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1. The time unit is seconds and the selection range is between 0 and 30 seconds with rises of 1 second Use UP DOWN to increase or decrease the seconds or enter the new value from the numeric keypad Once the requested value has been established press ENTER to confirm and finalize the setup Pumps Product Selection Screen Pieper felum Allows establishing the size of the product pump The available sizes of proportioning product pump are marked in bold cm moved in cm moved in one cycle one cycle o oa ee o o a o f or o2 w ws o a a e O os oa e Use UP DOWN to modify the pump size Once the requested value has been established press ENTER to confirm and finalize the setup 25 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Hydraulic Pumps Selection Screen Helja e Pjes Allows establishing the size of the hydraulic pump The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup Alternative Heating Screen ale lryeleinlalele vE hfe uel ON alternative heating option can be selected to avoid the summing of the total power of the two heaters when the electric resistances 18 Kw are on This way the momentary total power of the heaters 9 Kw is
2. Will show When PRESS CONTROL key is activated and the ISO and POL pressure is out of the established tolerance Out of Tolerance Hose Temperature Alarm Screen elit ref ffe wlole le rE me Will show When TEMP CONTROL key is activated and the ISO and POL temperature in the hoses is out of the established tolerance Empty Material Drum Alarm Screen eme rfv mafri faje forum Will show When the material drums screen is activated and either of both products remains without material Heater Temperature Probe Failure Alarm Screen lere feefee Will show When the ISO or POL heater temperature probe has some fault The temperature visualization display will show Hose Temperature Probe Failure Alarm Screen Will show When the ISO or POL hose temperature probe has some fault The temperature visualization display will show 30 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Disconnect the unit from the main power supply before working on the inside of the electrical console The electrical maintenance of the machine must only be performed by a qualified electrician INSTALLATION CAUTION Use suitable protection and follow the recommendations in the safety information provided by product suppliers when installing or working with the unit GAMA provides a series of tools and accessories necessary for assembling the machine The
3. The unit must be turned off to be able to work on the DIP selector 29 Pressure Transducers DIP Selector This enables the kind of transducers installed in the unit to be selected 4 20 mA 0 10 V the selection will be done in the factory and shall not be modified without previous authorisation from the GAMA technical service L ianei E NOTE The unit must be turned off to be able to work on the DIP selector 10 54 Issue 2 8 Ref NR 00015 ENG http www gamapur com Service Manual evolution VE PLURAL COMPONENT PROPORTIONER ce HEATERS CALENTADORES The Control Panel allows the optimum working conditions to be set and visualized depending on the characteristics and requirements of the products to be dispensed Using the MODE key the different parameters setting and control screens may be entered Use LEFT RIGHT to enter the different parameters Those parameters flashing in the screens can be modified fixed parameters are shown for information By pressing the UP DOWN keys you will be able to increase or decrease the value of each parameter Requested parameters can equally be entered from the numeric keypad Once the required value is set press the ENTER key to confirm set up Main Power Switch Turns the electric supply to the control panel on and off It must be turned ON for any operation to be performed with the unit When turned ON the LCD screen in the control panel will light
4. To determine whether the unbalancing is caused as a result of an obstruction or as a consequence of a problem in the pumping system spray with the gun observe the pressure indicated on the corresponding pressure gauge to the missing component and compare it with the pressure indicated by the gauge to the other component if the pressure of the missing component is higher the unbalancing is the result of an obstruction Should the pressure be lower the unbalancing is the consequence of a problem in the pumping system 3 Cavitation Cavitation occurs when the proportioning pump requires a larger volume of material than that supplied by the feeding system causing the formation of a vacuum in the inlet of the proportioning pump The causes of cavitation are the following a The transfer pump fails to supply the necessary volume The problem might be in the pump not meeting the required specifications in the lack of air supply to the pump or that the pump is faulty A pump is recommended with a ratio of 2 1 for transferring the lsocyanate and a supply hose with an interior diameter of at least 20 mm b High viscosity The polyurethane foaming systems normally require a minimum transfer temperature of 12 C at lower temperatures the product increases its viscosity making the pumping more difficult When the ambient conditions prevent the products from being maintained at a minimum temperature of 12 C auxiliary heating elements must be used
5. Ventilation System The Control Panel is equipped with a fan and an extractor in order to avoid overheating of its electrical components The filters in the fan and the extractor must be cleaned once a month 11 56 issue 2 8 http AWwww gamapur com Ame Service Manual Audible Alarm Should the unit present problems provoked by alterations in the correct functioning an audible alarm warning will sound and will be shown in the LCD screen Press RESET to stop the acoustic sound The system does not allow resetting an alarm if the problem that provoked it has not been resolved Hoses The displays show the temperature of the Isocyanate hose ISO and the temperature of the Polyol hose POL The hose heating control is automatic in this unit To enter or modify the value of the temperature press the MODE key as many times as necessary until you reach the HOSES TEMP screen see page 19 Then press UP DOWN or enter the required value from the numeric keypad Press the MODE key to enter the selected value into memory Repeat the process to select the Amps from the HOSES AMPS screen see page 19 The push buttons turn on or off the hose heating system of each product Each push button has a led that lights when the heater is on if the led flashes it indicates that the system is not heating if the led lights steady it indicates that the system is heating If the TCS stops working the temperature display
6. the POL pressure screen o Press the ISO PUMP key The top led of the key will light The Isocyanate proportioning pump will move alternatively p Press the POL PUMP key The top led of the key will light The Polyol proportioning pump will move alternatively 36 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Check the pressure of each proportioning pump on their respective gauges on the heater outlet The pressures must be practically the same and remain constant If the pressures fluctuate consult the fault section before continuing q Connect the air supply to the gun open the manual valves of each product make a test projection and check the pressures on the product gages Should the projection test be correct and the pressures remain equal proceed with the application 37 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual SHUTDOWN PROCEDURE Follow the recommended procedure in the indicated order for machine shut down when work is stopped for the day a Press the ISO PUMP key The top led of the key will go out b Press the POL PUMP key The top led of the key will go out c Use the gun to project into a waste container until the pressure of the products decreases to around 30 bar and the spray pattern starts to fall CAUTION To avoid possible product leakage and the early failure of the pump seals the pressure must not be reduced to zero It is recommended
7. 00015 ENG http AWwww gamapur com Ame Service Manual NB Do not fill the tank to maximum capacity 128 Lts 34 gal make sure the amount of oil is not more than 80 of its maximum capacity 100 Lts 26 gal Use the visual level indicator of temperature on the tank as a reference because the maximum temperature limit 80 C 176 F coincides with the advised capacity c Fill the lube reservoir of the Isocyanate pump with DOP It is not necessary to prime the system d Connect the hoses of the products to the outlets of the respective flow meters the Polyol hose to the Polyol flow meter and the Isocyanate hose to the lsocyanate flow meter NB The product hoses have been identified with red Isocyanate and blue Polyol enabling them to be rapidly distinguished To avoid errors in connecting the coupling connectors of the Isocyanate and Polyol hoses the connectors are of different sizes to make it impossible for connections to be swapped Figure 1 Method of union of the Hoses WARNING To join the hoses together or to connect them to the heaters or the gun use two spanners to hold the parts to be joined 1 and a third spanner to tighten or loosen the connecting nut 2 as shown in the illustrations in Figure 1 The connections must be tightened to a torque of 20 Nm The hoses receive vacuum drying treatment and are supplied interconnected at the ends to prevent them from absorbing moisture Do not s
8. HEAD d Tighten the Socket Head Set Screw of the PLUG SET SCREW terminals and place the Nylon Safety Plugs Repeat the same steps to connect the fast lock that you will find in the middle hose connections f Connect the rest of the product hoses to complete the required total length g Remember that the hoses are identified with red Isocyanate and blue Polyol h Connect the magnetic sensor wire connector to the output connector of the unit i Make the connection between the rest of the wire sensor connectors up to the gun connector so the total length is completed NB Assure the proper mechanical and electrical connection of the hoses to avoid possible product leakage and hose heat problems 33 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Ame Service Manual j Install the probe of control of temperature TCS between the last stretch of hose of product and the final stretch connected to the gun Stretch carefully the cable of the probe inserting it in the Ilsocyanate hose and in that of Poliol respectively k Wind the connectors of the probes to the connectors of the hose Realize SO many connections as stretches of 15 m hose you have I Realize the connections between the connectors of exit of the probes TCS of the first stretch of hose and the connectors proceeding from the machine m As soon as the connections were completed place the protections for the union fixing them with three
9. of excessive pressure in the lsocyanate system 11 Polyol Hydraulic Circuit Safety Valve Diverts pressure to the hydraulic tank in the event of excessive pressure in the Polyol system 12 Isocyanate Pressure Gauge Indicates the pressure of the Ilsocyanate circuit 13 Polyol Pressure Gauge Indicates the pressure of the Polyol system 14 lIsocyanate Safety Pressure Switch Stops the Isocyanate pump motor in the event of excessive pressure in the circuit 15 Polyol Safety Pressure Switch Stops the Polyol pump motor in the event of excessive pressure in the circuit 16 Isocyanate Temperature Probe Provides information on the temperature of the Ilsocyanate 17 Polyol Temperature Probe Provides information on the temperature of the Polyol 18 Isocyanate Needle Valve Adjusts the recirculation pressure of the Isocyanate 19 Polyol Needle Valve Adjusts the recirculation pressure of the Polyol 20 isocyanate Flow Meter Provides information about the volumetric flow supplied by the Isocyanate pump 21 Polyol Flow Meter Provides information about the volumetric flow supplied by the Polyol pump 9 56 Issue 2 8 Ref NR 00015 ENG http AWwww gamapur com CAs Service Manual 22 Isocyanate Inlet Filters Avoid the penetration of solid particles inside the Isocyanate pump of the unit The standard filter size is 30 Mesh Optionally available 20 60 80 Mesh 23 Polyol Inlet Filters Avoid the penetration of solid pa
