GAMA evolution G-50 H, Service Manual

Page 1: ...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 ...

Page 2: ...ts and accessories forming part of the Product and which have not been made by HI TECH will be limited to the guarantee offered by the original manufacturer thereof HI TECH WILL NOT RECOGNISE ANY EXPRESS ORAL OR WRITTEN GUARANTEES OTHER THAN THIS PRINTED LIMITED GUARANTEE ALL IMPLICIT GUARANTEES INCLUDING WITHOUT LIMIT ADAPTATION FOR A SPECIFIC USE ARE SUBJECT TO THE DURATION OF THIS WRITTEN GUARA...

Page 3: ...0 4 8 UNE EN 61000 4 11 BS UNE EN 61000 4 11 The Unit may experience a degradation of its immunity in the presence of radiated electromagnetic disturbances IEC 61000 4 3 in the frequency range between 80MHz and 700MHz under an electric field level of 10 V m resulting in a temporary loss of function self recoverable according to performance criterion C of the Standard Directive 2014 68 EU on pressu...

Page 4: ...ion 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 WARNING establishes information to alert on a situation that might cause serious injuries if the instructions are not followed PRECAUTION establishes information that indicates how to avoi...

Page 5: ...er 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 ...

Page 6: ...th a 4000 W isolation transformer that enables effective heating up to a total hose length of 93 meters 305 feet 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 This hose heating element design is extrem...

Page 7: ...nly be carried out by a qualified electrician Mechanical Maximum working pressure _______________________________________ 240 bar 24 MPa Maximum production ratio 1 1 ___________________________ 22 kg min 110 bar 11 MPa 17 kg min 160 bar 16 Mpa 12 kg min 240 bar 24 Mpa Minimum production ____________________________________________________ 1 kg min Maximum hose length ______________________________...

Page 8: ...evolution G 50 H Service Manual 8 48 Issue 3 2 Ref NR 00042 ENG http www gamapur com Figure 1 General Description GENERAL DESCRIPTION ...

Page 9: ... probe Provides information on the temperature of the Isocyanate 11 Polyol Pressure Gage Indicates the pressure in the Polyol system 12 Polyol Safety Pressure Switch Deactivates the directional valve in the event of excessive pressure in the Polyol system 13 Polyol Temperature Probe Provides information on the temperature of the Polyol 14 Recirculation Kit 15 Hydraulic Pressure Regulator Allows th...

Page 10: ...e control panel displays to Metric or English Set to EU for the pressure to be shown in bar and the temperature to be shown in degrees Celsius Set to USA for the pressure to be shown in psi and the temperature to be shown in degrees Fahrenheit Please be aware that after manipulating the DIP selector you should switch off the unit so the change in detected buy the board 18 DIP S3 selector Input Vol...

Page 11: ...s value by pressing the UP DOWN keys Once the change is made press the MODE key once more for the new value to be entered into memory and to select the next parameter for setting The modification mode will be interrupted automatically after 3 seconds without activity on the keyboard The parameters that may be selected and displayed are the following Hose temperature in automatic control mode maxim...

Page 12: ...th two hose transformer power locate the DIP Hose ISO and the DIP Hose RESIN to ON position if the hoses have TCS for the temperature control system or OFF position if the hoses not have TCS Please be aware that after manipulating the DIP selector you should switch off the unit so the change in detected buy the board ISO on RESIN off w TCS ISO off RESIN off manual control Dual Hose Heat optional T...

Page 13: ... amperage flashes press the UP DOWN keys to enter the number of amps required and press the MODE key once more to enter the value into memory Refer to the table shown below to select the power that is required to reach the application temperature 30 A 38º C 100º F 35 A 48º C 118º F 40 A 60º C 140º F 45 A 75º C 167º F 50 A 80º C 176º F Select the required amps for a quick pre heating NOTA The circu...

Page 14: ...layed in psi and the temperature in degrees Fahrenheit Please be aware that after manipulating the DIP selector you should switch off the unit so the change in detected buy the board 7 Counter Indicator displays the cycles used and the cycles remaining from the preset The cycle counter is incremental and may be reset by simultaneously pressing the UP DOWN keys The system allows pre selecting the r...

Page 15: ...o seconds before the alarm is set off The ratio control parameters are factory set When the key is active the led in its center will come on 11 Normal Key Activates the normal operation of the machine When the key is active the led in its center will come on 12 Retract Key Sets the piston rod of the Isocyanate metering pump to the retract position and prevents the crystallization of Isocyanate on ...

