Graco Gusmer H-20 Pro Instruction Manual

Graco Inc. P.O. Box 1441 Minneapolis, MN 55440-1441
Copyright 2006, Graco Inc. is registered to I.S. EN ISO 9001
311392 rev.C
Operation
H-20/35 Pro™
Proportioner
For spraying polyurethane foam and polyurea coatings.
Not for use in explosive atmospheres.
See page 3 for model information, including
maximum working pressure.
Important Safety Instructions
Read all warnings and instructions in this manual.
Save these instructions.
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Contents
2311392C
Contents
Contents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Related Manuals . . . . . . . . . . . . . . . . . . . . . . . . . . . 2
Models . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3
Warnings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4
Pressure Relief Procedure . . . . . . . . . . . . . . . . . . . 6
Flushing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
Typical Installation . . . . . . . . . . . . . . . . . . . . . . . . . 7
Component Identification . . . . . . . . . . . . . . . . . . . . 8
Initial Set-up . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
Main Power Installation . . . . . . . . . . . . . . . . . . . 14
Lubrication System Set-up . . . . . . . . . . . . . . . . 15
Material Supply Connections . . . . . . . . . . . . . . . 16
Heated Hose Installation . . . . . . . . . . . . . . . . . . 16
Air Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19
Hose Power Control System . . . . . . . . . . . . . . . 19
Digital Temperature Controllers . . . . . . . . . . . . . 20
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
Daily Start-up Procedure . . . . . . . . . . . . . . . . . . 21
Daily Shutdown Procedure . . . . . . . . . . . . . . . . 22
Technical Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
Graco Standard Warranty . . . . . . . . . . . . . . . . . . . 24
Graco Information . . . . . . . . . . . . . . . . . . . . . . . . . 24
Related Manuals
For Repair instructions and parts, see manual 311393.

Models
311392C 3
Models
Part No.,
Series Model
Maximum Working
Pressure
psi (MPa, bar) Voltage Amps
Total
Heater
Watts
295500, A H20 Pro 2000 (13.8, 138) 230V, 60 Hz, 1 phase 100 12000
295501, A H20 Pro 2000 (13.8, 138) 230V, 60 Hz, 3 phase 60 12000
295502, A H20 Pro 2000 (13.8, 138) 230V, 60 Hz, 3 phase 74 18000
295503, A H20 Pro 2000 (13.8, 138) 380V, 60 Hz, 3 phase 48 12000
295504, A H20 Pro 2000 (13.8, 138) 380V, 60 Hz, 3 phase 62 18000
295505, A H20 Pro 2000 (13.8, 138) 460V, 60 Hz, 3 phase 30 12000
295506, A H20 Pro 2000 (13.8, 138) 460V, 60 Hz, 3 phase 37 18000
295507, A H25 Pro 2500 (17.2, 172) 230V, 60 Hz, 1 phase 100 12000
295508, A H25 Pro 2500 (17.2, 172) 230V, 60 Hz, 3 phase 60 12000
295509, A H25 Pro 2500 (17.2, 172) 230V, 60 Hz, 3 phase 74 18000
295510, A H25 Pro 2500 (17.2, 172) 380V, 60 Hz, 3 phase 48 12000
295511, A H25 Pro 2500 (17.2, 172) 380V, 60 Hz, 3 phase 62 18000
295512, A H25 Pro 2500 (17.2, 172) 460V, 60 Hz, 3 phase 30 12000
295513, A H25 Pro 2500 (17.2, 172) 460V, 60 Hz, 3 phase 37 18000
295514, A H35 Pro 3500 (24.0, 240) 230V, 60 Hz, 1 phase 100 12000
295515, A H35 Pro, 104 size 2800 (19.3, 193) 230V, 60 Hz, 1 phase 100 12000
295516, A H35 Pro 3500 (24.0, 240) 230V, 60 Hz, 3 phase 60 12000
295517, A H35 Pro, 104 size 2800 (19.3, 193) 230V, 60 Hz, 3 phase 60 12000
295518, A H35 Pro 3500 (24.0, 240) 230V, 60 Hz, 3 phase 74 18000
295519, A H35 Pro, 104 size 2800 (19.3, 193) 230V, 60 Hz, 3 phase 74 18000
295520, A H35 Pro 3500 (24.0, 240) 380V, 60 Hz, 3 phase 48 12000
295521, A H35 Pro 3500 (24.0, 240) 380V, 60 Hz, 3 phase 62 18000
295522, A H35 Pro 3500 (24.0, 240) 460V, 60 Hz, 3 phase 30 12000
295523, A H35 Pro 3500 (24.0, 240) 460V, 60 Hz, 3 phase 37 18000

