GUSMER H-20/35 User manual

"Success through Unity"
H-
20/35 VR Series
Proportioning
Unit
Operating Manual
42942-VR-1
December 19, 2002
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 2002, GUSMER CORPORATION
®
http://www.gusmer.com
NOTICE: This manual contains important information about your GUSMER equipment. Read and retain for future reference.

H-20/35 VR Series Proportioning Unit
2 42942-VR-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 Contents
12/19/02 3
CONTENTS
LIST OF FIGURES..........................................................................................................4
WARRANTY ....................................................................................................................5
GENERAL SAFETY INFORMATION..........................................................................6
A CCEPTABLE E QUIPMENT U SES .......................................................................................6
O PERATIONAL S AFETY P ROCEDURES ...............................................................................7
DESCRIPTION.................................................................................................................8
SPECIFICATIONS.........................................................................................................16
INITIAL MACHINE SET-UP.......................................................................................17
RATIO ADJUSTMENT.................................................................................................25
R ATIO A DJUSTMENT P ROCEDURES ................................................................................25
OPERATION..................................................................................................................27
D AILY S TART - UP P ROCEDURES .....................................................................................27
D AILY S HUT - DOWN P ROCEDURES .................................................................................28
TROUBLESHOOTING.................................................................................................29
G ENERAL I NFORMATION ................................................................................................29
H OSE H EAT S YSTEM ......................................................................................................30
Solutions ...................................................................................................................30
P RIMARY H EATERS ........................................................................................................33
Solutions ...................................................................................................................34
P ROPORTIONING S YSTEM ...............................................................................................35
Solutions ...................................................................................................................36
H YDRAULIC D RIVE S YSTEM ..........................................................................................39
Solutions ...................................................................................................................40
MAINTENANCE............................................................................................................41
P RIMARY H EATERS ........................................................................................................41
Heating Element Replacement..................................................................................41
Thermocouple Replacement......................................................................................42
P ROPORTIONING S YSTEM ...............................................................................................42
Proportioning Pumps................................................................................................42
Pump Bases...............................................................................................................43
I NLET S TRAINER S CREEN ...............................................................................................43
P UMP L UBE S YSTEM ......................................................................................................44
H YDRAULIC D RIVE S YSTEM ..........................................................................................45
APPENDIX......................................................................................................................46
INSTRUCTION MANUAL DISCREPANCY REPORT............................................47

H-20/35 VR Series Proportioning Unit
4 42942-VR-1, Issue 1
LIST OF FIGURES
F IGURE 1. M AJOR C OMPONENTS .......................................................................................8
F IGURE 2. T RANSFORMER C OMPARTMENT E LECTRICAL C OMPONENTS .............................12
F IGURE 3. E LECTRICAL C ONSOLE C OMPONENTS ..............................................................14
F IGURE 4. T YPICAL I NSTALLATION ...................................................................................17
F IGURE 5. M AIN P OWER C ONNECTION ............................................................................18
F IGURE 6. G ROUND L UG .................................................................................................18
F IGURE 7. H YDRAULIC F LUID L EVEL ...............................................................................19
F IGURE 8. L UBE R ESERVOIR I NSTALLATION ......................................................................19
F IGURE 9. I SOLATION H OSE C ONNECTIONS ......................................................................19
F IGURE 10. H EATED H OSE A SSEMBLY C ONNECTIONS ........................................................20
F IGURE 11. T EMPERATURE S ENSING U NIT (TSU)..............................................................21
F IGURE 12. T EMPERATURE C ONTROLLER .........................................................................23
F IGURE 13. T AP S ETTINGS ................................................................................................24
F IGURE 14. H OSE H EAT P OWER S ET .................................................................................30
F IGURE 15. H OSE H EAT C IRCUIT B REAKER .......................................................................31
F IGURE 16. T ERMINAL J UMPER S TRIP I NSTALLATION .........................................................32
F IGURE 17. P RIMARY H EATER ..........................................................................................33
F IGURE 18. P RIMARY H EATER C IRCUIT B REAKERS ............................................................34
F IGURE 19. P ROPORTIONING S YSTEM ...............................................................................35
F IGURE 20. H YDRAULIC M ANIFOLD ..................................................................................38
F IGURE 21. M OTOR C IRCUIT P ROTECTOR .........................................................................40
F IGURE 22. T HERMOCOUPLE C OMPONENTS .....................................................................42
F IGURE 23. Y S TRAINER C OMPONENTS .............................................................................44

Operating Manual Warranty
12/19/02 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, 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 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

