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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 & 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.
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Summary of Contents for GUSMER H-3500
- 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 1999, GUSMER CORPORATION http://www.gusmer.com NOTICE: This manual contains important information for your GUSMER equipment. Read and retain for future reference.
- Page 2 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...
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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......................11 INITIAL MACHINE SET-UP ..................13 OPERATION ........................21 ..................21 AILY TARTUP ROCEDURES ...................22 AILY HUTDOWN ROCEDURES TROUBLESHOOTING ....................23 ......................23 NTRODUCTION ........................24 Solutions........................24 ......................27 RIMARY... -
Page 4: List Of Figures
Model H-2000/H-3500 Proportioning Unit LIST OF FIGURES 1. D H-2000 H-3500 M ....8 IGURE ESCRIPTION ONTROLS FOR BOTH ODELS 2. T ..................13 IGURE YPICAL NSTALLATION 3. P ................14 IGURE OWER TRAIN ELIEF 4. H ................15... -
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 SOVENTS AND CHEMICAL USED WITH THIS EQUIPMENT EXPOSE THE OPERATOR TO CERTAIN HAZARDS DEQUATE PERSONAL PROTECTIVE MEASURES MUST... -
Page 8: Description
Model H-2000/H-3500 Proportioning Unit DESCRIPTION Figure 1. Description Of Controls for both H-2000 and H-3500 Models. 159421A-1, Issue 2... - Page 9 Operating Manual Description Controls and protects power to all circuits; must be ON for any function of the MAIN CIRCUIT BREAKER proportioning unit to operate. Indicates when lighted that the main circuit breaker is on. Pilot light (White) Controls power to the electric motor; must be ON for the hydraulic drive system to MOTOR CONTROL operate.
- Page 10 Model H-2000/H-3500 Proportioning Unit Indicates when lighted that the temperature of the Isocyanate component in the Green Controller Light heater is within +/- 5° F of dial set point. Indicates when lighted that the temperature of the Isocyanate component in the Amber Controller Light heater is more than +/- 5°...
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Page 11: Specifications
GUSMER ® Equipment is operated. In poorly ventilated areas, Gusmer recommends using a fresh air type of respirator system. - Page 12 PRIMARY HEATER: 6000 Watts per heater at 220 Volts.* H-2000: ∆ t=60°F @ 30 lb./min. (14 Kg/min) * H-3500: ∆ t=60°F @ 20 lb./min. (9 Kg/min) * HOSE LENGTH: 310 feet (94.5 meters) maximum for heating purposes * Ideal values obtained in laboratory testing and may not be duplicated under working conditions.
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Page 13: Initial Machine Set-Up
Operating Manual Initial Machine Set-Up INITIAL MACHINE SET-UP Figure 2. Typical Installation 4/1/99... -
Page 14: Figure 3. Power Cord Strain Relief
Model H-2000/H-3500 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 An Accessory Package is included with the unit and contains the following parts that are required for setup: a) Isolation hose (Blue –... -
Page 15: Figure 4. Hydraulic Fluid Level
Operating Manual Initial Machine Set-Up 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. -
Page 16: Figure 7. Hose Connection Step (A)
A liberal amount of duct tape can be used in this area to make the bundle as proportioning unit. compact as possible. Gusmer strongly recommends installing the optional scuff jacket to protect the hose insulation and TSU extension from damage. A proper hose... -
Page 17: Figure 11. Temperature Sensing Unit
Operating Manual 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. - Page 18 Certain solvents, which are commonly in use with this equipment are flammable and may present a flash danger to the operator. a) The Gusmer 2:1 Transfer Pump has a ground lug. Ground this pump in accordance with the instructions provided with the pump.