Warnings
4311392C
Warnings
The following general warnings are for the setup, use, grounding, maintenance, and repair of this equipment. Addi-
tional, more specific warnings may be found throughout the body of this manual where applicable. Symbols appear-
ing in the body of the manual refer to these general warnings. When these symbols appear throughout the manual,
refer back to these pages for a description of the specific hazard.
WARNING
ELECTRIC SHOCK HAZARD
Improper grounding, setup, or usage of the system can cause electric shock.
• Turn off and disconnect power cord before servicing equipment.
• Use only grounded electrical outlets.
• Use only 3-wire extension cords.
• Ensure ground prongs are intact on sprayer and extension cords.
• Do not expose to rain. Store indoors.
TOXIC FLUID OR FUMES HAZARD
Toxic fluids or fumes can cause serious injury or death if splashed in the eyes or on skin, inhaled, or
swallowed.
• Read MSDS’s to know the specific hazards of the fluids you are using.
• Store hazardous fluid in approved containers, and dispose of it according to applicable guidelines.
PERSONAL PROTECTIVE EQUIPMENT
You must wear appropriate protective equipment when operating, servicing, or when in the operating
area of the equipment to help protect you from serious injury, including eye injury, inhalation of toxic
fumes, burns, and hearing loss. This equipment includes but is not limited to:
• Protective eyewear
• Clothing and respirator as recommended by the fluid and solvent manufacturer
•Gloves
• Hearing protection
SKIN INJECTION HAZARD
High-pressure fluid from gun, hose leaks, or ruptured components will pierce skin. This may look like just
a cut, but it is a serious injury that can result in amputation. Get immediate surgical treatment.
• Do not point gun at anyone or at any part of the body.
• Do not put your hand over the spray tip.
• Do not stop or deflect leaks with your hand, body, glove, or rag.
• Do not spray without tip guard and trigger guard installed.
• Engage trigger lock when not spraying.
• Follow Pressure Relief Procedure in this manual, when you stop spraying and before cleaning,
checking, or servicing equipment.

