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GAMA Easy Spray-H Service Manual

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Service Manual
Spray Unit
Easy Spray-H
Issue 1.9 15/02/19
Ref. NR-00088-ENG
Before preparing the unit and starting it up, please take the
time to read all the technical and safety instructions in this
manual. It is essential that you follow these instructions
carefully so that you can handle and use the unit properly.
These instructions are intended to maximize user safety and
avoid malfunctions deriving from the incorrect use of the unit.

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  • Page 1 Service Manual Spray Unit Easy Spray-H Issue 1.9 15/02/19 Ref. NR-00088-ENG Before preparing the unit and starting it up, please take the time to read all the technical and safety instructions in this manual. It is essential that you follow these instructions carefully so that you can handle and use the unit properly.

  • Page 2: Warranty

    Easy Spray-H Service manual WARRANTY HI-TECH SPRAY EQUIPMENT, S. A. (“HI-TECH”) provides this LIMITED WARRANTY (“Warranty”) to the original purchaser (“Customer”) covering the equipment and the original accessories delivered with the equipment (“Product”) against defects in the design, materials or manufacture of the Product from the moment of initial purchase by the user and for a period of two (2) years from this date.

  • Page 3: Safety And Handling

    SAFETY AND HANDLING The Easy Spray-H proportioning unit is designed and manufactured in accordance with the European “Machinery” Directive 89/392/EEC as modified by the legislation which transposed it to national statutes. It also complies with European directives on electromagnetic compatibility and electrical safety, as well as applicable Harmonized Standards.
  • Page 4 Easy Spray-H Service manual When working with the unit, it is essential that you wear suitable clothing and personal protective equipment including but not limited to gloves, protective goggles, safety footwear and face masks. Use breathing equipment when working with the unit in enclosed spaces or in areas with insufficient ventilation.

  • Page 5: Characteristics

    Easy Spray-H Service Manual CHARACTERISTICS The Easy Spray-H proportioning unit is designed for the application of polyurea chemical systems for polyurethane foaming and certain two-component epoxy systems. Principal heating system Consists of two independent heaters without gaskets. Each heater has two 900 W heating elements delivering total power of 1800 W, and the necessary control and safety mechanisms for the correct operation of the system.

  • Page 6: Technical Specifications

    Easy Spray-H Service manual TECHNICAL SPECIFICATIONS Electrical Voltage: ________________________________________________________________ 230V Frequency: ____________________________________________________________ 50/60Hz Connections 1 and 2:________________________ 2 x 220V phases /1 x 400V phase + neutral Connection 1 power consumption: ______ ____________3.3 kW (1.8 kW motor + 1.5 kW hoses) Connection 2 power consumption: _____________________________ ______ 3.6 kW (heaters)

  • Page 7: Overview

    Easy Spray-H Service Manual OVERVIEW . General view Figure 1 7/48 Issue 1.9 Ref. NR-00088-ENG http://www.gamapur.com/...
  • Page 8 Easy Spray-H Service manual 1. Isocyanate tank Contains chemical component “A”. Capacity 30 litres. 2. Polyol tank Contains chemical component “R”. Capacity 30 litres. 3. Isocyanate recirculation valve (recirculation hoses only) Enables selection between recirculation and spray for the isocyanate circuit.
  • Page 9 Easy Spray-H Service Manual 21. Hydraulic pressure regulator Enables the pressure of the hydraulic circuit to be increased or reduced. With VK Pump.- To increase pressure, turn the tap clockwise; to reduce pressure, turn the tap anti-clockwise. With BR Pump.- The pressure is set with the pressure setting screw (position D).
  • Page 10 Easy Spray-H Service manual 22. Hydraulic oil tank Contains the oil used by the unit’s hydraulic system. 23. Hydraulic cylinder Drives the pumps. 24. Oil level and thermometer Displays the fluid level and temperature of the hydraulic oil tank. 25. Electric motor Drives the hydraulic pump.

