GUSMER FF-2500 User manual

Model FF-2500
Proportioning Unit
Operating Manual
25942-1
February 12, 2004
Issue 4
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 2004, GUSMER CORPORATION ®
http://www.gusmer.com
NOTICE: This manual contains important information about your GUSMER equipment. Read and retain for future reference.

Model FF-2500 Proportioning Unit
2 25942-1, Issue 4
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 for a particular circumstance or application.

Operating Manual Contents
2/12/04 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 ......................................................................................12
MAIN POWER INSTALLATION ........................................................................................13
MATERIAL SUPPLY CONNECTIONS ................................................................................14
HOSE HEAT POWER PACK .............................................................................................15
TEMPERATURE CONTROLLERS ......................................................................................16
HEATED HOSE INSTALLATION.......................................................................................17
AIR PURGE ....................................................................................................................20
OPERATION..................................................................................................................21
DAILY START-UP PROCEDURE.......................................................................................21
DAILY SHUT-DOWN PROCEDURE ..................................................................................22
TROUBLESHOOTING.................................................................................................23
GENERAL INTRODUCTION..............................................................................................23
PRIMARY HEATING SYSTEM..........................................................................................24
Solutions...................................................................................................................25
PROPORTIONING SYSTEM ..............................................................................................27
Solutions...................................................................................................................27
HOSE HEAT SYSTEM......................................................................................................30
Solutions...................................................................................................................30
MAINTENANCE ...........................................................................................................34
PROPORTIONING PUMPS ................................................................................................34
PUMP BASES..................................................................................................................34
INLET FILTER SCREEN ...................................................................................................35
ISOCYANATE PUMP LUBRICANT ....................................................................................36
INSTRUCTION MANUAL DISCREPANCY REPORT ...........................................37

Model FF-2500 Proportioning Unit
4 25942-1, Issue 4
LIST OF FIGURES
FIGURE 1. MODEL FF-2500 PROPORTIONING UNIT...........................................................8
FIGURE 2. TYPICAL FF-2500 INSTALLATION ....................................................................12
FIGURE 3. MAIN POWER CONNECTIONS...........................................................................13
FIGURE 4. MANUAL TRANSFORMER CONNECTIONS...........................................................15
FIGURE 5. MANUAL TAP SETTINGS...................................................................................15
FIGURE 6. TEMPERATURE CONTROLLER...........................................................................16
FIGURE 7. ISOLATION HOSES...........................................................................................17
FIGURE 8. HOSE CONNECTION STEP (A)...........................................................................17
FIGURE 9. HOSE CONNECTION STEP (B & C)....................................................................18
FIGURE 10. HOSE CONNECTION STEP (D)........................................................................18
FIGURE 11. HOSE CONNECTION STEP (E & F)..................................................................18
FIGURE 12. TEMPERATURE SENSING UNIT (TSU).............................................................19
FIGURE 13. PUMP LUBRICANT CUP .................................................................................20
FIGURE 14. PRIMARY HEATER FEATURES.........................................................................24
FIGURE 15. PROPORTIONING PUMP FEATURES .................................................................27
FIGURE 16. TRANSFORMER FUSE LOCATION........................................................................29
FIGURE 17. TERMINAL JUMPER STRIP INSTALLATION........................................................32

Operating Manual Contents
2/12/04 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. For such Product, a written estimate will be
submitted to the 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, EXPRESS 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, express 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 ensure proper validation of your warranty, please complete the warranty card and return it to
Gusmer within two weeks of receipt of equipment.
Revised 09/02

Model FF-2500 Proportioning Unit
6 25942-1, Issue 4
GENERAL SAFETY INFORMATION
It is necessary to understand and follow the instructions in this manual to ensure 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 such as polyureas, and some two-component epoxy systems. 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.
Your Gusmer equipment incorporates design parameters, features, and functionality
developed in over 40 years of plural component equipment design and manufacture. It is
manufactured under the stringent standards of ISO 9001, and is backed by the Gusmer
Warranty included herein.
The use of genuine Gusmer replacement parts is recommended for your equipment.
Substitution of parts not designed, manufactured, or recommended by Gusmer may result
in reduced performance of, and/or damage to, your Gusmer equipment. Any alterations
to, or substitutions for, genuine Gusmer parts shall void the provisions of the Gusmer
Warranty.