Warnings
311392C 5
FIRE AND EXPLOSION HAZARD
Flammable fumes, such as solvent and paint fumes, in work area can ignite or explode. To help prevent
fire and explosion:
• Use equipment only in well ventilated area.
• Eliminate all ignition sources; such as pilot lights, cigarettes, portable electric lamps, and plastic drop
cloths (potential static arc).
• Keep work area free of debris, including solvent, rags and gasoline.
• Do not plug or unplug power cords, or turn power or light switches on or off when flammable fumes
are present.
• Ground all equipment in the work area. See Grounding instructions.
• Use only grounded hoses.
• Hold gun firmly to side of grounded pail when triggering into pail.
• If there is static sparking or you feel a shock, stop operation immediately. Do not use equipment
until you identify and correct the problem.
• Keep a fire extinguisher in the work area.
PRESSURIZED ALUMINUM PARTS HAZARD
Do not use 1,1,1-trichloroethane, methylene chloride, other halogenated hydrocarbon solvents or fluids
containing such solvents in pressurized aluminum equipment. Such use can cause serious chemical
reaction and equipment rupture, and result in death, serious injury, and property damage.
EQUIPMENT MISUSE HAZARD
Misuse can cause death or serious injury.
• Do not operate the unit when fatigued or under the influence of drugs or alcohol.
• Do not exceed the maximum working pressure or temperature rating of the lowest rated system
component. See Technical Data in all equipment manuals.
• Use fluids and solvents that are compatible with equipment wetted parts. See Technical Data in all
equipment manuals. Read fluid and solvent manufacturer’s warnings. For complete information
about your material, request MSDS forms from distributor or retailer.
• Check equipment daily. Repair or replace worn or damaged parts immediately with genuine Graco
(ASM) replacement parts only.
• Do not alter or modify equipment.
• Use equipment only for its intended purpose. Call your Graco distributor for information.
• Route hoses and cables away from traffic areas, sharp edges, moving parts, and hot surfaces.
• Do not kink or over bend hoses or use hoses to pull equipment.
• Keep children and animals away from work area.
• Comply with all applicable safety regulations.
MOVING PARTS HAZARD
Moving parts can pinch or amputate fingers and other body parts.
• Keep clear of moving parts.
• Do not operate equipment with protective guards or covers removed.
• Pressurized equipment can start without warning. Before checking, moving, or servicing equipment,
follow the Pressure Relief Procedure in this manual. Disconnect power or air supply.
BURN HAZARD
Equipment surfaces and fluid that’s heated can become very hot during operation. To avoid severe
burns, do not touch hot fluid or equipment. Wait until equipment/fluid has cooled completely.
WARNING

Pressure Relief Procedure
6311392C
Pressure Relief
Procedure
1. Select Park on Pump Control Switch.
2. Turn off feed pumps.
3. Trigger gun to relieve pressure.
4. Close gun inlet valves.
5. Close fluid supply inlet valves.
Flushing
• Flush out old fluid with new fluid, or flush out old
fluid with a compatible solvent, such as toluene,
naptha, or mineral spirts before introducing new
fluid.
• Use lowest possible pressure when flushing.
• To flush entire system, circulate through gun fluid
manifold (with manifold removed from gun).
• Always leave some type of fluid in system. Do not
use water.
Flush equipment only in a well-ventilated area. Do not
spray flammable fluids. Do not turn on heaters while
flushing with flammable solvents.
Only use flush solvents that are compatible with fluo-
roelastomer seals. Non-compatible solvents will dam-
age seals and cause hazardous conditions, such as
high pressure leaks and pressure switch failure.

Typical Installation
311392C 7
Typical Installation
FIG. 1: H-20/35 Proportioner Typical Installation
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Component Identification
8311392C
Component Identification
FIG. 2: Component Identification - Main Components
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Component Identification
311392C 9
1Hydraulic Pressure Control
Pressure control knob is factory-set (full clockwise)
to maximum rated hydraulic pressure. To decrease
hydraulic pressure, turn knob counterclockwise
(knob will stop after approximately 2 turns). To
return to maximum pressure, turn knob clockwise
until it stops. (See FIG. 3.)
2B- (Resin) Proportioning Pump
Draws in and dispenses a fixed volume of resin
material for delivery to mixing chamber of spray gun
or pour head.
3B- (Resin) Pressure Gauge
Indicates pressure in resin proportioning system.
4B- (Resin) Over-Pressure Safety Switch
Factory set to turn off hydraulic drive system when
resin proportioning pump exceeds safety switch
operating pressure limit. Restarts when pressure
drops below limit.
5A- (Isocyanate) Proportioning Pump
Draws in and dispenses a fixed volume of
isocyanate material for delivery to mixing chamber
of spray gun or pour head.
6A- (Isocyanate) Pressure Gauge
Indicates pressure in isocyanate proportioning
system.
7A- (Isocyanate Over-Pressure Safety Switch
Factory set to turn off hydraulic drive system when
isocyanate proportioning pump exceeds safety
switch operating pressure limit. Restarts when
pressure drops below limit.
8B- (Resin) Inlet Supply Ball Valve
Allows delivery of resin to proportioning unit.
9A- (Isocyanate) Inlet Supply Ball Valve
Allows delivery of isocyanate to proportioning unit.
10 Hydraulic Pressure Gauge
Indicates pressure in hydraulic drive system.
11 Hydraulic Tank Level Gauge
Shows level and temperature of hydraulic fluid in
tank.
12 Lube Pump System (Iso side only)
Continuously circulates pump lube to prevent
crystallization of isocyanate on pump shaft.
13 Hydraulic Directional Valve
Controls direction of hydraulic flow.
14 Hose Heat Connector
Connects power to heated hoses.
15 FTS Harness
Carries electrical signal from FTS sensor in
isocyanate hose to digital hose temperature
controller.
16 A- (Isocyanate) Primary Heater
Heats isocyanate to required dispensing
temperature.
17 B- (Resin) Primary Heater
(Located behind cover) Heats resin to required
dispensing temperature.
18 Inlet Pressure Gauge
(Both sides) Indicates chemical supply pressure at
proportioner inlet.
19 Inlet Temperature Gauge
(Both sides) Indicates chemical supply temperature
at proportioner inlet.
FIG. 3: Hydraulic Pressure Adjustment
4)'(4%.
,//3%.
Control
Knob