  • Page 11: Control Panel

    Easy Spray-H Service Manual CONTROL PANEL . Control panel Figure 2 The control panel enables you to set the optimum operating conditions for the characteristics and requirements of the products dispensed. Press the MODE button to enter the desired settings for temperature, intensity and number of cycles to run. The selected parameter remains flashing for a few seconds, allowing you to change the values by touching the UP / DOWN buttons.
  • Page 12 Easy Spray-H Service manual Power switch Connects and disconnects the unit from the electricity supply. This switch must be in the ON position for the unit to work. When this switch is in the ON position, the green pilot light above the switch lights up.
  • Page 13 Easy Spray-H Service Manual The sequence for entering commands is as follows:  First we set the temperature of the ISO and POL heaters.  Next, we set the temperature of the ISO hoses.  Then we set the hose current consumption in amps.
  • Page 14 Easy Spray-H Service manual Heaters / Calentadores This display shows the temperatures in the isocyanate (ISO) and polyol (RESIN) heaters. To enter new temperature settings, press the MODE button, select the desired temperature by pressing the UP/DOWN buttons and press the MODE button again to confirm the selected value.
  • Page 15 Easy Spray-H Service Manual Motor button This button starts and stops the hydraulic motor. When pressed, this button lights up. To switch off the hydraulic motor, press this button again. The hydraulic motor switches off automatically in the event of hydraulic motor overload (alarm 8). The “Motor” function is only available on units with hydraulic drive.

  • Page 16: Alarms

    Easy Spray-H Service manual ALARMS In the event of a malfunction affecting the operation of the unit, it emits an audio signal and shows an alarm code on the COUNTER/CONTADOR display. An alarm cannot be cleared until the problem which caused it has been resolved. After clearing the alarm, press the MODE button.
  • Page 17 Easy Spray-H Service Manual Hose heating system malfunction (CONTROL/POWER cut-out)  Replace the faulty triac. 000000 Preselected cycles completed (solenoid valve cut-out)  Press the MODE button to reset the counter.  Set the cycle selector to zero. Disconnect the unit from the power supply before opening the electrical console.

  • Page 18: Preparing The Unit For Operation

    Easy Spray-H Service manual PREPARING THE UNIT FOR OPERATION WARNING! Use suitable protective gear and follow the safety recommendations of the suppliers of the chemical components when preparing or working with the unit. HI-TECH provides some accessories. This set comprises the following elements: Tube of grease, magnet holder, parts manual and service manual.

  • Page 19: Preparation (Units With Recirculation Hose)

    Easy Spray-H Service Manual WARNING! To join hoses to each other, to the heaters, or to the gun, hold each hose end in place with a spanner (1), and with a third spanner tighten or loosen the coupling nut (2) as required (see Figure 3 18. These couplers should be tightened to a torque of 20 c) Put 18 litres of hydraulic oil in the unit’s oil tank.

  • Page 20: Purge Method For Hoses With Recirculation

    Easy Spray-H Service manual b) Connect the air hose to the supply connector. c) Connect the pressure hoses to the gun couplers, making sure the gun’s manual valves are closed (the isocyanate hose to the isocyanate coupler and the polyol hose to the polyol coupler).
  • Page 21 Easy Spray-H Service Manual g) When the products contained in the hoses have reached working temperature, press the ISO and RESIN buttons located under the HEATERS/CALENTADORES display. Both LEDs will light up. WARNING! To avoid excess pressure in the heating hoses, wait for the products contained in the hoses to reach the required temperature before starting the hydraulic system.

  • Page 22: Preparation (Units With Heated Hose)

    Easy Spray-H Service manual aa) When the products contained in the hoses have reached working temperature, press the ISO and RESIN buttons located under the HEATERS/CALENTADORES display. Both LEDs will light up. bb) Press the MOTOR button. The LED will light up.