10. original Warranty for the remainder of original Warranty Period or for three 3 months from the repair or replacement date whichever is longer No Rights Implied Nothing in the sale lease or rental of any Product by GAMA shall be construed to grant any right interest or license in or under any patent trademark copyright trade secret or other proprietary right or material owned by anyone nor does GAMA encourage the infringement of same Exclusive Warranty This writing is the final complete and exclusive expression of the Warranty covering the Product Any statements made by GAMA its employees or agents that differ from the terms of this Warranty shall have no effect It is expressly understood that Customer s acceptance of this Warranty by performance or otherwise is upon and subject solely to the terms and conditions hereof and any additional or different terms and conditions proposed or expressed by Customer or anyone whether in writing or otherwise are null and void unless specifically agreed to in writing by an Officer of GAMA 2 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual All information provided in this Service Manual is assumed to be correct although this does not constitute any implicit or explicit liability or guarantee GAMA reserves the right at any time and without prior warning to make all improvements and modifications necessary to this Service Manual in order to rectify any possible
11. parts or accessories with the Product that have not been approved or manufactured by GAMA e Failure to follow the operating instructions and recommendations provided by GAMA e Cosmetic damage e Fire flood acts of God or other contingencies beyond the control of GAMA THE WARRANTY DESCRIBED HEREIN IS THE EXCLUSIVE REMEDY FOR THE CUSTOMER AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS IMPLIED STATUTORY OR OTHERWISE AND THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER WARRANTIES ARE HEREBY DISCLAIMED TO THE FULLEST EXTENT PERMITTED BY LAW GAMA SHALL NOT BE RESPONSIBLE WHETHER BASED IN CONTRACT TORT INCLUDING WITHOUT LIMITATION NEGLIGENCE WARRANTY OR ANY OTHER LEGAL OR EQUITABLE GROUNDS FOR ANY CONSEQUENTIAL INDIRECT INCIDENTAL LOST PROFITS SPECIAL PUNITIVE OR EXEMPLARY DAMAGES WHETHER TO PERSON OR PROPERTY ARISING FROM OR RELATING TO THE PRODUCT EVEN IF GAMA HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH LOSSES OR DAMAGES Non Warranty Service by GAMA If GAMA determines that the suspected Defect of the Product is not covered by this Warranty disposition of the Product will be made pursuant to the terms and conditions of GAMA s written estimate on a time and materials basis Continuing Warranty for Products Repaired or Replaced under Warranty Following the repair or replacement of a Product covered by this Warranty such Product will continue to be subject to the
12. plastic bridles Later cover the union with the ends of the cases NB To protect the TCS sensor you must pay special attention not to kink or excessively bend the hoses Do not roll up the hoses with a radius of under one meter 3 feet n Connect the air hoses o Connect the hoses to the connectors of the coupling block of the gun making sure that the manual valves are closed Proceed to install the transfer pumps paying special attention to connect each pump to its respective product as changing the pumps would cause a reaction in the products inside them and make them useless Identifying each pump with a tape of the same color as that of the hoses blue for the Polyol pump and red for the Isocyanate pump might be a good method for avoiding errors in connection 34 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Do the following steps to install the pumps a Make sure that the inlet valves of the products to the unit are closed b Connect one end of the Polyol hose 3 4 thread to the Polyol valve and the other end to the transfer pump of the same product c Connect one end of the Isocyanate hose 3 4 thread to the Isocyanate valve and the other end to the transfer pump of the same product d Connect the air hose to the transfer pumps e Install the unit ground connection The movement of the product inside the hose can cause Static electricity and produce electrical dis
13. reduced to the half Use RIGHT LEFT to select mode and press ENTER to confirm and finalize the setup Flow Meters Option Screen re efer efef of Allows establishing the working mode with or without FLOW METERS Use RIGHT LEFT to select mode and press ENTER to confirm and finalize the setup Serial Number Visualization Screen Allows visualizing the serial number of the proportioning unit Master Menu Access Screen NOTE Only for the use of Garraf Maquinaria S A 26 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Allows accessing the constants screen of the manufacturer through the introduction of a password The numeric interval of the password is between 00000 and 99999 Enter the PASSWORD through the numeric keypad and press ENTER and MODE Probe Calibration Screen Prefete felat efra ole This screen must be activated every time that a probe calibration needs to be done Select ON to activate the screen and OFF to deactivate it Use UP DOWN to select one of the two options and press ENTER to confirm the setup Probe Calibration Screen Jrirjefele feai eleaf loin eof ede rime jele efel foja The procedure for the heater probes and the cold union is made through direct comparison with the known room temperature Use UP DOWN to increase or decrease the temperature of the cold union in the electronic card TMP in the Isocyanate ISO heater probe an
14. the lsocyanate filter will be minimized NB Clean the Isocyanate inlet filter before the daily start up it should not be cleaned after the machine has been stopped for the day Immediate spraying after cleaning the filter reduces the risk of moisture contamination or contamination through the reaction with the solvent used in the cleaning operation To check the product inlet filters proceed as follows a Disconnect the unit from the power supply and close the inlet valve from the filter you wish to check b Place a suitable vessel under the filter to collect the product coming out on removal Carefully loosen the filter stopper to allow the product to be emptied into the vessel below Completely unscrew the stopper c Remove the seal the spring and the mesh and clean it all with the solvent used for cleaning the gun Dry it all and check that the mesh is not obstructed The holes in the mesh must be completely free Replace the mesh if more than 10 of the surface is obstructed d Re assemble the mesh the spring and the seal Screw on the stopper e Open the product inlet valve of the filter make sure there are no leaks and proceed with the normal operation 54 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Isocyanate Pump Lubrication System Each day inspect the lube reservoir of the Isocyanate pump and check the condition of the DOP Replace the oil when it shows changes in color or signs
15. the alarm that has occurred The system does not allow an alarm to be reset until the fault causing the alarm has been corrected After resetting RESET must be pressed to re establish the system The procedures recommended to determine the possible causes activating the alarms are indicated in the following Frequency Converter Alarm Screen rirjejajufenjef feloffv E rrje Will show in the following scenarios When some internal operation inaccuracy is detected by the frequency converter When there is not enough electrical feeding power arriving to the converter after the POWER CONTROL key has been pressed When an overcharge of electrical intensity is produced in either of the two motors which turn the hydraulic pumps on Over pressure Alarm Screen Will show When an excess of pressure in either of the circuits ISO POL is produced safety pressure switches contacts separated Heaters High Temperature Alarm Screen Hefe fhet iee Will show When an excess of temperature in either of the circuits ISO POL is produced safety thermostats contacts separated Out of Tolerance Flow Alarm Screen elvir rlolelelnajwfele Few Will show When FLOW CONTROL key is activated and the ISO and POL flow is out of the established tolerance 29 56 Issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Out of Tolerance Pressure Alarm Screen elit rlolelelnlalmiele falesi
16. the gr sec dispensed by the unit It will not be possible to make any adjustment to the flow meters One can visually appreciate the automatic correction that the CPU of the unit makes using the information received constantly from the flow meters If the unit does not have flow meters the screen will show the equivalent Hertz to the gr sec established in the Output Screen The adjustment can be carried out with a 2 precision The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup Drums Material Screen Pirjulms mialrielele laf els Shows the kilograms of product inside the feeding drums Once the initial quantity inside the drums has been established the CPU will deduce the kilograms as they keep consuming When any of both components reaches 0 value a audible alarm will turn on the motors of the unit will stop and the screen will show EMPTY DRUM Press RESET to turn the alarm off In case you wish to change the value of kilograms established initially select the new value from the numeric keypad Press RESET again to maintain the same initial value The decreasing counter will be activated when a positive value between 1 and 9 999 kilograms is entered with rises of 1 kg The flashing value of kilograms can be
17. the unit and the operating procedures By following the instructions and recommendations contained herein you will reduce the potential risk of accidents in the installation use or maintenance of the unit you will provide greater output a better opportunity for incident free operation for a longer time and the possibility of detecting and resolving problems fast and simply Keep this Service Manual for future consultation of useful information at all times If you lose this manual ask for a new copy from your GAMA local distributor or directly contact Garraf Maquinaria S A WARNING The evolution VR series proportioning unit does not allow its use in potentially explosive atmospheres or to exceed the pressure and temperature limits described in the technical specifications of this manual 3 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual When working with the unit it is recommended that the operator wear suitable clothing and elements of personal protection including without limitation gloves protective goggles safety footwear and face masks Use breathing equipment when working with the machine in enclosed spaces or in areas with insufficient ventilation The introduction and follow up of safety measures must not be limited to those described in this manual Before starting up the unit a comprehensive analysis must be made of the risks derived from the products to be dispensed the type of application and
18. the working environment gt Popp 4 54 To prevent all possible bodily harm caused by incorrect handling of the raw materials and solvents used in the process carefully read the safety information provided by your supplier Deal with the waste caused according to current regulations Disconnect the unit from the power supply before carrying out any operation inside the electrical console The electrical maintenance of the machine must only be performed by a qualified electrician To avoid damage caused by the impact of pressurized fluids do not open any connection or perform maintenance work on components subject to pressure until the pressure has been completely eliminated Use suitable protection when operating during maintenance or whilst remaining in the operating area of the unit This includes but is not limited to the use of masks protective goggles gloves shoes and safety clothing The unit includes components that reach temperatures that are liable to cause burns The hot parts of the unit must not be handled until they have cooled To prevent serious harm by crushing or loss of limbs do not work with the unit without the safety guards installed on all moving parts Make sure that all of the safety protections are correctly reinstalled after all repair or maintenance work is completed issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Kalla Service Manual CHARACTERISTICS The evolu
