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Service Manual - GAMA spray equipment

1. rings do not reduce the pressure to zero We recommend keeping the system at a minimum pressure of 30 bars to prolong the life of the seal rings c Press the MOTOR button The LED will go out d Press the ISO and RESIN buttons located below the heater temperature display Both LEDs will go out e Press the button located under the HOSES MANGUERAS display The LED will go out f Press the CONTROL POWER button The LED will go out g Rotate the power switch to the OFF position The upper pilot light goes out h Close the stop valves controlling intake of the products i Close the manual valves on the coupling block and dismount the gun for carrying out the necessary maintenance 27 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual CLEANING PROCEDURE HEATED HOSES WARNING This unit includes parts which reach temperatures likely to cause burns Do not touch or handle the hot parts of the unit until they have cooled down To avoid possible contamination all of the unit s circuits pumps heaters and hoses must be cleaned before applications which require a change of components Follow the steps given below to clean the unit before changing any of its components NOTE Save reusable products to suitable recipients following the instructions of the manufacturer a Open the manual purge valves located under each tank b Place the tubs containing the DOP cleaning agent near the uni
2. NOTE Do not fill the tank to its maximum capacity 26 litres the oil level should not exceed 85 of the maximum capacity 22 litres approx Use the visor of the oil thermometer to check the oil level as this should always be completely full 20 litres d Check the oil level in the hydraulic pump by removing the drain coupler from the pump and making sure the oil level reaches the top of the filler neck Add oil if necessary and reconnect the coupler Preparation units with recirculation hose WARNING Use suitable protective gear and follow the safety recommendations of the suppliers of the chemical components when preparing or working with the unit NOTE To ensure the correct operation of the unit the electrical power supply must meet the specifications given on p 6 of this manual and on the unit s rating plate After following steps a b c and d of the preparation procedure see p 17 follow the procedure given below to prepare the unit for recirculation a Connect the recirculation hose of each product to the recirculation valves located in the respective product tanks the isocyanate hose to the isocyanate tank valve and the polyol hose to the polyol tank valve 18 46 Issue 1 0 Ref NR 00088 ENG http Awww gamapur com Easy Spray H Biatan Service Manual b Connect the air hose to the supply connector c Connect the pressure hoses to the gun couplers making sure the gun s manual valves are
3. This section contains information on the possible causes of malfunctions in the unit Most problems with the unit can be detected and resolved using the information provided in this section Please refer to this information before requesting technical assistance from your authorized dealer or GAMA technical services Feel free to contact the technical assistance service of Garraf Maquinaria S A at any time Our team of qualified technicians is on hand to help and advise you when necessary NOTE Repairs by unqualified personnel or the use of non original replacement parts can damage the unit and endanger the safety of the operator To avoid bodily damage caused by the incorrect handling of the substances and solvents used in the spraying process read carefully the safety information provided by suppliers Dispose of waste as required by applicable legislation Disconnect the unit from the power supply before opening the electrical console Electrical maintenance should only be carried out by a qualified electrician To avoid exposure to pressurized fluids do not release any connectors or perform maintenance work on parts subjected to pressure until the pressure has been completely eliminated Use suitable protection when using or performing maintenance on the unit or when in its vicinity This protection includes but ts not limited to the use of masks protective goggles gloves safety footwear and safety clothing This unit inc
4. closed the isocyanate hose to the isocyanate coupler and the polyol hose to the polyol coupler d Connect the recirculation hoses to the gun couplers the isocyanate hose to the isocyanate coupler and the polyol hose to the polyol coupler e Fill the tanks with their respective product WARNING When handling chemical products always follow the supplier s safety and storage instructions To prevent splash contamination between one tank and the other open only the cap of the tank being filled with product Never swap parts between one tank and the other and always use the same tank for the same product WARNING To prevent cross contamination of products make sure the tanks are properly closed To avoid spillage during transportation of the unit never fill the tanks completely always leave about 20 of the tank capacity free each tank holds 30 litres We recommend using small vessels 10 15 litres maximum for pouring product into the tanks Fill the tanks with the amount of product required for each application Purge method for hoses with recirculation Before using the unit all air pockets and residual oil from in factory testing must be eliminated To purge the full circuit proceed as follows a Disconnect the isocyanate and polyol recirculation tubes and place them in separate waste recipients b Open the manual purge valves located under each tank c Open the manual recirculation valves d Rotate
5. have been completely eliminated Follow the procedure below in the sequence given to rectify the problem and avoid expensive repairs Check that all automatic switches are in the correct working position before proceeding to locate faults PROBLEMS SOLUTIONS The electric motor does not start or stops during operation 1 The hydraulic pump delivers no pressure 2 Little or no pressure with chirps 2 3 SOLUTIONS 1 Automatic switch The electric motor is protected by an automatic safety switch which trips when too much current is delivered to the motor Disconnect the unit from the power supply and allow the motor to cool down Open the control panel and re prime the automatic switch The motor should now work normally If too much current is being delivered to the motor it is important to identify why this is happening for in the event of failure by the automatic switch the electric motor may be damaged by overheating 2 Little or no pressure The most likely cause of lack of pressure is that the hydraulic pump is not delivering enough pressure due to mis priming caused by a lack of oil or a clogged intake filter Check these points to ensure correct operation 3 Noise A chirping noise is a common symptom of cavitation This noise is normal upon power up and normally disappears after about thirty seconds If the chirping continues stop the unit to protect the hydraulic pump and check that the hose couplings are properly tightene
6. the hose heating temperature and intensity For hoses with recirculation s Close the recirculation valves if open and open each product s manual valves on the gun Perform a test spray and check the pressure readings on each product s pressure gauge If the test spray is satisfactory and the pressure readings remain identical proceed with application Pressure readings should be practically identical and should remain constant One direction indicator light should remain on and the other off The light which is on indicates the direction of movement of the pumps If the pressures oscillate with each movement consult the Malfunctions section before continuing t Connect the air supply to the gun open the manual valves for each product perform a test spray and check the readings on the pressure gauges of each product If the test spray is satisfactory and the pressure readings remain identical proceed with application 26 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual POWER DOWN Follow the recommended procedure in the sequence given to power down the unit when you have finished using it a Press the RETRACT button The LED will light up b Operate the gun spraying into a waste recipient until the isocyanate proportioning pump is in the retracted position and the spray angle begins to decrease WARNING To prevent product leakage and premature deterioration of the pump s seal
7. the product hoses fitted to the unit 22 Hydraulic oil tank Contains the oil used by the unit s hydraulic system 23 Hydraulic cylinder Drives the pumps 24 Oil level and thermometer Displays the fluid level and temperature of the hydraulic oil tank 25 Electric motor Drives the hydraulic pump 26 Hydraulic pump Pumps oil to the hydraulic cylinder 27 Hydraulic return filter Filters impurities from the hydraulic oil 28 Hydraulic oil fill cap For topping up the oil tank 29 Heated hose sensor switch Enables control of the temperature in the hoses 30 TCS DIP switches Enables selection of the hose heater control mode depending on whether hoses incorporate a temperature control sensor TCS see page 11 point 2 of this manual for instructions on selecting the correct control mode The unit must be disconnected before operating the DIP switch 31 Temperature units DIP switch Enables selection of temperature units on the control panel displays Set this switch to the EU position to display the USAAU qr a temperature in degrees Celsius C or USA to display the temperature in degrees Fahrenheit The unit must be disconnected before operating the DIP switch 32 Motor DIP switch Activates deactivates the hydraulic drive Factory settings depend on the model The Motor DIP selector function is only active YY gt Nia q a Ob in units with hydraulic drive The unit must be disconnected bef