Operating Manual General Safety Information
2/12/04 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 SOLVENTS AND CHEMICALS USED WITH THIS EQUIPMENT EXPOSE THE
OPERATOR TO CERTAIN HAZARDS. ADEQUATE PERSONAL PROTECTIVE MEASURES MUST BE
TAKEN 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. OBTAIN INFORMATION CONCERNING PERSONAL
PROTECTION AND PROPER HANDLING FROM THE SUPPLIER OF SUCH SOLVENTS AND
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 SHUTTING OFF AND
LOCKING OUT 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 AND
CHEMICAL COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI. TO AVOID SERIOUS
BODILY INJURY FROM INJECTION OF FLUID, NEVER OPEN OR SERVICE ANY CONNECTIONS OR
COMPONENTS WITHOUT BLEEDING ALL PRESSURES TO ZERO.
Personal Protective
Equipment
WARNING: TO AVOID SERIOUS BODILY INJURY, PROPER PROTECTIVE GEAR, APPROPRIATE
FOR THE TASK BEING ACCOMPLISHED, 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 TO PROVIDE PERSONAL PROTECTION FROM SOLVENTS AND
CHEMICALS; HIGH PRESSURE RELEASES; HIGH TEMPERATURES; ELECTRIC SHOCK; AND OTHER
HAZARDS ASSOCIATED WITH HYDRAULIC/ELECTRO-MECHANICAL EQUIPMENT. REFER TO THE
APPROPRIATE WARNINGS ON THIS PAGE FOR FURTHER INFORMATION.
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 THE INFORMATION ASSOCIATED WITH THIS
SYMBOL MAY RESULT IN PERSONAL INJURY AND/OR DAMAGE TO THE EQUIPMENT.

Model FF-2500 Proportioning Unit
8 25942-1, Issue 4
DESCRIPTION
Figure 1. Model FF-2500 Proportioning Unit

Operating Manual Description
2/12/04 9
1. MAIN SWITCH - Controls power to all circuits and must be ON for any function
of the proportioning unit to operate.
White pilot light indicates the main switch is ON.
WARNING: INCOMING POWER LEADS FROM THE MAIN ELECTRICAL SOURCE REMAIN
ENERGIZED WHEN THE MAIN SWITCH IS OFF. TO FULLY DE-ENERGIZE THE ELECTRICAL
CONSOLE, SWITCH OFF AND LOCK OUT INCOMING POWER AT THE SOURCE.
2. PRIMARY HEATER CIRCUIT BREAKER- Controls and protects the primary
heater. It must be ON for the primary heater to operate.
3. HOSE HEATER CIRCUIT BREAKER- Controls and protects the low voltage
power pack. It must be ON for the hose heater to operate.
4. HOSE TEMPERATURE CONTROLLER- Controls the temperature of the hose
heater. Adjust the set point to the desired temperature. From this point, the
temperature control is automatic.
5. PRIMARY HEATER TEMPERATURE CONTROL- Controls the temperature
of the primary heater. Adjust the set point to the desired temperature. From this
point, the temperature control is automatic.
6. PUMP SWITCH- Controls operation of the air drive system.
• OFF- Air drive system is off.
• NORMAL- Must be in this position for the proportioning pumps to operate.
• RETRACT- Use this position for shutdown. It will stop the air motor at the
bottom of the stroke with the proportioning pumps in the retracted position.
7. 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.
8. COUNTER- Records the cycle count of the proportioning pumps. One cycle count
equals two (2) strokes (one in each direction).
9. DOWNSTROKE AIR PRESSURE REGULATOR- Controls the air pressure to
the air motor on the downstroke.
10. UPSTROKE AIR PRESSURE REGULATOR- Controls the air pressure to the air
motor on the upstroke.
11. DOWNSTROKE AIR PRESSURE GAUGE- Displays the air pressure in the air
drive system during the downstroke.
12. UPSTROKE AIR PRESSURE GAUGE- Displays the air pressure in the air drive
system during the upstroke.
13. MAIN AIR FILTER- Filters the system air supply.
14. RESIN PRESSURE GAUGE- Displays the pressure in the resin proportioning
system.

