GUSMER FF-2500, Operating Manual

Page 1: ...usmer 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 2004 GUSMER CORPORATION http www gusmer...

Page 2: ...ur 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 express...

Page 3: ...CTIONS 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 I...

Page 4: ...NGS 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 CONNECT...

Page 5: ...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...

Page 6: ...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...

Page 7: ...ressure WARNING THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC AND CHEMICAL COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI TO AVOID SERIOUS BODILY INJURY FROM INJECTION OF FLUID NEVER...

Page 8: ...Model FF 2500 Proportioning Unit 8 25942 1 Issue 4 DESCRIPTION Figure 1 Model FF 2500 Proportioning Unit...

Page 9: ...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...

Page 10: ...ide 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 fr...

Page 11: ...i maximum 27 bars AIR MOTOR 32 scfm 112 psi 12 liters sec 7 7 bars ELECTRICAL 38 amps 220 volts 50 60 Hertz single phase AC 29 amps 380 volts 50 60 Hertz three phase AC WEIGHT 140 pounds 63 kg DIMENSI...

Page 12: ...Model FF 2500 Proportioning Unit 12 25942 1 Issue 4 INITIAL MACHINE SET UP Figure 2 Typical FF 2500 Installation...

Page 13: ...URE THAT INCOMING POWER IS DISCONNECTED AND LOCKED OUT AT THE SOURCE IMPORTANT The main power source must be capable of meeting the electrical requirements specified on the nameplate of the proportion...

Page 14: ...a generator will be powering the unit consult with your electrician about additional grounding measures that may be required Material Supply Connections Connect the material supply to the inlets of th...

Page 15: ...line fuse B into the Power Lock hose heat connector on the end of the console wire A See Figure 4 Figure 4 Manual Transformer Connections 3 Using Figure 5 and the chart below connect the power lead C...

Page 16: ...NOTE The temperature controller normally displays the set point When illuminated the red LED number 1 on the temperature controller indicates that the heater is in heating mode The LED goes out when t...

Page 17: ...CKET TO PROTECT THE HOSES AND TSU EXTENSION HARNESS FROM DAMAGE 1 Connect the isolation hoses to their respective primary heater outlet fittings see Figure 7 IMPORTANT The heated hose assemblies are c...

Page 18: ...the hoses are pressurized and found to be free of leaks Figure 10 Hose Connection Step d See Figure 11 for Steps e and f e Connect the TSU harness plugs together To ensure a secure electrical connect...

Page 19: ...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 ensuring a leak proof chemical connection e Connect the...

Page 20: ...3 8 Hold the coupling block with the A and R ports over separate containers and open both manual valves Figure 13 Pump Lubricant Cup 9 Set the pump switch to NORMAL If necessary gradually adjust both...

Page 21: ...N the main switch The pilot light should be on 8 Uncoil the heated hose assemblies WARNING UNCOIL THE HOSES BEFORE SWITCHING ON THE HOSE HEAT CIRCUIT BREAKER TO PREVENT OVERHEATING THE HOSE ASSEMBLIES...

Page 22: ...ired so that the proportioning pump pressure is equal on both the up and down strokes The proportioning unit is now ready for operation Daily Shut Down Procedure 1 Set the pump switch to RETRACT 2 Tri...

Page 23: ...etent Certified Gusmer Technician Obtain information on these schools from SPI GUSMER maintains a competent staff of Technical Representatives and authorized Distributors who can resolve almost any pr...

Page 24: ...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 Turn off all swit...

Page 25: ...ensure all electrical power is OFF e Reset the thermal limit switch by pushing in the red button on the switch f If the thermal limit switch does not feel as though it reset then disconnect one lead...

Page 26: ...ing power at the source b Remove the heater cover box by removing the acorn nut and sliding the cover box away from the heater c Read the resistance across the four Heating Rods The resistance should...

Page 27: ...or lights are out 4 5 6 Pump movement is erratic 7 Unequal pressure or speed on the upstroke verses the down stroke 8 SOLUTIONS 1 LEAKING BALL CHECK VALVE Determine which inlet and discharge ball valv...

Page 28: ...erably lower than the isocyanate gauge see step 3 below 3 CAVITATION Cavitation is the formation of a partial vacuum or void created within the pump cylinder during the fill stroke It is actually a sh...

Page 29: ...As this is a non lockout type of system the proportioning pumps will resume normal operation when the pressure bleeds off to approximately 200 psi However the cause of the over pressure condition sho...

Page 30: ...the FF 2500 hose heater allows it to operate with up to 310 feet of hose Hose lengths greater than that reduce the ability of the hose heat to reach temperature See Initial Machine Set up In addition...

Page 31: ...clockwise until the ammeter reads zero then turn OFF the hose heat circuit breaker and main switch and repeat Steps c through e until the fault is located 5 DIGITAL HOSE HEAT SOLID STATE RELAY SSR It...

Page 32: ...lation WARNING DO NOT ALLOW HOSE TO OVERHEAT DURING MANUAL CONTROL OF THE HOSE HEAT SYSTEM HOSE TEMPERATURE AS INDICATED BY A PROPERLY INSTALLED HOSE THERMOMETER MUST NOT EXCEED 170 F 76 C CLOSELY MON...

Page 33: ...ch primary heater and hose heater circuit breakers OFF change the sensor leads on terminal numbers 1 and 2 10 SENSOR TYPE MISMATCHED The preprogrammed controller operates with a type E Thermocouple on...

Page 34: ...seep past the pump packing onto the pump shaft Maintain proper packing adjustment to minimize seepage Routinely inspect the shaft and wipe away any residue when the proportioner is turned off Disasse...

Page 35: ...appropriate container open the corresponding manual valve of the side to be worked on and bleed chemical pressure to ZERO 2 Disconnect the transfer pump air supply and close the material inlet supply...

Page 36: ...of isocyanate past the pump packing during operation However if the packing within the isocyanate pump is functioning properly pump lubricant replacement due to discoloration should not be more freque...

Page 37: ...ber Field Title Description 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...

Page 38: ...e 4 Issue Number Enter the Issue number of the Instruction Manual from the title page If there is no issue number enter NONE 5 Date of Issue Enter the date of Issue of the Instruction Manual from the...