GUSMER H-3500, H-2000 Operating Manual

"Teamwork & 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 & 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.
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 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
2 15942A-1, Issue 2
Operating Manual Contents

CONTENTS

LIST OF FIGURES..........................................................................................................4
WARRANTY.....................................................................................................................5
GENERAL SAFETY INFORMATION..........................................................................6
CCEPTABLE EQUIPMENT USES
A
PERATIONAL SAFETY PROCEDURES
O
DESCRIPTION .................................................................................................................8
SPECIFICATIONS.........................................................................................................11
INITIAL MACHINE SET-UP.......................................................................................13
OPERATION ..................................................................................................................21
AILY STARTUP PROCEDURES
D
AILY SHUTDOWN PROCEDURES
D
.......................................................................................6
...............................................................................7
.......................................................................................21
...................................................................................22
TROUBLESHOOTING.................................................................................................23
NTRODUCTION
I
OSE HEAT
H
..............................................................................................................23
....................................................................................................................24
Solutions....................................................................................................................24
RIMARY HEATER
P
..........................................................................................................27
Solutions....................................................................................................................28
ROPORTIONING SYSTEM
P
...............................................................................................30
Solutions....................................................................................................................31
YDRAULIC DRIVE SYSTEM
H
...........................................................................................34
Solutions....................................................................................................................35
MAINTENANCE............................................................................................................36
UMP LUBE SYSTEM
P
NLET STRAINER SCREEN
I
YDRAULIC SYSTEM
H
ROPORTIONING PUMPS
P
UMP BASES
P
RIMARY HEATERS
P
..................................................................................................................39
......................................................................................................36
...............................................................................................37
......................................................................................................38
.................................................................................................39
........................................................................................................40
4/1/99
APPENDIX......................................................................................................................42
INSTRUCTION MANUAL DISCREPANCY REPORT............................................43
3

LIST OF FIGURES

Model H-2000/H-3500 Proportioning Unit
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
ESCRIPTION OF CONTROLS FOR BOTH
1. D
YPICAL INSTALLATION
2. T
OWER CORD STRAIN RELIEF
3. P
YDRAULIC FLUID LEVEL
4. H
UBE RESERVOIR
5. L
SOLATION HOSES
6. I
OSE CONNECTION STEP (A
7. H
OSE CONNECTION STEP (B
8. H
OSE CONNECTION STEP (C
9. H
OSE CONNECTION STEP (D
10. H
EMPERATURE SENSING UNIT
11. T
ELL HOUSING
12. B
AP SETTINGS (SINGLE TRANSFORMER
13. T
AP SETTINGS (DUAL TRANSFORMER
14. T
IRECTIONAL INDICATOR LIGHTS
15. D
IRE CONNECTION
16. W
IRE CONNECTION
17. W
.................................................................................... 13
................................................................................ 15
............................................................................................. 15
............................................................................................ 15
.............................................................................................. 17
........................................................................................ 24
........................................................................................ 25
H-2000
AND
H-3500 M
ODELS
. ............. 8
........................................................................... 14
)............................................................................ 16
)............................................................................ 16
)............................................................................ 16
) ......................................................................... 16
........................................................................ 17
).......................................................... 19
) ............................................................ 20
EVERSING SWITCH ROCKER ARM
& R
........... 22
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
IGURE
F
OLID STATE RELAY
18. S
19. TSU C
20. T
21. P
22. P
23. P
24. P
25. H
26. C
27. P
28. P
29. S
30. H
31. T
ONNECTION ERMINAL JUMPER STRIP RIMARY HEATER RIMARY HEATER FUSES RIMARY HEATER FUSES ROPORTIONING SYSTEM
YDRAULIC MANIFOLD
ONTROL TRANSFORMER FUSE OWER CONTACTOR UMP LUBE SYSTEM TRAINER
YDRAULIC SYSTEM HERMOCOUPLE
....................................................................................................... 37
....................................................................................... 25
......................................................................................... 25
............................................................................... 26
........................................................................................... 27
................................................................................ 28
................................................................................ 29
............................................................................... 30
.................................................................................. 33
...................................................................... 34
....................................................................................... 35
....................................................................................... 36
....................................................................................... 38
............................................................................................ 41
4 159421A-1, Issue 2
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 workm anship for a peri od of one year from the d ate of shipme nt f rom Gusmer facilities.
In the event Product is suspect ed to be defe ctive in materi al or work mansh ip, it mu st be ret urned 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. 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 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 spe cial i ndire ct, in ciden tal or con sequ entia l dama ges. Furt her, G usmer shall have no l iabil ity for any expenses including, but not limited to personal injury or property damage resulting from failure of per for ma n ce of t he pr od u ct , us e of t he p r od uct , or a p pli cat i on of t he mat e ri al d is p ens ed t hrou gh 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 in sure prop er vali dation of your war rant y, please complet e the w arrant y card a nd ret urn it to Gusm er wit hin two w eeks of r eceipt of equipment.
Revi sed 1 1/12/ 98
4/1/99
5
Model H-2000/H-3500 Proportioning Unit

