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GAMA Easy Spray Service Manual

Proportioning unit
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Service Manual
Proportioning Unit
Easy Spray
Issue 3.1 15/02/19
Ref. NR-00019-ENG
Before installing the unit and starting it up, read all the technical and
safety documentation included in this manual carefully. 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 unit.

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  • Page 1 Service Manual Proportioning Unit Easy Spray Issue 3.1 15/02/19 Ref. NR-00019-ENG Before installing the unit and starting it up, read all the technical and safety documentation included in this manual carefully. Pay special attention to the information to know and understand the operation and the conditions of use of the unit.

  • Page 2: Warranty

    Service Manual WARRANTY HI-TECH SPRAY EQUIPMENT, S. A. (hereinafter “HI-TECH”) provides this LIMITED WARRANTY (hereinafter “Warranty”) to the original purchaser (hereinafter “Customer”) covering this equipment and the original HI-TECH manufactured accessories delivered with the equipment (hereinafter “Product”) against defects in material or workmanship of the Product (hereinafter “Defect”...

  • Page 3: Safety And Handling

    SAFETY AND HANDLING This chapter contains information on the safety, handling and use of the Easy Spray series proportioning unit. Before installing the unit and starting it up, read all the technical and safety documentation included in this manual carefully.
  • Page 4 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.

  • Page 5: Characteristics

    Service Manual CHARACTERISTICS The Easy Spray proportioning unit has been designed and built for the application of Polyureas, chemical systems for polyurethane foaming, and some two-component Epoxy systems. Its reduced size allows easy transport to site. Its easy operation (simply turn one switch and push the START button) reverts into time saving during set up and application.

  • Page 6: Recirculation System

    Service Manual Recirculation System Allows keeping the products in temperature prior to start spraying and during breaks. Proportioning System (OPTIONAL) Designed with a 2000 W isolation transformer that enables effective heating up to a total hose length of 48 meters (165 feet). The system includes an innovative hose heating concept in which the copper heating element is spread evenly around the circumference of the...

  • Page 7: Technical Specifications Easy Spray-100

    Service Manual TECHNICAL SPECIFICATIONS EASY SPRAY-100 Electrical Main Voltage: ____________________________________________________________ 230 V Frequency: ____________________________________________________________ 50/60 Hz Electrical Consumption: ______________________________________ 16 amp @ 1 x 400 V+ N @ 2x 230 V Total Active Power: ______________________________________________________ 3.6 Kw Heater Power:_________________________________________________ (2 x 1.8 Kw) 3.6 Kw...

  • Page 8: Technical Specifications Easy Spray-200

    Manual de Servicio TECHNICAL SPECIFICATIONS EASY SPRAY-200 Electrical Main Voltage: ____________________________________________________________ 230 V Frequency: ____________________________________________________________ 50/60 Hz Electrical Consumption: ______________________________________ 16 amp @ 1 x 400 V+ N @ 2x 230 V Total Active Power: ______________________________________________________ 3.6 Kw Heater Power:_________________________________________________ (2 x 1.8 Kw) 3.6 Kw...

  • Page 9: General Description

    Service Manual GENERAL DESCRIPTION . General Description Easy Spray Figure 1 9/46 Issue 3.1 Ref. NR-00019-ENG http://www.gamapur.com/...
  • Page 10 Service Manual 1. Isocyanate Tank Contains the A chemical element. Capacity 30 liters. 2. Polyol Tank Contains the R chemical element. Capacity 30 liters. 3. Isocyanate Recirculation Valve Allows selecting recirculation or spraying in the Isocyanate circuit. 4. Polyol Recirculation Valve Allows selecting recirculation or spraying in the Polyol circuit.

  • Page 11: Control Panel And Hose Heated System

    Service Manual CONTROL PANEL AND HOSE HEATED SYSTEM . Control Panel and Hose Heating Figure 2 Comprises two electrical components for an accurate working of the unit. 1. 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.
  • Page 12 Manual de Servicio 4. Hoses (OPTIONAL) Hose heating is activated and deactivated by the orange pushbutton located at the front of the transformer. It will lit up when heating is activated. Turn the potentiometer clockwise to increase amps, and anti-clockwise if you wish to decrease amps.

