembly section of the Parts I.D.

  • Page 44: Pump Lube System

    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-20/35 VR minimizes exposure to moisture, but moisture contamination is still possible.

  • Page 45: Hydraulic Drive System

    Operating Manual Maintenance Drain the reservoir and flush it with pump lube. Fill the Lube Reservoir with fresh Pump Lube. Thread the reservoir onto the Reservoir Cap Assembly and place it into the bracket. (See Figure 8 in the Initial Machine Set-up section of this manual.) Push the Supply Tube approximately 1/3 of the way down into the Lube Reservoir.

  • Page 46: Appendix

    Q (lbs/min) = [C (cycles/min/ISO pump)+C(cycles/min/POLYOL PUMP)] x .31 Recommended Hydraulic fluid or equivalent: Mobil DTE 24 Mobil DTE 25 Cooks Albavis 10 The H-20/35 VR Series interfaces with all of the following equipment: • GAP Spray Gun (35100-R-02-SW) • GX-8-400 Spray Gun (32140-CSTM) IMPORTANT: Refer to gun specifications for maximum pressure rating.

  • Page 47: Instruction Manual Discrepancy Report

    Date of Issue Page Number 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, NJ 08701 12/19/02...
  • Page 48 H-20/35 VR Series Proportioning Unit Number Field Title Description Date Enter date report is submitted. Name Enter name of person making report. IM Number Enter the Part Number of the Instruction Manual from the title page. Issue Number Enter the Issue number of the Instruction Manual from the title page. If there is no issue number, enter NONE.

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