8. the switch lights up 2 Hoses Mangueras Hose heating control can be automatic optional when a temperature control sensor is used for direct temperature control or manual where no temperature control sensor is used The control mode is selected via a DIP switch on the printed circuit board Set the HOSE TEMP DIP to ON if the isocyanate hose incorporates a temperature control sensor If the isocyanate hose does not incorporate a temperature control sensor or if it is not working due to malfunction or other reasons set the DIP to OFF In automatic control mode the temperature in the isocyanate ISO hose is shown on the corresponding display In manual control mode only the selected amperage value is shown The unit must be disconnected before operating the DIP selector HOSE TEMP ON with temperature control sensor in ISO hose HOSES MANGUERAS HOSE TEMP OFF manual control HOSES MANGUERAS Pi To select the temperature when the unit is working in automatic heating control mode touch the MODE button select the desired temperature using the UP DOWN buttons and touch the MODE button again to confirm the setting Follow the same procedure to select the amperage When the unit is operating in automatic control mode this value should be set to between 4 5 and 5 0 amps The temperature setting of the hoses cannot be higher than the temperature setting of the heaters In cases where only one automatic temper
9. unit WARNING Do not start the power up procedure described below until all necessary prior adjustments have been made correctly a Check the condition of the DOP plasticizer contained in the isocyanate pump s lube reservoir Change the oil if it is discoloured or shows signs of solidification and tighten the packing nut to make the seal tight b Make sure the product tanks are full or have the minimum content for application to begin c Check the product intake filters Clean them if necessary d Open the manual purge valves located under each tank e Open the manual recirculation valves hoses with recirculation NOTE Only perform this step if you wish to recirculate the products NOTE Recirculation of products enables heater temperature settings to be reached quicker heating both the hoses and the gun For more efficient heating during recirculation fill the tanks with the minimum amount of product necessary for the application WARNING The product tanks are made of a plastic material which can withstand a maximum temperature of 80 C The temperature of the products inside the tanks must never exceed this limit WARNING Never recirculate when the tanks are completely full as this can cause abnormally high pressure in the tanks f Check the hydraulic oil level Add oil if the level is low g Make sure the products are at the minimum required temperature for their delivery to the unit via the transfer pumps Co
10. Aft Service Manual Spray Unit Easy Spray H Issue 1 0 19 12 14 Ref NR 00088 ENG Before preparing the unit and starting it up please take the time to read all the technical and safety instructions in this manual It is essential that you follow these instructions carefully so that you can handle and use the unit properly These instructions are intended to maximize user safety and avoid malfunctions deriving from the incorrect use of the unit Easy Spray H Service manual WARRANTY GARRAF MAQUINARIA S A GAMA provides this LIMITED WARRANTY Warranty to the original purchaser Customer covering the equipment and the original accessories delivered with the equipment Product against defects in the design materials or manufacture of the Product from the moment of initial purchase by the user and for a period of two 2 years from this date If during the Warranty Period and under conditions of normal use the Product stops working correctly for reasons connected with its design materials or manufacture the authorized dealer for the country where the Product was purchased or the GAMA technical assistance service shall repair or replace the Product in accordance with the following CONDITIONS a This Warranty is only valid if accompanied on presentation of the Product for its repair or substitution by the original invoice issued by a GAMA dealer authorized to sell the Product and whi
11. F THE PRODUCT OR BY THE MATERIAL DISPENSED BY THE PRODUCT INCLUDING ALL LOSSES DERIVING FROM DAMAGES TO PERSONS OR PROPERTY GAMA SHALL NOT IN ANY CIRCUMSTANCES BE HELD LIABLE FOR LOSSES IN SPECULATIVE GAINS OR PROFITS THE REPAIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT SHALL CONSTITUTE THE FULL DISCHARGE OF GAMA S RESPONSIBILITIES TOWARDS THE CUSTOMER GAMA CANNOT GUARANTEE THE SUITABILITY OR FITNESS FOR PURPOSE OF ITS PRODUCT FOR ANY GIVEN USE OR APPLICATION All information on parts not manufactured by GAMA and based on the statements of the original manufacturer is given without warranty or liability of any kind express or implied even if considered accurate and reliable Under no circumstances shall the transfer sale or financial leasing of the Product by GAMA constitute express or implied authorization assent or permission for the use of rights or patents or provide grounds for encourage or endorse their violation Warranty restrictions do not limit the legal rights of the consumer as provided in applicable national legislation or affect the rights deriving from the purchase agreement between consumer and provider 2 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual All of the information in this Service Manual is given in good faith but is not subject to any implied or explicit warranty GAMA reserves the right to make the necessary improvements and modifications to this Service Manual at
12. Pa 2 489 psi Maximum output at 1 1 ratio 4 kg min 9 Ib min Minimum output 1 kg min 2 2 lb min Length of recirculation hose 11m Maximum heated hose length 230V 15m Recommended compressor 1 HP single phase Approximate weight 165 kg Dimensions H 1165 mm W 605 mm D 744 mm 6 46 Issue 1 0 Ref NR 00088 ENG http www gamapur com Canis Easy Spray H Service Manual OVERVIEW Figure 1 General view 7 46 Issue 1 0 Ref NR 00088 ENG http AWwww gamapur com Easy Spray H Service manual 1 isocyanate tank Contains chemical component A Capacity 30 litres 2 Polyol tank Contains chemical component R Capacity 30 litres 3 Isocyanate recirculation valve recirculation hoses only Enables selection between recirculation and spray for the isocyanate circuit 4 Polyol recirculation valve recirculation hoses only Enables selection between recirculation and spray for the polyol circuit 5 Hoses with built in heating 230V Keeps spray products at the right temperature 6 Hose temperature sensor heated hoses only Monitors the temperature of the spray products 7 Control panel Controls the correct operation of the unit 8 lIsocyanate proportioning pump Delivers metered quantities of isocyanate to the system 9 Polyol proportioning pump Delivers metered quantities of polyol to the system 10 Ilsocyanate heater Heats the isocyanate to the pre set temperature 11 Polyol he
13. To avoid excess pressure in the heating hoses wait for the products contained in the hoses to reach the required temperature before starting the hydraulic system g Press the MOTOR button The LED will light up Once the above operations have been completed you now have to check the direction of rotation of the motor Proceed as follows to make sure the motor is rotating in the clockwise direction h 5 O O Sr Nr 23 46 Rotate the hydraulic pressure regulator in the anticlockwise direction as far as it will go Rotate the power switch to the ON position The upper pilot light goes on Press the CONTROL POWER button Position yourself so that you can see the motor fan on the side of the unit Press the MOTOR button to start the motor then press it again to stop the motor Check that the fan blades are turning in the clockwise direction Rotate the hydraulic pressure regulator in the anticlockwise direction as far as it will go Rotate the power switch to the ON position The upper pilot light goes on Press the CONTROL POWER button Press the MOTOR button The LED will light up Press the NORMAL button The LED will light up One of the direction indicator lights comes on and the proportioning pumps begin to operate If necessary rotate the hydraulic pressure regulator to reach the required pressure and check the pressure of each proportioning pump on the respective pressure gauges at the unit s outlets The hydra
14. any time and without prior notice with the intention of rectifying possible typographical errors expanding on existing information or incorporating changes to the characteristics and performance of the unit SAFETY AND HANDLING The Easy Spray H proportioning unit is designed and manufactured in accordance with the European Machinery Directive 89 392 EEC as modified by the legislation which transposed it to national statutes It also complies with European directives on electromagnetic compatibility and electrical safety as well as applicable Harmonized Standards This section contains important information on the safe handling and operation of the Easy Spray H proportioning unit Before preparing the unit and starting it up please take the time to read all the technical and safety instructions in this manual It is essential that you follow these instructions carefully so that you can handle and use the unit properly These instructions are intended to maximize user safety and avoid malfunctions deriving from the incorrect use of the unit A DANGER indication alerts you to situations which may result in serious injury if the instructions are not followed A WARNING indication gives information on how to avoid damaging the unit and situations likely to cause minor injury A NOTE indication provides useful information on the procedure in question Read this manual carefully to familiarize yourself with the unit s characterist