H-20/35 VR Series Proportioning Unit
6 42942-VR-1, Issue 1
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, 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
12/19/02 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: T
HE SOLVENTS AND CHEMICALS USED WITH THIS EQUIPMENT EXPOSE THE
OPERATOR TO CERTAIN HAZARDS . A DEQUATE PERSONAL PROTECTIVE MEASURES MUST BE
TAKEN SO AS TO AVOID EXCEEDING THE
T HRESHOLD L IMIT V ALUE (TLV) OF THE PRODUCTS
BEING USED
, AS ESTABLISHED BY THE O CCUPATIONAL S AFETY AND H EALTH A DMINISTRATION
(OSHA) OR OTHER QUALIFIED AGENCY . O BTAIN I NFORMATION CONCERNING PERSONAL
PROTECTION AND PROPER HANDLING FROM THE SUPPLIER OF SUCH CHEMICALS
.
High Voltage
WARNING:
T O 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
. T HE ELECTRICAL SERVICE MUST BE INSTALLED AND MAINTAINED BY
A QUALIFIED ELECTRICIAN
.
High Pressure
WARNING:
T HIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HYDRAULIC AND
CHEMICAL COMPONENTS CAPABLE OF PRODUCING UP TO 3500 PSI . T O 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:
T O AVOID SERIOUS BODILY INJURY , PROPER PROTECTIVE GEAR MUST BE WORN
WHEN OPERATING , SERVICING , OR BEING PRESENT IN THE OPERATIONAL ZONE OF THIS
EQUIPMENT
. T HIS INCLUDES , BUT IS NOT LIMITED TO , EYE AND FACE PROTECTION , GLOVES ,
SAFETY SHOES , AND RESPIRATORY EQUIPMENT AS REQUIRED .
High Temperature
WARNING: T
HIS EQUIPMENT HAS OR IS USED WITH EQUIPMENT THAT HAS HIGH
TEMPERATURE COMPONENTS SUCH AS PRIMARY HEATERS AND HEATED HOSES . T O PREVENT
SERIOUS BODILY INJURY FROM HOT FLUID OR HOT METAL
, NEVER ATTEMPT TO SERVICE THE
EQUIPMENT BEFORE ALLOWING IT TO COOL
.
Warning
WARNING:
F AILURE 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
.

H-20/35 VR Series Proportioning Unit
8 42942-VR-1, Issue 1
DESCRIPTION
Figure 1. Major Components

Operating Manual Description
12/19/02 9
1. MAIN POWER DISCONNECT- Controls power to all circuits. Must be ON for
any function of the proportioning unit to operate. The disconnect can be locked in
the OFF position for OSHA required lockout/tagout during machine maintenance.
2. MAIN POWER LIGHT (WHITE)- Lights up when the Main Disconnect Switch is
in the ON position and the control power transformer is operational.
3. CONTROL POWER SWITCH- Turns the unit’s 120VAC control power circuit on
and off. In the ON position, the amber light within the switch lights up. Removal of
control power stops all machine operation including motion and heating.
4. EMERGENCY STOP SWITCH- Interrupts the units control power circuit to stop
all motion and heating. Switch mechanically locks in the stop position. Turn the
switch clockwise to reset it and restore normal operation.
5. HYDRAULIC MOTOR SWITCH- Controls power to motor circuit. In the ON
position, the green light within the switch lights up.
6. POLYOL COUNTER- Records the cycle count of the Polyol proportioning pump.
One cycle equals two strokes (one in each direction); used to determine ratio.
7. ISOCYANATE COUNTER- Records the cycle count of the Isocyanate
proportioning pump. One cycle equals two strokes (one in each direction); used to
determine ratio.
8. PUMP MODE SWITCH- Controls operation of the proportioning pump Hydraulic
Drive System
• RUN- Should be in this position for the pump system to operate properly.
This position is used for all normal operation of the pump system, while
dispensing chemical. Hydraulic system will be energized when a special
dispensing gun is triggered.
• RETRACT- The pump system is energized so that the Isocyanate pump
shaft is retracted into the pump cylinder. This shields the Isocyanate pump
shaft from air to limit crystallization during periods of machine inactivity.
The retract position should be used during any period of machine inactivity
• SERVICE – With the recirculating ball valves open, the pump system is
energized and ratio can be determined with the counters or material can be
conditioned. With the recirculating ball valves closed, the system will build
pressure.
9. ISOCYANATE RECIRCULATING BALL VALVE – Ball valve on the Iso
material that either allows the system to recirculate chemical back to the chemical
drums during Service Pump Mode or prevents chemical from returning to the
chemical drums during Run Pump Mode.
10. POLYOL RECIRCULATING BALL VALVE – Ball valve on the Polyol material
that either allows the system to recirculate chemical back to the chemical drums
during Service Pump Mode or prevents chemical from returning to the chemical
drums during Run Pump Mode.