Page 16: ... Excessive POL Pressure deactivates the directional valve and the heating system Check the product pressure Check the number 11 led of the printed circuit it must be lit Check the over pressure safety switch 5 Excessive ISO temperature deactivates the POWER CONTROL Check the heater heating system Check the connections of the safety thermostat and allow it to cool so that it makes an automatic rese...

Page 17: ...ducer if there is no reading Press the ratio key to cancel the function 11 000000 Cycle Pre selection made deactivates the directional valve Press the MODE key to reset the counter Set the cycle selector to zero 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 electr...

Page 18: ...of the hoses to be connected tighten a swivel nut by hand without using spanner until there is resistance on the nut Fit two spanners 1 on the fixed ends of the hoses and turn the swivel nut with a third spanner 2 as many flats from wrench resistance FFWR as indicated in Table 1 Table 1 Tightening Threaded Joints THREAD SIZE TORQUE Nm FFWR 1 2 20 23 2 or 120º 9 16 18 30 1 1 2 or 90º NOTE 1 FFWR co...

Page 19: ... 00003 Pin extractor 1x MA 00102 12 Hoses Connection Cover 2x EL 00051 00E ISO TCS Assy with POL hose extension For units with TCS 1x EM 00012 Hose TCS packaging 1x EL 00093 01 White Flange 300 x 4 8 3x HT 00045 Allen key 1 8 1x EL 00100 06 Blue Terminal for Cable 16 mm2 L 12mm 2x TN 00242 Threaded Rod 1 4 20 UNC x 14 nylon 2x OPTIONALS EL 00052 00E ISO POL TCS Assy For units with 2 Transformers 1...

Page 20: ...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 Use the proper size of cable according to the voltage current and maximum power required by the Unit The sizing of the cable is calculated for a length of 25m for longer lengths you must recalculate the appropriate section 56 0 A 3PE 400V 100 A 3PE 230V Cabl...

Page 21: ...f the respective heaters the Isocyanate hose to the Isocyanate heater and the Polyol hose to the Polyol heater 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 b...

Page 22: ... to which it is connected is suitable for the resulting total length Otherwise change the connection f Connect the heated hoses wires to the fast lock connector coming out of the hose transformers as follow 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 int...

Page 23: ...th 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 4 feet l Connect the air hoses m Connect the hoses to the connectors of the coupling block of the gun making sure that the manual valves are closed Having performed the above operations you must note the direction i...

Page 24: ...e movement of the product inside the hose can cause static electricity and produce electrical discharges 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 hydraulic pressure regulator counter clockwise to the limit...

Page 25: ...he two leds will light i Press the ISO and RESIN keys under the HEATERS display when the products in the hoses reach the working temperature The two leds will light PRECAUTION 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 j Press the MOTOR key The led will light k Press the NORMAL key The led ...

Page 26: ...tem with a minimum pressure of 30 bar 400 psi to extend the life of the seals c Press the MOTOR key The led will go out d Press the ISO and RESIN keys under the heater temperature display The two leds will go out e Press the ISO key under the HOSES display The led will go out In machines fitted with two transformers the ISO and RESIN keys must be pressed The two leds will go out f Press the POWER ...

Page 27: ...e them in the drums of the DOTP cleaning agent d Place a vessel under the coupling block to gather up the products contained inside the machine e Open the manual valves on the coupling block and press the MOTOR and NORMAL keys to start up the metering pumps f Allow the products to come out until you see that only DOTP cleaning agent comes out free of impurities g Close the valves on the coupling b...

Page 28: ...al valves on the coupling block and press the MOTOR and NORMAL keys to start up the dosing pumps f Allow the products to come out until you see that only DOTP cleaning agent comes out free of impurities g Deactivate the MOTOR and NORMAL keys close the valves on the coupling block turn the general switch OFF disconnect the supply system of the transfer pumps and the process is finished The metering...

Page 29: ...nts 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 fl...

Page 30: ...y by deactivating the POWER CONTROL The thermostat will not reset until the temperature in the heater is below 120º C 248º F If the temperature in the Isocyanate heater or the Polyol heater is over 120º C 248º F an alarm will be activated and the corresponding number will be shown on the control panel 5 for Isocyanate and 6 for Polyol Follow the recommended procedure in the order indicated to try ...