Component Identification
10 311392C
20 Main Power Disconnect
Controls power to all circuits. Must be ON for any
function of proportioning unit to operate. Lock
disconnect in OFF position during machine
maintenance.
21 Main Power Light (White)
Illuminates when main disconnect switch is in ON
position and control power transformer is
operational.
22 Control Power Switch
Controls120 VAC control power circuit. In ON
position, amber light within switch illuminates.
In OFF position, all machine operation stops
including motion and heating.
23 Emergency Stop Switch
Interrupts units control power circuit to stop all
motion and heating. Switch mechanically locks in
stop position. Turn switch clockwise to reset and
restore normal operation.
24 Motor Control Switch
Controls power to electric motor circuit. In ON
position, green light within switch illuminates and
hydraulic oil begins circulating.
25 Counter
Records cycle count of proportioning pumps. One
cycle equals two strokes (one in each direction).
FIG. 4: Component Identification - Front Controls
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28
Incoming power leads from main electrical source
remain energized when main power disconnect is off.
To fully de-energize the electrical console, switch off
and lock out incoming power at source.

Component Identification
311392C 11
26 Pump Switch
Controls operation of proportioning pump hydraulic
drive cylinder. Pump switch has 3 settings:
•Off - Deactivates pump system and shuts off
hydraulic directional valve. Hydraulic pressure
cannot be generated in this position.
•Spray- Powers pump; must be set for system to
operate. Used for all normal operation of the
pump system, including pressurizing system
and dispensing chemical.
•Park - Use during any period of machine inac-
tivity. Pump system is energized so that isocy-
anate pump shaft is retracted into pump
cylinder. Also, shields isocyanate pump shaft
from moisture to limit crystallization during peri-
ods of machine inactivity.
27 Pump Directional Indicator Lights
Indicate direction of proportioning pump travel. Both
lights are off when pump switch is in OFF position or
when chemical pump pressure exceeds setting of
overpressure safety switches.
28 Hose Heater Switch
Energizes hose heat system circuit. In ON position,
green light within switch illuminates.
29 Hose Heat Temperature Controller
Digital display of controller is energized when
control power switch is activated. Hose heater
switch must be in ON position before heating
process begins. (See Digital Temperature
Controllers, page 20.)
30 A- (Isocyanate) Primary Heater Switch
Energizes A-primary heater system circuit. In ON
position, green light within switch illuminates.
31 A- (Isocyanate) Primary Heater Temperature
Controller
Digital display of controller is energized when
control power switch is activated. A- primary heater
switch must be in the ON position before heating
process begins. (See Digital Temperature
Controllers, page 20.)
32 B- (Resin) Primary Heater Switch
Energizes B-primary heater system circuit. In ON
position, green light within switch illuminates.
33 B- (Resin) Primary Heater Temperature
Controller
Digital display of controller is energized when
control power switch is activated. B- primary heater
switch must be in ON position before heating
process begins. (See Digital Temperature
Controllers, page 20.)
34 Hose Heat Secondary Circuit Breaker
50-amp circuit breaker; protects hose heat system
by limiting current to hose heat element. Must be
ON for heated hoses to function.
35 Control Circuit Transformer
Reduces incoming line voltage to 120 VAC for use
by control circuit system.
36 Hose Power System Controller
Automatically manages electrical current supplied to
hose heat system.
37 Hose Heat System Transformer
Provides isolated low-voltage output for heating
various chemical hose lengths.
FIG. 5: Transformer Compartment Electrical
Components
36
37
35
34