H-20/35 VR Series Proportioning Unit
10 42942-VR-1, Issue 1
11. ACTIVATOR PLATE – Works with the reversing switches to change pump
direction.
12. HYDRAULIC PUMP (ISOCYANATE) – Hydraulic pump that supplies the
pressure and flow rate to the hydraulic drive system that attaches to the Isocyanate
proportioning pump.
13. HYDRAULIC PUMP (POLYOL) – Hydraulic pump that supplies the pressure and
flow rate to the hydraulic drive system that attaches to the Polyol proportioning
pump.
14. HYDRAULIC PUMP FLOW ADJUSTMENT (ISOCYANATE) – Adjustment
allows the flow rate of the hydraulic pump to be increased or decreased, which
increases or decreases output of the Isocyanate pump.
15. HYDRAULIC PUMP FLOW ADJUSTMENT (POLYOL) – Adjustment allows
the flow rate of the hydraulic pump to be increased or decreased, which increases or
decreases output of the Polyol pump. (Not Shown)
16. HYDRAULIC PUMP PRESSURE CONTROL ADJUSTMENT
(ISOCYANATE) – Controls the hydraulic pressure available to the Hydraulic Drive
System. This adjustment must be set high enough so the pump will not reduce flow
rate for the Isocyanate pump.
17. HYDRAULIC PUMP PRESSURE CONTROL ADJUSTMENT (POLYOL) –
Controls the hydraulic pressure available to the Hydraulic Drive System. This
adjustment must be set high enough so the pump will not reduce flow rate for the
Polyol pump.
18. HOSE HEATER SWITCH- Energizes the Hose Heat System circuit. In the ON
position, the green light within the switch lights up.
19. HOSE HEAT TEMPERATURE CONTROLLER- Digital display of controller
will be energized when Control Power Switch is activated. Controller will display set
point temperature. Press the “SET” button to display the process temperature.
Display will shift back to set point after 10 seconds. The Hose Heater Switch must
be in the ON position before heating process will begin.
20. ISOCYANATE PRIMARY HEATER SWITCH- Energizes the Iso Primary
Heater system circuit. In the ON position, the green light within the switch lights up.
21. ALARM- Audible alarm that sounds when a low or over-pressure condition occurs.
22. ALARM RESET- Momentary switch that silences alarm after a low or over-
pressure condition occurs.
23. ISOCYANATE PRIMARY HEATER TEMPERATURE CONTROLLER-
Digital display of controller will be energized when Control Power Switch is
activated. Controller will display set point temperature. Press the "SET" button to
display the process temperature. Display will shift back to set point after 10 seconds.
Iso Primary Heater Switch must be in the ON position before heating process will
begin.

Operating Manual Description
12/19/02 11
24. POLYOL PRIMARY HEATER SWITCH- Energizes the Polyol Primary Heater
system circuit. In the ON position, the green light within the switch lights up.
25. POLYOL PRIMARY HEATER TEMPERATURE CONTROLLER- Digital
display of controller will be energized when Control Power Switch is activated.
Controller will display set point temperature. Press the "SET" button to display the
process temperature. Display will shift back to set point after 10 seconds. Polyol
Primary Heater Switch must be in the ON position before heating process will begin.
26. HOSE HEAT AMMETER- Displays the amperage (power) flowing in the Hose
Heat System.
27. HOSE HEAT POWER SET- Controls and adjusts the amount of amperage in the
Hose Heat System. Loosen lock nut before adjusting potentiometer. Tighten lock
nut after adjustment is completed.
28. POLYOL OVER-PRESSURE SAFETY SWITCH- Turns off the Hydraulic Drive
System when the Polyol Proportioning Pump exceeds the safe pressure limitation.
29. ISOCYANATE OVER-PRESSURE SAFETY SWITCH- Turns off the Hydraulic
Drive System when the Isocyanate proportioning pump exceeds the safe pressure
limitation.
30. POLYOL LOW-PRESSURE SAFETY SWITCH- Turns off the Hydraulic Drive
System when the Polyol proportioning pump falls below 40 psi. (Not Shown)
31. ISOCYANATE LOW-PRESSURE SAFETY SWITCH- Turns off the Hydraulic
Drive System when the Isocyanate proportioning pump falls below 40 psi.
32. POLYOL PRESSURE GAUGE- Indicates the pressure in the Polyol proportioning
system.
33. ISOCYANATE PRESSURE GAUGE- Indicates the pressure in the Isocyanate
proportioning system.
34. POLYOL INLET PRESSURE GAUGE- Indicates the inlet pressure prior to the
Polyol proportioning system.
35. ISOCYANATE INLET PRESSURE GAUGE- Indicates the inlet pressure prior to
the Isocyanate proportioning system
36. POLYOL BULKHEAD RECIRCULATING FITTING- Fitting provides a means
of returning chemical back to drum via a return hose. (Not Shown)
37. ISOCYANATE BULKHEAD RECIRCULATING FITTING- Fitting provides a
means of returning chemical back to drum via a return hose.
38. POLYOL INLET SUPPLY BALL VALVE- Allows delivery of Polyol to the
proportioning unit. (Not Shown)
39. ISOCYANATE INLET SUPPLY BALL VALVE- Allows delivery of Isocyanate
to the proportioning unit.
40. HYDRAULIC PRESSURE GAUGE - Indicates the pressure in the Hydraulic Drive
System for the Isocyanate pump.

