GUSMER Ff-1600 Bedienungsanleitung

"Teamwork & Communication"

Model FF-1600

without Heat

Operating Manual

17942C-1

January 7, 2000

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

http://www.gusmer.com

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

Model FF-1600 with out Heat

217942C-1, Issue 1

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.

Operating Manual General Safety Information

01/07/00 3

CONTENTS

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

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

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

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

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

DESCRIPTION OF CONTROLS...................................................................................8

SPECIFICATIONS.........................................................................................................10

INITIAL MACHINE SET-UP.......................................................................................11

AIR PURGE.....................................................................................................................13

NORMAL OPERATING PROCEDURES...................................................................14

DAILY START-UP PROCEDURE .......................................................................................14

DAILY SHUT-DOWN PROCEDURE...................................................................................14

TROUBLESHOOTING PROCEDURES.....................................................................15

GENERAL INFORMATION................................................................................................15

PROPORTIONING SYSTEM...............................................................................................16

Solutions....................................................................................................................16

MAINTENANCE............................................................................................................19

PUMP LUBE SYSTEM......................................................................................................19

INLET FILTER SCREEN....................................................................................................20

PROPORTIONING PUMPS.................................................................................................21

PUMP BASES ..................................................................................................................21

NOTES.............................................................................................................................22

INSTRUCTION MANUAL DISCREPANCY REPORT............................................23

Model FF-1600 with out Heat

417942C-1, Issue 1

LIST OF FIGURES

FIGURE 1 MODEL 17000C-1 PROPORTIONING UNIT............................................................ 8

FIGURE 2 HOSE CONNECTION LOCATIONS ......................................................................... 12

FIGURE 3 HOSE CONNECTION STEP (A)............................................................................. 12

FIGURE 4 HOSE CONNECTION STEP (B)............................................................................. 12

FIGURE 5 PUMP LUBE CUP LOCATION............................................................................... 13

FIGURE 6. PROPORTIONING PUMP FEATURES ................................................................... 16

Operating Manual Contents

01/07/00 5

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. 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

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, 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 insure proper validation of your warranty, please complete the warranty card and return it to

Gusmer within two weeks of receipt of equipment.

Revised 11/12/98

Model FF-1600 with out Heat

617942C-1, Issue 1

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 all-

inclusive, 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.

Operating Manual General Safety Information

01/07/00 7

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

WARNING: THE SOVENTS AND CHEMICAL USED WITH THIS EQUIPMENT EXPOSE THE

OPERATOR TO CERTAIN HAZARDS. ADEQUATE PERSONAL PROTECTIVE MEASURES MUST

BETAKEN SO AS TO AVOID EXCEEDING THE THRESHOLD LIMIT VALUE (TLV) OF THE

PRODUCTS BEING USED, AS ESTABLISHED BY THE OCCUPATIONAL SAFETY AND HEALTH

ADMINISTRATION (OSHA) OR OTHER QUALIFIED AGENCY. INFORMATION CONCERNING

PERSONAL PROTECTION AND PROPER HANDLING FROM THE SUPPLIER OF SUCH CHEMICALS.

High Voltage

WARNING: TO PREVENT SERIOUS BODILY INJURY FROM ELECTRICAL SHOCK, NEVER OPEN

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. THE ELECTRICAL SERVICE MUST BE INSTALLED AND MAINTAINED BY

A QUALIFIED ELECTRICIAN.

High Pressure

WARNING: THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC

COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI. TO AVOID SERIOUS BODILY INJURY

FROM HYDRAULIC INJECTION OF FLUID, NEVER OPEN ANY HYDRAULIC CONNECTIONS OR

SERVICE HYDRAULIC COMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO.

Personal Protective

Equipment

WARNING: TO AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR MUST BE WORN

WHEN OPERATING, SERVICING, OR BEING PRESENT IN THE OPERATIONAL ZONE OF THIS

EQUIPMENT. THIS INCLUDES, BUT IS NOT LIMITED TO, EYE AND FACE PROTECTION, GLOVES,

SAFETY SHOES, AND RESPIRATORY EQUIPMENT AS REQUIRED.

Warning

WARNING: FAILURE TO READ AND FOLLOW THIS SAFETY INFORMATION MAY RESULT IN

PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT FROM ONE OR MORE OF THE ABOVE

LISTED HAZARDS

Model FF-1600 with out Heat

817942C-1, Issue 1

DESCRIPTION OF CONTROLS

Figure 1 Model 17000C-1 Proportioning Unit

1. MAIN SWITCH- Controls power to all circuits.

•OFF- Main Power is off.

•POWER- Turn the Main Switch to this position. To supply Main Power to the

Console. A White pilot light will indicate this.

•ON- Turn the Main Switch to this position and allow it to return to the POWER

position to enable the Console Controls. An Amber pilot light will indicate this.

2. 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

3. 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.

4. COUNTER- Records the cycle count of the Proportioning Pumps. One cycle count

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

5. AIR PRESSURE REGULATOR- Controls the speed of the air motor on the up and

downstroke.

Operating Manual Initial Machine Set-up

01/07/00 9

6. AIR PRESSURE GAUGE- Displays the air pressure in the air drive system during

the up and downstroke.

7. MAIN AIR FILTER- Filters the system air supply. (3/8 NPT Female)

8. ISOCYANATE PRESSURE GAUGE- Displays the pump out put pressure in the

Isocyanate proportioning system.

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

10. A-INLET FILTER SCREEN

11. A-PUMP BASE

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

13. RESIN PRESSURE GAUGE- Displays the pump out put pressure in the resin

proportioning system.

14. R-INLET FILTER SCREEN

15. R-PUMP BASE

16. 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

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

coils to reverse direction.

18. EMERGENCY STOP BUTTON- Disables the Console Controls when engaged.

Amber Control Power pilot light will remain off until the button has been reset and

the Console Controls re-enabled. The White Lamp will remain illuminated.

(Twist to reset)

19. ISOCYANATE OUTLET- 1/2 FPT (Swivel) Fitting

20. RESIN OUTLET- 3/4 FPT (Swivel) Fitting

Model FF-1600 with out Heat

10 17942C-1, Issue 1

SPECIFICATIONS

Air 26 scfm @100 psi (12 liters/sec @7 bars)

Electric 2 amps @ 110 volts, 50/60 Hertz single phase, AC.

Maximum Output 16 lbs/min. (7.25 kg/min)

Maximum Pressure 1600 psi (108 bars) @ 100 psi Air

Viscosity 25-3000 cps (25-3000 cps)

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