GUSMER FF-2500 Operating Manual

Model FF-2500

Proportioning Unit

Operating Manual

25942-1

February 12, 2004

Issue 4

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: [phone]

Fax: [phone]

®

Copyright 2004, GUSMER CORPORATION

NOTICE: This manual contains important information about your GUSMER equipment. Read and retain for future reference.

http://www.gusmer.com

Model FF-2500 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 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. The user should not assume that all safety measures are indicated or that other
measures may not be required for a particular circumstance or application.

2 25942-1, Issue 4

Operating Manual Contents

CONTENTS

LIST OF FIGURES..........................................................................................................4

WARRANTY....................................................................................................................5

GENERAL SAFETY INFORMATION.........................................................................6

ACCEPTABLE EQUIPMENT USES ......................................................................................6

OPERATIONAL SAFETY PROCEDURES ..............................................................................7

DESCRIPTION ................................................................................................................8

SPECIFICATIONS........................................................................................................11

INITIAL MACHINE SET-UP ......................................................................................12

MAIN POWER INSTALLATION ........................................................................................13

MATERIAL SUPPLY CONNECTIONS ................................................................................14

HOSE HEAT POWER PACK .............................................................................................15

TEMPERATURE CONTROLLERS ......................................................................................16

HEATED HOSE INSTALLATION.......................................................................................17

AIR PURGE ....................................................................................................................20

OPERATION..................................................................................................................21

DAILY START-UP PROCEDURE.......................................................................................21

DAILY SHUT-DOWN PROCEDURE ..................................................................................22

TROUBLESHOOTING.................................................................................................23

GENERAL INTRODUCTION..............................................................................................23

PRIMARY HEATING SYSTEM..........................................................................................24

Solutions...................................................................................................................25

PROPORTIONING SYSTEM ..............................................................................................27

Solutions...................................................................................................................27

HOSE HEAT SYSTEM......................................................................................................30

Solutions...................................................................................................................30

MAINTENANCE ...........................................................................................................34

PROPORTIONING PUMPS ................................................................................................34

PUMP BASES..................................................................................................................34

INLET FILTER SCREEN ...................................................................................................35

INSTRUCTION MANUAL DISCREPANCY REPORT ...........................................37

2/12/04 3

ISOCYANATE PUMP LUBRICANT ....................................................................................36

Model FF-2500 Proportioning Unit

LIST OF FIGURES

FIGURE 1. MODEL FF-2500 PROPORTIONING UNIT...........................................................8

FIGURE 2. TYPICAL FF-2500 INSTALLATION....................................................................12

FIGURE 3. MAIN POWER CONNECTIONS...........................................................................13

FIGURE 4. MANUAL TRANSFORMER CONNECTIONS........................................................... 15

FIGURE 5. MANUAL TAP SETTINGS...................................................................................15

FIGURE 6. TEMPERATURE CONTROLLER...........................................................................16

FIGURE 7. ISOLATION HOSES...........................................................................................17

FIGURE 8. HOSE CONNECTION STEP (A)...........................................................................17

FIGURE 9. HOSE CONNECTION STEP (B & C)....................................................................18

FIGURE 10. HOSE CONNECTION STEP (D)........................................................................18

FIGURE 11. HOSE CONNECTION STEP (E & F)..................................................................18

FIGURE 12. TEMPERATURE SENSING UNIT (TSU).............................................................19

FIGURE 13. PUMP LUBRICANT CUP .................................................................................20

FIGURE 14. PRIMARY HEATER FEATURES.........................................................................24

FIGURE 15. PROPORTIONING PUMP FEATURES .................................................................27

FIGURE 16. TRANSFORMER FUSE LOCATION........................................................................29

FIGURE 17. TERMINAL JUMPER STRIP INSTALLATION........................................................32

4 25942-1, Issue 4

Operating Manual 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 or
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 prepaid. 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. For such Product, a written estimate will be
submitted to the 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 MAKE S N O WA RR ANTY WH ATSO EV ER AS TO THE MER CH ANT ABI LITY O F,
OR SUITABILITY FOR, ITS PRODUCT TO PERFORM ANY 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, EXPRESS 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, express 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 ensure proper validation of your warranty, please complete the warranty card and return it to
Gusmer within two weeks of receipt of equipment.

Revised 09/02

2/12/04 5

Model FF-2500 Proportioning Unit

GENERAL SAFETY INFORMATION

It is necessary to understand and follow the instructions in this manual to ensure 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 all­inclusive, 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 such as polyureas, and some two-component epoxy systems. 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.

Any use of this equipment other than as indicated above constitutes misuse unless
express written approval is obtained from GUSMER.

Your Gusmer equipment incorporates design parameters, features, and functionality
developed in over 40 years of plural component equipment design and manufacture. It is
manufactured under the stringent standards of ISO 9001, and is backed by the Gusmer
Warranty included herein.