H-20/35 VR Series Proportioning Unit
12 42942-VR-1, Issue 1
41. HYDRAULIC PRESSURE GAUGE- Indicates the pressure in the Hydraulic Drive
System for the Polyol pump.
42. HYDRAULIC TANK LEVEL GAUGE- Shows the level of oil in the tank.
43. LUBE PUMP SYSTEM (Iso side only)- Continuously circulates Pump Lube to
prevent the crystallization of Isocyanate on the pump shaft.
44. HYDRAULIC DIRECTIONAL VALVE (ISO) - Controls the direction of
hydraulic flow.
45. HYDRAULIC DIRECTIONAL VALVE (POLYOL) - Controls the direction of
hydraulic flow.
46. HOSE HEAT POWER LOCK CONNECTOR- Provides power to the Heated
Hoses.
47. TSU HARNESS- Carries the electrical signal from the TSU Sensor in the Iso Hose
to the Hose Heat Temperature Controller.
48. HOSE HEAT SYSTEM SOLID
STATE RELAY (SSR)- The Hose
Heat System SSR is controlled by the
Hose Heat Temperature Controller.
The SSR acts as a switch allowing
current to flow in the Hose Heat
System Heating Element as required
by the Temperature Controller.
49. HOSE HEAT SSR JUMPER- The
jumper is used to bypass the hose
heat system SSR in the event that the
SSR fails. This allows continued to
operation of the machine by running
the Hose Heat System manually.
(See step 10 on page 32.) Figure 2. Transformer Compartment
Electrical Components
50. HOSE HEAT SYSTEM CIRCUIT BREAKER- A 50-amp circuit breaker that
protects the Hose Heat System by limiting current to the Hose Heat Element.
51. CONTROL CIRCUIT TRANSFORMER- Steps down the incoming line voltage
to 120 VAC for use by the control circuit system.
52. PHASE CONTROLLER- Used in conjunction with the hose heat transformer tap
settings to adjust and fine tune the amperage supplied to the hose heat system heating
elements.
53. HOSE HEAT SYSTEM TRANSFORMER- Steps down incoming line voltage to
lower voltages used to heat various lengths of hose.
54. HOSE HEAT SYSTEM TERMINAL BLOCK ASSEMBLY- Used to select hose
heat voltage of 15, 30, 45, 60, 75, or 90 VAC for various lengths of hose.
(See step 16 on page 24.)

Operating Manual Description
12/19/02 13

H-20/35 VR Series Proportioning Unit
14 42942-VR-1, Issue 1
Figure 3. Electrical Console Components

