GAMA evolution G-50 H Service Manual

Proportioning unit

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Proportioning Unit

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 of the information is aimed at enhancing

User Safety and avoiding possible breakdowns derived from the incorrect

use of the unit.

Service Manual

evolution G-50 H

Issue 3.2 3/21/2023

Ref. NR-00042-ENG

Table of Contents

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Summary of Contents for GAMA evolution G-50 H

Page 1 Service Manual Proportioning Unit evolution G-50 H Issue 3.2 3/21/2023 Ref. NR-00042-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.
Page 2: Warranty
G-50 H Service Manual WARRANTY HI-TECH SPRAY EQUIPMENT, S. A. (hereinafter “HI-TECH”) grants this Limited Guarantee to the original buyer (hereinafter the “Client”) for the unit and the original accessories given with the unit (hereinafter the “Product”) against any fault in the design, materials or manufacture of the Product at the time of the first purchase by the user and for a duration of two (2) years thereafter.
Page 3: Safety And Handling
G-50 H Service Manual SAFETY AND HANDLING The equipment described in this manual has been designed and manufactured in compliance with the following European Directives, following as application guide the harmonized standards detailed and in conformity with the relevant UK...
Page 4 24 hours. Also, appropriate means to prevent damage from moisture, vibrations or shocks must be foreseen. This chapter contains information on the safety, handling and use of the evolution G-50 H series metering unit. Before installing the unit and starting it up, carefully read all the technical and safety documentation included in this manual.
Page 5 G-50 H 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 6: Characteristics
G-50 H Service Manual CHARACTERISTICS The evolution G-50 H metering unit has been designed and built for the application of Polyureas, chemical systems for polyurethane foaming and some two-component epoxy systems. Principal Heating System Consists of two independent heaters without seals. 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.
Page 7: Technical Specifications
G-50 H Service Manual TECHNICAL SPECIFICATIONS Electrical Main voltage: _________________________________________________________ 400/200 V Frequency: ____________________________________________________________ 50/60 Hz Electrical consumption: ________________________ 56 A @ 3PE~400V / 100 A @ 3PE~200V Pre Heater power: _______________________________________________ (2 x 9 kW) 18 kW Hose Transformer Power: ___________________________________________________ 4 kW...
Page 8: General Description
G-50 H Service Manual GENERAL DESCRIPTION General Description. Figure 8/48 Issue 3.2 Ref. NR-00042-ENG http://www.gamapur.com/...
Page 9 G-50 H Service Manual Control Panel Controls and regulates the operation of the unit. Isocyanate Metering Pump Meters the Isocyanate. Polyol Metering Pump Meters the Polyol. Isocyanate Pre Heater Heats the Isocyanate to the pre-set temperature. Polyol Pre Heater Heats the Polyol to the pre-set temperature.
Page 10 G-50 H Service Manual 16. DIP S1 Selector TPC Probes This sets the hose heating control mode to be selected, depending on whether system includes single Temperature Control Sensor (TCS) for automatic temperature control or no TCS for manual temperature control.
Page 11: Control Panel
G-50 H Service Manual CONTROL PANEL . Control Panel Figure 2 The Control Panel allows the optimum working conditions to be selected and set, depending on the characteristics and requirements of the products to be dispensed. Using the MODE key, the different control parameters may be entered.
Page 12 G-50 H Service Manual 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 green pilot at the top of the switch will come...
Page 13 G-50 H Service Manual For the data input, the order will be as follows: • Temperature set-point for A(ISO) heater and B or R (POL). • Temperature set-point for A(ISO) hose and B or R (POL). • Amps set-point for A (ISO) and B or R (POL).
Page 14 G-50 H Service Manual Heaters The display shows the temperature in the Isocyanate heater (ISO) and the temperature in the Polyol heater (RESIN). To enter new temperature values, press the MODE key until the respective temperature flashes; select the required temperature by pressing the UP/DOWN keys and press the MODE key to enter the value into memory.
Page 15 G-50 H Service Manual Motor Key Pushbutton turns on and off the hydraulic motor. When the key is active, the led in its centre will come on. This may be turned off at will by pressing the key once more, or automatically in the event of overload in the hydraulic motor (alarm 8).
Page 16: Alarms
G-50 H Service Manual ALARMS When the unit has faults caused by conditions affecting its correct operation, an audible alarm will sound and a fault number will show on the COUNTER display. The system does not allow an alarm to be reset until the fault causing the alarm has been corrected. After resetting, the MODE key must be pressed.
Page 17 G-50 H Service Manual 10. Fault Ratio Off Tolerance (deactivates the directional valve) • Check the product pressures. • Replace the pressure transducer if there is no reading. • Press the ratio key to cancel the function. 11. 000000 Cycle Pre-selection made (deactivates the directional valve) •...
Page 18: Method Of Threaded Union Of The Hoses
G-50 H Service Manual METHOD OF THREADED UNION OF THE HOSES Follow the torques for threaded joints listed in Table 1 according to thread sizes of hose fittings to ensure their proper assembly. There is also an alternative procedure to obtain an...
Page 19: Installation
G-50 H Service Manual INSTALLATION PRECAUTION! Use suitable protection and follow the recommendations in the safety information provided by product suppliers when installing or working with the unit. HI-TECH provides a series of tools and accessories necessary for assembling the machine. The...
Page 20 G-50 H Service Manual Inside the console there is a terminal strip for connecting the principal electrical wire (not supplied) to the unit. The electrical connection of the unit must only be carried out by a qualified electrician. 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 21: Figure 3. Method Of Union Of The Hoses
G-50 H Service Manual Do not fill the tank to maximum capacity (78 Lts – 20.6 gal); make sure the amount of oil is not more than 80% of its maximum capacity (63 Lts. – 16.6 gal). Use the visual level indicator of temperature on the tank as a reference, because the maximum temperature limit (80ºC –...