Component Identification
12 311392C
38 Control Main Terminal Block
Termination/distribution point for control system
component wires.
39 Control Transformer Secondary Circuit Breaker
Provides over-current protection for control
transformer secondary 120 VAC output.
40 Master Relay
Controls distribution of 120 VAC to control power
system. Control power switch energizes relay.
41 A- (Isocyanate) Heater Control Relay
Controls distribution of line voltage to A-primary
heater circuit. A-primary heater temperature
controller controls relay.
42 B- (Resin) Primary Heater Control Relay
Controls distribution of line voltage to B-primary
heater circuit. B-primary heater temperature
controller controls relay.
43 Motor Contractor
Supplies line voltage to electric motor. Hydraulic
motor switch controls contractor.
44 A- (Isocyanate) Primary Heater Contractor
Supplies line voltage to A-primary heater. A-
primary heater switch controls contractor.
45 B- (Resin) Primary Heater Control Contractor
Supplies line voltage to B-primary heater. B-primary
heater switch controls contractor.
46 Hose Heat Contractor
Supplies line voltage to hose heat system. Hose
heater switch controls contractor.
47 Motor Circuit Protector
Provides thermal overload and over-current
protection for hydraulic motor circuit.
48 A- (Isocyanate) Heater Circuit Breaker
Provides over-current protection for A-primary
heater circuit.
49 B- (Resin) Primary Heater Circuit Breaker
Provides over-current protection for B-primary
heater circuit.
FIG. 6: Electrical Console Components
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48
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52
Front of Machine

Component Identification
311392C 13
50 Hose Heat Transformer Primary Circuit Breaker
Provides over-current protection for hose heat
transformer primary circuit.
51 Control Transformer Primary Circuit Breaker
Provides over-current protection for control
transformer primary circuit.
52 Power Distribution Block
Provides power distribution point for incoming line
voltage to circuit breaker bank.
53 Main Power Disconnect (Inside View)
Provides termination point for incoming power.
Disconnects incoming power from machine circuits.
54 Latching Relay
Provides electrical power to directional valve
solenoid coils and directional indicator lights.

InitialSet-up
14 311392C
Initial Set-up
Main Power Installation
1. Open electrical console and connect main power
cord as follows:
a. Feed power cord through strain relief in bottom
of console.
Single-Phase Units: connect power leads to L1
and L2.
Three-Phase Units: connect power leads to L1,
L2, and L3.
380V Three-Phase Units: also connect neutral
wire to blue neutral terminal block on circuit
breaker rail.
b. Connect ground wire to Ground Lug located
inside console near strain relief opening.
2. Fill hydraulic reservoir through vented filler neck with
approximately 24 gallons of hydraulic fluid. Recom-
mended fluid: Mobil DTE 24 or 25. (Iso Grade
32/46, Viscosity Index 98-100, Superior Anti-wear
Type.)
3. Check hydraulic pump to ensure it is full with
hydraulic fluid as follows:
a. Disconnect hydraulic hose from 90° fitting on
top of pump.
b. Remove 90° fitting from top of pump and deter-
mine that fluid level is to top of threaded hole.
Installing this equipment requires access to parts that
may cause electric shock or other serious injury if work
is not performed properly. Have a qualified electrician
connect power and ground to main power switch termi-
nals. Ensure your installation complies with all
National, State, and Local safety and fire codes.
CAUTION
Ensure main power source meets all electrical
requirements specified on nameplate of proportioning
unit. Also ensure main power source has a dedicated
fuse disconnect. Power cord is not supplied.
FIG. 7: Main Power Connection
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Main Power
Disconnect
(Rear)
FIG. 8: Ground Lug
Do not overfill reservoir. Level indicator should read
approximately 1/2 full with fluid.
FIG. 9: Hydraulic Fluid Level
4"