GENERAL SAFETY 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 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, 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 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

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 BETAKEN SO AS TO AVOID EXCEEDING THE PRODUCTS BEING USED
DMINISTRATION
A
PERSONAL PROTECTION AND PROPER HANDLING FROM THE SUPPLIER OF SUCH CHEMICALS
WARNING:
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 A QUALIFIED ELECTRICIAN
WARNING:
COMPONENTS CAPABLE OF PRODUCING UP TO FROM HYDRAULIC INJECTION OF FLUID SERVICE HYDRAULIC COMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO
WARNING:
WHEN OPERATING, SERVICING, OR BEING PRESENT IN THE OPERATIONAL ZONE OF THIS EQUIPMENT SAFETY SHOES, AND RESPIRATORY EQUIPMENT AS REQUIRED
HE SOVENTS AND CHEMICAL USED WITH THIS EQUIPMENT EXPOSE THE
DEQUATE PERSONAL PROTECTIVE MEASURES MUST
. A
HRESHOLD LIMIT VALUE
T
AS ESTABLISHED BY THE OCCUPATIONAL SAFETY AND HEALTH
,
(OSHA)
TO PREVENT SERIOUS BODILY INJURY FROM ELECTRICAL SHOCK, NEVER OPEN
OR OTHER QUALIFIED AGENCY. INFORMATION CONCERNING
HE ELECTRICAL SERVICE MUST BE INSTALLED AND MAINTAINED BY
. T
(TLV)
OF THE
.
THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC
PSI
3500
NEVER OPEN ANY HYDRAULIC CONNECTIONS OR
,
O AVOID SERIOUS BODILY INJURY
. T
.
TO AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR MUST BE WORN
HIS INCLUDES, BUT IS NOT LIMITED TO, EYE AND FACE PROTECTION, GLOVES
. T
.
.
,
High Temperature
Warning
4/1/99
WARNING: T
TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES SERIOUS BODILY INJURY FROM HOT FLUID OR HOT METAL EQUIPMENT BEFORE ALLOWING IT TO COOL
WARNING: F
PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT FROM ONE OR MORE OF THE ABOVE LISTED HAZARDS
HIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HIGH
O PREVENT
. T
NEVER ATTEMPT TO SERVICE THE
,
.
AILURE TO READ AND FOLLOW THIS SAFETY INFORMATION MAY RESULT IN
7

DESCRIPTION

Model H-2000/H-3500 Proportioning Unit
Figure 1. Description Of Controls for both H-2000 and H-3500 Models.
8 159421A-1, Issue 2
Operating Manual Description
1. MAIN CIRCUIT BREAKER
Pilot light (White)
2. MOTOR CONTROL
Pilot light (Amber)
3. PUMP SWITCH
OFF
NORMAL
RETRACT
4. PUMP DIRECTIONAL INDICATOR LIGHTS (Amber)
5. COUNTER
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).
6. R-PRIMARY HEATER CIRCUIT BREAKER
Pilot light (Amber)
7. A-PRIMARY HEATER CIRCUIT BREAKER
Pilot light (Amber)
8. PUSH TO TEST BUTTON
9. R-PRIMARY HEATER CONTROLLER
Green Controller Light
Amber Controller Light
Red Controller Light
10. A-PRIMARY HEATER CONTROLLER
Controls and protects power to the R primary heater; must be ON for the primary heater 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.
4/1/99
9
Model H-2000/H-3500 Proportioning Unit
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 Controller Light
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.
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
Controls the 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.
10 159421A-1, Issue 2
Operating Manual Specifications