19. to keep the system with a minimum pressure of 30 bar to extend the life of the seals d Press the ISO and POL keys next to the heater temperature displays The two leds will go out e Press the ISO and POL key under the HOSES display The led will go out f Press the POWER CONTROL key The led will go out g Turn the general switch OFF h Close the product inlet ball valves i Disconnect the air supply to the transfer pumps j Disconnect the magnetic switch of the gun k Close the manual valves of the coupling block and dismantle the gun to carry out the corresponding maintenance 38 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual CLEANING PROCEDURE CAUTION The unit includes components that reach temperatures that are liable to cause burns The hot parts of the unit must not be handled until they have cooled To avoid possible contamination the circuits of the unit must previously be cleaned pumps heaters and hoses whenever applications have to be made that require a change of components Follow the recommended procedure in the order indicated to perform the cleaning when you have to change the components of the system a b 39 56 Place two drums of DOP cleaning agent close to the machine Dismantle the gun and leave the coupling block connected to the hoses Remove the transfer pumps of the product drums and place them in the drums of the DOP cleaning agent Place a vessel un
20. will show the symbol and the heating will be automatically turned off Using the DIP selector labeled USA and EU the units of pressure and temperature can be set Set the DIP selector to EU for the pressure to be displayed in bar and the temperature in degrees Celsius set the DIP selector to USA for the pressure to be displayed in psi and the temperature in degrees Fahrenheit NOTE Please bear in mind that whilst manipulating the DIP selector the unit must be switched off Heaters The display shows the temperature in the lsocyanate heater ISO and the temperature in the Polyol heater POL Temperature control is automatic in this unit To enter or modify the value of the temperature press the MODE key as many times as necessary until you reach the HEATERS TEMP screen see page 19 Then press UP DOWN or enter the required value from the numeric keypad Press the MODE key to enter the selected value into memory The push buttons turn on or off the heater of each product Each push button has a led that lights when the heater is on if the led flashes it indicates that the system is not heating if the led lights steady it indicates that the system is heating If the TCS stops working the temperature display will show the symbol and the heating will be automatically turned off Using the DIP selector labeled USA and EU the units of pressure and temperature can be set Set the DIP selector to EU for the p
21. AiG Service Manual Proportioning Unit evolution VR Issue 2 8 17 09 14 Ref NR 00015 ENG Before installing the unit and starting it up carefully read all the technical and safety documentation included in this manual Pay special attention to the information to know and understand the operation and the conditions of use of the unit All the information is aimed at enhancing User Safety and avoiding possible breakdowns derived from the incorrect use of the proportioning unit Service Manual WARRANTY GARRAF MAQUINARIA S A hereinafter GAMA provides this LIMITED WARRANTY hereinafter Warranty to the original purchaser hereinafter Customer covering this equipment and the original GAMA manufactured accessories delivered with the equipment hereinafter Product against defects in material or workmanship of the Product hereinafter Defect or Defective for a period of two 2 years from the date of first purchase as shown on the original GAMA invoice hereinafter Warranty Period If during the Warranty Period under normal use the Product is suspected by Customer to be Defective in material or workmanship it is Customer s responsibility to contact GAMA and return the Product to GAMA as directed by GAMA freight prepaid If GAMA determines that the Product is Defective and that such Defect is covered by this Warranty GAMA will credit Customer for the reasonable freight char
22. Feler ffe lol Set temperature for both heaters during the time that recirculation will remain active is set in the first menu left hand side The range of temperatures goes from 0 C to 90 C 32 F to 194 F with rises of 1 C 34 F Heaters are automatically activated when the set temperature is over the room temperature Set the DIP selector to EU for the temperature to be displayed in degrees Celsius set the DIP selector to USA for the temperature to be displayed in degrees Fahrenheit The time that recirculation will remain active is set in the central menu The time unit is minutes and the selection range is between 1 and 99 minutes with rises of 1 minute NOTE Should any alarm turn on at some stage recirculation will turn off automatically Recirculation pause time is set in the third menu right hand side During this time the motors which turn the hydraulic pumps on will remain stopped until automatic recirculation is turned on again The time unit is minutes and the selection range is between 1 and 99 minutes with rises of 1 minute The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one menu to another Once the requested value has been established press ENTER to confirm and finalize the setup NOTE Recirculation will only turn on if both the first menu and the central menu show a positive value between 1 and 99 POL Reci
23. L displays will show the grams second dispensed by each component s pump Total Output Display When the unit works with flow meters the display shows the total real output grams second of both components Automatic Manual Mode The lit led indicates the working mode established in the LCD screen see page 17 13 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com CANA Service Manual Power Control Key Turns on and off the control voltage to the electrical circuit of the heaters the hoses heating system and the frequency converters When the key is on the LCD screen and the led placed at the left top part light on It may turn off voluntarily if the key is pressed again or automatically if an alarm is caused due to excessive temperature in the heaters or due to excessive current in the hose heating system ISO Pump POL Pump Key Turns on and off the motors which activate the hydraulic pumps When the key is on the left top led is lit It may turn off voluntarily if the key is pressed again or automatically if an electric intensity overcharge in the motors or excessive pressure in the ISO POL circuits is produced Temp Control Key Turns on and off the preset ISO POL temperature tolerance control in the hoses The system is activated once the preset temperature has been reached and 10 seconds after the magnetic switch in the spray gun has turned on the solenoid valves which make the proportioning pu
24. Visualization Screen Allows visualizing the revision status of the control panel and the CPU Date Configuration Screen Eee Allows establishing the date YEAR MONTH DAY The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one datum to the other YEAR MONTH DAY Once the requested value has been established press ENTER to confirm and finalize the setup NOTE Ensure that the date is formed correctly when a DATA LOGGER is connected Clock Configuration Screen etel fatele loej efe l mefe foja Allows establishing the hour and minutes The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one datum to the other HOUR MINUTE 24 54 Issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Once the requested value has been established press ENTER to confirm and finalize the setup NOTE Ensure that the date is formed correctly when a DATA LOGGER is connected Winter summer automatic time change is not formed Delay Time Selection Screen rlelelelniajmiele eeej Allows establishing the time delay before the audible alarm of the unit is activated The time delay counter will be activated whenever some flow pressure or temperature control is activated and any variation out of the established tolerances is produced
25. alve which direction indicator light is on to determine in which direction the pump fails to maintain the pressure If the lit lamp is the rear one check the discharge valve ball of the pump If the lit lamp is the front one check the suction ball valve Proceed as follows to check the valve balls a Disconnect the unit from the power supply and close both product inlet valves plus the supply system to the transfer pumps b Depressurize the proportioning pump and remove the corresponding ball valve c The loss from the valve ball is usually caused by foreign particles that prevent the perfect coupling of the ball with the ball seat Clean the ball and the seat and make sure there are no faults from knocks marks or scratches to the seat or the ball Should the cleaning fail to resolve the problem or any fault be observed replace the seat and the ball 2 Unbalanced Pressures Pressures are unbalanced when there is an obstruction in the hose or in the gun that prevents one of the components from coming freely through the gun chamber when spraying Or when a problem in the pumping system prevents one of the components reaching the gun in the required amount It is relatively easy to identify which component is problematic if we bear in mind that the chemical components used in the Polyurethane foaming are of a different color By observing the color of the material that comes through the gun we can determine which component is missing
26. and shiny in appearance If it is blackened or has material adhered replace it c Check the new element with a tester the reading of the value of the resistance must be as shown in Table 1 on pag 43 d Apply Teflon or sealing paste to the thread and assemble the element into its housing e Reconnect the wires to the terminal block make sure the connection Is in parallel and fit the heater cover NB If the heating element that has to be replaced is the one in contact with the temperature probe remove the probe first 2 Temperature Probe The temperature probe is fixed to the connector with a ferule and a torque nut Once inserted in its housing the ferule forms to the probe and does not allow it to be relocated or moved The location of the probe is very important and must be done correctly before fitting the torque nut a Depressurize the unit and disconnect it from the power supply Check the torque of the body of the connector inserted in the heater to prevent leaks b Assemble the heating element c Insert the torque nut and the ferule in the probe and insert this in the connector body until it comes into positive physical contact with the heating element Make sure the spring does not prevent the probe from making contact with the resistance d Hold the probe in place and tighten the torque nut 52 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Hydraulic Unit WARNING Before perfor
27. ating area of the unit This includes but is not limited to the use of face masks protective goggles gloves shoes and safety clothing The unit includes components that reach temperature that are liable to cause burns The hot parts of the unit must not be handled until they have cooled To prevent serious harm by crushing or loss of limbs do not work with the unit without the safety duly installed on all moving parts Make sure that all of the safety protections are correctly fitted after all repair or maintenance work issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Ame Service Manual Heaters WARNING Before resolving any kind of defect make sure all of the push buttons are off that the general switch is in shutdown position and that the unit is disconnected from the power supply Never handle the inside of the control panel with the unit connected to the power supply The heaters are components that reach high temperatures wait until they have cooled before handling NB The thermostat is a safety element in contact with the heater If the temperature exceeds 120 C 248 F the thermostat will cut off the electric supply by deactivating the POWER CONTROL The thermostat will not reset until the temperature in the heater is below 120 C 248 F If the temperature in the Isocyanate heater or the Polyol heater is over 120 C 248 F an audible alarm will be activated and the control panel will show th
