GUSMER H-3500 User 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: [phone]
Fax: [phone]
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
215942A-1, Issue 2
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 Contents
4/1/99 3
CONTENTS
LIST OF FIGURES ..........................................................................................................4
WARRANTY.....................................................................................................................5
GENERAL SAFETY INFORMATION..........................................................................6
ACCEPTABLE EQUIPMENT USES.......................................................................................6
OPERATIONAL SAFETY PROCEDURES...............................................................................7
DESCRIPTION.................................................................................................................8
SPECIFICATIONS.........................................................................................................11
INITIAL MACHINE SET-UP.......................................................................................13
OPERATION ..................................................................................................................21
DAILY STARTUP PROCEDURES.......................................................................................21
DAILY SHUTDOWN PROCEDURES...................................................................................22
TROUBLESHOOTING .................................................................................................23
INTRODUCTION ..............................................................................................................23
HOSE HEAT....................................................................................................................24
Solutions....................................................................................................................24
PRIMARY HEATER..........................................................................................................27
Solutions....................................................................................................................28
PROPORTIONING SYSTEM...............................................................................................30
Solutions....................................................................................................................31
HYDRAULIC DRIVE SYSTEM...........................................................................................34
Solutions....................................................................................................................35
MAINTENANCE............................................................................................................36
PUMP LUBE SYSTEM......................................................................................................36
INLET STRAINER SCREEN...............................................................................................37
HYDRAULIC SYSTEM......................................................................................................38
PROPORTIONING PUMPS.................................................................................................39
PUMP BASES..................................................................................................................39
PRIMARY HEATERS........................................................................................................40
APPENDIX......................................................................................................................42
INSTRUCTION MANUAL DISCREPANCY REPORT ............................................43

Model H-2000/H-3500 Proportioning Unit
4159421A-1, Issue 2
LIST OF FIGURES
FIGURE 1. DESCRIPTION OF CONTROLS FOR BOTH H-2000 AND H-3500 MODELS. ............. 8
FIGURE 2. TYPICAL INSTALLATION .................................................................................... 13
FIGURE 3. POWER CORD STRAIN RELIEF........................................................................... 14
FIGURE 4. HYDRAULIC FLUID LEVEL ................................................................................ 15
FIGURE 5. LUBE RESERVOIR ............................................................................................. 15
FIGURE 6. ISOLATION HOSES ............................................................................................ 15
FIGURE 7. HOSE CONNECTION STEP (A)............................................................................ 16
FIGURE 8. HOSE CONNECTION STEP (B)............................................................................ 16
FIGURE 9. HOSE CONNECTION STEP (C)............................................................................ 16
FIGURE 10. HOSE CONNECTION STEP (D) ......................................................................... 16
FIGURE 11. TEMPERATURE SENSING UNIT ........................................................................ 17
FIGURE 12. BELL HOUSING .............................................................................................. 17
FIGURE 13. TAP SETTINGS (SINGLE TRANSFORMER).......................................................... 19
FIGURE 14. TAP SETTINGS (DUAL TRANSFORMER) ............................................................ 20
FIGURE 15. DIRECTIONAL INDICATOR LIGHTS & REVERSING SWITCH ROCKER ARM........... 22
FIGURE 16. WIRE CONNECTION........................................................................................ 24
FIGURE 17. WIRE CONNECTION........................................................................................ 25
FIGURE 18. SOLID STATE RELAY ....................................................................................... 25
FIGURE 19. TSU CONNECTION......................................................................................... 25
FIGURE 20. TERMINAL JUMPER STRIP............................................................................... 26
FIGURE 21. PRIMARY HEATER........................................................................................... 27
FIGURE 22. PRIMARY HEATER FUSES................................................................................ 28
FIGURE 23. PRIMARY HEATER FUSES................................................................................ 29
FIGURE 24. PROPORTIONING SYSTEM ............................................................................... 30
FIGURE 25. HYDRAULIC MANIFOLD.................................................................................. 33
FIGURE 26. CONTROL TRANSFORMER FUSE ...................................................................... 34
FIGURE 27. POWER CONTACTOR....................................................................................... 35
FIGURE 28. PUMP LUBE SYSTEM....................................................................................... 36
FIGURE 29. STRAINER....................................................................................................... 37
FIGURE 30. HYDRAULIC SYSTEM ....................................................................................... 38
FIGURE 31. THERMOCOUPLE............................................................................................ 41

Operating Manual Contents
4/1/99 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 H-2000/H-3500 Proportioning Unit
6159421A-1, Issue 2
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
4/1/99 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.
High Temperature
WARNING: THIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HIGH
TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES. TO PREVENT
SERIOUS BODILY INJURY FROM HOT FLUID OR HOT METAL, NEVER ATTEMPT TO SERVICE THE
EQUIPMENT BEFORE ALLOWING IT TO COOL.
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 H-2000/H-3500 Proportioning Unit
8159421A-1, Issue 2
DESCRIPTION
Figure 1. Description Of Controls for both H-2000 and H-3500 Models.