15. ater Heats the polyol to the pre set temperature 12 Isocyanate pressure gauge Indicates the pressure in the isocyanate circuit 13 Polyol pressure gauge Indicates the pressure in the polyol circuit 14 Isocyanate heater sensor Provides information on the temperature of the isocyanate heater 15 Polyol heater sensor Provides information on the temperature of the polyol heater 16 Isocyanate intake filters Prevent solid particles from the entering the unit s isocyanate pump 17 Polyol intake filters Prevent solid particles from the entering the units polyol pump 18 Hydraulic pressure gauge Indicates the pressure of the hydraulic circuit 19 Ilsocyanate circuit safety pressure switch Shuts off the solenoid valve in the event of excess pressure in the isocyanate circuit 20 Polyol circuit safety pressure switch Shuts off the solenoid valve in the event of excess pressure in the polyol circuit 8 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual 21 Hydraulic pressure regulator Enables the pressure of the hydraulic circuit to be increased or reduced To increase pressure turn the tap clockwise to reduce pressure turn the tap anti clockwise The NORMAL or RETRACT commands must be active before you can adjust the pressure of the hydraulic circuit The hydraulic circuit should be regulated to ensure that the unit s output pressure never exceeds the working pressure of
16. ature control system is working ISO or POL the limit temperature value is the higher of the two heater settings Maximum temperature settings are 80 C for hoses and 90 C for heaters 11 46 Issue 1 0 Ref NR 00088 ENG http www gamapur com Easy Spray H Service manual The sequence for entering commands is as follows e First we set the temperature of the ISO and POL heaters e Next we set the temperature of the ISO hoses e Then we set the hose current consumption in amps e Finally we enter the cycle preselector setting If the temperature control sensor is not active the symbol appears on the display and the heating switches off In versions with a transformer the lower pushbutton on the transformer switches the hose heating on and off This pushbutton incorporates an LED which lights up when the heating is operating a flashing LED indicates that the heater is on but is not heating up The hose heating command is not memorized by the unit and therefore it must be activated on every power up To select intensity when the unit is working in manual heating control mode press the MODE button then the UP DOWN buttons to reach the desired value Then press the MODE button again to confirm the new setting The table below shows the amp settings necessary for reaching the required working temperatures 3 0A 38 C 100 F 3 5 A 48 C 118 F 4 0 A 60 C 140 F 4 5A 75 C 167 F 5 0A 80 C 194 F Select the requi
17. by a problem in the pumping system operate the spray gun and check the reading on the pressure gauge of the missing component Compare this reading with the pressure indicated on the other component s pressure gauge if the pressure of the missing component is higher the pressure imbalance is caused by an obstruction if it is lower the imbalance is due to a problem in the pumping system 3 Cavitation Cavitation occurs when the proportioning pump requires a greater volume of material than the feed system is supplying giving rise to the formation of voids in the proportioning pump There are three possible causes of cavitation a High viscosity Polyurethane foam spray systems normally require a minimum transfer temperature of 12 C at lower temperatures the viscosity of the component products increases and it is more difficult to pump them When ambient conditions do not allow the component products to be kept at the minimum temperature of 12 C auxiliary heating equipment must be used to keep the component products at the minimum required transfer temperature b The product intake filter is clogged see Maintenance c The intake ball valve is leaking as a result of wear or defects in the ball or the closing surface of the bushing which causes some of the material to return to the tank Therefore the volume of material delivered by the proportioning pump in the discharge cycle is lower than required giving rise to an incorrect produ
18. ch should indicate the date of purchase and serial number GAMA reserves the right to withhold the provision of Warranty where the aforementioned information does not appear on the invoice or has been altered after the purchase of the Product b The repaired or replaced Product shall be covered by the original Warranty for the time remaining until its expiry or for three 3 months subsequent to the repair date where the remaining Warranty period is shorter c This Warranty does not apply to Product malfunctions caused by its defective installation natural wear of parts its use for purposes other than those considered normal for this Product or in a manner which does not strictly comply with the instructions for use provided by GAMA accident recklessness or adjustments alterations or modifications to the Product not authorized by GAMA or the use of accessories heating devices pumping apparatus and or dispensers not approved or manufactured by GAMA d Parts and accessories which are part of the Product and not manufactured by GAMA are covered by the warranties offered by their original manufacturers GAMA SHALL HONOUR NO VERBAL OR WRITTEN WARRANTY OTHER THAN THE PRESENT LIMITED WARRANTY IN ITS PRINTED FORM ALL IMPLIED WARRANTIES INCLUDING AND WITHOUT LIMIT FITNESS FOR A PARTICULAR PURPOSE EXPIRE WHEN THIS WRITTEN GUARANTEE EXPIRES GAMA SHALL NOT BE HELD LIABLE FOR ANY DAMAGE OR LOSSES CAUSED BY THE DEFECTIVE PERFORMANCE OR OPERATION O
19. ct ratio 4 Fault in the direction change sensor The hydraulic cylinder which drives the proportioning pumps is fitted with two inductive sensors which control its change of direction Accidental displacement from the detection position will mean the pumps do not change direction and so the sensor has to be returned to it correct position The only way to adjust the position of the sensors is by inserting them to a greater or lesser degree in the cylinder body 5 Tank empty As there is no way of visually checking the level of product in the tanks during the normal operation of the unit there is a risk that air will enter the circuit if the level in one tank is too low This will cause the pumping system to malfunction If this problem occurs purge the air from the circuit as described in the corresponding section on p 19 hoses with recirculation or p 22 heated hoses 37 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual Hydraulic drive WARNING Before attempting to fix any kind of malfunction make sure that no lights are lit on the control panel the power switch is set to the OFF position and the unit is disconnected from the power supply Never open the electrical console when the unit is connected to the power supply The hydraulic motor operates under pressure Do not release any connection or perform repair or maintenance work on components subjected to pressure until all pressures
20. d and that the pump is correctly primed Remove the pump drain coupler and fill the pump if necessary Another cause of pump noise is excessive temperature of the hydraulic oil Make sure the oil is being delivered in the correct quantity and if necessary improve ventilation to allow greater dissipation of heat from the hydraulic tank 38 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual MAINTENANCE To obtain optimum performance from the Easy Spray H unit you must perform certain maintenance operations on a daily or regular basis beO gt p 39 46 To avoid bodily damage caused by the incorrect handling of the substances and solvents used with this unit read carefully the safety information provided by their suppliers Dispose of waste as required by applicable legislation Disconnect the unit from the power supply before opening the electrical console Electrical maintenance should only be carried out by a qualified electrician To avoid exposure to pressurized fluids do not release any connectors or perform maintenance work on parts subjected to pressure until the pressure has been completely eliminated Use suitable protection when using or performing maintenance on the unit or when in its vicinity This protection includes but is not limited to the use of masks protective goggles gloves safety footwear and safety clothing This unit includes parts which reach tempe