Operating Manual Description
12/19/02 15
55. CONTROL MAIN TERMINAL BLOCK- Termination/distribution point for
control system component wires.
56. CONTROL TRANSFORMER SECONDARY CIRCUIT BREAKER- Provides
over-current protection for the control transformer secondary 120-volt AC output.
57. MASTER RELAY- Controls distribution of 120 volt AC to control power system.
The Control Power Switch energizes the relay.
58. ISOCYANATE HEATER CONTROL RELAY- Controls distribution of line
voltage Iso Primary heater circuit. The Iso Primary Heater Temperature Controller
controls the relay.
59. POLYOL PRIMARY HEATER CONTROL RELAY- Controls distribution of
line voltage to Polyol Primary heater circuit. The Polyol Primary Heater
Temperature Controller controls the relay.
60. MOTOR CONTACTOR- Supplies line voltage to electric motor. The Hydraulic
Motor Switch controls the contactor.
61. ISOCYANATE PRIMARY HEATER CONTACTOR- Supplies line voltage to
the Iso Primary Heater. The Iso Primary Heater Switch controls the contactor.
62. POLYOL PRIMARY HEATER CONTROL CONTACTOR- Supplies line
voltage to the Polyol Primary Heater, which controls the contactor.
63. HOSE HEAT CONTACTOR- Supplies line voltage to Hose Heat System. The
Hose Heater Switch controls the contactor.
64. MOTOR CIRCUIT PROTECTOR- Provides thermal overload and over-current
protection for the hydraulic motor circuit.
65. ISOCYANATE HEATER CIRCUIT BREAKER- Provides over-current
protection for the Iso Primary Heater circuit.
66. POLYOL PRIMARY HEATER CIRCUIT BREAKER- Provides over-current
protection for the Polyol Primary Heater circuit.
67. HOSE HEAT TRANSFORMER PRIMARY CIRCUIT BREAKER- Provides
over-current protection for the Hose Heat Transformer Primary circuit.
68. CONTROL TRANSFORMER PRIMARY CIRCUIT BREAKER- Provides
over-current protection for the hose transformer primary circuit.
69. POWER DISTRIBUTION BLOCK- Provides power distribution point for
incoming line voltage to the circuit breaker bank.
70. MAIN POWER DISCONNECT (Inside View)- Provides termination point for
incoming power. Disconnects incoming power from machine circuits.
71. GUN/PUMP CONTROL RELAY- Enables the pump directional valves to operate
when the gun is triggered.
72. ALARM RELAY – Controls the operation of the Audible Alarm and disables the
pump circuit when an over- or under-pressure condition occurs.
73. DISPENSING GUN FUSE – ½ amp fuse to protect the gun trigger circuit

H-20/35 VR Series Proportioning Unit
16 42942-VR-1, Issue 1
SPECIFICATIONS
AIR: The Model H-20/35 VR is hydraulically driven. There are no air requirements for the
proportioning unit itself.
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.
Polyol Inlet-3/4" NPT (FE) swivel
Isocyanate Inlet-1/2" NPT (FE) swivel
RECIRCULATING OUTLET: Polyol Outlet-3/4" JIC (Male)
Isocyanate Outlet-3/4" JIC (Male)
CHEMICAL VISCOSITY: 250-1500 cps
HYDRAULIC SERVICING: 34 gallons (129 Liters)
Recommended operating temperature: 120°F (48°C)
Maximum operating temperature: 160°F (71°C)
WEIGHT: Empty: 685pounds (311 kilograms)
Serviced: 1025 pounds (465 kilograms)
DIMENSIONS: Height: 47 inches (119 centimeters)
Width: 40 inches (102 centimeters)
Depth: 22 inches (56 centimeters)
DISPENSING PRESSURE: H-20 VR: 1900 psi maximum (131 Bars)
H-25 VR: 2400 psi maximum (165 bars)
SUPPLY PRESSURE:400 psi maximum (27 Bars)
OUTPUT: H-20 VR: 31 lb./min. maximum (14 kg/min)
H-25 VR: 24 lb./min. maximum (11 kg/min)
INLET FILTER: 80 Mesh Standard (Optional - 60/40 Mesh)
PRIMARY HEATER: 6000 Watts per heater at 220 Volts*
H-20 VR: ∆t=52°F @ 31 lb./min. (14 kg/min) *
H-25 VR: ∆t=69°F @ 24 lb./min. (11 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
12/19/02 17
INITIAL MACHINE SET-UP
Figure 4. Typical Installation
* Consult Gusmer Sales for the correct hose sizes for your application