Page 31: ...ch element is as shown in the table according to the installed power and voltage Table 2 Elements Values List W V x1 Ω x2 Ω x4 Ω x6 Ω 450 230 117 2 58 2 29 2 19 2 900 230 58 2 29 2 14 2 9 2 900 400 177 2 88 2 44 2 29 2 1250 230 42 2 21 2 10 2 7 2 1250 400 128 2 64 2 32 2 21 2 1250 440 154 2 77 2 38 2 25 2 1500 230 35 2 17 2 8 2 5 2 1500 400 106 2 53 2 26 2 17 2 1500 440 129 2 64 2 32 2 21 2 1800 2...

Page 32: ...www gamapur com 4 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: ... heated 5 The hose display shows the symbol 6 The automatic switch is triggered 3 SOLUTIONS 1 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 2 Hose Transformer T...

Page 34: ...ve the Fast Lock connector from the last section of hose and make a bridge 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 in the last but one section of hose Replace it If not repeats steps c and d until you find the point of the fault 6 TCS Temperature Control T...

Page 35: ...nts 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 metering pumps 1 2 3 There is cavitation in the metering pump 1 2 3 The metering pumps do not change direction 4 The metering pumps fail to move and the direction indicator lights are o...

Page 36: ...the decompensation is the consequence of a problem in the pumping system 3 Cavitation Cavitation occurs when the metering 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 metering pump The causes of cavitation are the following a The transfer pump fails to supply the necessary volume The problem might be in the...

Page 37: ...hether the reels are changed and the direction indicator lights if the reels 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 reels of the directional valve 5 Over Pressure Safety Switch Each metering pump is protected by a safety pressure switch factory set to limit the pressure depending on the size of the pumps insta...

Page 38: ...e electric motor is protected by an overload safety switch that triggers when the motor draws excessive current Disconnect the machine from the power supply allow the motor to cool open the control panel and reset the automatic switch for the motor It is important to determine the reason why the motor has been subject to an overload Reset one time only or the electric motor may be damaged due to o...

Page 39: ...fied 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 operating area of the unit This includes but is not limited to the use of face masks protective goggles gloves s...

Page 40: ...e of the resistance must be as shown in Table 2 on pag 31 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 element that has to be replaced is the one in contact with the temperature probe first remove the probe 2 Temperature The temperature p...

Page 41: ...ach year as indicated below a Depressurise 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 pipe from the connection with 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 If the...

Page 42: ...ged it can cause premature wear in the remaining components the NR 00065 Components Manual includes the joint kits that correspond to each pump model and size Pump distribution bases must also be inspected checking that the ball valves show no signs of wear dents or marks that affect the pump s proper operation Perform a daily inspection of the Isocyanate pump lubrication bowl and check the condit...

Page 43: ... piston bearing seal and washer into the piston shaft Face the lips of the seal towards the end of the shaft Face the grooves of the washer towards the seal Thread the plunger assembly onto the shaft as far as it will go the pin holes in the shaft and plunger should line up Insert the spring pin so that it is recessed in the groove of the shaft Insert the snap ring into the groove Groove in contac...

Page 44: ...st the seal housing 4 Place the shaft bearing 6 and the seal housing along with its corresponding O rings 7 on the packing retainer flange 8 Insert the shaft assembly 10 into the pump body 9 and place the tool C 11 on the tip of the shaft Mount the packing retainer flange assembly with all components assembled 12 on the front face of the pump The shaft bearing should be visible from the outside Re...

Page 45: ... 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 ball 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 sto...

Page 46: ... 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 Project the gun until the Isocyanate metering pump is placed on the right hand side Press the NORMAL key to interrupt the working cycle The pushbutton led will go out b Press the MOTOR and POWER CONTROL keys and turn the general switch OFF Dis...

Page 47: ...________ 19 Start UP Procedures _________________________________________ 25 Shutdown proedures __________________________________________ 26 Cleaning ____________________________________________________ 27 long term shutdown procedures_________________________________ 28 Troubleshooting______________________________________________ 29 Heaters_______________________________________________________...

Page 48: ...___________________ 8 Figure 2 Control Panel ________________________________________ 11 Figure 3 Method of union of the Hoses ___________________________ 21 Table 1 Tightening Threaded Joints _____________________________ 18 Table 2 Elements Values List ___________________________________ 31 Table 3 Tools for shaft seal assembly____________________________ 43 LIST OF ILLUSTRATIONS LIST OF TABLES ...