21. duct tanks with DOP cleaning agent approx 5 litres Open the manual purge valves located under each tank Make sure the taps on the coupling block in the case of heated hoses or the recirculation taps in the case of hoses with recirculation are closed Rotate the power switch to the ON position Press the CONTROL POWER and MOTOR buttons Press the RETRACT button and wait for the proportioning pumps to descend into the retract position Press the RETRACT MOTOR and CONTROL POWER buttons to stop the proportioning pumps Rotate the power switch to the OFF position Reduce product pressure by opening the taps on the coupling block in the case of heated hoses or the recirculation taps in the case of recirculation hoses and then closing them To prevent product leakage and the premature wear of pump packing seals do not reduce pressure to zero We recommend keeping the system at a minimum pressure of 30 bars to prolong the service life of packing seals Proportioning pumps heaters and hoses should always be filled with DOP plasticizer when the unit is not in use Never leave the unit or its hoses empty of product or DOP plasticizer 31 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual MALFUNCTION The Easy Spray H unit has been designed and built to operate in severe working conditions It will work with a high degree of reliability on condition that it is used and maintained correctly
22. ent heaters without gaskets Each heater has two 900 W heating elements delivering total power of 1800 W and the necessary control and safety mechanisms for the correct operation of the system Their special configuration permits a temperature differential AT of 30 C and application temperatures of 80 C under normal ambient temperature conditions Hose heating system The unit features two systems for keeping the products hot while in the hoses e Recirculation hoses maximum length 11 metres e Hose heated by woven elements at 230V fitted with temperature sensor maximum length 15 metres If longer hoses are required a standard Gama hose maximum length 48 metres heated by transformer can be used Proportioning pumps This assembly comprises two positive displacement piston pumps operated by a dual piston hydraulic cylinder The parallel piston pump configuration ensures constant volume and guarantees uniformity of pressure in both directions of pump movement 5 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual TECHNICAL SPECIFICATIONS Electrical Voltage 230V Frequency 50 60Hz Connections 1 and 2 2 x 220V phases 1 x 400V phase neutral Connection 1 power consumption 3 3 kW 1 8 kW motor 1 5 kW hoses Connection 2 power consumption 3 6 kW heaters Connection 1 consumption 16A Connection 2 consumption 16A Mechanical Maximum working pressure 175 kgf cm 17 2 M
23. eparation units with heated hose 21 Purge method for heated hoses 22 Power up procedure 25 Power down 27 Cleaning procedure heated hoses 28 Cleaning procedure hoses with recirculation 29 Temporary LAYOFF of the unit 31 Malfunction 32 Heaters 33 Hose heating 34 Proportioning pumps 36 Hydraulic drive 38 Maintenance 39 Heaters 40 Proportioning pumps 41 Product intake filters 41 Isocyanate pump lubrication system 42 Hydraulic drive 43 44 46 Issue 1 0 Ref NR 00088 ENG http www gamapur com Easy Spray H Service Manual Contents 44 List of illustrations 46 45 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual LIST OF ILLUSTRATIONS Figure 1 General view 7 Figure 2 Control panel 10 Figure 3 Hose coupling method 17 46 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com
24. f an alarm for excess temperature in the heaters alarms 6 and 7 or an alarm for excess intensity in the hose heating alarm 9 8 Motor button This button starts and stops the hydraulic motor When pressed this button lights up To switch off the hydraulic motor press this button again The hydraulic motor switches off automatically in the event of hydraulic motor overload alarm 8 The Motor function is only available on units with hydraulic drive 9 Normal button Press this button to activate normal operation When pressed this button lights up 13 46 Issue 1 0 Ref NR 00088 ENG http AWwww gamapur com Easy Spray H Service manual 10 Retract button Pressing this button sets the piston of the isocyanate proportioning pump to the retracted position to prevent product residue from crystallizing on the piston Press the RETRACT button every time you stop the unit When pressed this button lights up 11 Direction indicator lights These lights indicate the direction of movement of the proportioning pumps When there is excess pressure in the system both these lights go out and alarms 3 and 4 are activated The NORMAL and RETRACT buttons remain active 14 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual ALARMS In the event of a malfunction affecting the operation of the unit it emits an audio signal and shows an alarm code on the COUNTER CONTADOR display An alarm cann
25. g the required temperature See the section on heater problems 3 Hose connector Check the hose connector s electrical connection on the left hand side of the console 4 Heating element disconnected Check that the resistance reading in the hose is 330 20 5 F4 automatic switch Protects against current spikes in the hose circuit This switch is located inside the control panel Check that it is set to the ON position If the switch is not working properly replace it with one of equal amperage WARNING Replacing the automatic switch with another of different characteristics can damage the unit and endanger the safety of the operator 6 Triac If the other checks have not revealed any problems check the triac Replace the triac if it is not working properly 7 TCS temperature control sensor Temperature sensor malfunctions are automatically displayed on the control panel To determine whether the fault is caused by the sensor itself or by a defective electrical connection perform the following check unscrew the temperature control sensor s electrical connector from the end of the hose and without removing any other connection connect it directly to the unit s electrical outlet If the control function reappears check the electrical connections of the temperature control sensors at both ends of the hose and if necessary replace the temperature control sensors 8 Adjusting the hose heating temperature The purpose of the
26. ges With the power disconnected open the control panel and make sure the switch is primed see circuit diagram If not prime it 4 Temperature sensor Temperature sensor malfunctions are automatically displayed on the control panel In the event of a malfunction replace the sensor being careful not to damage it during installation The sensor should be in contact with the element Hose heating WARNING Before attempting to fix any kind of malfunction make sure that no buttons are lit on the electrical panel that the power switch is in the OFF position and that the unit is disconnected from the power supply Never open the electrical console when the unit is connected to the power supply Hoses can reach high temperatures Always wait until they have cooled down before handling them Follow the procedure below in the sequence given to rectify the problem and avoid expensive repairs Check that all automatic switches are in the correct working position before proceeding to locate faults PROBLEMS SOLUTIONS The hose heats up but does not reach the programmed temperature 1 2 8 The hose does not heat up but the LED is lit 3 4 5 6 The symbol appears on the hose display 7 The automatic switch trips 3 34 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual SOLUTIONS 1 Hoses without product or air pockets in hoses Purge the air from the hoses 2 The ISO heater is not deliverin
27. hose heating system is to keep the temperature of the products in the hose at the same temperature as they left the heaters Therefore the maximum hose temperature setting 80 C is the same as the maximum setting on the heaters display 35 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual Proportioning pumps WARNING Before attempting to fix any kind of malfunction make sure the power switch is in the OFF position and that the unit is disconnected from the power supply Never open the electrical console when the unit is connected to the power supply Proportioning pumps work under pressure Do not release any connection or perform repair or maintenance work on components subjected to pressure until all pressures have been completely eliminated PROBLEMS SOLUTIONS The pumps lose pressure when the unit is stopped 1 The pressure readings in the proportioning pumps are different 1 2 3 There is cavitation in the proportioning pump 1 2 3 The proportioning pumps do not reverse direction 4 The proportioning pumps do not move 4 The movement of the proportioning pumps is erratic 4 5 SOLUTIONS 1 Pressure loss in ball valves Observe the pressure gauges to identify which pump is losing pressure To determine which ball valve is faulty check in which direction of movement the pump loses pressure If pressure is lost in the upward stroke check the discharge upper ball valve If pressure is lost on
28. ics and operating procedures By following the instructions and recommendations contained in this manual you will reduce the risk of accidents in the preparation use and maintenance of the unit ensuring incident free operation for a longer time improved performance and the quick and easy detection of problems Keep this Service Manual handy for reference at all times If you lose this manual ask for a new copy from your local GAMA distributor or directly contact Garraf Maquinaria S A WARNING The Easy Spray H proportioning unit is not designed for use in potentially explosive environments Pressure and temperature must not exceed the limits indicated in the technical specifications of this manual 3 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual When working with the unit it is essential that you wear suitable clothing and personal protective equipment including but not limited to gloves protective goggles safety footwear and face masks Use breathing equipment when working with the unit in enclosed spaces or in areas with insufficient ventilation The safety measures given in in this manual are part of a wider safety procedure Before powering up the unit you must perform a comprehensive analysis of the risks associated with the products it dispenses the type of application and the working environment bO gt p 4 46 To avoid bodily damage caused by the incorrect handling of the