Model FF-2500 Proportioning Unit
10 25942-1, Issue 4
15. ISOCYANATE PRESSURE GAUGE- Displays the pressure in the isocyanate
proportioning system.
16. A-INLET SUPPLY VALVE (R on other side)
17. A-INLET FILTER SCREEN (R on other side)
18. A-PACKING NUT, LUBE CUP (R on other side)
19. 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)
20. PRIMARY HEATER THERMOCOUPLE– Senses the temperature of the
primary heater and inputs that information.
21. THERMAL LIMIT SWITCH- (under thermostat cover not shown)
Interrupts power to the primary heater when the surface temperature approaches the
designed operating temperature limit.
22. POWER PACK (TRANSFORMER) CORD- Provides AC power to the primary
side of the transformer.
23. LOW VOLTAGE POWER PACK (TRANSFORMER)- Provides selectable low
voltage outputs for heating various chemical hose lengths.
24. TSU EXTENSION ADAPTER- Carries the electrical signal from the TSU sensor
in the isocyanate hose to the hose temperature controller.
25. AIR MOTOR REVERSING SWITCH- Energizes and de-energizes the air valve
coils to reverse direction.
26. HOSE HEAT POWER SET- Adjusts the amount of amperage supplied to the hose
heating system.
27. HOSE HEAT AMMETER- Indicates the amount of amperage supplied to the hose
heating system.
28. PRIMARY HEATER- Heats the materials to the required dispensing temperature.
29. A- (ISOCYANATE) PROPORTIONING PUMP- Draws in and dispenses a fixed
volume of isocyanate for delivery to the gun or pour head.
30. R- (RESIN) PROPORTIONING PUMP- (Opposite side, not shown) Draws in and
dispenses a fixed volume of resin for delivery to the gun or pour head.
31. POWER-LOCK™ HOSE HEAT CONNECTION- Connects power from the
transformer to the heated hoses.

Operating Manual Description
2/12/04 11
SPECIFICATIONS
MATERIAL SUPPLY: Required chemical viscosity: 250-1500 centipoise (cP). Consult your chemical supplier
about material temperatures required to maintain correct viscosity.
Protect the chemical supply from atmospheric moisture with a blanket of dry nitrogen or
desiccated air.
Resin Inlet: 3/4" NPT (FE) swivel
Isocyanate Inlet: 1/2" NPT (FE) swivel
Material supply pressure: 400 psi maximum (27 bars)
AIR MOTOR: 32 scfm @112 psi (12 liters/sec @7.7 bars)
ELECTRICAL: 38 amps @ 220 volts, 50/60 Hertz single-phase, AC.
29 amps @ 380 volts, 50/60 Hertz three-phase, AC.
WEIGHT: 140 pounds (63 kg)
DIMENSIONS: Height: 24 inches (61 centimeters)
Width: 26 inches (66 centimeters)
Depth: 30 inches (76 centimeters)
PROPORTIONING PUMPS:Operating
Pressure: 2500 psi (173 bars)
Output: 10 lbs./min. (4.54 kg/min) *
INLET FILTER: 80 Mesh Standard (Optional - 60/40 Mesh)
PRIMARY HEATER: 6000 Watts: ∆t=40°F (22°C) @ 10 lb./min. (4.5 kg/min) *
HOSE LENGTH: 310 feet (94.5 meters) maximum for heating purposes
*Theoretical: actual results will vary with operating conditions.

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

Operating Manual Initial Machine Set-up
2/12/04 13
The Accessory Package included with the unit contains the following parts required for set-
up:
• Tape Roll
• Isolator
• (2) Swivel Unions
• Isolation Hoses
Blue – Resin
Red – Isocyanate
• 1/4 x 30” (76 cm) Air Hose
• Temperature Sensing Unit (TSU)
• Parts Identification Manual
• Binder
• Warranty Card
• Hose Jumper Plug
• TSU Extension Adapter ∗
∗Refer to Figure 2 for additional parts required for set-up.
IMPORTANT: Complete and return the Warranty Validation Card within 2 weeks
of receipt of equipment.
Main Power Installation
WARNING: BEFORE PROCEEDING, BE SURE THAT INCOMING POWER IS DISCONNECTED AND
LOCKED OUT AT THE SOURCE.
IMPORTANT: The main power source must be capable of meeting the electrical
requirements specified on the nameplate of the proportioning unit and an accessible
quick disconnect provided.
1. Remove and retain four (4) screws from the console cover. Open the cover.
2. Connect the main power cord to the electrical console using wire size #10 or larger.
(Not supplied) (See Figure 3.)
a) Feed the power cord through the strain relief in the back of the console and
connect the power leads to L1 and L2 (220V) –or- L1, L2 and L3 (380V).
b) Connect the ground wire to the ground lug.
c) For 380V models, connect the white Neutral lead to position N on the terminal
block.
(220V Single-Phase) (380V-Three Phase)
Figure 3. Main Power Connections