The use of genuine Gusmer replacement parts is recommended for your equipment.
Substitution of parts not designed, manufactured, or recommended by Gusmer may result
in reduced performance of, and/or damage to, your Gusmer equipment. Any alterations
to, or substitutions for, genuine Gusmer parts shall void the provisions of the Gusmer
Warranty.

6 25942-1, Issue 4

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.

Solvents and Chemicals

High Voltage

High Pressure

Personal Protective

Equipment

WARNING: T

OPERATOR TO CERTAIN HAZARDS. ADEQUATE PERSONAL PROTECTIVE MEASURES MUST BE
TAKEN SO AS TO AVOID EXCEEDING THE
BEING USED

HE SOLVENTS AND CHEMICALS USED WITH THIS EQUIPMENT EXPOSE THE

THRESHOLD LIMIT VALUE (TLV) OF THE PRODUCTS

, AS ESTABLISHED BY THE OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION

(OSHA) OR OTHER QUALIFIED AGENCY. OBTAIN INFORMATION CONCERNING PERSONAL

PROTECTION AND PROPER HANDLING FROM THE SUPPLIER OF SUCH SOLVENTS AND
CHEMICALS

WARNING:

THE ELECTRIC CONSOLES OR OTHERWISE SERVICE THIS EQUIPMENT AND/OR EQUIPMENT USED
WITH IT BEFORE SWITCHING OFF THE MAIN POWER DISCONNECT AND SHUTTING OFF AND
LOCKING OUT SUPPLY VOLTAGE AT THE SOURCE
INSTALLED AND MAINTAINED BY A QUALIFIED ELECTRICIAN

WARNING:

CHEMICAL COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI. TO AVOID SERIOUS
BODILY INJURY FROM INJECTION OF FLUID
COMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO

WARNING:

FOR THE TASK BEING ACCOMPLISHED, MUST BE WORN WHEN OPERATING, SERVICING, OR BEING
PRESENT IN THE OPERATIONAL ZONE OF THIS EQUIPMENT
LIMITED TO
EQUIPMENT AS REQUIRED TO PROVIDE PERSONAL PROTECTION FROM SOLVENTS AND
CHEMICALS
HAZARDS ASSOCIATED WITH HYDRAULIC
APPROPRIATE WARNINGS ON THIS PAGE FOR FURTHER INFORMATION

.

TO PREVENT SERIOUS BODILY INJURY FROM ELECTRICAL SHOCK, NEVER OPEN

. THE ELECTRICAL SERVICE MUST BE

.

THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC AND

, NEVER OPEN OR SERVICE ANY CONNECTIONS OR

.

TO AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR, APPROPRIATE

. THIS INCLUDES, BUT IS NOT

, EYE AND FACE PROTECTION, GLOVES, SAFETY SHOES, AND RESPIRATORY

; HIGH PRESSURE RELEASES; HIGH TEMPERATURES; ELECTRIC SHOCK; AND OTHER

/ELECTRO-MECHANICAL EQUIPMENT. REFER TO THE

.

WARNING: T

TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES. TO PREVENT
SERIOUS BODILY INJURY FROM HOT FLUID OR HOT METAL
EQUIPMENT BEFORE ALLOWING IT TO COOL

High Temperature

WARNING:

SYMBOL MAY RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT.

Warning

2/12/04 7

HIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HIGH

, NEVER ATTEMPT TO SERVICE THE

.

FAILURE TO READ AND FOLLOW THE INFORMATION ASSOCIATED WITH THIS

Model FF-2500 Proportioning Unit

DESCRIPTION

Figure 1. Model FF-2500 Proportioning Unit

8 25942-1, Issue 4

Operating Manual Description

1. MAIN SWITCH - Controls power to all circuits and must be ON for any function

of the proportioning unit to operate.
White pilot light indicates the main switch is ON.

WARNING:

ENERGIZED WHEN THE MAIN SWITCH IS OFF. TO FULLY DE-ENERGIZE THE ELECTRICAL
CONSOLE

2. PRIMARY HEATER CIRCUIT BREAKER- Controls and protects the primary

INCOMING POWER LEADS FROM THE MAIN ELECTRICAL SOURCE REMAIN

, SWITCH OFF AND LOCK OUT INCOMING POWER AT THE SOURCE.

heater. It must be ON for the primary heater to operate.

3. HOSE HEATER CIRCUIT BREAKER- Controls and protects the low voltage

power pack. It must be ON for the hose heater to operate.

4. HOSE TEMPERATURE CONTROLLER- Controls the temperature of the hose

heater. Adjust the set point to the desired temperature. From this point, the
temperature control is automatic.

5. PRIMARY HEATER TEMPERATURE CONTROL- Controls the temperature

of the primary heater. Adjust the set point to the desired temperature. From this
point, the temperature control is automatic.

6. PUMP SWITCH- Controls operation of the air drive system.

• OFF- Air drive system is off.

• NORMAL- Must be in this position for the proportioning pumps to operate.