  • Page 23: Purge Method For Heated Hoses

    Easy Spray-H Service Manual e) Insert a contact thermometer under the hose’s outer sheath so that the lower part of the thermometer is in contact with the hoses and the upper part projects from the hose’s outer sheath. Position the thermometer in such a way that you can see the temperature while spraying.
  • Page 24 Easy Spray-H Service manual e) Press the button located under the HOSES/MANGUERAS display. The LED inside the button will light up. When the products contained in the hoses have reached working temperature, press the ISO and RESIN buttons located under the HEATERS/CALENTADORES display.
  • Page 25 Easy Spray-H Service Manual y) Press the button located under the HOSES/MANGUERAS display. The LED inside the button will light up. z) When the products contained in the hoses have reached working temperature, press the ISO and RESIN buttons located under the HEATERS/CALENTADORES display.

  • Page 26: Power-Up Procedure

    Easy Spray-H Service manual POWER-UP PROCEDURE Follow the recommended procedure, in the sequence given, to power-up the unit: WARNING! Do not start the power-up procedure described below until all necessary prior adjustments have been made correctly. a) Check the condition of the DOTP plasticizer contained in the isocyanate pump’s lube reservoir.
  • Page 27 Easy Spray-H Service Manual WARNING! To avoid excess pressure in the heating hoses, wait for the products contained in the hoses to reach the required temperature before starting the hydraulic system. m) Press the MOTOR button. The LED will light up.

  • Page 28: Power-Down

    Easy Spray-H Service manual POWER-DOWN Follow the recommended procedure, in the sequence given, to power-down the unit when you have finished using it: a) Press the RETRACT button. The LED will light up. b) Operate the gun, spraying into a waste recipient until the isocyanate proportioning pump is in the retracted position and the spray angle begins to decrease.

  • Page 29: Cleaning Procedure (Heated Hoses)

    Easy Spray-H Service Manual CLEANING PROCEDURE (HEATED HOSES) WARNING! This unit includes parts which reach temperatures likely to cause burns. Do not touch or handle the hot parts of the unit until they have cooled down. To avoid possible contamination, all of the unit’s circuits (pumps, heaters and hoses) must be cleaned before applications which require a change of components.

  • Page 30: Cleaning Procedure (Hoses With Recirculation)

    Easy Spray-H Service manual CLEANING PROCEDURE (HOSES WITH RECIRCULATION) WARNING! This unit includes parts which reach temperatures likely to cause burns. Do not touch or handle the hot parts of the unit until they have cooled down. To avoid possible contamination, all of the unit’s circuits (pumps, heaters and hoses) must be cleaned before applications which require a change of components.
  • Page 31 Easy Spray-H Service Manual Let the unit recirculate for 2-3 minutes to clean the hoses and tanks. For better tank cleaning results, heat the cleaning agent with the heaters. u) Press the NORMAL, MOTOR and CONTROL/POWER buttons to stop the proportioning pumps.

  • Page 32: Temporary Layoff Of The Unit

    Easy Spray-H Service manual TEMPORARY LAYOFF OF THE UNIT WARNING! This unit includes parts which reach temperatures likely to cause burns. Do not touch or handle the hot parts of the unit until they have cooled down. When the unit is to be out of service for over five weeks, you must replace the products contained in the unit with DOTP plasticizer.

  • Page 33: Malfunction

    Service Manual MALFUNCTION The Easy Spray-H unit has been designed and built to operate in severe working conditions. It will work with a high degree of reliability on condition that it is used and maintained correctly. This section contains information on the possible causes of malfunctions in the unit. Most problems with the unit can be detected and resolved using the information provided in this section.

  • Page 34: Heaters

    Each heater contains two 900 W heating elements, connected in parallel and delivering a total heating power of 1800 W (Easy Spray-H model). If a heater fails to reach the required temperature after two or three minutes, it’s possible that one of its two elements is faulty.

  • Page 35: Hose Heating

    Easy Spray-H Service Manual Disconnect the elements and check that the individual resistance of each element is 60 Ohms. Extreme environmental conditions may affect the operation of the heaters, preventing them from reaching the required temperature. In such circumstances, try moving the unit to a warmer location or use an auxiliary heating system.
  • Page 36 Easy Spray-H Service manual SOLUTIONS Hoses without product or air pockets in hoses Purge the air from the hoses. The ISO heater is not delivering the required temperature See the section on heater problems. Hose connector Check the hose connector’s electrical connection on the left hand side of the console.