90° Fitting

Initial Set-up
311392C 15
Add fluid as required and reattach fitting and
hose.
4. Single-Phase Units: proceed to Step 5.
Three-Phase Units only: Ensure electrical motor is
rotating clockwise. A counterclockwise rotation indi-
cates that incoming power leads are incorrectly
wired to unit. (See Step 1.)
To check for clockwise rotation:
a. Ensure pump, heat hose, A-primary heater
switch, and B-primary heater switch are in OFF
position and main power source is ON.
b. Turn ON red main disconnect; white pilot light
will illuminate.
c. Turn ON amber control power switch; light within
switch and temperature controllers will illumi-
nate.
d. While observing fan on end of electric motor,
turn hydraulic motor switch ON and OFF.
Ensure fan rotates clockwise. If it does not, turn
OFF red main disconnect switch and discon-
nect; lockout incoming power at source.
e. Open electric console and switch any two of the
three main power leads on main disconnect.
(See FIG. 7.) Recheck direction of rotation and
check hydraulic connections for leaks.
5. Set up chemical supply, air supply, and moisture
control systems as required. Refer to system
instructions for proper set-up and operating proce-
dures.
6. Properly ground all auxiliary equipment.
a. Ground material supply (transfer pumps/day
tanks).
b. The 2:1 Transfer Pump has a ground lug.
Ground pump in accordance with the 2:1 Trans-
fer Pump manual.
c. Ensure proportioning unit ground at main elec-
trical source is installed in accordance with the
National Electrical Code. If generator will power
unit, consult an electrician regarding additional
grounding measures that may be required.
Lubrication System Set-up
1. Fill lubricant reservoir with pump lubricant (TSL, one
quart; 206995).
2. Thread reservoir onto reservoir cap assembly and
place into bracket.
3. Push larger diameter supply tube approximately 1/3
of the way into reservoir.
4. Push smaller diameter return tube into reservoir
until it reaches bottom.
Lubrication system is ready for operation. No priming is
required.
If not grounded, high velocity fluid flow can create a
static charge, which may spark and cause a fire or
explosion. Certain solvents commonly used with this
equipment are flammable and present a fire and explo-
sion hazard.
FIG. 10: Lubricant Reservoir Installation
Ensure larger diameter supply tube is at upper level
of reservoir and return tube is at lower level of res-
ervoir. This ensures any isocyanate crystals settle
to bottom of reservoir and not return to isocyanate
pump shaft.

InitialSet-up
16 311392C
Material Supply Connections
Connect material supply to inlets of proportioning unit as
follows:
1. Ensure that A- and B-inlet ball valves on proportion-
ing unit are closed.
2. Connect and tighten B- (resin) supply hose to 3/4
FPT swivel fitting on B-inlet ball valve and to resin
transfer pump.
3. Connect and tighten A- (isocyanate) supply hose to
1/2 FPT swivel fitting on A-inlet ball valve and to iso-
cyanate transfer pump.
4. Connect air supply to 1/4 npt nipple on the 2:1
Transfer Pump. Remove cap to access nipple.
Heated Hose Installation
1. Connect isolation hoses to respective primary
heater outlet fittings.
Main air supply must be clean and free of contami-
nants. Use a minimum of 3/8 in. (10 mm.) ID air line
(not supplied) to deliver air supply to heated hoses.
A main air shutoff valve to transfer pumps and
heated hoses is recommended.
Hose connection points are a potential source of
chemical and air leaks. These areas are also most
exposed to damage due to scuffing and snagging. It is
strongly recommended to install a scuff jacket to pro-
tect hoses and a FTS extension harness to protect
from damage.
Heated hose assemblies are connected end to end
when shipped to protect them from moisture. Do
not separate hoses until you are ready to connect
them to proportioning unit.
FIG. 11: Isolation Hose Connections
Hose Heat Power
Lock Connector
FTS Harness
Tape
Iso (Red)
Resin (Blue)