29. ing filled with product Never swap parts between one tank and the other and always use the same tank for the same product WARNING To prevent cross contamination of products make sure the tanks are properly closed To avoid spillage during transportation of the unit never fill the tanks completely always leave about 20 of the tank capacity free each tank holds 30 litres We recommend using small vessels 10 15 litres maximum for pouring product into the tanks Fill the tanks with the amount of product required for each application Purge method for heated hoses Before using the unit all air pockets and residual oil from in factory testing must be eliminated To purge the full circuit proceed as follows a Open the manual purge valves located under each tank b Place the coupling block so that each product drains into a separate recipient and open the manual valves of each product c Rotate the power switch to the ON position The upper pilot light goes on d Press the CONTROL POWER button The LED will light up 22 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual e f Press the button located under the HOSES MANGUERAS display The LED inside the button will light up When the products contained in the hoses have reached working temperature press the ISO and RESIN buttons located under the HEATERS CALENTADORES display Both LEDs will light up WARNING
30. iven to rectify the problem and avoid expensive repairs Check that all automatic switches are in the correct working position before proceeding to locate faults PROBLEM SOLUTIONS The heater does not heat up although the LED in the heater button is lit 1 2 3 The symbol appears on the heater display 4 SOLUTIONS 1 Heating elements Each heater contains two 900 W heating elements connected in parallel and delivering a total heating power of 1800 W Easy Spray H model If a heater fails to reach the required temperature after two or three minutes it s possible that one of its two elements is faulty To check the elements proceed as follows With the power switch in the OFF position use a tester to check the total resistance of the heater which should be 30 Ohms A higher reading may indicate that one or more elements are faulty 33 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual Disconnect the elements and check that the individual resistance of each element is 60 Ohms Extreme environmental conditions may affect the operation of the heaters preventing them from reaching the required temperature In such circumstances try moving the unit to a warmer location or use an auxiliary heating system 2 Static relay If the above checks have not revealed any problems check the static relay 3 Automatic switch The automatic switch protects the heating elements against voltage sur
31. ke sure the taps on the coupling block are closed Z Rotate the power switch to the ON position aa Press the CONTROL POWER MOTOR and NORMAL buttons to start the proportioning pumps bb Check that the product pumps are working cc Let the cleaning agent drain from the recirculation tubes until the tanks are empty dd Press the NORMAL MOTOR and CONTROL POWER buttons to stop the proportioning pumps The displays on the temperature regulators will go out ee Rotate the power switch to the OFF position ff Close the manual valves located below each product tank gg Close the manual recirculation valves hh Proceed as indicated in the instructions for preparing the unit 30 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual TEMPORARY LAYOFF OF THE UNIT WARNING This unit includes parts which reach temperatures likely to cause burns Do not touch or handle the hot parts of the unit until they have cooled down When the unit is to be out of service for over five weeks you must replace the products contained in the unit with DOP plasticizer Follow the steps given below to replace the products with DOP plasticizing agent NOTE If the products contained in the unit can be reused save them to suitable recipients following the instructions of the supplier Perform the cleaning procedure for hoses with recirculation see p 29 or heated hoses see p 28 as appropriate Fill the pro
32. l and replace the heater cap NOTE If the element to be replaced is the element in contact with the temperature sensor first remove the sensor 2 Temperature sensor The temperature sensor is secured to the hose coupling with a ferrule and a torque nut Once inserted in its housing the ferrule forms part of the sensor and may not be moved out of position Check that the sensor has been correctly inserted before securing it in place with the torque nut a Depressurize the unit and disconnect it from the power supply Check that the body of the coupler inserted in the heater is correctly tightened to prevent leaks b Fit the heating element c Fit the torque nut and ferrule to the sensor and insert the sensor into the body of the connector until it touches the heating element Make sure the spring inside the heater is not impeding contact between the sensor and the element d Secure the sensor and tighten the locking nut 40 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual Proportioning pumps WARNING Before proceeding to any kind of maintenance work make sure the power switch is in the OFF position and that the unit is disconnected from the power supply Never open the electrical console when the unit is connected to the power supply Proportioning pumps work under pressure Do not release any connection or perform repair or maintenance work on components subjected to pressure until al
33. l pressures have been completely eliminated Proportioning pumps must be specially serviced annually they should be completely dismantled to check that linings or pistons do not exhibit scratches or other signs of friction which may cause leaks and damage the pump s gaskets and seal rings All components subject to wear principally o rings and oil seals should be replaced as a preventive maintenance measure The distributor bases of the pumps should also be inspected to make sure the ball valves do not exhibit any signs of wear impact or marks which may affect the correct operation of the pump Product intake filters Filter bodies are fitted with an inner mesh which prevents solid particles from entering the unit and potentially interfering with the operation of the ball valves when the product is taken into the unit Filters should be inspected and cleaned daily as part of the power up routine Replace the inner mesh if necessary lsocyanate is a product which crystallizes under the action of ambient humidity or freezing To minimize the risk of contaminating the isocyanate filter make sure the product is properly stored and decanted and the operating procedures are followed NOTE The isocyanate intake filter should be cleaned every day before starting the unit Do not clean the filter after stopping the unit To reduce the risk of absorption of humidity and the possibility of contamination by reaction with the cleaning solvent begin sp
34. lic motor e Check the electrical connections of the hydraulic motor e Check LED no 15 on the printed circuit board it should be off NOTE Alarm 8 motor malfunction is only included in units with hydraulic drive 15 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual 9 Hose heating system malfunction CONTROL POWER cut out e Replace the faulty triac 000000 Preselected cycles completed solenoid valve cut out e Press the MODE button to reset the counter e Set the cycle selector to zero Disconnect the unit from the power supply before opening the electrical console Electrical maintenance of the machine should only be carried out by a qualified electrician 16 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Canis Easy Spray H Service Manual PREPARING THE UNIT FOR OPERATION WARNING Use suitable protective gear and follow the safety recommendations of the suppliers of the chemical components when preparing or working with the unit GAMA provides a set of tools and accessories for servicing the unit This set comprises the following elements 12 adjustable spanner 6 adjustable spanner universal pliers screwdriver Allen keys wrench oil can tube of grease magnet holder gauge for position sensors parts manual and service manual NOTE To ensure the correct operation of the unit the electrical power supply must meet the specifications given on
35. ludes parts which reach temperatures likely to cause burns Do not touch or handle the hot parts of the unit until they have cooled down To avoid the risk of crushing or amputation only use this unit when its moving parts are fitted with correctly installed safety guards Make sure all safety guards are correctly mounted after completing repair or maintenance work Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Canis Easy Spray H Service Manual Heaters WARNING Before attempting to fix any kind of malfunction make sure that no buttons are lit on the electrical panel that the power switch is in the OFF position and that the unit is disconnected from the power supply Never open the electrical console when the unit is connected to the power supply Heaters can reach high temperatures Always wait until they have cooled down before handling them NOTE The thermostat is a safety device which is in contact with the heater If the temperature exceeds 120 C 248 the thermostat will cut off the power supply to the TERMOSTATO DE temperature regulator The thermostat will not SEGURIDAD start working again until the temperature of the heater falls below 120 C 248 F If the temperature of either heater isocyanate or polyol exceeds 90 C 194 F an alarm will activate and the corresponding number will appear on the control panel 5 for isocyanate and 6 for polyol Follow the procedure below in the sequence g