Operating Manual Description
4/1/99 9
1. MAIN CIRCUIT BREAKER Controls and protects power to all circuits; must be ON for any function of the
proportioning unit to operate.
Pilot light (White) Indicates when lighted that the main circuit breaker is on.
2. MOTOR CONTROL Controls power to the electric motor; must be ON for the hydraulic drive system to
operate.
Pilot light (Amber) Indicates when lighted that the electric motor is on.
3. PUMP SWITCH controls operation of the hydraulic drive system;
OFF Hydraulic Directional Drive System is off, and cannot generate hydraulic pressure
in this position.
NORMAL Must be in this position for the proportioning pumps to operate.
RETRACT This position should be used for shutdown and will stop the Hydraulic Drive
System with the A proportioning pump in the retracted position.
4. PUMP DIRECTIONAL
INDICATOR LIGHTS (Amber) 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.
5. COUNTER Records the cycle count of the proportioning pumps; one cycle equals two (2)
strokes (one in each direction).
6. R-PRIMARY HEATER CIRCUIT
BREAKER Controls and protects power to the R primary heater; must be ON for the primary
heater to operate.
Pilot light (Amber) Indicates when lighted that the R Primary Heater Circuit Breaker is on.
7. A-PRIMARY HEATER CIRCUIT
BREAKER Controls and protects power to the A Primary Heater; must be ON for the Primary
Heater to operate.
Pilot light (Amber) Indicates when lighted that the A Primary Heater Circuit Breaker is on.
8. PUSH TO TEST BUTTON Push button daily to test Primary Heater Circuit Breakers. Circuit Breaker must
trip when this button is pushed.
9. R-PRIMARY HEATER
CONTROLLER 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.
Green Controller Light Indicates when lighted that the temperature of the Resin component in the heater
is within +/- 5° F of dial set point.
Amber Controller Light Indicates when lighted that the temperature of the Resin component in the heater
is more than +/- 5° F cooler than dial set point.
Red Controller Light Indicates when lighted that the temperature of the Resin component in the heater
is more than +/- 5°F warmer than dial set point.
10. A-PRIMARY HEATER
CONTROLLER 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.

Model H-2000/H-3500 Proportioning Unit
10 159421A-1, Issue 2
Green Controller Light Indicates when lighted that the temperature of the Isocyanate component in the
heater is within +/- 5° F of dial set point.
Amber Controller Light Indicates when lighted that the temperature of the Isocyanate component in the
heater is more than +/- 5° F cooler than dial set point.
Red Controller Light Indicates when lighted that the temperature of the Isocyanate component in the
heater is more than +/- 5°F warmer than dial set point.
11. HOSE HEATER CIRCUIT
BREAKER Protects hose heater circuit; must be ON for the hose heater to operate.
Pilot light (Amber) Indicates when lighted that the Hose Heater Circuit Breaker is on.
12. HOSE HEATER CONTROLLER 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.
Green Controller Light Indicates when lighted that the temperature of the hose heater is within +/- 5° F of
dial set point.
Amber Controller Light Indicates when lighted that the temperature of the hose heater is more than +/- 5°
F cooler than dial set point.
Red Controller Light Indicates when lighted that the temperature of the hose heater is more than +/-
5°F warmer than dial set point.
13. POWER SET Controls the amount of power delivered to the hose heater.
14. HOSE HEATER AMMETER Indicates the amount of heating power delivered to the hose heater.
15. HYDRAULIC PRESSURE
CONTROL Controls the hydraulic pressure available to the hydraulic drive system.
16. RESIN OVER-PRESSURE
SAFETY SWITCH Turns off the hydraulic drive system when the Resin proportioning pump exceeds
the safe pressure limitation.
17. RESIN PRESSURE GAUGE Indicates the pressure in the Resin proportioning system.
18. ISOCYANATE PRESSURE
GAUGE Indicates the pressure in the Isocyanate proportioning system.
19. R-INLET SUPPLY BALL VALVE
20. A-INLET SUPPLY BALL VALVE
21. HYDRAULIC PRESSURE
GAUGE Indicates the pressure in the hydraulic drive system.
22. ISOCYANATE OVER
PRESSURE SAFETY SWITCH Turns off the hydraulic drive system when the Isocyanate proportioning pump
exceeds the safe pressure limitation.