Initial Set-up
311392C 17
2. Connect heated hose assembly to isolation hoses:
a. Lay out hose assemblies end-to-end as shown
in FIG. 12. A- (isocyanate) hoses are RED. B-
(resin) hoses are BLUE.
b. Connect heated hoses to isolation hoses. To
ensure a leak-proof chemical connection, do not
cross-thread or over-tighten fittings. See FIG.
13.
c. Connect air hoses and tighten fittings. See FIG.
13.
d. Install isolator between chemical hose fittings.
Use small amount of tape to hold in place. See
FIG. 14.
e. Connect FTS harness plugs. To ensure a
secure electrical connection, place protective
isolator boot over each plug and tape together.
See FIG. 15.
f. Plug Power-Lock™hose heat connectors.
Secure connection with cable tie provided; fail-
ure to do so will disrupt hose heat system if con-
nectors separate. See FIG. 15.
3. Repeat Step 2 to add additional hose assemblies.
FIG. 12: Hose Connection (step a)
FIG. 13: Hose Connection (steps b and c)
Always install isolator to prevent damage to fittings,
but do not tape fully in place until after hoses are
pressurized and free of leaks.
FIG. 14: Hose Connection (step d)
FIG. 15: Hose Connection (steps e and f)
Hose Heat Power-Lock
Connection secured with cable tie
FTS Harness
Connection
secured with
tape

InitialSet-up
18 311392C
4. Install Fluid Temperature Sensing unit (FTS) to gun
whip hose as follows:
a. Pull out and carefully straighten loose end of
temperature probe from FTS.
b. Insert temperature probe into isocyanate hose
and connect FTS to gun whip hose. To ensure a
leak-proof chemical connection, do not
cross-thread or over tighten fittings.
c. Connect ground wire on gun whip hose to
ground point on FTS.
d. Connect heated hose assemblies to FTS. To
ensure a leak-proof chemical connection, do not
cross-thread or overtighten fittings.
e. Connect FTS harness to FTS. To ensure a
secure electrical connection, place protective
electrical isolator boot over each plug and tape
together.
f. Connect and tighten air hoses.
g. Cut isolator in half crosswise and secure two
pieces in place between hydraulic fittings.
h. Plug Power-Lock hose heat connectors. Secure
connection with cable tie provided; failure to do
so will disrupt hose heat system if connectors
separate.
5. Connect main air source to end of air hose included
with heated hose assemblies.
6. Install optional hose scuff jacket (if used) over hose
lengths.
7. Connect coupling block to gun whip hose; ensure
manual valves are closed. See Gun Operation Man-
ual.
Ensure hose that contains FTS is kept insulated for
accurate hose bundle temperature readings.
Do not crush hose or bend hose where sensor is
located. Do not coil hose tighter than the recom-
mended 3 ft. (0.9 m.) minimum bend radius.
FIG. 16: FTS Connection
Gun Whip Power-Lock Connector
Ground Lug
Ground Point
Hose Heat
Power-Lock
Connector
Air Hose
Isolator
FTS
Isolator
FTS Harness
Heated Hose Assembly
Air Hose
Gun Whip
TI9583a