  • Page 37: Proportioning Pumps

    Easy Spray-H Service Manual Proportioning pumps WARNING! Before attempting to fix any kind of malfunction, make sure the power switch is in the OFF position and that the unit is disconnected from the power supply. Never open the electrical console when the unit is connected to the power supply.
  • Page 38 Easy Spray-H Service manual To ascertain whether the pressure imbalance is caused by an obstruction or by a problem in the pumping system, operate the spray gun and check the reading on the pressure gauge of the missing component. Compare this reading with the pressure indicated on the other component’s pressure gauge: if the pressure of the missing component is higher, the pressure imbalance is caused by an obstruction;...

  • Page 39: Hydraulic Drive

    Easy Spray-H Service Manual Hydraulic drive WARNING! Before attempting to fix any kind of malfunction, make sure that no lights are lit on the control panel, the power switch is set to the OFF position, and the unit is disconnected from the power supply. Never open the electrical console when the unit is connected to the power supply.

  • Page 40: Maintenance

    Easy Spray-H Service manual MAINTENANCE To obtain optimum performance from the Easy Spray-H unit you must perform certain maintenance operations on a daily or regular basis. To avoid bodily damage caused by the incorrect handling of the substances and solvents used with this unit, read carefully the safety information provided by their suppliers.

  • Page 41: Heaters

    Easy Spray-H Service Manual Heaters WARNING! Before proceeding to any kind of maintenance work, make sure the power switch is in the OFF position and that the unit is disconnected from the power supply. Never open the electrical console when the unit is connected to the power supply.

  • Page 42: Proportioning Pumps

    Easy Spray-H Service manual Proportioning pumps WARNING! Before resolving any kind of defect, make sure all of the pushbuttons 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.

  • Page 43: Product Intake Filters

    Easy Spray-H Service Manual Product intake filters Filter bodies are fitted with an inner mesh which prevents solid particles from entering the unit and potentially interfering with the operation of the ball valves when the product is taken into the unit.

  • Page 44: Isocyanate Pump Lubrication System

    Easy Spray-H Service manual Isocyanate pump lubrication system Inspect the isocyanate pump lube reservoir every day and check the condition of the DOTP plasticizer oil it contains. Replace the oil if it is discoloured or exhibits signs of solidification. DOTP oil solidifies as a consequence of moisture absorption. The frequency of oil changes depends on the working conditions.

  • Page 45: Hydraulic Drive

    Easy Spray-H Service Manual Hydraulic drive WARNING! Before proceeding to any kind of maintenance work, make sure all lights on the control panel are off, the power switch is in the OFF position, and the unit is disconnected from the power supply. Never open the electrical console when the unit is connected to the power supply.

  • Page 46: Table Of Contents

    Easy Spray-H Service manual CONTENTS Warranty _____________________________________________________ 2 Safety and handling ____________________________________________ 3 Characteristics ________________________________________________ 5 Principal heating system ___________________________________________________ 5 Hose heating system ______________________________________________________ 5 Proportioning pumps ______________________________________________________ 5 Technical specifications ________________________________________ 6 Electrical _______________________________________________________________ 6 Mechanical ______________________________________________________________ 6...
  • Page 47 Easy Spray-H Service Manual Contents ____________________________________________________ 46 List of illustrations ____________________________________________ 48 47/48 Issue 1.9 Ref. NR-00088-ENG http://www.gamapur.com/...
  • Page 48 Easy Spray-H Service manual LIST OF ILLUSTRATIONS Figure 1. General view __________________________________________ 7 Figure 2. Control panel ________________________________________ 11 Figure 3. Hose coupling method _________________________________ 18 48/48 Issue 1.9 Ref. NR-00088-ENG http://www.gamapur.com/...

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