36. n into the recipient from the recirculation hoses until the tanks are completely empty k Press the NORMAL MOTOR and CONTROL POWER buttons to stop the proportioning pumps The displays on the temperature regulators will go out I Rotate the power switch to the OFF position m Close the manual valves located below each product tank Fill the product tanks with DOP cleaning agent approx 5 litres o Open the manual purge valves located under each tank h Nr Close the recirculation valves for each product Reconnect the recirculation hoses to their respective tanks and re open the recirculation valves r Rotate the power switch to the ON position s Press the CONTROL POWER MOTOR and NORMAL buttons to start the proportioning pumps 29 46 Issue 1 0 Ref NR 00088 ENG http www gamapur com Easy Spray H Service manual t Let the unit recirculate for 2 3 minutes to clean the hoses and tanks For better tank cleaning results heat the cleaning agent with the heaters u Press the NORMAL MOTOR and CONTROL POWER buttons to stop the proportioning pumps The displays on the temperature regulators will go out v Rotate the power switch to the OFF position w Close the recirculation valves located under each product tank x Disconnect the recirculation tubes from the isocyanate and polyol tanks and place them in separate waste recipients y Open the recirculation valves located under each product tank and ma
37. ns Increase or decrease the value of each parameter 6 Counter Contador This display indicates the number of cycles completed and the number of cycles remaining The cycle counter is incremental and can be reset to zero by pressing the UP and DOWN buttons simultaneously The system offers a certain number of work cycle pre selects When the unit completes the pre selected number of cycles it stops dispensing product To enter the desired number of cycles press and hold the MODE button until the cycle counter starts flashing then select the number of cycles by pressing the UP DOWN buttons as required Then press the MODE button again to confirm the number of cycles When the unit starts the number of completed cycles is deducted from the number of pre set cycles When all the pre set cycles have completed the counter displays zero and the unit stops The counter display alternately shows at intervals of two or three seconds the number of cycles completed totalizer and cycles remaining preselector The remaining cycles are displayed with a minus sign in front KXXXX The cycle counter display also shows alerts in the event of malfunction 7 Control Power button This button controls the power switch providing electrical power to the heating circuits of the heaters and hoses When pressed this button lights up To disconnect the power supply press this button again The power supply automatically cuts out in the event o
38. ntact your supplier for information on the minimum delivery temperature h Check the product intake filters Clean them if necessary i Rotate the power switch to the ON position The upper pilot light goes on j Press the CONTROL POWER button The LED will light up k Press the button located under the HOSES MANGUERAS display The LED inside the button will light up When the products contained in the hoses have reached working temperature press the ISO and RESIN buttons located under the HEATERS CALENTADORES display Both LEDs will light up 25 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual WARNING To avoid excess pressure in the heating hoses wait for the products contained in the hoses to reach the required temperature before starting the hydraulic system m Press the MOTOR button The LED will light up n Press the NORMAL button The LED will light up One of the direction indicator lights comes on and the proportioning pumps begin to operate o Rotate the hydraulic pressure regulator to reach the required pressure and check the pressure of each proportioning pump on the respective pressure gauges at the unit s outlets The hydraulic circuit should be regulated to ensure that the unit s output pressure never exceeds the working pressure of the product hoses fitted to the unit p Set the isocyanate heater temperature q Set the polyol heater temperature r Set
39. o prevent product leakage and avoid heating system malfunction make sure the hoses are correctly connected electrically and mechanically b Connect the air hose to the unit s power socket and to the gun c Connect the 60 cm whip hose to the gun s coupling block connectors making sure the manual valves are closed d Fit the temperature control sensor with its extension nozzle between the heated hose and the whip hose connected to the gun Carefully insert the sensor cable into the heated isocyanate hose NOTE Once fitted with a temperature control sensor hoses should be handled with care and should not be folded to excess When coiling the hoses make sure the winding radius is at least one metre 21 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Fistral Easy Spray H Service manual e Insert a contact thermometer under the hose s outer sheath so that the lower part of the thermometer is in contact with the hoses and the upper part projects from the hose s outer sheath Position the thermometer in such a way that you can see the temperature while spraying With hoses incorporating a temperature control sensor there is no need to fit a contact thermometer f Fill the tanks with their respective product WARNING When handling chemical products always follow the supplier s safety and storage instructions To prevent splash contamination between one tank and the other open only the cap of the tank be
40. ore operating the DIP switch 9 46 Issue 1 0 Ref NR 00088 ENG http AWwww gamapur com si Easy Spray H Service manual CONTROL PANEL PLURAL COMPONENT PF OPORTIONER COUNTER CON AGOS Figure 2 Control panel The control panel enables you to set the optimum operating conditions for the characteristics and requirements of the products dispensed Press the MODE button to enter the desired settings for temperature intensity and number of cycles to run The selected parameter remains flashing for a few seconds allowing you to change the values by touching the UP DOWN buttons After changing the value press the MODE button again to confirm your selection The parameter modification function automatically cancels after a few seconds if there is no further activity on the buttons The parameters that can be selected and viewed are e Hose temperature in automatic control mode maximum 80 C e Hose heating intensity in manual control mode maximum 5 0 amps e lsocyanate heater temperature maximum 90 C e Polyol heater temperature maximum 90 C e Number of cycles to run e Number of cycles completed 10 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual 1 Power switch Connects and disconnects the unit from the electricity supply This switch must be in the ON position for the unit to work When this switch is in the ON position the green pilot light above
41. ot be cleared until the problem which caused it has been resolved After clearing the alarm press the MODE button Procedures for determining the causes of alarms are given below 1 Operating voltage under 170V e Check the electrical power connection e Check the transformer s thermomagnetic protection 2 Operating voltage above 270V e Check the electrical power connection 3 Excess pressure ISO solenoid valve and heating system cut out e Check product pressure e Check LED no 10 on the printed circuit board it should be on e Check the safety pressure switch 4 Excess pressure POL solenoid valve and heating system cut out e Check product pressure e Check LED no 11 on the printed circuit board it should be on e Check the safety pressure switch 5 Excess temperature ISO CONTROL POWER cut out e Check the heater heating system e Check the safety pressure switch connection and allow it to cool down so it can automatically reset e Check LED no 12 on the printed circuit board it should be on 6 Excess temperature POL CONTROL POWER cut out e Check the heater heating system e Check the safety pressure switch connection and allow it to cool down so it can automatically reset e Check LED no 13 on the printed circuit board it should be on 7 Button malfunction only active when machine is connected to the power supply e Check the buttons 8 Motor malfunction motor stoppage e Check the consumption of the hydrau