28. charges Before using the unit the residual air and oil from factory testing must be eliminated To purge the whole circuit proceed as follows f Pressurize the transfer pumps and open the inlet ball valves Make sure there are no leaks g Turn the general switch ON The top pilot light will come on NB After the general switch has been turned on wait for 2 seconds before the feeding supply arriving into the unit stabilizes h Press the POWER CONTROL key The top led in the key will light on Hold the coupling block with the outlet of each product in separate vessels and open the manual valves of each product The capacity of the vessels must be of approximately 3 liters i Keep pressing the ISO PRESS key to pressurize the Isocyanate circuit up to 100 bar approximately NB The maximum pressurization pressure will be established as the maximum value in the ISO pressure screen Keep pressing the POL PRESS key to pressurize the Polyol circuit up to 100 bar approximately NB The maximum pressurization pressure will be established as the maximum value in the POL pressure screen j Press the ISO PUMP key to start the engine The top led of the key will light on k Press the POL PUMP key to start the engine The top led of the key will light on Allow the materials to come out of the coupling block until the residual oil and the air bubbling has disappeared completely approximately 2 3 liters I Close the manual valves
29. correct functioning 3 Noises A noise similar to screeching is a symptom of cavitation The noise is normal if it occurs during the start up and lasts for approximately thirty seconds Should the noise continue stop the machine to protect the hydraulic pump and make sure that the connectors are tight and that the pump has been correctly primed Another possible cause of noises in the pump is excessive temperature in the hydraulic oil Make sure the oil supply is correct and if necessary improve the ventilation to allow better spreading of the heat inside the hydraulic tank 50 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual MAINTENANCE To achieve maximum output from your evolution VR unit several daily or periodical maintenance operations are needed gt Pp Op gt 51 56 To prevent possible bodily harm caused by incorrect handling of the raw materials and solvents used in the process read carefully the safety information provided by your supplier Deal with the waste created according to current regulations Disconnect the unit from the power supply before carrying out any operation inside the electrical console The electrical maintenance of the machine must only be performed by a qualified electrician To avoid damage caused by the impact of pressurized fluids do not open any connection or perform maintenance work on components subject to pressure until the pressures have bee
30. d Check the input filters of the products Clean them if necessary e Pressurize both transfer pumps and open the inlet valves of the products to the unit f Ensure that the emergency push button is not activated g Turn the general switch ON h Press the POWER CONTROL key The top led will light i Press the ISO key under the HOSES display The top led of the key will light Once the product has reached the set temperature the led will flash j Press the POL key under the HOSES display The top led of the key will light Once the product has reached the set temperature the led will flash k Press the ISO key under the HEATERS display The top led of the key will light Once the product has reached the set temperature the led will flash I Press the POL key under the HEATERS display The top led of the key will light Once the product has reached the set temperature the led will flash CAUTION To avoid excessive pressure in the heating hoses wait for the product in them to reach the required temperature before starting up the hydraulic system m Press the ISO PRESS key to pressurize the Isocyanate circuit to the required working pressure NB The maximum pressurization pressure will be established as the maximum value in the ISO pressure screen n Press the POL PRESS key to pressurize the Polyol circuit to the required working pressure NB The maximum pressurization pressure will be established as the maximum value in
31. d the Polyol POL heater probe or else introduce the new value from the numeric keypad Once the requested value has been established press ENTER to confirm and finalize the setup Use LEFT RIGHT to go from one value to another NOTE Ensure that the hoses are totally depressurized when making the calibration Internal Clock Adjustment Screen sir ele efef apels ir me nr Allows establishing the timing of the internal clock of the CPU valid for the processing of the different parameters in the screen Impulses Litre Selection Screen Meese Hiire Allows establishing the impulses per litre of the flow meter so that the CPU can do the corresponding processing The range of selection goes from 1 to 9 999 impulses with rises of 1 impulse 27 56 Issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup Pressure Transducers Selection Screen r eja mie olujele leis rimiels s ulnle Allows establishing the maximum value of the pressure range of the transducers The range of selection goes from 1 to 999 bar with rises of 1 bar Use UP DOWN to increase or decrease the pressure or else introduce the new value from the numeric keypad Once t
32. der the coupling block to gather up the products contained inside the machine Open the manual valves on the coupling block Turn the general switch ON Press the POWER CONTROL key The top led of the key will light Press the ISO PRESS key and keep pressing it you see that only DOP cleaning agent comes out free of impurities Press the POL PRESS key and keep pressing it you see that only DOP cleaning agent comes out free of impurities Close the valves on the coupling block and press the POWER CONTROL key The top led of the key will go out Place the transfer pumps in the drums of the new products Place a vessel under the coupling block to collect the DOP cleaning agent Open the valves on the coupling block Press the POWER CONTROL key The top led of the key will light on Press the ISO PRESS key and keep pressing it you see that only the new product comes out Press the POL PRESS key and keep pressing it you see that only the new product comes out When the products come out without the contamination produced by the effect of the DOP cleaning agent the cleaning process is complete and you can proceed as normal issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual LONG TERM SHUTDOWN PROCEDURES CAUTION The unit includes components that reach temperature that are liable to cause burns The hot parts of the unit must not be handled until they have cooled When you plan to shut down the machine for mor
33. e 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Recirculation System The recirculation system allows heating the products automatically therefore reducing the time of preparation prior to start spraying The system features a manual valve to close the recirculation system at one s discretion When in recirculation mode products pushed by the proportioning pumps flow through the heaters and go back to the feeding tanks Central Processing Unit CPU The CPU s software processes and controls all program instructions depending on the application parameters entered on the screens Any alteration that may occur affecting the set parameters will be corrected while the unit continues working When the problem cannot be resolved within the established tolerance parameters the CPU will stop the unit and will display the type of failure occurred 6 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual TECHNICAL SPECIFICATIONS Electrical Main voltage EU 400 V Frequency 50 60 Hz Electrical consumption EU 54 62 A 3 x 400 V N Heaters power 2x9 kW 18 kW Hose Transformers Power 2 x 4 kW 8 Kw Electrical Motor Power 2 x 3 kW 2 x 4 Kw 6 8 Kw Total Active Power 32 34 kW There are three terminals for the main supply cable connection wire not supplied in the control box The electrical connection of the unit must be carried out by a qualified electrician Mechanical Maxim
34. e Control Selection Screen lolsiele fefe fefefe e Allows establishing the maximum Derivation tolerance of the temperature in the hoses with respect to the nominal values established in A Hose Paonia Selection Screen ISO POL Tolerance is symmetrical nominal value the established value Any Derivation by excess or by defect produced out of the established limits will make the audible alarm be activated and the motors of the unit be stopped The screen will show the hose temperature out of tolerance ISO or POL warning The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup Set the DIP selector to EU for the temperature to be displayed in degrees Celsius set the DIP selector to USA for the temperature to be displayed in degrees Fahrenheit NOTE Press TEMP CONTROL in the control panel to activate the temperature control then establish a positive value between 1 and 90 C The range of temperatures goes from 0 C to 90 C 32 F to 194 F with rises of 1 C 34 F in the product that we wish to control Flow Control Selection Screen Hem fefefe efle Allows establishing the maximum Derivation tolerance of gr sec with respect to the nominal values established in the output displays ty Tolerance
35. e HEATER ISO POL HIGH TEMPERATURE screen Follow the recommended procedure in the order indicated to try to solve the problem and avoid costly repairs Make sure all the automatic switches and control elements are in the correct working position before determining the existence of a fault PROBLEMS SOLUTIONS The heater fails to heat the push button led is lit 1 2 3 The heater display shows the symbol 4 SOLUTIONS 1 Static Relay This determines that the static relay is not working when all of the previous checks have been correct 42 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual 2 Heating Resistances Each heater has six 1250 W elements connected in parallel which give the system a total power of 7500 W optional 9000 W If under normal conditions of ambient temperature it is not possible to reach the temperature required in two or three minutes it is possible that one or several heating elements are not working To check the state of the element proceed as follows With the main switch off check with a tester that reading the total value of the heater resistance is indicated in the table according to the power voltage and number for each installed heater elements a higher value would indicate that one or more elements are faulty Disconnect them and check that the individual value of each element is as shown in the table according to the installed power and voltage Table 1 Elemen
36. e sure all the automatic switches and control elements are in the correct working position before determining the existence of a fault PROBLEMS SOLUTIONS The hose is hot but fails to reach the selected temperature 1 2 7 The hose is not hot the push button led is lit 2 3 4 5 Only the sections of the hose closest to the unit are heated 5 The hose display shows the symbol 6 The automatic switch trips 3 SOLUTIONS 1 Hose Length The evolution VR unit has been designed to work with a maximum hose length of 93 meters 310 ft A longer length will render the heating capacity less effective Under extreme ambient conditions the hose heating system may be affected and fail to reach the required temperature 2 Hose Transformer The transformer offers the option of connecting to a 45 V output voltage valid for the connection of hose sections with a total length of up to 45 meters or an output voltage of 90 V for connecting hose lengths of over 45 meters connect to either position depending on the total hose length installed in the machine If the connection is performed incorrectly the hoses will not reach the required temperature 3 Automatic Switch This protects the secondary circuit of the transformer The switch is located on the front of the transformer make sure it is activated otherwise activate it Replace it with one of equal amperage if the switch fails to work correctly CAUTION The replacement of the automatic switc