Model FF-2500 Proportioning Unit
14 25942-1, Issue 4
3. Close the console cover. Reinstall the four (4) screws retained from Step 1.
4. Set up the chemical supply, air supply and moisture control systems as required.
See the system instructions for proper set-up and operating procedures.
5. Properly ground all auxiliary equipment. If not grounded, the high velocity flow of
fluid can create a static charge, which may spark and cause fire or explosion.
Certain solvents that are commonly in use with this equipment are flammable and
may present a flash danger to the operator.
a) Ground the material supply (transfer pumps/day tanks).
b) The 2:1 transfer pump has a ground lug. Ground the pump in accordance with
the instructions provided with the pump.
c) Check that the proportioning unit ground at the main electrical source is
installed in accordance with the National Electrical Code. If a generator will
be powering the unit, consult with your electrician about additional grounding
measures that may be required.
Material Supply Connections
Connect the material supply to the inlets of the proportioning unit as follows:
1. Ensure that the A- and R- inlet ball valves on the proportioning unit are closed.
2. Connect and tighten the R- (resin) supply hose to the 3/4 FPT swivel fitting on the
R- inlet ball valve, and to the resin transfer pump.
3. Connect and tighten the A- (isocyanate) supply hose to the 1/2 FPT swivel fitting on
the A- inlet ball valve, and to the isocyanate transfer pump.
4. Connect the air supply to the 1/4 MPT nipple on the 2:1 transfer pump. Remove the
cap to access it.
5. Connect the main air supply to the proportioning unit. The main air inlet at the air
filter requires a 3/8 NPT fitting.
IMPORTANT: The main air supply must be clean and free of contaminants.
A minimum of 3/8-inch inside diameter air line (not supplied) should be used to
deliver the air supply to the proportioning unit. A main air shutoff valve to the
proportioning unit is recommended.

Operating Manual Initial Machine Set-up
2/12/04 15
Hose Heat Power Pack
The power pack provides low-voltage electrical power to the heating element embedded
in each section of hose. The output voltage of the power pack is adjusted by changing
the tap settings of the transformer. To ensure proper functioning of the heated hoses, the
transformer tap settings must be adjusted to match the total length of hose to be used.
To connect the power pack and select the correct tap settings, proceed as follows:
1. Turn OFF and lock out incoming electrical power at the source.
2. Plug the tap wire with inline fuse (B) into the Power-Lock hose heat connector on
the end of the console wire (A). (See Figure 4.)
™
Figure 4. Manual Transformer Connections
3. Using Figure 5 and the chart below, connect the power lead (C) and the tap wire (B)
to the transformer taps that match the hose length to be used.
IMPORTANT: The power pack must be set to match the hose length used. Too
much power will cause the hose heat circuit fuse to open; too little power will result
in insufficient hose heating.
Hose Length Tap Wire Power Lead
25 ft. (7.6m) S1 S2
35 ft. (10.6m) S2 S3
60 ft. (18.2m) S1 S3
110 ft. (33.3m) S1 S4
160 ft. (48.5m) S4 S5
210 ft. (63.6m) S3 S5
260 ft. (78.8m) S1 S5
310 ft. (94m) S1 S5
Figure 5. Manual Tap Settings
4. Connect the power cord (D) from the power pack to the electric console. Twist the
plug to lock it into the receptacle.