42. p 6 of this manual and on the unit s rating plate The hoses have been subjected to a vacuum drying treatment and are delivered with their ends joined to prevent humidity from entering them Do not separate them until the moment they are to be fitted to the unit Proceed as follows to prepare the unit a Remove the front protective covering from the pump guides and fill the lube reservoir of the isocyanate pump with DOP plasticizer b Connect the hose for each product to the outlet of its respective heater the isocyanate hose to the isocyanate heater and the polyol hose to the polyol heater NOTE The hoses are colour coded for easy identification red for isocyanate and blue for polyol To prevent connection errors the isocyanate and polyol hose couplers are of different sizes which makes it impossible to connect a hose to the wrong heater Figure 3 Hose coupling method 17 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Fistral Easy Spray H Service manual WARNING To join hoses to each other to the heaters or to the gun hold each hose end in place with a spanner 1 and with a third spanner tighten or loosen the coupling nut 2 as required see Figure 3 17 These couplers should be tightened to a torque of 20 Nm c Put 22 litres of hydraulic oil in the unit s oil tank The oil should comply with the characteristics and specifications of standard DIN 51524 sections 1 and 2 for example ISO VG 46
43. ratures likely to cause burns Do not touch or handle the hot parts of the unit until they have cooled down To avoid the risk of crushing or amputation only use this unit when its moving parts are fitted with correctly installed safety guards Make sure all safety guards are correctly mounted after completing repair or maintenance work Issue 1 0 Ref NR 00088 ENG http www gamapur com Easy Spray H Service manual Heaters WARNING Before proceeding to any kind of maintenance work make sure the power switch is in the OFF position and that the unit is disconnected from the power supply Never open the electrical console when the unit is connected to the power supply Heaters can reach high temperatures Always wait until they have cooled down before handling them 1 Heating elements To replace a defective heating element proceed as follows a Depressurize the unit disconnect it from the power supply and remove the heater cap b Disconnect the element from the terminal block using the appropriate tool loosen the element and remove it from its housing The element should be smooth and shiny in appearance If it is blackened or shows accretions of material replace it c Check the new element with a tester the resistance reading should be 60 Ohms d Apply PTFE or thread locking compound and screw the element into place in its housing e Re connect the cables in the terminal block make sure the connection is paralle
44. raying immediately after cleaning the filter To check the product intake filters proceed as follows a Disconnect the unit from the power supply and close the tap valve regulating the intake of the product into the filter to be checked b Place a suitable recipient underneath the filter to collect the product that comes out Carefully loosen the filter cap to allow the product to drain into the recipient Unscrew the cap completely c Remove the gasket the spring and the mesh and clean all components with the solvent used for cleaning the gun Dry the components and check there are no obstructions in the mesh All mesh orifices should be completely clear Replace the mesh if over 10 of its surface area is clogged d Put the mesh the spring and the gasket back in place Screw the cap in place e Open the valve tap regulating the intake of product into the filter check there are no leaks and proceed with normal operations 41 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual Isocyanate pump lubrication system Inspect the isocyanate pump lube reservoir every day and check the condition of the DOP plasticizer oil it contains Replace the oil if it is discoloured or exhibits signs of solidification DOP oil solidifies as a consequence of moisture absorption The frequency of oil changes depends on the working conditions Discolouration of the oil is due to the thin film of isocyanate which i
45. red amp setting for rapid preheating When you select an intensity higher than 3 5 amps this setting will self regulate down to 3 5 amps after 20 minutes The intensity setting cannot be increased above 3 5 amps until the hose heaters are switched off and back on again The setting entered is stored for the next time the heating is switched on 12 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual 3 Heaters Calentadores This display shows the temperatures in the isocyanate ISO and polyol RESIN heaters To enter new temperature settings press the MODE button select the desired temperature by pressing the UP DOWN buttons and press the MODE button again to confirm the selected value The lower pushbuttons switch the heater of each product on and off Each pushbutton incorporates an LED which lights up when the heater is operating a flashing LED indicates that the heater is on but is not heating up The heater will temporarily stop working in the event of excess pressure in either of the heating circuits and will switch on again once the problem has disappeared If the temperature control sensor is not active the symbol will appear on the display and the heater will switch off The hose heating command is not memorized by the unit and therefore it must be activated on every power up 4 Mode button Press this button to modify the different control parameters 5 Up Down butto
46. rvice Manual aa When the products contained in the hoses have reached working temperature press the ISO and RESIN buttons located under the HEATERS CALENTADORES display Both LEDs will light up bb Press the MOTOR button The LED will light up cc Press the NORMAL button The LED will light up One of the direction indicator lights comes on and the proportioning pumps begin to operate The unit is now ready to operate Preparation units with heated hose The 15 m heated hose assembly includes a power supply socket and a terminal for temperature control WARNING Use suitable protective gear and follow the safety recommendations of the suppliers of the chemical components when preparing or working with the unit NOTE To ensure the correct operation of the unit the electrical power supply must meet the specifications given on p 6 of this manual and on the unit s rating plate After following steps a b c and d of the preparation procedure see p 17 follow the procedure given below to prepare the unit to work with heated hoses a Connect the hose heating temperature control cable to the connector on the side of the electric cabinet WARNING To join hoses to each other to the heaters or to the gun hold each hose end in place with a spanner 1 and with a third spanner tighten or loosen the coupling nut 2 as required see Figure 3 on p 1717 These couplers should be tightened to a torque of 20 Nm NOTE T
47. s deposited on the pump piston when the pump is operating The plasticizing oil needs to be changed less frequently if the seal rings and gaskets are in good condition To replace the plasticizing oil in the pump proceed as follows a Operate the spray gun until the isocyanate proportioning pump is at the highest point on its upward stroke Rotate the power switch to the OFF position b Disconnect the unit from the power supply c Remove the protective panels from the pump guides d Remove the DOP oil contained in the chamber the clean the chamber and the pump piston to eliminate any residue of contaminated oil or crystallized accumulations Use a wooden or plastic implement to clean the piston Fill the chamber with new DOP plasticizing oil 42 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual Hydraulic drive WARNING Before proceeding to any kind of maintenance work make sure all lights on the control panel are off the power switch is in the OFF position and the unit is disconnected from the power supply Never open the electrical console when the unit is connected to the power supply The hydraulic motor operates under pressure Do not release any connection or perform repair or maintenance work on components subjected to pressure until all pressures have been completely eliminated The hydraulic motor should be serviced every year To do this proceed as follows a Depressurize the
48. substances and solvents used with this unit read carefully the safety information provided by their suppliers Dispose of waste as required by applicable legislation Disconnect the unit from the power supply before opening the electrical console Electrical maintenance should only be carried out by a qualified electrician To avoid exposure to pressurized fluids do not release any connectors or perform maintenance work on parts subjected to pressure until the pressure has been completely eliminated Use suitable protection when using or performing maintenance on the unit or when in its vicinity This protection includes but is not limited to the use of masks protective goggles gloves safety footwear and safety clothing This unit includes parts which reach temperatures likely to cause burns Do not touch or handle the hot parts of the unit until they have cooled down To avoid the risk of crushing or amputation only use this unit when its moving parts are fitted with correctly installed safety guards Make sure all safety guards are correctly mounted after completing repair or maintenance work Issue 1 0 Ref NR 00088 ENG http www gamapur com Canis Easy Spray H Service Manual CHARACTERISTICS The Easy Spray H proportioning unit is designed for the application of polyurea chemical systems for polyurethane foaming and certain two component epoxy systems Principal heating system Consists of two independ