37. e than five weeks the products contained in the machine must be replaced by DOP plasticizing agent Follow the recommended process in the order indicated to change the products for DOP oil a b 40 54 Place two drums of DOP cleaning agent close to the machine Dismantle the gun and leave the coupling block connected to the hoses Remove the transfer pumps of the product drums and place them in the drums of the DOP cleaning agent Place a vessel under the coupling block to gather up the products contained inside the machine Open the manual valves on the coupling block Turn the general switch ON Press the POWER CONTROL key The top led of the key will light Press the ISO PRESS key and keep pressing it you see that only DOP cleaning agent comes out free of impurities Press the POL PRESS key and keep pressing it you see that only DOP cleaning agent comes out free of impurities Close the valves on the coupling block and press the POWER CONTROL key The top led of the key will go out Turn the general switch OFF Disconnect the supply system of the transfer pumps and the process is finished The proportioning pumps the heaters and the hoses must be full of DOP plasticizing oil Never leave the machine or the hoses empty of product or DOP plasticizing oil issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual TROUBLESHOOTING The evolution VR unit has been designed and built to withstand severe workin
38. el with the unit connected to the power supply The hydraulic unit is a component that works under pressure do not open any connection or carry out maintenance work on components subject to pressure until all of the pressures have been completely eliminated Follow the recommended procedure in the order indicated to try to solve the problem and avoid costly repairs Make sure all the automatic switches and control elements are in the correct working position before determining the existence of a fault PROBLEMS SOLUTIONS The electric motor does not start or stops while it is working 1 The hydraulic pump fails to develop pressure 2 Little or no pressure with screeching 2 3 SOLUTIONS 1 Frequency Converter Should the electric motor draw excessive current it will stop and the frequency converter will warn with an alarm Press the POWER CONTROL key allow the motor to cool down wait for the frequency converter to reset and press the POWER CONTROL key again so that the motor is operational again It is paramount to determine the reason why the motor has been subject to an overload Should the frequency converter fail the electric motor may be damaged due to overheating 2 Little or No Pressure The most likely cause for no pressure is usually a deficient supply of the hydraulic fluid to the pump This can be provoked by incorrect priming a lack of hydraulic fluid or dirt in the suction filter Check the indicated points to guarantee
39. eparate them until they are going to be installed in the unit The hose connection system includes special terminals fast lock to facilitate the electrical connection to the transformer and between the different sections installed in the unit 32 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Amir Service Manual The transformer offers the Move black wire to option of connecting to a 45 the correct tap setting V output voltage valid for a total hose length of up to 48 meters 158 ft or an output voltage of 90 V for hose lengths of over 48 meters 158 ft connect to one output voltage or the other depending on the total hose length installed Before starting up the unit make sure that the connection made in the factory adapts to the total length of hose installed If you add or eliminate sections of hose make sure the output voltage of the transformer to which it is connected is suitable for the resulting total length Otherwise change the connection 90v Tap Settings 45v Tap Settings e Connect the wires of the heated hoses system of the products to the fast lock connector coming out of the hose transformers as follows a Unscrew the Nylon Safety Plug from the fast lock connector body b Unscrew partially the Socket Head Set Screw from electrical wires c Insert the heated hose electrical wire with terminals into the fast lock connector body NYLON SAFETY SOCKET
40. ered between the two run end reversing switches If when pressing the slide it moves freely the excess run is due to an electrical problem Press the POWER CONTROL key and the ISO PUMP and POL PUMP keys approach a metallic body e g the tip of a screw driver to the front of the switches and observe if the change of the solenoids and the change of the direction indicator lights is produced if the solenoids are not changed or the direction indicator lights fail to come on there is an electrical problem in the run end micro or in the solenoid of the directional valve 5 Safety Pressure Switches Each proportioning pump is protected by a safety pressure switch factory set at a limit pressure of 300 bar When the limit pressure is reached the pressure switch interrupts the electrical supply to the directional valve stopping the pumps An alarm will be activated and the control panel will show the ISO POL HIGH PRESSURE alarm screen When the pressure reaches lower values than the established limit the proportioning pumps will restart However the causes of the excess pressure must be determined and corrected 49 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Hydraulic Unit WARNING Before resolving any kind of defect make sure that all of the push buttons are off the general switch is in shutdown position and the unit is disconnected from the power supply Never handle the inside of the control pan
41. et the DIP selector to USA for the temperature to be displayed in degrees Fahrenheit The range of temperatures goes from 0 C to 90 C 32 F to 194 F with rises of 1 C 34 F The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup Hoses Temperature Selection Screen fejse ree i Ele Allows establishing the set temperature in the hoses of the components Set the DIP selector to EU for the temperature to be displayed in degrees Celsius set the DIP selector to USA for the temperature to be displayed in degrees Fahrenheit The range of temperatures goes from 0 C to 90 C 32 F to 194 F with rises of 1 C 34 F The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup Hose temperature settings that are higher than the temperature settings of the heaters cannot be programmed If only one temperature control system is working ISO or POL the limiting temperature value will be the highest set in the heaters If both temperature control systems are working ISO and POL the limiting value will be related to eac
42. fferent screens for the setup of the working parameters Reset Key Turns the audible alarm off and restores the system in its initial conditions The system does not allow to reset an alarm if the problem that provoked it has not been resolved before The led placed in the left top part of the key lights on when an e alarm turns on and flashes rapidly when the magnetic switch of the spray gun is activated 14 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Kaila Service Manual Enter Key Allows confirming and memorizing of the new parameters which have been entered or modified in the different screens Up Down Keys Allow the value of each of the parameters and the selection of the preset working options to be increased or decreased Right Left Keys Allow movement of the cursor to access the different parameters and screens Numeric Keypad Allows entering or altering the values of each parameter In case of mistake use the SUPR key to cancel the last digit that you have introduced 15 56 Issue 2 8 Ref NR 00015 ENG http www gamapur com Service Manual CONTROL SCREENS NOTE Those parameters flashing in the screens can be modified fixed parameters are shown for information Language Selection Screen This screen appears when the unit is switched on for the first time It will only be visible this first time Allows setting of the text in five different languages Spanish Italia
43. g conditions with a high degree of reliability provided it is used suitably This chapter contains information on possible faults that may prevent the continuation of work with the unit The information provided must serve as guideline to detect and resolve the large majority of the problems before calling for the assistance of the authorized distributor or GAMA technical service In any case feel free to contact the technical assistance service of Garraf Maquinaria S A where a qualified technician will advise you on whatever you may need NB All repairs performed by unqualified personnel or the use of spares other than originals may cause damage to the unit and put the operator at risk gt p gt Op p gt 41 56 To prevent possible bodily harm caused by incorrect handling of the raw materials and solvents used in the process carefully read the safety information provided by your supplier Deal with the waste caused according to current regulations Disconnect the unit from the power supply before carrying out any operation inside the electrical console The electrical maintenance of the machine must only be performed by a qualified electrician To avoid damage caused by the impact of pressurized fluids do not open any connection or perform maintenance work on components subject to pressure until the pressures have been completely eliminated Use suitable protection when operating maintaining or remaining in the oper
44. ges incurred by Customer in returning the Defective Product to GAMA and GAMA or its authorized agent will at GAMA s option repair or replace the Product subject to the following Original Invoice The original invoice must be kept as proof of the date of first sale and the Product serial number The Warranty does not cover any Product if the Original Invoice appears to have been modified or altered or when the serial number on the Product appears to have been altered or defaced Product Maintenance It is the Customer s responsibility to maintain the Product properly See your maintenance schedule and owner s manual for details The Warranty does not cover an improperly maintained Product Non GAMA Components and Accessories Non GAMA manufactured components and accessories that are used in the operation of the Product are not covered by this Warranty Such components and accessories shall be subject to the warranty offered to the Customer if any by the original manufacturer of such component or accessory Other Warranty Exclusions The Warranty does not cover any Product that GAMA determines has been damaged or fails to operate properly due to misuse negligence abuse carelessness neglect or accident By way of example only this includes e Normal wear an tear e Improper or unauthorized installation repair alteration adjustment or modification of the Product e Use of heating devices pumping equipment dispensers or other
45. h of their corresponding heaters Temperature settings are restricted to 80 C maximum for hoses and 90 C maximum for heaters To enter data the order will be as follows e The temperatures in ISO and POL heaters are set e The temperatures in ISO and POL hoses are set e Finally the settings of the rest of the data can be entered in the date range and cycle pre selector 20 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Hoses Electrical Intensity Selection Screen Allows establishing the electrical current intensity to be applied to the resistance of each hose The range of regulation goes from 10 to 50 Amps with rises of 1 Amp Since the unit always works with automatic temperature control the value of the current intensity must be set usually between 45 and 50 Amps The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup Shooting Time Screen siatofolrle mel rie i i Allows establishing the time of spraying or injection To activate the time counter system select option ON in the central menu of the screen by pressing UP DOWN keys If the spraying or injection are done manually the shooting time will start counting when the spray gun trigger is pushed and the inductive detec