Operating Manual Specifications
4/1/99 11
SPECIFICATIONS
ENVIRONMENT: The equipment is not of explosion-proof design and should never be used in an
atmosphere requiring this design.
RECOMMENDED USE: 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, it is not abrasion proof and those parts
damaged from using abrasive materials will not be covered under warranty.
SAFETY EQUIPMENT: 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 approved safety glasses or goggles when servicing or operating 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.
APPLICATION: 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.
WARNING: INFORMATION CONCERNING PERSONAL PROTECTION AND PROPER HANDLING
AND APPLICATION PROCEDURES OF THE CHEMICALS AND SOLVENTS USED WITH THIS
EQUIPMENT MUST BE OBTAINED FROM THE SUPPLIERS OF SUCH CHEMICALS AND SOLVENTS.
Electric Requirements are as follows:
(5HP) , 220 Volts AC current 60
HZ, Single Phase 103 AMPS at 220 Volts, AC current.
23 KVA (18.4 kw) peak power at 220 Volts.
(5HP), 220 Volts, AC current 50/60
HZ; 3 Phase 45 AMPS at 220 Volts, AC current.
17 KVA (13.6 kw) peak power at 220 Volts.
(5HP), 3 x 380, 50 HZ, AC current. 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: DAMAGE TO THE EQUIPMENT COULD RESULT IF THE UNIT IS OPERATED AT
OTHER THAN THE NAME PLATE VOLTAGE.
AIR: The Model H-2000/H-3500 is hydraulically driven. There are no air requirements for the
proportioning unit itself.

Model H-2000/H-3500 Proportioning Unit
12 159421A-1, Issue 2
MATERIAL SUPPLY: 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
CHEMICAL VISCOSITY: There is no established maximum limitation and, assuming adequate supply, viscosity’s of
5,000 cps or more may be possible.
HYDRAULIC SERVICING: 16 gallons (62 Liters)
Recommended operating temperature: 120°F (48°C)
Maximum operating temperature: 160°F (71°C)
WEIGHT: Empty: 385 pounds (175 kilograms)
Serviced: 482 pounds (219 kilograms)
DIMENSIONS: Height: 47 inches (119 centimeters)
Width: 40 inches (102 centimeters)
Depth: 22 inches (56 centimeters)
OPERATING PRESSURE: H-2000 - 2000 psi maximum (136 Bars)
H-3500 - 3500 psi maximum (238 Bars)
SUPPLY PRESSURE:400 psi maximum (27 Bars)
OUTPUT: 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.)
INLET FILTER: 80 Mesh Standard (Optional - 60/40 Mesh)
PRIMARY HEATER: 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) *
HOSE LENGTH: 310 feet (94.5 meters) maximum for heating purposes
* Ideal values obtained in laboratory testing and may not be duplicated under working conditions.

Operating Manual Initial Machine Set-Up
4/1/99 13
INITIAL MACHINE SET-UP
Figure 2. Typical Installation

Model H-2000/H-3500 Proportioning Unit
14 159421A-1, Issue 2
WARNING: PROPER PROTECTIVE GEAR MUST BE WORN WHEN SERVICING OR OPERATING
THIS EQUIPMENT, WHICH INCLUDES BUT IS NOT LIMITED TO GLOVES, EYE PROTECTION, AND
RESPIRATORY PROTECTION AS REQUIRED.
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.
WARNING: THE ELECTRIC SERVICE MUST BE DONE BY A QUALIFIED ELECTRICIAN.
NOTE:
The power source must be capable
of meeting the electrical
requirements specified on the
nameplate of the proportioning
unit and an accessible quick
disconnect provided.
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.
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. 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.