Model FF-2500 Proportioning Unit
16 25942-1, Issue 4
Temperature Controllers
The FF-2500 digital temperature controllers automatically maintain the temperature
selected for both the hose heat system and primary heater. Each controller has its own
program and is not interchangeable with the other. (See Figure 6.)
To enter the set point, proceed as follows:
WARNING: DO NOT TURN THE TEMPERATURE CONTROLLER ON UNTIL ALL PURGING
PROCEDURES ARE COMPLETED AND THE HEATERS COMPLETELY FILLED WITH CHEMICAL.
ADDITIONALLY, DO NOT CHANGE ANY OF THE PREPROGRAMMED PARAMETERS.
a) Check that the red main disconnect is ON. The white pilot light should be lit.
b) Check that the amber control
power switch is ON. The light
within the switch should be lit.
NOTE:
The temperature controller
normally displays the set point.
When illuminated, the red LED
number 1 on the temperature
controller indicates that the heater
is in heating mode. The LED goes
out when the liquid in the heater
reaches the set temperature. The
LED will continue to cycle on and
off, indicating that the controller is
maintaining the set point
temperature.
c) To enter or change the set point,
press and hold the “Set” button
down while pressing the or
button to increase or decrease
the value. After entering the set
point release the “Set” button and
the set point should display after
10 seconds.
Figure 6. Temperature Controller
WARNING: THE CONTROLLERS ARE FACTORY PROGRAMMED AND ARE NOT FIELD
PROGRAMMABLE. IF YOU ENCOUNTER ANY PROBLEMS WITH EITHER CONTROLLER CONTACT
GUSMER FOR A REPLACEMENT. DO NOT SUBSTITUTE A CONTROLLER FROM AN ALTERNATE
SUPPLIER AS ITS USE MAY RESULT IN DAMAGE TO THE EQUIPMENT AND/OR BODILY INJURY.

Operating Manual Initial Machine Set-up
2/12/04 17
Heated Hose Installation
WARNING: TO MAKE PROPER AND SAFE HOSE CONNECTIONS, READ AND UNDERSTAND
FOLLOWING:
ISOCYANATE HOSES ARE COLOR-CODED RED AND RESIN HOSES ARE COLOR-CODED BLUE FOR
POSITIVE IDENTIFICATION. IN ADDITION, THE RESIN AND ISOCYANATE HOSE FITTINGS HAVE
DIFFERENT THREAD SIZES TO VIRTUALLY ELIMINATE INTERCHANGING THE HOSES.
THE HOSE CONNECTION POINTS ARE A POTENTIAL SOURCE OF CHEMICAL AND AIR LEAKS AND
ARE THE AREAS MOST EXPOSED TO DAMAGE FROM SCUFFING AND SNAGGING ON ABRASIVE
SURFACES. GUSMER CORPORATION STRONGLY RECOMMENDS INSTALLING THE OPTIONAL
SCUFF JACKET TO PROTECT THE HOSES AND TSU EXTENSION HARNESS FROM DAMAGE.
1. Connect the isolation hoses to
their respective primary heater
outlet fittings (see Figure 7).
IMPORTANT: The heated hose
assemblies are connected end to
end during shipment to protect
them from moisture intrusion. Do
not separate the hoses until they
are ready to connect to the
proportioning unit. Figure 7. Isolation Hoses
2. Plug the TSU extension adapter into the left side of the electric console.
3. Connect the air hose extension adapter to the outlet fitting on the proportioning unit.
4. Connect the heated hose assembly to the isolation hoses as follows:
a) Lay out the hose
assemblies end-to-end as
shown
(see Figure 8).
• A- (Isocyanate) hoses are
color-coded RED.
• R- (Resin) hoses are color-
coded BLUE.
See Figure 9 for Steps b) and
c).
Figure 8. Hose Connection Step (a)

Model FF-2500 Proportioning Unit
18 25942-1, Issue 4
b) Connect the heated hoses
to the isolation hoses and
tighten. Take care not to
cross-thread or over-
tighten the fittings,
ensuring a leak-proof
chemical connection.
c) Connect the air hoses and
tighten the fittings.
Figure 9. Hose Connection Step (b & c)
d) Install the isolator
between the chemical
hose fittings. Use a small
amount of tape to hold it
in place
(see Figure 10).
IMPORTANT: Always install
the isolator to prevent damage
to the fittings, but do not tape
fully in place until after the
hoses are pressurized and
found to be free of leaks.
Figure 10. Hose Connection Step (d)
See Figure 11 for Steps e) and
f).
e) Connect the TSU harness
plugs together. To ensure
a secure electrical
connection, place the
protective electrical
isolator boot over each
plug and tape together.
™
Figure 11. Hose Connection Step (e & f)
f) Plug the Power-Lock hose heat connectors together. Secure the connection in
place with the cable tie provided; failure to do so could cause a disruption in the
hose heat system, should the connectors separate.
*** Repeat Step 4 for adding additional hoses. ***
5. Install the temperature sensing unit (TSU) to the gun whip hose as follows:
a) Pull out and carefully straighten the loose end of the temperature probe from the
TSU.