46. h with another of different characteristics may cause damage to the equipment and put the operator at risk 45 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual 4 Triac This determines that the triac is faulty when all of the previous checks have been correct Replace the triac if is fails to work correctly 5 Hose Heating Components a With the general switch turned off make sure the hose connections and the electrical connections between the hoses and the unit are correct and tight If the connections are correct and the hoses do not heat up check section by section to locate the connection that is at fault b Proceed as follows c Disconnect the unit from the power supply by deactivating the general switch and start to check the hose section closest to the gun Remove the Fast Lock connector and make a bridge bypass on the connection immediately before d Restore the power supply press the POWER CONTROL key and the ISO and RESIN keys under the HOSES display If the heating works the problem will be located in the last section of hose Replace it If not follow these steps e Disconnect the unit from the power supply by deactivating the general switch remove the Fast Lock connector from the second last section of hose and make a bridge bypass on the connection immediately before f Restore the power supply press the POWER CONTROL key and the ISO and RESIN keys under
47. he requested value has been established press ENTER to confirm and finalize the setup Proportionality Constant Selection Screen rrefej oja vja Allows establishing the proportionality constant for the automatic control system in the temperature of the heaters PID Use UP DOWN to increase or decrease the value or else introduce the new value from the numeric keypad Once the requested value has been established press ENTER to confirm and finalize the setup Integration Constant Selection Screen Merefea viajelle Allows establishing the integration constant for the automatic control system in the temperature of the heaters PID Use UP DOWN to increase or decrease the value or else introduce the new value from the numeric keypad Once the requested value has been established press ENTER to confirm and finalize the setup Derivation Constant Selection Screen eift vi ve eeel Allows establishing the derivation constant for the automatic control system in the temperature of the heaters PID Use UP DOWN to increase or decrease the value or else introduce the new value from the numeric keypad Once the requested value has been established press ENTER to confirm and finalize the setup 28 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual ALARMS When the unit has faults caused by conditions affecting its correct operation an audible alarm will sound and a screen will show
48. ical 7 General Description Main Components 8 Control Panel 11 Control Screens 16 Alarms 29 Installation 31 Start UP Procedures 36 Shutdown proCedure 38 Cleaning PROCEDURE 39 Long Term Shutdown Procedures 40 Troubleshooting 41 Heaters 42 Hose Heating 45 Proportioning Pumps 47 Hydraulic Unit 50 Maintenance 51 Heaters 52 Hydraulic Unit 53 Proportioning Pumps 54 Product Inlet Filters 54 Isocyanate Pump Lubrication System 55 Content 56 56 54 Issue 2 8 Ref NR 00015 ENG http www gamapur com
49. is symmetrical nominal value the established value Any Derivation by excess or by defect produced out of the established limits will make the audible alarm be activated and the motors of the unit be stopped The screen will show the hose temperature out of tolerance ISO or POL warning The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup 23 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual NOTE Press FLOW CONTROL in the control panel to activate the flow control then establish a positive value between 0 and 99 gr sec with rises of 1 gr sec in the product that we wish to control Password Introduction Screen elolnielriarmiris meme The CPU of the unit has a password function to prevent incorrect manipulation of the factory pre set constants by unauthorized operators The numeric interval of the password is between 000 and 999 The factory pre set password must be known to access the password screens Enter the PASSWORD through the numeric keypad and press ENTER and MODE keys NOTE All the constants in the screens that will be shown next are factory pre set They should not be modified without permission from GARRAF MAQUINARIA S A qualified technical personnel Revision Level
50. kit is made up of the following elements 12 spanner 6 spanner universal pliers screwdriver allen keys socket oiling unit tube of grease magnet holder tools pin extractor component manual and service manual electrical wire not supplied to the unit The electrical connection of the unit must only be carried out by a qualified electrician f Inside the console there is a terminal strip for connecting the principal NB To ensure that the unit works correctly the electrical supply must meet the specifications indicated on page 6 of this manual and appearing on the machine specifications plate Follow the recommended procedure in the indicated order to install the unit a Insert the main power cable by passing it through the wire stop at the bottom of the electrical console and connect as shown in the diagram 3 x 400V 50 60 Hz NOTE Make sure the power cable is disconnected from the mains source before connecting it to the terminal strip in the console It is compulsory to connect the unit to an ground connection The unit features a control circuit that verifies the inlet voltage and the presence of the three phases Once the control is made it allows voltage to arrive to the power supply b Load 100 litres 26 gal of hydraulic fluid into the tank of the unit The oil must be of the characteristics and specifications of DIN 51524 standard sections 1 and 2 for example ISO VG 46 31 56 issue 2 8 Ref NR
51. ll of the push buttons are off the general switch is in shutdown position and the unit is disconnected from the power supply source Never handle the inside of the control panel with the unit connected to the power supply The proportioning pumps are components that work under pressure do not open any connection or perform repair or maintenance work on components subject to pressure until all of the pressures have been completely eliminated The proportioning pumps require specific annual maintenance they must be completely dismantled to check that the sleeve and the shaft show no marks or scratches which would cause leaks or damage the pump seals for damage which may cause the pump seals to fail All wear components mainly o rings and seals must be changed as a measure of preventive maintenance The pump base must also be inspected to ensure that the ball valves show no sign of wear knocks or marks that affect the correct operation of the pump Product Inlet Filters The filter bodies have a screen that prevents solid particles from entering the unit thus affecting the correct functioning of the ball valve during the suction of the product Inspect the filters each day as part of the machine start up and clean them Replace the filter screen if necessary lsocyanate is a product that crystallizes with ambient moisture or freezing If the storage and transfer is correct and the operating procedures are respected the risk of contamination of
52. llows establishing the density value of each chemical component The measuring unit for the density must be g cm IMPORTANT Whenever the mixing ratio comes in volume the density value of ISO and POL must be 1 However if the mixing ratio comes in weight densities indicated by the chemical product supplier must be entered The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup NOTE Both motors of the unit must be stopped if you wish to modify or enter new values The magnetic switch of the spray gun must be in OFF position Mixing Ratio Selection Screen Tit mele eae Allows establishing the mixing ratio between both chemical components both in weight or volume The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup 18 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual NOTE Both motors of the unit must be stopped if you wish to modify or enter new values The magnetic switch of the spray gun must be in OFF position ISO Pressure Selection Screen Allows establishing the minimum and maximum spra
53. ming any maintenance work make sure that all of the push buttons are off the general switch is in shutdown position and the unit is disconnected from the power supply Never handle the inside of the control panel with the unit connected to the power supply The hydraulic unit is a component that works under pressure do not open any connection or carry out maintenance work on components subject to pressure until all of the pressures have been completely eliminated The hydraulic unit must be serviced each year as indicated below a Depressurize the unit and disconnect it from the power supply Clean the hydraulic tank lid to prevent foreign bodies from falling into the tank when the lid is removed b Remove the suction and pressure pipes from the hydraulic pump and the tank lid c Separate the lid and the suction pipe from the hydraulic tank Inspect the bottom of the tank for sediments Should sediment be present the tank must be emptied completely and the bottom must be cleaned eliminating all the sediment and filling it once more with new hydraulic fluid d Clean the suction and pressure pipes and their connections e Replace the oil suction filter f Fit the suction and pressure pipes in the tank and fix the lid Connect the pipes to the hydraulic distributor 53 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Proportioning Pumps WARNING Before performing any maintenance work make sure that a
54. modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one product to the other ISO POL Once the requested value has been established press ENTER to confirm and finalize the setup NOTE This screen will only appear if you have selected the ON flow meters option 17 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Working Mode Selection Screen Allows selecting the operating mode of the unit Automatic or Manual The Automatic Mode with flow meters activated CLOSED CIRCUIT allows the CPU to receive constant information about the volumetric flow dispensed by each pump It also allows to correct automatically those Derivations produced in relation to the preset gr sec to dispense and the mixing ratio The Manual Mode with flow meters activated OPEN CIRCUIT allow setting the feeding frequency Hertz of the motors that turn the hydraulic pumps on This working mode is adequate in the following scenarios when calibration of the components is needed when working tests of the unit before changing to automatic mode are needed when maintenance and cleaning e g when one product circuit needs cleaning are needed or whenever it becomes convenient to compare the parameters visualized in the display in closed circuit Use UP DOWN to select either option Press ENTER to confirm and finalize the setup Density Selection Screen efesi LTT oie fe A
55. mps start working It allows temperatures to stay out of ratio for the mentioned 10 seconds plus the time set at the TOLERANCE DELAY see page 24 The alarm of the unit will sound after 10 seconds from the start of the pumping plus the set time for the delay if the temperature of the components is not within the set tolerance Flow Control Key Turns on and off the preset ISO POL mixing ratio tolerance control The system is activated 10 seconds after the magnetic switch in the spray gun has turned on the solenoid valves which make the proportioning pumps start working It allows the mixing ratio to stay out of ratio for the mentioned 10 seconds plus the time set at the TOLERANCE DELAY see page 24 The alarm of the unit will sound after 10 seconds from the start of the pumping plus the set time for the delay if the mixing ratio is not within the set tolerance Press Control Key Turns on and off the preset ISO POL pressure tolerance control The system is activated 10 seconds after the magnetic switch in the spray gun has turned on the solenoid valves which make the proportioning pumps start working It allows the pressures to stay out of ratio for the mentioned 10 seconds plus the time set at the TOLERANCE DELAY see page 24 The alarm of the unit will sound after 10 seconds from the start of the pumping plus the set time for the delay if the pressures are not within the set tolerance Mode Key Allows access to the di