Operating Manual Initial Machine Set-Up
4/1/99 15
4. Check the hydraulic pump to insure
that it is full with hydraulic fluid.
Remove the 90°-elbow fitting from the
top of the pump and determine that the
fluid level is to the top of the threaded
hole. Add fluid as required and
reattach fitting.
Figure 4. Hydraulic Fluid Level
5. Install the pump lube reservoir and
bracket. Thread it onto the reservoir
cap assembly and place it into the
bracket. No priming of the system is
required.
Figure 5. Lube Reservoir
6. Connect the isolation hoses to their respective primary heaters.
Important: Every precaution has been taken to prevent the inadvertent connection of a
hose to the wrong chemical source. The Resin hoses are color-coded blue and the
Isocyanate hoses are color coded red for easy identification. In addition, the Resin and
Isocyanate hose fittings thread sizes are different, making it virtually impossible to
improperly connect the hoses. The Resin thread is 9/16-18, whereas the Isocyanate thread
is ½-20. Connect the hose heater wire leads to each isolation hose. Take care to make the
connection tight. It is recommended that electrical tape be applied to the connection to
prevent loosening from vibration
Figure 6. Isolation Hoses

Model H-2000/H-3500 Proportioning Unit
16 159421A-1, Issue 2
7. Connect the heated hose assemblies.
NOTE:
The hoses are Connected end to
end during shipment to protect
them from moisture intrusion. Do
not separate the hoses until they
are ready to couple to the
proportioning unit.
Important: The importance of making proper hose connections cannot be overly
emphasized. The connection points are a potential source of chemical and air leaks
and are the points, most exposed to damage from scuffing and snagging on abrasive
surfaces. A liberal amount of duct tape can be used in this area to make the bundle as
compact as possible. Gusmer strongly recommends installing the optional scuff jacket
to protect the hose insulation and TSU extension from damage. A proper hose
connection is shown in sequence on the following page
The key areas of extra attention during installation are as follows:
a) DO NOT interchange the
hoses: Resin hoses are
color coded BLUE,
Isocyanate hoses are color
coded RED.
Figure 7. Hose Connection Step (a)
b) To assure a leak proof
chemical connections,
take care not to cross
thread the fitting and DO
NOT over-tighten.
Figure 8. Hose Connection Step (b)
c) Tape the electrical
isolator securely in place
between the hydraulic
fittings: failure to do so
will cause a short circuit
in the hose heating
system. Figure 9. Hose Connection Step (c)
d) To assure a secure
electrical connection:
place the protective
electrical isolator boot
over each plug and tape
together.
Figure 10. Hose Connection Step (d)
*** Repeat Step 7 for adding additional hoses. ***

Operating Manual Initial Machine Set-Up
4/1/99 17
8. Install the Temperature Sensing Unit (TSU) onto the gun hose. Pull out and carefully
straighten the LOOSE END of the temperature probe from the TSU. Insert the
temperature probe into the Isocyanate hose. Connect the ground wire on the gun hose
to the ground lug on the TSU.
Figure 11. Temperature Sensing Unit
WARNING: THE TEMPERATURE SENSOR EXTENDS APPROXIMATELY 8 INCHES INTO THE
ISOCYANATE HOSE AND ALTHOUGH IT IS A RUGGEDLY BUILT ASSEMBLY, IT WILL NOT WITHSTAND
REPEATED ABUSE. CARE MUST BE TAKEN NOT TO CRUSH THE HOSE OR SUBJECT IT TO SEVERE
BENDING IN THE AREA WHERE THE SENSOR IS LOCATED. TAKE CARE NOT TO COIL THE HOSE
TIGHTER THAN THE RECOMMENDED 3 FT. MINIMUM BEND RADIUS.
9. Connect the TSU extension harness to the proportioning unit using the adapter
furnished in the provided package. Connect the main air source to the heated hose.
NOTE:
Power lead L3 is not used for
single-phase installation. Connect
the ground wire to the ground lug.
Close the electric control console.
Important: (for 3 phase units only) At this point it is necessary to check the rotation of
the electric motor. An arrow located on the Hydraulic Pump and on the Bell Housing
indicates a correct direction of rotation. Perform steps 10, 11, 12, 13.
10. Remove the Bell Housing Safety Plug to allow you to see the shaft coupling. Turn the
hydraulic pressure control counter-clockwise to the end. Make sure the pump switch is
in the OFF position.
11. Determine that all circuit breakers, on the main console, are OFF. Switch the main
circuit breaker to ON.
12. While observing the shaft coupling,
cycle the motor ON and OFF. The
rotation of the coupling must agree with
the directional indicator. If the rotation
does not agree, turn off all circuit
breakers and disconnect the main power
at the source. Open the electric console
and switch any two of the three power
leads. Recheck the rotation.
Figure 12. Bell Housing
13. Replace the plug in the motor bell housing.