  • Page 13: Regulator Of Temperature Heaters

    Service Manual REGULATOR OF TEMPERATURE HEATERS This machine equips each heater with separate temperature regulators. Instructions When the power is connected to the machine, the displays will show the current temperature values. To modify the values press as required. For more details about the settings, follow the instructions from the manufacturer's manual attached.
  • Page 14 Manual de Servicio 14/46 Issue 3.1 Ref. NR-00019-ENG http://www.gamapur.com/...
  • Page 15 Service Manual The temperature regulators are not inter-changeable with those attached to previous versions of the machine 15/46 Issue 3.1 Ref. NR-00019-ENG http://www.gamapur.com/...

  • Page 16: Installation (Recirculation Unit)

    Manual de Servicio INSTALLATION (RECIRCULATION UNIT) CAUTION! Use suitable protection and follow the recommendations in the safety information provided by product suppliers when installing or working with the unit. NOTE: To ensure that the unit works correctly, the electrical supply must meet the specifications indicated on page six of this manual and appearing on the machine specifications plate.
  • Page 17 Service Manual d) Connect the air hoses. e) Connect the two pressure hoses to the connectors of the coupling block of the gun, making sure that the manual valves are closed. (the Polyol hose to the Polyol connector and the Isocyanate hose to the Isocyanate connector). Connect the recirculation hoses to the connectors of the coupling block of the gun.
  • Page 18 Manual de Servicio WARNING! In order to avoid product contamination, make sure that the tanks are well closed. Do not fill the tank to maximum capacity; check the level on the tank to make sure that 20% of its maximum capacity is vacant. Each tank is 30 liters. Small vessels (10-15 liters maximum) are recommended to pour the product inside the tanks.

  • Page 19: Start-Up Procedures

    Service Manual START-UP PROCEDURES Follow the recommended procedure in the indicated order. CAUTION! The start-up procedures assume that all of the necessary adjustments have been correctly performed. a) Check the state of the DOTP plasticizer in the Isocyanate pump lubrication cup. Change the oil if you see changes in the color or signs of solidification and retighten the packing nut to ensure the seal.

  • Page 20: Daily Shutdown

    Service Manual DAILY SHUTDOWN Follow the recommended procedure in the indicated order for machine shut down when work is stopped for the day. a) Close the “RETRACT” valve, (horizontal position). b) Close the manual valves at the bottom of the tanks. c) Use the gun to project into a waste container until the Isocyanate proportioning pump is in the retract position and the pressure begins to fall.

  • Page 21: Cleaning

    Service Manual CLEANING 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 be flushed clean (pumps, heaters and hoses) whenever applications have to be made that require a change of components.
  • Page 22 Service Manual w) Allow the materials to come out of the recirculating hoses until the tanks are empty. x) Turn the general switch “OFF”. y) Close the manual valves at the bottom of the tanks. z) Close the recirculation manual valves. aa) Fill the product tanks with new product.

  • Page 23: Shutdown Procedures

    Service Manual SHUTDOWN PROCEDURES 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. When you plan to shut down the machine for more than five weeks, the products contained in the machine must be replaced by DOTP plasticizing agent.
  • Page 24 Service Manual v) Turn the general switch “OFF”. The temperature regulator will go out. w) Close the manual valves at the bottom of the tanks. x) Close the recirculation manual valves. y) Move the recirculation hoses to the tanks again and make sure that the manual valves are open.

  • Page 25: Instalation (Heated Hoses Unit)

    Service Manual INSTALATION (HEATED HOSES UNIT) CAUTION! Use suitable protection and follow the recommendations in the safety information provided by product suppliers when installing or working with the unit. NOTE: To ensure that the unit works correctly, the electrical supply must meet the specifications indicated on page six of this manual and appearing on the machine specifications plate.
  • Page 26 Manual de Servicio NOTE: Assure the proper mechanical and electrical connection of the hoses to avoid possible product leakage and hose heat problems. e) Connect the air hoses. Connect the hoses to the connectors of the coupling block of the gun, making sure that the manual valves are closed.
  • Page 27 Service Manual WARNING! 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. To avoid splashing open only one tank Isocyanate or Polyol. Never change the chemical components, use always the same tank for each component.

  • Page 28: Start Up Procedures

    Manual de Servicio START UP PROCEDURES Follow the recommended procedure in the indicated order. CAUTION! The start-up procedure assumes that all of the necessary adjustments have been correctly performed. a) Check the state of the DOTP plasticizer in the Isocyanate pump lubrication cup. Change the oil if you see changes in the color or signs of solidification and retighten the packing nut to ensure the seal.

  • Page 29: Shutdown Procedures

    Service Manual SHUTDOWN PROCEDURES Follow the recommended procedure in the indicated order for machine shut down when work is stopped for the day. a) Close the “RETRACT” valve (horizontal position). b) Close the manual valves at the bottom of the tanks. c) Use the gun to project into a waste container until the Isocyanate proportioning pump is in the retract position and the pressure begins to fall.