SPECIFICATIONS

ENVIRONMENT:
RECOMMENDED USE:
SAFETY EQUIPMENT:
APPLICATION:
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, i t is damaged from using abrasive materials
will not be covered
not abrasion proof
under warranty.
and those parts
Ware sufficient protective clothing when servicing or operating this equipment to prevent skin and eye contact with the chemicals or solvents used in or with this equipment,
Ware app roved safety glasses or goggles when servicing or o perating 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.
AIR:
WARNING:
AND APPLICATION PROCEDURES OF THE CHEMICALS AND SOLVENTS USED WITH THIS EQUIPMENT MUST BE OBTAINED FROM THE SUPPLIERS OF SUCH CHEMICALS AND SOLVENTS
INFORMATION CONCERNING PERSONAL PROTECTION AND PROPER HANDLING
.
Electric Requirements are as follows:
(5HP) , 220 Volts AC current 60 HZ, Single Phase
(5HP), 220 Volts, AC current 50/60 HZ; 3 Phase
(5HP), 3 x 380, 50 HZ, AC current.
103 AMPS at 220 Volts, AC current. 23 KVA (18.4 kw) peak power at 220 Volts.
45 AMPS at 220 Volts, AC current. 17 KVA (13.6 kw) peak power at 220 Volts.
38 AMPS at 3 x 380, 50 HZ, AC current 25 KVA (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 certified electrician must perform all electrical servicing to the unit. Electrical service must meet federal and local codes.
WARNING:
OTHER THAN THE NAME PLATE VOLTAGE
DAMAGE TO THE EQUIPMENT COULD RESULT IF THE UNIT IS OPERATED AT
.
The Model H-2000/H-3500 is hydraulically driven. There are no air requirements for the proportioning unit itself.
4/1/99
11
Model H-2000/H-3500 Proportioning Unit
MATERIAL SUPPLY:
CHEMICAL VISCOSITY:
HYDRAULIC SERVICING:
WEIGHT:
DIMENSIONS:
OPERATING PRESSURE:
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)
SUPPLY PRESSURE: OUTPUT:
INLET FILTER: PRIMARY HEATER:
HOSE LENGTH:
* Ideal values obtained in laboratory testing and may not be duplicated under working conditions.
400 psi maximum (27 Bars) H-2000 - 30 lb./min. maximum (14 kg/min.) 28 lb./min. at 50 HZ (13 kg/min.) H-3500 - 20 lb./min. maximum (9 kg/min.) 80 Mesh Standard (Optional - 60/40 Mesh) 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) *
310 feet (94.5 meters) maximum for heating purposes
12 159421A-1, Issue 2
Operating Manual Initial Machine Set-Up

INITIAL MACHINE SET-UP

4/1/99
Figure 2. Typical Installation
13
Model H-2000/H-3500 Proportioning Unit
WARNING:
THIS EQUIPMENT, WHICH INCLUDES BUT IS NOT LIMITED TO GLOVES, EYE PROTECTION, AND RESPIRATORY PROTECTION AS REQUIRED
ROPER PROTECTIVE GEAR MUST BE WORN WHEN SERVICING OR OPERATING
P
.
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.
The power source must be capable
NOTE:
of meeting the electrical
requirements specified on the
nameplate of the proportioning
unit and an accessible quick
disconnect provided.
NOTE:
The material supply valves are
loosely assembled to the unit so
that they may be oriented in the
position that best suits the setup.
WARNING:
THE ELECTRIC SERVICE MUST BE DONE BY A QUALIFIED ELECTRICIAN
.
1. Connect the main power cord (not supplied) to the electric console. Open the electric control console. Feed the power cord through the strain relief.
Figure 3. Power Cord Strain Relief
2. Set up the supply and moisture control systems as required. Refer to the individual instruction manuals for the proper procedures.
3. 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 filled with liquid.
14 159421A-1, Issue 2
Loading...
+ 30 hidden pages