• RETRACT- Use this position for shutdown. It will stop the air motor at the

bottom of the stroke with the proportioning pumps in the retracted position.

7. PUMP DIRECTIONAL INDICATOR LIGHTS (Amber)- Indicate the direction

the proportioning pump is traveling. Both lights will be off when the pump switch is
OFF or when either proportioning pump exceeds its designed operating pressure
limit.

8. COUNTER- Records the cycle count of the proportioning pumps. One cycle count

equals two (2) strokes (one in each direction).

9. DOWNSTROKE AIR PRESSURE REGULATOR- Controls the air pressure to

the air motor on the downstroke.

10. UPSTROKE AIR PRESSURE REGULATOR- Controls the air pressure to the air

motor on the upstroke.

11. DOWNSTROKE AIR PRESSURE GAUGE- Displays the air pressure in the air

drive system during the downstroke.

12. UPSTROKE AIR PRESSURE GAUGE- Displays the air pressure in the air drive

system during the upstroke.

13. MAIN AIR FILTER- Filters the system air supply.

14. RESIN PRESSURE GAUGE- Displays the pressure in the resin proportioning

2/12/04 9

system.

Model FF-2500 Proportioning Unit

15. ISOCYANATE PRESSURE GAUGE- Displays the pressure in the isocyanate

proportioning system.

16. A-INLET SUPPLY VALVE (R on other side)

17. A-INLET FILTER SCREEN (R on other side)

18. A-PACKING NUT, LUBE CUP (R on other side)

19. PRESSURE LIMIT SWITCH- Factory set to turn off the air drive system when

the proportioning pump exceeds the designed operating pressure limit. (A side
shown, R on other side)

20. PRIMARY HEATER THERMOCOUPLE– Senses the temperature of the

primary heater and inputs that information.

21. THERMAL LIMIT SWITCH- (under thermostat cover not shown)

Interrupts power to the primary heater when the surface temperature approaches the
designed operating temperature limit.

22. POWER PACK (TRANSFORMER) CORD- Provides AC power to the primary

side of the transformer.

23. LOW VOLTAGE POWER PACK (TRANSFORMER)- Provides selectable low

voltage outputs for heating various chemical hose lengths.

24. TSU EXTENSION ADAPTER- Carries the electrical signal from the TSU sensor

in the isocyanate hose to the hose temperature controller.

25. AIR MOTOR REVERSING SWITCH- Energizes and de-energizes the air valve

coils to reverse direction.

26. HOSE HEAT POWER SET- Adjusts the amount of amperage supplied to the hose

heating system.

27. HOSE HEAT AMMETER- Indicates the amount of amperage supplied to the hose

heating system.

28. PRIMARY HEATER- Heats the materials to the required dispensing temperature.

29. A- (ISOCYANATE) PROPORTIONING PUMP- Draws in and dispenses a fixed

volume of isocyanate for delivery to the gun or pour head.

30. R- (RESIN) PROPORTIONING PUMP- (Opposite side, not shown) Draws in and

dispenses a fixed volume of resin for delivery to the gun or pour head.

31. POWER-LOCK™ HOSE HEAT CONNECTION- Connects power from the

transformer to the heated hoses.

10 25942-1, Issue 4

Operating Manual Description

SPECIFICATIONS

MATERIAL SUPPLY:

AIR MOTOR:

ELECTRICAL:

WEIGHT:

DIMENSIONS:

PROPORTIONING PUMPS:

Required chemical viscosity: 250-1500 centipoise (cP). Consult your chemical supplier
about material temperatures required to maintain correct viscosity.

Protect the chemical supply from atmospheric moisture with a blanket of dry nitrogen or

desiccated air.

Resin Inlet: 3/4" NPT (FE) swivel

Isocyanate Inlet: 1/2" NPT (FE) swivel

Material supply pressure: 400 psi maximum (27 bars)

32 scfm @112 psi (12 liters/sec @7.7 bars)

38 amps @ 220 volts, 50/60 Hertz single-phase, AC.

29 amps @ 380 volts, 50/60 Hertz three-phase, AC.

140 pounds (63 kg)

Height: 24 inches (61 centimeters)
Width: 26 inches (66 centimeters)
Depth: 30 inches (76 centimeters)

Operating

Pressure:

2500 psi (173 bars)

Output: 10 lbs./min. (4.54 kg/min) *

INLET FILTER:

PRIMARY HEATER:

HOSE LENGTH:

*Theoretical: actual results will vary with operating conditions.

80 Mesh Standard (Optional - 60/40 Mesh)

6000 Watts: ∆ t=40°F (22°C) @ 10 lb./min. (4.5 kg/min) *

310 feet (94.5 meters) maximum for heating purposes

2/12/04 11

Model FF-2500 Proportioning Unit

INITIAL MACHINE SET-UP

12 25942-1, Issue 4

Figure 2. Typical FF-2500 Installation