56. n English German and French Use UP DOWN to go from one language to another Press ENTER to confirm and finalize the setup of the languages Unit Model Screen Eekeren viel tt ejajmja sje rja v ejajuji r m enr Shows the model of proportioning unit Output Selection Screen epel T eiet eaaa Allows establishing the total gr sec requested for both chemical components The CPU will calculate the gr sec to be dispensed depending on the mixing ratio and the densities set for each component The bottom menu shows the maximum and minimum gr sec that can be selected depending on the characteristics of the hydraulic pumps mounted on the unit Use UP DOWN to increase or decrease the value of the gr sec or enter the new value from the numeric keypad Once the requested value has been established press ENTER to confirm and finalize the setup NOTE This screen will not appear if you have selected Manual working mode with flow meters activated 16 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Hertz Selection Screen Selection of Manual mode with flow meters activated see page 17 allows establishing the feeding frequency Hertz of the motors that turn the hydraulic pumps on The range of regulation is 20 to 100 Hertz with rises of 0 1 Hertz Should the Automatic mode with flow meters activated see page 17 be selected the screen will show the equivalent Hertz to
57. n completely eliminated Use suitable protection when operating maintaining or remaining in the operating area of the unit This includes but is not limited to the use of face masks protective goggles gloves shoes and safety clothing The unit includes components that reach temperature that are liable to cause burns The hot parts of the unit must not be handled until they have cooled To prevent serious harm by crushing or loss of limbs do not work with the unit without the safety duly installed on all moving parts Make sure that all of the safety protections are correctly fitted after all repair or maintenance work issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Heaters WARNING Before performing any maintenance work make sure that all of the push buttons are off the general switch is in shutdown position and the unit is disconnected from the power supply source Never handle the inside of the control panel with the unit connected to the power supply The heater is a component that reaches high temperatures wait until it has cooled before handling 1 Heating Elements To replace a faulty element proceed as follows a Depressurize the unit disconnect it from the power supply and remove the cover on the heater b Disconnect the heating element from the terminal block and with an appropriate spanner loosen the element and remove it from its housing Inspect the element it must be smooth
58. of each product and clean the coupling block of the remains of product m Pressing the ISO PRESS and POL PRESS keys slowly increase the pressure of the products to check for product leaks in the hose joints Retighten if necessary and tape the connectors to protect them from possible damage NB The maximum pressurization pressure will be established as the maximum value in the ISO and POL pressure screens n Press the ISO PUMP key to stop the engine The top led of the key will go out o Press the POL PUMP key to stop the engine The top led of the key will go out p Place the gun in the coupling block 35 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual START UP PROCEDURES For the start up follow the recommended procedure in the indicated order CAUTION The start up procedure described next must be started only after all the temperature pressure and remaining parameter values have been correctly established in the corresponding screens a Check the state of the DOP plasticizing oil in the lubrication tank of the Isocyanate pump Change the oil if you see changes in the color or signs of solidification b Check the hydraulic oil level Add oil if the level is low c Make sure that the chemical products to be processed are above the minimum temperature required to be supplied to the unit through the transfer pumps Ask your product supplier for information on the minimum supply temperature
59. of solidification Oil solidification is the result of the absorption of moisture and the maintenance interval will depend on the working conditions The closed circuit system reduces contamination Oil discoloration is due to the small film of Isocyanate that lies on the pump shaft during the pumping operation If the gaskets and the seals are in a good condition the plasticizer will not have to be changed so frequently To replace the plasticizer proceed as follows a Spray with the gun until the Isocyanate proportioning pump is placed at the front Press the ISO PUMP key to interrupt the working cycle The push button led will go out b Press the POWER CONTROL key and turn the general switch OFF Disconnect the machine from the power supply c Remove the tank from the support unscrew the lid remove the non return valve of the suction hose empty the contaminated plasticizer in a suitable vessel and fix the non return valve in the suction hose again d Clean the tank fill it with DOP screw on the lid and refit the tank in the support The system is auto suction and does not need previous priming 55 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual CONTENT Warranty 2 Safety and Handling 3 Characteristics 5 Principal Heating System 5 Hose Heating System 5 Double Acting Piston Proportioning Pumps 5 Recirculation System 6 Central Processing Unit CPU 6 Technical Specifications 7 Electrical 7 Mechan
60. psi place the DIP in EU position if you wish the pressure unit to be bar If the PRESS CONTROL key is activated the CPU of the unit will ensure that the pressure in the Polyol circuit is within the established limits Should the pressure of the circuit be over the maximum value or below the minimum the audible alarm of the unit will turn on and the motors will stop The screen will show PRESSURE OUT OF TOLERANCE The pressure tolerance control system is activated 10 seconds after the magnetic switch in the spray gun has turned on the solenoid valves which make the proportioning pumps start working It allows pressure to stay out of ratio for the mentioned 10 seconds plus the time set at the TOLERANCE DELAY see page 24 The alarm of the unit will sound after 10 seconds from the start of the pumping plus the set time for the delay if the mixing ratio is not within the set tolerance The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one option to the other MIN MAX Once the requested value has been established press ENTER to confirm and finalize the setup 19 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Heaters Temperature Selection Screen lejar freme Pe Allows establishing the set temperature in the heaters of the components Set the DIP selector to EU for the temperature to be displayed in degrees Celsius s
61. rculation Selection Screen isle rleef rejali joe Allows activating the automatic recirculation system of each product Follow the steps below to activated the recirculation system Open the valve of the product to re circulate only in those units with manual recirculation This step is not necessary in those units with automatic recirculation valve Turn the manual handle of the needle valve of the product to be re circulated anti clockwise to the end Turn the main switch to the ON position Press the POWER CONTROL key The top led in the key will light on Establish the temperature of the products See previous screen Establish the time that it will remain active see previous screen Establish the time that will remain on stand by See previous screen Select the ON option in the product to be re circulated ISO POL 22 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Select the ON option to activate the recirculation The unit will beep when the recirculation is activated To pressurize the recirculation circuit approx 50 bar turn the manual handle of the needle valve of the product to be re circulated clockwise to the end The turning frequency of the two motors that turn the hydraulic pumps on during the recirculation time is 20 Hz 580 r p m NOTE Should any alarm turn on at some stage recirculation will turn off automatically Hoses Temperatur
62. ressure to be displayed in bar and the temperature in degrees Celsius set the DIP selector to USA for the pressure to be displayed in psi and the temperature in degrees Fahrenheit 12 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Ame Service Manual NOTE Please bear in mind that whilst manipulating the DIP selector the unit must be switched off Pressure Indicators display the Isocyanate pressure ISO and the Polyol POL In order to pressurize each component s circuit keep ISO or POL pressed until the requested working pressure is achieved The maximum pressurization value must be established as the maximum value in the PRESSURE ISO POL screens see page 18 This operation must be done with the motors stopped and the POWER CONTROL key activated Using the DIP selector labeled USA and EU the units of pressure and temperature can be set Set the DIP selector to EU for the pressure to be displayed in bar and the temperature in degrees Celsius set the DIP selector to USA for the pressure to be displayed in psi and the temperature in degrees Fahrenheit PRESSURE PRESION NOTE Please bear in mind that whilst manipulating the DIP selector the unit must be switched off ISO POL Output Displays If your unit does not have flow meters ISO POL displays will show the frequency Hertz of the motor that activates the hydraulic pump of each circuit If your unit has flow meters ISO PO
63. rticles inside the Polyol pump of the unit The standard filter size is 30 Mesh Optionally available 20 60 80 Mesh 24 USB port for data to be stored in an external storage unit This allows a massive storage unit to be connected to collect details of the unit operation 25 Airborne USB port for connecting on line to an external PC This allows an external PC to be connected to the machine for the on line processing of the data generated by the metering unit 26 USB output port directing selector This allows the predetermined USB port to be directed for data output PC VDRIVE 27 DIP3 Selector This allows the connection of an external PC to the machine to be selected for the on line processing of the data generated by the metering unit NOTE In VDRIVE position and with DIP3 OFF this enables data to be caught in the massive storage device located on the front of the machine In PC position and with DIP3 ON this allows the on line processing of the data in a PC connected by means of the airborne USB port 28 Pressure Unit DIP Selector This enables the pressure and temperature units to be selected which are shown on the displays of the control panel Turn the selector to EU for the pressure to be expressed in bar and the temperature units to be expressed in degrees Celsius Turn the selector to USA for the pressure to be expressed in psi and the temperature units to be expressed in degrees Fahrenheit NOTE