Operating Manual Initial Machine Set-up
2/12/04 19
b) Insert the temperature probe into the isocyanate hose and connect the TSU to
the gun whip hose, taking care not to cross-thread or over-tighten the fittings,
thereby ensuring a leak-proof chemical connection. (See Figure 12.)
WARNING: THE TEMPERATURE PROBE EXTENDS APPROXIMATELY 8 INCHES INTO THE
ISOCYANATE HOSE AND ALTHOUGH IT IS A RUGGEDLY BUILT ASSEMBLY, IT WILL NOT
WITHSTAND REPEATED ABUSE. DO NOT TO CRUSH THE HOSE OR SUBJECT IT TO SEVERE
BENDING IN THE AREA WHERE THE THERMOCOUPLE IS LOCATED. DO NOT TO COIL SMALLER
THAN THE RECOMMENDED 3-FT. BEND RADIUS.
™
™
Figure 12. Temperature Sensing Unit (TSU)
c) Connect the ground wire on the gun hose to the ground point on the TSU.
d) Connect the heated hose assemblies to the TSU, taking care not to cross-thread
or over-tighten the fittings, thereby ensuring a leak-proof chemical connection.
e) Connect the TSU harness to the TSU. To ensure a secure electrical connection,
place the protective electrical isolator boot over each plug and tape together.
f) Cut the isolator in half crosswise and secure the two pieces in place between the
hydraulic fittings.
g) Connect and tighten the air hoses.
h) Plug the Power-Lock hose heat connectors together. Secure the connection in
place with the cable tie provided; failure to do so could cause a disruption in the
hose heat system should the connectors separate.
6. Install the optional hose scuff jacket, if used, over the hose lengths.
7. Connect the coupling block to the gun whip hose and make sure that the manual
valves are closed. (See the Gun Operating Manual.)

Model FF-2500 Proportioning Unit
20 25942-1, Issue 4
Air Purge
Before using the equipment, it is necessary to purge the entire chemical system of air and
mineral oil left over from the functional testing of the equipment at the factory.
To purge the machine proceed as follows:
1. Turn on the main air supply.
2. With the resin and isocyanate transfer pumps in their respective drums and the A
and R-inlet supply valves closed, pressurize the transfer pumps. Check for chemical
leaks.
3. Open the A and R-inlet supply valves.
4. Switch ON the main switch. (The white pilot light should be ON.)
5. Adjust both air pressure regulators to zero. (Fully counterclockwise).
6. Set the pump switch to NORMAL.
7. Adjust both the air pressure regulators
clockwise until the pumps begin to move
(approximately 15-psi air pressure). When
the pumps reach the top of their stroke, turn
the pump switch to OFF. This will allow
access to the pump lubricant cup on the
isocyanate pump. Fill the cup to about 1/4-
inch from the top with Gusmer pump
lubricant (see Figure 13).
8. Hold the coupling block with the A- and R-
ports over separate containers and open
both manual valves.
Figure 13. Pump Lubricant
Cup
9. Set the pump switch to NORMAL. If necessary, gradually adjust both the air
pressure regulators clockwise to start the proportioning pumps moving slowly.
Please dispose of waste chemicals
in accordance with applicable
local, state, and federal codes.
10. Allow material to flow out of the coupling block until all spitting of air stops and all
traces of residual material have disappeared. Close the manual valves and flush any
residual chemical from the outside of the coupling block (see Gun Operating
Manual).
11. Slowly increase the air pressure and check all fittings for signs of hydraulic and
chemical leakage. Tighten fittings as required.
12. Turn OFF the pump switch.
13. Mount the gun to the coupling block. (See the Gun Operating Manual.)
IMPORTANT: After the proportioning system has been brought up to operating
pressure and all hose connections are tight and free of leaks, wrap together the hoses
and electrical wires around the area of the rubber isolators with a liberal amount of duct
tape to form a compact bundle. If a scuff jacket is being used, pull it over the bundle and
secure with tape.