Page 22 G-50 H Service Manual hose connection system includes special terminals (fast lock) facilitate electrical connection transformer and between different sections installed in the unit. The transformer offers the option of connecting to a 45 V output voltage valid for a...
Page 23 G-50 H Service Manual h) 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 Isocyanate hose.
Page 24 G-50 H Service Manual e) Open the console of the control panel and change the position of two of the three wires of the electrical connection of the unit. Check the turning direction once more. Proceed to install the transfer pumps paying special attention to connect each pump to “its”...
Page 25: Start - Up Procedures
G-50 H Service Manual START - UP PROCEDURES Follow the recommended procedure in the indicated order. PRECAUTION! The start-up procedures assume that all of the necessary adjustments have been correctly performed. a) Check the state of the DOTP plasticizing oil in the lubrication tank of the Isocyanate pump.
Page 26: Shutdown Proedures
G-50 H Service Manual SHUTDOWN PROEDURES Follow the recommended procedure in the indicated order for machine shut down when work is stopped for the day. a) Press the RETRACT key. The led will light. b) Use the gun to project into a waste container until the Isocyanate metering pump is in the retract position and the pressure begins to fall.
Page 27: Cleaning
G-50 H Service Manual CLEANING PRECAUTION! 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.
Page 28: Long Term Shutdown Procedures
G-50 H Service Manual LONG TERM SHUTDOWN PROCEDURES PRECAUTION! 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 FOUR weeks, the products contained in the machine must be replaced by DOTP plasticizing agent.
Page 29: Troubleshooting
Service Manual TROUBLESHOOTING The evolution G-50 H 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 30: Heaters
G-50 H Service Manual 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 power supply.
Page 31: Table 2. Elements Values List
G-50 H Service Manual Heating Resistances Each heater has six 1500 W elements connected in parallel, which give the system a total power of 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.
Page 32 G-50 H Service Manual Temperature The control panel automatically detects any fault in the operation of the temperature. 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 element.
Page 33: Hose Heating
SOLUTIONS Hose Length The evolution G-50 H 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.
Page 34 G-50 H Service Manual 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. Hose Heating Components 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.
Page 35: Metering Pumps
G-50 H Service Manual Metering 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 36 G-50 H Service Manual Proceed as follows to check the valve balls: a) Disconnect the machine from the power supply and close both inlet ball valves and the supply system to the transfer pumps. b) Depressurise the metering pump and remove the corresponding valve ball.
Page 37 G-50 H Service Manual a) Determine the direction in which the plate must move; this depends on which micro has been passed. b) Locate the slide for the manual activation of the directional valve in the hydraulic distributor: this is located on the same side of the machine towards which the activation plate must work.
Page 38: Hydraulic Unit
G-50 H Service Manual Hydraulic unit 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 power supply.
Page 39: Maintenance
G-50 H Service Manual MAINTENANCE To achieve maximum output from the evolution G-50 H unit, certain daily or regular maintenance operations are needed. 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.
Page 40: Heaters
G-50 H 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 power supply source. Never handle the inside of the control panel with the unit connected to the power supply.
Page 41: Hydraulic Unit
G-50 H Service Manual Hydraulic unit 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 power supply. Never handle the inside of the control panel with the unit connected to the power supply.
Page 42: Metering Pumps
G-50 H Service Manual Metering pumps WARNING! Before proceeding with maintenance works, make sure that all push buttons are switched off, the general switch is in the off position, and the Unit is unplugged from the power supply. Never handle the control panel interior while the Unit is plugged into the electricity grid.
Page 43: Seals Assembly
G-50 H Service Manual Table 3. Tools for shaft seal assembly Tool (A) Tool (B) Tool (C) #0.80 Pump HT-00036 HT-00124 HT-00125 #1.20 Pump HT-00035 Seals assembly PISTON SEAL Groove contact with the seal Lips faced to the shaft...
Page 44 G-50 H Service Manual SHAFT SEAL Insert the seal (1) into Tool A Place tool A with the seal (3) Place the shaft bearing (6) (2). Make sure that the lips inside the seal housing (4). and the seal housing along are facing upwards.
Page 45: Inlet Supply Filters
G-50 H 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.
Page 46: Isocyanate Pump Lubrication System
G-50 H Service Manual Isocyanate pump lubrication system Each day, inspect the lube reservoir of the Isocyanate pump and check the condition of the DOTP. Replace the oil when it shows changes in color or signs of solidification. Oil solidification is the result of the absorption of moisture and the maintenance interval will depend on the working conditions.
Page 47: Table Of Contents
G-50 H Service Manual CONTENT Warranty _____________________________________________________ 2 Safety and Handling ____________________________________________ 3 Characteristics ________________________________________________ 6 Principal Heating System___________________________________________________ 6 Hose Heating System _____________________________________________________ 6 Double Acting Opposed Piston Metering Pumps ________________________________ 6 Technical Specifications ________________________________________ 7 Electrical _______________________________________________________________ 7...
Page 48: List Of Illustrations
G-50 H Service Manual List Of Tables ________________________________________________ 48 LIST OF ILLUSTRATIONS Figure 1. General Description. ___________________________________ 8 Figure 2. Control Panel ________________________________________ 11 Figure 3. Method of union of the Hoses ___________________________ 21 LIST OF TABLES Table 1. Tightening Threaded Joints _____________________________ 18 Table 2.