Model H-2000/H-3500 Proportioning Unit
18 159421A-1, Issue 2
14. Connect the coupling block to the gun hose and determine that the manual valves are
closed.
15. Properly ground all equipment. The high velocity flow of fluid can create static
sparking which may cause fire or explosion. Certain solvents, which are commonly in
use with this equipment are flammable and may present a flash danger to the operator.
a) The Gusmer 2:1 Transfer Pump has a ground lug. Ground this pump in
accordance with the instructions provided with the pump.
b) Ground the proportioning unit at the main electrical source. In the event, that the
unit is being powered by a generator, the generator must also be grounded directly
to a suitable electrical electrode such as an underground water system, the metal
frame of a building, or a driven pipe. Electrodes of pipe or conduit shall not be
smaller than ¾ inch diameter, galvanized for corrosion protection, and driven
below the moisture level. For additional information, consult the National Electric
Code.
c) Connect the material supply system to the inlet of the proportioning unit. Exercise
caution to ensure connecting chemicals to the appropriate proportioning pumps.
We now have the proportioning unit, heated hose, and material supply system set
up. Before the equipment is ready for use, it is necessary to purge the entire
system of air and mineral oil that left over from the functional testing of the
equipment conducted at the factory.
16. To purge the machine proceed as follows:
a) Pressurize the transfer pumps and open the material supply valves. It is a good
practice at this point to check for hydraulic leaks.
b) Determine that the hydraulic pressure control is full decrease (counter-clockwise).
c) Switch ON the main circuit breaker and motor control.
d) With the Coupling Block Ports held over separate containers, open both manual
valves.
e) Switch the pump switch to the NORMAL Position.
f) Allow material to flow out of the coupling block until all spitting of air stops and
all traces of residual material have disappeared.
NOTE:
Disposal of waste chemicals must
be in accordance with local, state,
and federal codes. g) Switch the pump switch to OFF.
h) Close both manual valves and flush any residual material from the outside of the
coupling block.
i) Mount the gun to the coupling block.
Important: During the initial start-up, slowly increase the hydraulic pressure and check
all fittings for signs of hydraulic and chemical leakage. Tighten as required.
HOSE HEATER
The hose heater transformer tap settings must match the length of hose in use. Therefore,
this procedure will have to be executed during the initial installation and when changing the
hose length, according to the figure below.
NOTE:
These procedures are not required
on a daily basis but may have to
be executed periodically as part of
the daily start-up routine a) Loosen the shaft lock on the hose heater power set control and adjust to zero (full
counter-clockwise).

Operating Manual Initial Machine Set-Up
4/1/99 19
b) Switch ON both the main and hose heater circuit breakers. The white and amber
pilot lights respectively should be on. The hose heater ammeter should be zero.
c) Adjust the hose temperature controller for maximum temperature. The amber
pilot light, on the hose heater controller, should be on.
NOTE:
As the hose heater warms-up, the
amperage will drop slightly and
not need readjusting.
d) Adjust the power set control (clockwise) to maximum setting. Tighten the shaft
lock nut, as no further adjustments to this control will be required. Reset the
temperature controller to the desired temperature setting.
NOTE:
The default tap setting for the
transformer is 10V
Figure 13. Tap Settings (Single Transformer)
Hose Length (ft) Setting Voltage
- S1-S2 4.23
35 S2-S3 10.54
60 S1-S3 14.77
- S3-S4 16.93
- S2-S4 27.47
110 S1-S4 31.7
160 S4-S5 40.2
210 S3-S5 57.13
- S2-S5 67.67
260 & above S1-S5 71.9

Model H-2000/H-3500 Proportioning Unit
20 159421A-1, Issue 2
Figure 14. Tap Settings (Dual Transformer)
Hose Length (ft) Setting Voltage
35 S1-S2 4.23
60 S2-S3 10.54
110 S1-S3 14.77
- S3-S4 16.93
160 S2-S4 27.47
210 S1-S4 31.7
260 & above S4-S5 40.2
- S3-S5 57.13
- S2-S5 67.67
- S1-S5 71.9