64. t the unit is disconnected from the power supply source Never handle the inside of the control panel with the unit connected to the power supply The proportioning pumps are components that work under pressure do not open any connection or perform repair or maintenance work on components subject to pressure until all of the pressures have been completely eliminated If excessive pressure is caused in the lsocyanate circuit or the Polyol circuit an audible alarm will be activated and the control panel will show the alarm screen ISO POL HIGH PRESSURE Follow the recommended procedure in the order indicated to try to solve the problem and avoid costly repairs Make sure all the automatic switches and control elements are in the correct working position before determining the existence of a fault PROBLEMS SOLUTIONS The pumps fail to maintain the pressure when the unit is shut down 1 There are pressure differences between the proportioning pumps 1 2 3 There is cavitation in the proportioning pump 1 2 3 The proportioning pumps do not change direction 4 The proportioning pumps fail to move and the direction indicator lights are 4 5 out The movement of the proportioning pumps is erratic 4 47 56 Issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual SOLUTIONS 1 Loss in the Ball Valves Observe the pressure gauges to identify which pump fails to maintain the pressure and check in the solenoid of the solenoid v
65. the HOSES display If the heating works the problem will be located in the second last section of hose Replace it If not repeat steps c and d until you find the point of the fault 6 TCS Temperature Control Probe The control panel automatically detects any fault in the operation of the temperature sensor Should a fault be detected an audible alarm will turn on and the control panel will show the alarm screen ISO POL HOSE PROBE To determine if the mistake is caused by the proper probe or by a defective electrical connection realize the following cross check dismantling the electrical connector of the probe TCS of the last stretch of hose and without dismantling any other connection connect it straight to the electrical capture of the exit of the machine if the control is restored check the electrical connections of the probe existing TCS in the intermediate stretches of the hoses in the opposite case replace the probe TCS 7 Hose Heating Temperature Adjustment The hose heating system maintains the temperature of the products coming through the heaters This is the reason why the value set for the temperature of the hoses must be the same as that selected on the heaters display 46 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Amn Service Manual Proportioning Pumps WARNING Before resolving any kind of defect make sure all of the push buttons are off that the general switch is in shutdown position and tha
66. tion VR proportioning unit has been designed and built for the application of Polyureas chemical systems for polyurethane foaming and some two component epoxy systems It features a precise automatic temperature control pressure and mixing ratio Principal Heating System Consists of two independent heaters Each heater has six 1500 W heating elements that give the unit a total power of 9000 W and the necessary control and safety components for precise operation of the system Its singular configuration allows a temperature differential of 50 C and application temperatures of up to 90 C under normal conditions of ambient temperature Hose Heating System Designed with two 4000 W transformers each which enable effective independent heating up to a total hose length of 93 meters The system includes an innovative hose heating concept in which the copper heating element is spread evenly around the circumference of the hose providing a uniform heating watt density and precise control of the product application temperature Double Acting Piston Proportioning Pumps Driven by two double acting piston hydraulic cylinders to deliver constant output and guarantee pressure stability for both displacement directions of the pumps Several pump sizes can be incorporated helping to obtain the required minimum and maximum flow in the standard setup of the unit woe teeh a S meres o no Se ee ee 7 4 3 EES Sa es 5 56 issu
67. to condition the products as the minimum temperature required for the transfer c The product inlet filter is obstructed see Maintenance d The suction ball valve has leaks as a result of wear or possible faults in the ball or the closing surface of the seat which means that part of the material supplied returns to the supply tank and that the proportioning pump supplies a smaller volume of material in the discharge cycle causing an incorrect ratio 48 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual 4 Fault in the Reversing Switch The proportioning pump system has a plate that activates the reversing switches to carry out the change of direction A fault in the movement of the directional valve will cause the activation plate to pass over the switch and not make the change of direction Proceed as follows to solve this problem a b Determine the direction in which the plate must move this depends on which switch has been passed over Locate the slide for the manual activation of the directional valve in the hydraulic distributor this is located at the same side of the machine towards which the activation plate must work Turn the general switch ON press the POWER CONTROL key and the ISO PUMP and POL PUMP keys With the manual valves of the coupling block open point the gun at a waste container Press the manual slide of the directional valve and hold it until the activation plate is cent
68. tor is activated The gun will close once the time established in the screen is finished The requested time must be established in the right hand menu of the screen The CPU counter will deduct the seconds gone from the beginning of the shot until the total time established has finished Once 0 value is reached the gun will close automatically and the unit will beep The time unit is seconds and the selection range is between 0 and 999 9 seconds with rises of 0 1 seconds Should an alarm turn on during the shooting time the counter will stop and show the seconds remaining until the total established shooting time Resolve the problem caused by the alarm and activate the trigger again to consume the remaining time or press RESET with no need to exit the current sreen to re establish the total time from the beginning The time established initially is shown in the left hand menu of the screen The time counter will only be activated again after the trigger is released and the detector has lost its signal Use UP DOWN to modify the established time or else enter the new value from the numeric keypad Use RIGHT LEFT to go from one menu to another NOTE This working mode is optional the basic proportioning unit will need to incorporate additional components and an automatic gun to operate with the timer 21 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Recirculation Parameters Selection Screen
69. ts Values List w v xt oy 2a x4 0 o ee ee ee ee 400 440 Under extreme environmental conditions the heater might be affected and fail to reach the required temperature In this case put the unit in a more favorable place or use an auxiliary heating system 3 Automatic Switch This protects the elements against any possible change in voltage With the general switch turned off open the control panel and make sure the switch is activated see electrical diagram otherwise activate it 43 56 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual 4 Temperature Probe The control panel automatically detects any fault in the operation of the temperature probe If the fault occurs replace the probe paying special attention not to damage it when assembling The probe must be in firm physical contact with the heating element 44 54 issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Service Manual Hose Heating WARNING Before resolving any kind of defect make sure all of the push buttons are off that the general switch is in shutdown position and that the unit is disconnected from the power supply source Never handle the inside of the control panel with the unit connected to the power supply The hoses can reach high temperatures wait until they have cooled before handling Follow the recommended procedure in the order indicated to try to solve the problem and avoid costly repairs Mak
70. typographical errors supplement the information contained or insert changes predicated by the performance or use of the unit SAFETY AND HANDLING The evolution VR series proportioning unit has been designed and manufactured in full compliance to the provisions of Machine Directive 89 392 CEE in its modified form and the National Regulations that transpose it It also meets all European Directives concerning electromagnetic compatibility and electrical safety and the provisions of the Harmonised Norms that are applicable This chapter contains information on the safety handling and use of the evolution VR series proportioning unit Before installing the unit and starting it up carefully read all the technical and safety documentation included in this Service Manual Pay special attention to the information to know and understand the operation and the conditions of use of the unit All of the information is aimed at enhancing User Safety and avoiding possible breakdowns derived from the incorrect use of the proportioning unit WARNING establishes information to alert on a situation that might cause serious injuries if the instructions are not followed CAUTION establishes information that indicates how to avoid damage to the unit or how to avoid a situation that could cause minor injuries NB is relevant information on a procedure being described Careful study of this manual will enable the operator to know the characteristics of
71. um working pressure 275 kgf cm2 27 MPa 3910 psi Maximum production ratio 1 1 15 kg min 33 Ib min Minimum production 1 kg min 2 2 lb min Maximum hose length 93 m 310 ft Recommended compressor Three phase 3 HP Approximate weight hydraulic tank empty 450 kg 992 Ibs Approximate weight hydraulic tank full 545 kg 1202 Ibs Dimensions H 125 cm 49 in W 111 cm 43 in L 120 cm 47 in 7 56 Issue 2 8 Ref NR 00015 ENG http AWwww gamapur com Kana Service Manual GENERAL DESCRIPTION MAIN COMPONENTS 8 54 Issue 2 8 Ref NR 00015 ENG http www gamapur com Service Manual 1 Control Panel Controls and regulates the operation of the unit 2 isocyanate Proportioning Pump Provides the system with Isocyanate 3 Polyol Proportioning Pump Provides the system with Polyol 4 isocyanate Heater Heats the Isocyanate to the pre set temperature 5 Polyol Heater Heats the Polyol to the pre set temperature 6 Polyol Hose Heating Transformer Supplies the required voltage for the heating of the Polyol hoses 7 lIsocyanate Hose Heating Transformer Supplies the required voltage for the heating of the lsocyanate hoses 8 lIsocyanate Hydraulic Pressure Gauge Indicates the pressure in the Isocyanate hydraulic circuit 9 Polyol Hydraulic Pressure Gauge Indicates the pressure in the Polyol hydraulic system 10 Isocyanate Hydraulic Circuit Safety Valve Diverts pressure to the hydraulic tank in the event
72. ying pressure in the Isocyanate circuit Place the DIP in USA position if you wish the pressure unit to be psi place the DIP in EU position if you wish the pressure unit to be bar If the PRESS CONTROL key is activated the CPU of the unit will ensure that the pressure in the Isocyanate circuit is within the established limits Should the pressure of the circuit be over the maximum value or below the minimum the audible alarm of the unit will turn on and the motors will stop The screen will show PRESSURE OUT OF TOLERANCE The pressure tolerance control system is activated 10 seconds after the magnetic switch in the spray gun has turned on the solenoid valves which make the proportioning pumps start working It allows pressure to stay out of ratio for the mentioned 10 seconds plus the time set at the TOLERANCE DELAY see page 24 The alarm of the unit will sound after 10 seconds from the start of the pumping plus the set time for the delay if the mixing ratio is not within the set tolerance The flashing value can be modified using UP DOWN or entering the new value from the numeric keypad Use RIGHT LEFT to go from one option to the other MIN MAX Once the requested value has been established press ENTER to confirm and finalize the setup POL Pressure Selection Screen Allows establishing the minimum and maximum spraying pressure in the Polyol circuit Place the DIP in USA position if you wish the pressure unit to be

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