H-20/35 VR Series Proportioning Unit
18 42942-VR-1, Issue 1
WARNING:
P ROPER 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
.
The Accessory Package included with the unit contains the following parts required for
set-up:
• Tape Roll • Parts Identification Manual
• Binder
• Electrical Isolator
• Isolation Hoses
Blue – Polyol
Red – Isocyanate
• (2) Swivel Unions • Temperature Sensing Unit (TSU)
• Lube Reservoir • Warranty Card
• Operating Manual • Dip Tube Kit
* Refer to Figure 4 for additional parts required for set-up.
IMPORTANT: Complete and return the Warranty Validation Card within 2 weeks of
receipt of equipment.
WARNING:
T HE P ROPORTIONING U NIT ELECTRIC SERVICE
MUST BE INSTALLED BY A QUALIFIED ELECTRICIAN IN
ACCORDANCE WITH THE
N ATIONAL E LECTRICAL C ODE AND
ALL APPLICABLE STATE AND LOCAL CODES
.
IMPORTANT: Before proceeding, be sure that the
main power is disconnected and locked out at the
source.
1. Connect the main power cord to the electrical console
as follows (See Figure 5 and Figure 6.):
Figure 5. Main Power
Connection
a) Feed the power cord through the strain relief in
the bottom of the console. Connect the power
leads to L1, L2, and L3. For 380V, 3-Phase units,
connect the neutral wire to the blue neutral
terminal block on the circuit breaker rail.
b) Connect the ground wire to the Ground Lug
located inside the console near the strain relief
opening.
NOTE:
The dashed lines in Figure 5
signify the additional wires
found on three- phase units.
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.
2. Insert transfer pumps and the dip tube assemblies into
the chemical drums (See Figure 4.)
Figure 6. Ground Lug
3. Set up the air supply and moisture control systems as required. Refer to the system’s
instruction manuals for the proper procedures (See Figure 4.).
4. Fill the hydraulic reservoir through the vented filler neck with approximately 34
gallons of hydraulic fluid. Refer to the listing in the Appendix on page 46 for the
recommended types of fluid.

Operating Manual Initial Machine Set-up
12/19/02 19
IMPORTANT: DO NOT overfill the reservoir. The Level Indicator should read
approximately 1/2 full with liquid.
5. The hydraulic pumps need to be full
with hydraulic fluid. Remove each
case drain hose from the reservoir.
Gradually add fluid until the pump
and hose is full and air bubbles stop.
6. Locate the Pump Lube Reservoir
included with the Accessory Package.
Prepare the Lube System for use as
follows:
Figure 7. Hydraulic Fluid Level
NOTE:
Use only Gusmer Pump Lube
(P/N 0960-1-GAL)
NOTE:
The tube that supplies Pump Lube
to the Lube Cup must be at the
upper level of the reservoir and
the return tube is at the lower level
of the reservoir. This will ensure
that any Isocyanate Crystals will
settle to the bottom of the
reservoir and not return to the
Lube Cup
a) Fill the Lube Reservoir.
b) Thread the reservoir onto the
Reservoir Cap Assembly and
place it into the bracket.
c) Push the Supply Tube
approximately 1/3 of the
way down into the Lube
Reservoir.
d) Push the Return Tube down
into the Lube Reservoir until
it reaches the bottom.
e) Place the Lube Reservoir
into the Bracket. The Lube
System is now ready for
operation. No priming of
the system is required. Figure 8. Lube Reservoir Installation
7. Connect the Isolation Hoses to their
respective Primary Heater outlet
fittings.
IMPORTANT: To prevent the
inadvertent connection of a hose to
the wrong chemical source, the
Isocyanate hoses are color-coded red
and the Polyol hoses are color-coded
blue for easy identification. In
addition, the Polyol and Isocyanate
hose fittings have different thread
sizes, making it virtually impossible to
improperly connect the hoses.
Figure 9. Isolation Hose Connections

H-20/35 VR Series Proportioning Unit
20 42942-VR-1, Issue 1
8. Connect the Heated Hose Assemblies as follows:
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: Be sure to make proper hose connections. 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 Harness from damage.
a) Connect the Heated Hoses to the Isolation Hoses. Take care not to cross-thread
or over-tighten the fittings, ensuring a leak-proof chemical connection.
b) Tape the Isolator securely in place between the hydraulic fittings.
IMPORTANT: While the Isolator is no longer used to prevent an electrical short, its
purpose is now to protect the fittings.
™
Figure 10. Heated Hose Assembly Connections
c) Connect the Air Hoses and tighten the fittings with open-end wrenches.
d) Digital Hose Heat Machines Only: Connect the TSU Harness Plugs together.
To ensure a secure electrical connection, place the protective electrical isolator
boot over each plug and tape together.
e) Plug the Hose Heat Power-Lock™ 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.
*** Repeat Step 8 for adding additional Hose Assemblies. ***
9. Install the Temperature Sensing Unit (TSU) on the Gun Whip as follows:
a) Pull out and carefully straighten the loose end of the temperature probe
from the TSU.