49. t c Dismount the gun and leave the coupling block joined to the hoses d Place a recipient below the coupling block to collect the products contained in the tanks and inside the unit e Rotate the power switch to the ON position f Open the taps on the coupling block and press the CONTROL POWER MOTOR and NORMAL buttons to start the proportioning pumps g Let the materials drain into their recipients from the coupling block until the tanks are completely empty h Press the NORMAL MOTOR and CONTROL POWER buttons to stop the proportioning pumps The displays on the temperature regulators will go out i Rotate the power switch to the OFF position j Close the manual valves located below each product tank k Close the taps on the coupling block I Fill the product tanks with DOP cleaning agent approx 5 litres m Rotate the power switch to the ON position n Open the manual purge valves located under each tank o Open the taps on the coupling block and press the CONTROL POWER MOTOR and NORMAL buttons to start the proportioning pumps p Let the DOP cleaning agent drain into the recipient from the coupling block until the tanks are completely empty q Press the NORMAL MOTOR and CONTROL POWER buttons to stop the proportioning pumps The displays on the temperature regulators will go out r Rotate the power switch to the OFF position s Close the manual valves located below each product tank t Close the taps on the co
50. the downward stroke check the intake lower ball valve Proceed as follows to check the ball valves a Disconnect the unit from the power supply and shut the stop valves controlling product intake underneath the tanks b Depressurize the proportioning pump and dismount the faulty ball valve c Pressure loss in ball valves is usually caused by foreign particles which prevent the ball from coupling perfectly with the seat in the upper part of the closing bushing Clean the ball and the surface of the bushing seat and check there are no nicks marks or scratches on the bushing or the ball If cleaning does not resolve the problem or if any defects are detected replace the bushing and the ball 2 Pressure reading imbalances Pressure reading imbalances occur when an obstruction in the hose or gun prevents one of the spray components from exiting the nozzle during spraying or when a problem in the pumping system prevents one of the components from reaching the gun in the required quantities Identifying which component is causing the imbalance is relatively easy as the component chemical products used in the polyurethane foam spray system are of different colours By observing the colour of the component coming out of the gun you can determine which component is missing 36 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual To ascertain whether the pressure imbalance is caused by an obstruction or
51. the anticlockwise direction as far as it will go Rotate the power switch to the ON position The upper pilot light goes on Press the CONTROL POWER button Press the NORMAL button The LED will light up One of the direction indicator lights comes on and the proportioning pumps begin to operate If necessary rotate the hydraulic pressure regulator to reach the required pressure and check the pressure of each proportioning pump on the respective pressure gauges at the unit s outlets The hydraulic circuit should be regulated to ensure that the unit s output pressure never exceeds the working pressure of the product hoses fitted to the unit Allow the air and oil to escape from the recirculation tubes until there is no more residual oil and the air has stopped gurgling Close the manual recirculation valves for each product Remove any product residue from the recirculation tubes and re connect them to the tanks Slowly increase the hydraulic pressure to check for any product leakage at any point in the circuit Rotate the power switch to the OFF position All displays will switch off Place the gun in the coupling block Rotate the power switch to the ON position The upper pilot light goes on Press the CONTROL POWER button The LED will light up Press the button located under the HOSES MANGUERAS display The LED inside the button will light up Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Se
52. the power switch to the ON position The upper pilot light goes on e Press the CONTROL POWER button The LED will light up f Press the button located under the HOSES MANGUERAS display The LED inside the button will light up 19 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com g Easy Spray H Service manual When the products contained in the hoses have reached working temperature press the ISO and RESIN buttons located under the HEATERS CALENTADORES display Both LEDs will light up WARNING To avoid excess pressure in the heating hoses wait for the products contained in the hoses to reach the required temperature before starting the hydraulic system h Press the MOTOR button The LED will light up Once the above operations have been completed you now have to check the direction of rotation of the motor Proceed as follows to make sure the motor is rotating in the clockwise direction i j k I O O Sr Nr N 20 46 Rotate the hydraulic pressure regulator in the anticlockwise direction as far as it will go Rotate the power switch to the ON position The upper pilot light goes on Press the CONTROL POWER button Position yourself so that you can see the motor fan on the side of the unit Press the MOTOR button to start the motor then press it again to stop the motor Check that the fan blades are turning in the clockwise direction Rotate the hydraulic pressure regulator in
53. ulic circuit should be regulated to ensure that the unit s output pressure never exceeds the working pressure of the product hoses fitted to the unit Open the coupling block manual valves Allow the materials to escape via the coupling block until there is no more residual oil and the air has stopped gurgling Close the manual valves for each product and remove residual product from the coupling block Rotate the power switch to the OFF position All displays will switch off Place the gun in the coupling block Rotate the power switch to the ON position The upper pilot light goes on Press the CONTROL POWER button The LED will light up Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual y Press the button located under the HOSES MANGUERAS display The LED inside the button will light up Zz When the products contained in the hoses have reached working temperature press the ISO and RESIN buttons located under the HEATERS CALENTADORES display Both LEDs will light up aa Press the MOTOR button The LED will light up bb Press the NORMAL button The LED will light up One of the direction indicator lights comes on and the proportioning pumps begin to operate The unit is now ready to operate 24 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual POWER UP PROCEDURE Follow the recommended procedure in the sequence given to power up the
54. unit and disconnect it from the power supply Clean the cap of the hydraulic tank to prevent extraneous matter from falling into the tank during removal of the hydraulic components b Dismount and replace the tank s return filter c Inspect the bottom of the tank through the filter housing to check for the presence of sediment If sediment is present empty the tank completely through the purge hole located on its side WARNING Do not mislay the purge hole cap or gasket Without either of these components you will be unable to refill the tank Clean the interior of the pump intake and drain tubes located inside the tank Clean the bottom of the tank eliminating all sediment d Place the return filter in its operating position e Ifthe tank has been emptied or if it needs more oil fill it up as required WARNING Bear in mind the recommendations on oil see p 18 f Check that the hydraulic pump is full of oil and make sure coupler connections are tight enough for normal operation 43 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service manual CONTENTS Warranty 2 Safety and handling 3 Characteristics 5 Principal heating system 5 Hose heating system 5 Proportioning pumps 5 Technical specifications 6 Electrical 6 Mechanical 6 OVERview 7 Control panel 10 Alarms 15 Preparing the unit for operation 17 Preparation units with recirculation hose 18 Purge method for hoses with recirculation 19 Pr
55. upling block u Proceed as indicated in the instructions for preparing the unit 28 46 Issue 1 0 Ref NR 00088 ENG http Wwww gamapur com Easy Spray H Service Manual CLEANING PROCEDURE HOSES WITH RECIRCULATION WARNING This unit includes parts which reach temperatures likely to cause burns Do not touch or handle the hot parts of the unit until they have cooled down To avoid possible contamination all of the unit s circuits bumps heaters and hoses must be cleaned before applications which require a change of components Follow the steps given below to clean the unit before changing any of its components a Disconnect the isocyanate and polyol recirculation tubes and place them in separate waste recipients NOTE Save reusable products to suitable recipients following the instructions of the manufacturer b Open the manual purge valves located under each tank c Open the manual recirculation valves d Place the tubs containing the DOP cleaning agent near the unit e Dismount the gun and leave the coupling block joined to the hoses Put the recirculation hose end in a recipient to collect the products contained in the tanks and inside the unit g Rotate the power switch to the ON position h Check that the taps on the coupling block are closed and press the CONTROL POWER MOTOR and NORMAL buttons to start the proportioning pumps i Check that the product pumps are working j Let the materials drai

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