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Page 19: Figure 13. Tap Settings (Single Transformer)
Operating Manual Initial Machine Set-Up 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. Adjust the hose temperature controller for maximum temperature. The amber pilot light, on the hose heater controller, should be on. -
Page 20: Figure 14. Tap Settings (Dual Transformer)
Model H-2000/H-3500 Proportioning Unit Figure 14. Tap Settings (Dual Transformer) Hose Length (ft) Setting Voltage S1-S2 4.23 S2-S3 10.54 S1-S3 14.77 S3-S4 16.93 S2-S4 27.47 S1-S4 31.7 260 & above S4-S5 40.2 S3-S5 57.13 S2-S5 67.67 S1-S5 71.9 159421A-1, Issue 2... -
Page 21: Operation
Operating Manual Operation OPERATION Daily Startup Procedures NOTE: SERVICING-check the condition of the hydraulic and pump lubrication systems and The daily start-up procedures will service as required. Generally, change the lubricating fluid when it shows signs of describe normal operation and will color change. -
Page 22: Daily Shutdown Procedures
Model H-2000/H-3500 Proportioning Unit Figure 15. Directional Indicator Lights & 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 Set the pump switch to the RETRACT position. -
Page 23: Troubleshooting
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: T HE TROUBLESHOOTING SECTION OF THIS MANUAL IS BASED ON THE... -
Page 24: Hose Heat
OLUTIONS 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. -
Page 25: Figure 17. Wire Connection
MAY DAMAGE THE EQUIPMENT AND WOULD CREATE A POTENTIAL SOURCE OF INJURY TO THE OPERATOR HOSE HEAT CONTROL UNIT-the three heat control units on the H-2000/H-3500 are directly interchangeable with one another. To determine if the control unit is operating correctly, with power OFF, swap the suspected control with one known to be good. -
Page 26: Figure 20. Terminal Jumper Strip
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. -
Page 27: Primary Heater
Operating Manual Troubleshooting Primary Heater Figure 21. Primary Heater WARNING: B EFORE 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 O NOT ENTER THE ELECTRIC CONSOLE WITH POWER ON WARNING: T HERE IS HIGH VOLTAGE INSIDE THE PRIMARY HEATER COVER BOX... -
Page 28: Solutions
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. -
Page 29: Figure 23. Primary Heater Fuses
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. -
Page 30: Proportioning System
Model H-2000/H-3500 Proportioning Unit Proportioning System Figure 24. Proportioning System A-Pump Base Rocker Arm R-Pump Base (Not shown, located on far side) A-Discharge Ball Check Valve Reversing Plate R-Discharge Ball Check Valve (Not shown, located on far side) A-Inlet Ball Check Valve... -
Page 31: Solutions
Operating Manual Troubleshooting 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. Problems Solutions Proportioning pump does not hold pressure when stalled. - Page 32 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.
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Page 33: Figure 25. Hydraulic Manifold
Operating Manual 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. -
Page 34: Hydraulic Drive System
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. -
Page 35: Solutions
Operating Manual Troubleshooting OLUTIONS Figure 27. Power Contactor 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. -
Page 36: Maintenance
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: W HENEVER WORKING WITH THE EQUIPMENT INSURE THAT EYE PROTECTION IS WORN AND THAT SKIN IS PROTECTED AGAINST EXPOSURE TO CHEMICALS AND SOLVENTS BEING... -
Page 37: Inlet Strainer Screen
Operating Manual Maintenance WARNING: D O NOT FILL THE LUBE CYLINDER WITH PUMP LUBE HIS WOULD OVER SERVICE THE SYSTEM AND MAY CAUSE THE LUBE RESERVOIR TO BURST HE SYSTEM IS SELF PRIMING AND THE LUBE CYLINDER WILL FILL DURING NORMAL OPERATION OF THE MACHINE Inlet Strainer Screen 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. -
Page 38: Hydraulic System
Model H-2000/H-3500 Proportioning Unit clean. Proceed with operation. Hydraulic System WARNING: T 3500 HE HYDRAULIC COMPONENTS ARE PRESSURIZED UP TO EFORE OPENING ANY HYDRAULIC CONNECTIONS OR SERVICING HYDRAULIC COMPONENTS EXTREME CAUTION TO INSURE THAT ALL PRESSURES HAVE BEEN BLED TO ZERO TO AVOID... -
Page 39: Proportioning Pumps
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. -
Page 40: Primary Heaters
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. -
Page 41: Figure 31. Thermocouple
Operating Manual 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 be relocated or removed. The location of the thermocouple is critical to the operation of the heater and requires proper positioning before tightening the compression nut. -
Page 42: Appendix
Q (lbs) = S (strokes) x .31 Recommended Hydraulic fluid or equivalent Mobil DTE 24 Mobil DTE 25 Cooks Albavis 10 The H-2000 and H-3500 interfaces with all the following Equipment. • GX-7 High Pressure Spray Guns • GX-7 Auto High Pressure Spray Gun •... -
Page 43: 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 4/1/99... - Page 44 Model H-2000/H-3500 Proportioning Unit Field Field Title Description Number 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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