  • Page 30: Cleaning

    Manual de Servicio CLEANING 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 be flushed clean (pumps, heaters and hoses) whenever applications have to be made that require a change of components.
  • Page 31 Service Manual z) When the products come out without the contamination produced by the effect of the DOTP cleaning agent, the cleaning process is complete and you can proceed as normal. aa) Close the “RETRATC” valve (horizontal position). bb) Turn the general switch “OFF”. The temperature regulator displays will go out. cc) Close the coupling block and mount the gun.

  • Page 32: Long-Term Shutdown Procedures

    Manual de Servicio 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 more than five weeks, the products contained in the machine must be replaced by DOTP plasticizing agent.

  • Page 33: Troubleshooting

    Service Manual TROUBLESHOOTING The Easy Spray unit has been designed and built to withstand severe working 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 HI-TECH technical service.

  • Page 34: Heaters

    Manual de Servicio Heaters 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. Never handle the inside of the control panel with the unit connected to the main power supply.
  • Page 35 Service Manual 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. Elements Values List x1 (Ω) x2 (Ω) x4 (Ω) x6 (Ω) 117±2 58±2 29±2 19±2...

  • Page 36: Hose Heating (Optional)

    SOLUTIONS 1. Hose Length The Easy Spray has been designed to work with a maximum hose length of 48 meters /160 ft. A longer length will render the heating capacity less effective. Under extreme environmental conditions, the hose heating system may be affected and fail to reach the required temperature.
  • Page 37 Service Manual 5. Hose Heating Components With the general switch turned off, make sure the hose connectors and the electrical connections between the hoses and the unit are correct and well fixed. If the connections are correct and the hoses do not heat up, check section by section to locate the connection that is failing.
  • Page 38 Manual de Servicio 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 39 Service Manual To determine whether the unbalance is caused as a result of an obstruction or as a consequence of a problem in the pumping system, project with the gun, observe the pressure indicated on the corresponding pressure gage to the missing component and compare it with the pressure indicated by the gage to the other component: if the pressure of the missing component is higher, the unbalance is the result of an obstruction, if the pressure is lower, the unbalance is the consequence of a problem in the pumping system.

  • Page 40: Maintenance

    Manual de Servicio MAINTENANCE To achieve maximum output from the Easy Spray unit, certain daily or regular maintenance operations are needed. To prevent all possible body harm caused by incorrect handling of the raw materials and solvents used in the process, carefully read the safety information provided by your supplier.

  • Page 41: Heaters

    Service Manual Heaters WARNING! Before performing any maintenance work, make sure all of the pushbuttons are off, that the general switch is in shutdown position and that the unit is disconnected from the main power supply source. Never handle the inside of the control panel with the unit connected to the power supply.

  • Page 42: Proportioning Pumps

    Manual de Servicio 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: Inlet Supply Filters

    Service Manual Inlet supply filters The filter bodies have a filter screen that prevents solid particles from entering the unit. Inspect the filters each day as part of the machine start-up, and clean them. Replace the filter screen if necessary. Isocyanate is a product that crystallizes with ambient moisture or freezing.

  • Page 44: Isocyanate Pump Lubrication System

    Manual de Servicio Isocyanate pump lubrication system Each day, inspect the lubrication cup of the Isocyanate pump and check the state of the DOTP plasticizing oil. Replace the oil when it shows changes in color or signs of solidification. The DOTP oil solidifies as a result of the absorption of moisture and the maintenance interval will depend on the working conditions.

  • Page 45: Table Of Contents

    Characteristics ________________________________________________ 5 Principal Heating System __________________________________________ 5 Proportioning Pumps ______________________________________________ 5 Recirculation System _____________________________________________ 6 Proportioning System (OPTIONAL) ___________________________________ 6 Technical Specifications Easy Spray-100 __________________________ 7 Electrical _______________________________________________________ 7 Mechanical _____________________________________________________ 7 Technical Specifications Easy Spray-200 __________________________ 8 Electrical _______________________________________________________ 8...

  • Page 46: List Of Illustrations

    Manual de Servicio LIST OF ILLUSTRATIONS Figure 1. General Description Easy Spray __________________________ 9 Figure 2. Control Panel and Hose Heating _________________________ 11 Figure 3. Method of union of the Hoses ___________________________ 16 46/46 Issue 3.1 Ref. NR-00019-ENG http://www.gamapur.com/...

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