Initial Set-up
311392C 19
Air Purge
Prior to using equipment, purge chemical system of air
and test oil residual from functional testing at factory.
1. Turn on main air supply to transfer pumps and
drums/day tanks.
2. Open A- and B-inlet supply valves. Check for chemi-
cal leaks.
3. Turn hydraulic pressure control fully counterclock-
wise.
4. Turn ON red main disconnect. White main power
light will illuminate.
5. Turn ON amber control power switch; light within
switch will illuminate.
6. Hold coupling block with A- and B-ports over sepa-
rate containers and open both manual valves.
7. Turn ON hydraulic motor switch.
8. Turn pump switch to NORMAL position. If neces-
sary, gradually increase hydraulic pressure by turn-
ing hydraulic pressure control clockwise to start
proportioning pumps moving slowly.
9. Allow material to flow out of coupling block until spit-
ting of air stops and all traces of residual material
have disappeared. Close manual valves and flush
any residual chemical from outside of coupling
block. See Gun Operation Manual.
10. Slowly increase hydraulic pressure and check all fit-
tings for signs of hydraulic chemical leaks. Tighten
fittings as required.
11. Turn OFF pump switch.
12. Mount spray gun to coupling block.
Hose Power Control System
The Hose Power Control System automatically main-
tains optimum power setting for hose heat systems with
any hose length from 50 ft. (15 m.) up to 410 ft. (125 m.).
There are no operator controls or adjustments required.
The system eliminates the need for manual adjustment
of transformer tap settings or manual hose heat power
control.
A screeching noise is a characteristic of cavitation
and is normal at initial start-up for a maximum of 30
seconds. If screeching continues for more than 30
seconds, switch off pump switch and hydraulic
motor switch, and ensure that inlet fittings are tight
and that pump has not lost its prime.
Properly dispose of waste chemicals in accordance
with applicable local, state, and federal codes.
Af
After proportioning unit is at operating pressure and
hose connections are tight and free of leaks, use
duct tape to wrap hoses and electrical wires around
rubber isolators forming a compact bundle. If using
a scuff jacket, pull it over bundle and secure with
duct tape.

InitialSet-up
20 311392C
Digital Temperature Controllers
The proportioner has three temperature controllers that
automatically manage the temperature for the primary
heaters and the hose heater.
To change or enter the set point, proceed as follows:
1. Ensure red main disconnect is ON. White pilot light
will illuminate.
2. Ensure amber control power switch is ON. Light
within switch and controllers will illuminate.
3. Press and release button. Display will read
“SP1”. Press and release or button to
display set point.
4. Press and hold button or button to
increase or decrease value.
5. After set point is entered, press and release
and buttons together to display actual
temperature.
Change Between Fahrenheit and Celsius
The temperature controller is factory-set to display in
Fahrenheit units.
To change to Celsius units:
1. Press and release button 3 times. Controller
will display “UNIT”.
2. Press and release button once to display “F”.
3. Press and release button once again to dis-
play “C”.
4. Press and release button 2 times. Controller
will display Celsius units.
To change back to Fahrenheit units:
1. Press and release button 3 times. Controller
will display “UNIT”.
2. Press and release button once to display “C”.
3. Press and release button once again to dis-
play “F”.
4. Press and release button 2 times. Controller
will display Fahrenheit units.
To prevent damage to primary heaters and hoses,
do not turn on heat controller switches under tem-
perature controllers until purging procedures are
complete and heater and hoses are filled with
chemical.
FIG. 17: Temperature Controller
Temperature controller normally displays actual
temperature. When illuminated, red “01” display at
upper left indicates that heater is in heating mode.
The “01” disappears when liquid in heater reaches
set point temperature. The “01” cycles on and off to
indicate temperature maintenance.
%42
/
Controllers are factory programmed and are not field
programmable. If you encounter problems with a con-
troller, order a replacement. Do not change any pro-
grammed parameters. Do not substitute with controller
from alternate supplier; its use may damage equip-
ment and/or cause bodily injury.