GUSMER ff-1600 User manual

"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: [phone]
Fax: [phone]
Copyright 2000, GUSMER CORPORATION ®
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)