GAMA ESH150-3PE, Service Manual

Page 1: ...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 T...

Page 2: ...s 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 EXPRE...

Page 3: ...BS UNE EN 61000 4 3 UNE EN 61000 4 4 BS UNE EN 61000 4 4 UNE EN 61000 4 5 BS UNE EN 61000 4 5 UNE EN 6100 4 6 BS UNE EN 6100 4 6 UNE EN 61000 4 8 BS UNE EN 61000 4 8 UNE EN 61000 4 11 BS UNE EN 61000...

Page 4: ...d 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 safe...

Page 5: ...their suppliers Dispose of waste as required by applicable legislation Disconnect the unit from the power supply before opening the electrical console Electrical maintenance should only be carried out...

Page 6: ...ing system Designed with a 3000 W isolation transformer that enables effective heating up to a total hose length of 93 meters 305 ft for foam and 78 meters 256 ft for polyurea The system includes an i...

Page 7: ...Maximum output at 1 1 ratio 7 6 size pumps _______________________________ 9 kg min Maximum output at 1 1 ratio 4 5 size pumps _______________________________ 4 kg min Minimum output _________________...

Page 8: ...RECIRCULACI N RECIRCULACI N TRANSF 3Kw 400v 3Kw 400v 3Kw 400v 3Kw 400v 1 6Kw 230v 1 6Kw 230v INTEGRATED TANKS NO NO NO NO YES YES YES YES PUMPS 7 6 7 6 4 5 4 5 7 6 7 6 4 5 4 5 4 5 4 5 4 5 4 5 4 5 4 5...

Page 9: ...ESH150 3PE 400V Service Manual 9 56 Issue 1 0 Ref NR 000144 ENG http www gamapur com Figure 1 General view OVERNIEW...

Page 10: ...temperature 12 Isocyanate pressure gauge Indicates the pressure in the isocyanate circuit 13 Polyol pressure gauge Indicates the pressure in the polyol circuit 14 Isocyanate heater sensor Provides in...

Page 11: ...fluid level and temperature of the hydraulic oil tank 25 Electric motor Drives the hydraulic pump 26 Hydraulic pump Axial piston pumps are swash plate design variable displacement pumps The flow and p...

Page 12: ...ontrol mode depending on whether hoses incorporate a temperature control sensor TCS See page 14 point 2 of this manual for instructions on selecting the correct control mode The unit must be disconnec...

Page 13: ...a few seconds allowing you to change the values by touching the UP DOWN buttons After changing the value press the MODE button again to confirm your selection The parameter modification function autom...

Page 14: ...matic control mode the temperature in the isocyanate ISO hose is shown on the corresponding display In manual control mode only the selected amperage value is shown The unit must be disconnected befor...

Page 15: ...ure 30 A 38 C 100 F 35 A 48 C 118 F 40 A 60 C 140 F 45 A 75 C 167 F 50 A 80 C 176 F NOTE The circuit breaker software of the transformer has a safety system to prevent the hoses from being exposed to...

Page 16: ...pre selects When the unit completes the pre selected number of cycles it stops dispensing product To enter the desired number of cycles press and hold the MODE button until the cycle counter starts fl...

Page 17: ...n the heaters alarms 6 and 7 or an alarm for excess intensity in the hose heating alarm 9 8 Motor button This button starts and stops the hydraulic motor When pressed this button lights up To switch o...

Page 18: ...ressure switch 4 Excess pressure POL solenoid valve and heating system cut out Check product pressure Check LED no 11 on the printed circuit board it should be on Check the safety pressure switch 5 Ex...

Page 19: ...t 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 s...

Page 20: ...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 th...

Page 21: ...ging 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 OPTIONAL NR 00093 ENG Recirc...

Page 22: ...in the console b Put 18 litres of hydraulic oil in the unit s oil tank The oil should comply with the characteristics and specifications of standard DIN 51524 sections 1 and 2 for example ISO VG 46 PR...

Page 23: ...the outlet of its respective heater the isocyanate hose to the isocyanate heater and the polyol hose to the polyol heater NOTE The hoses are colour coded for easy identification red for isocyanate an...

Page 24: ...a 40 V output voltage valid for a total hose length of up to 48 meters 158 ft or an output voltage of 75 V for hose lengths exceeding 48 meters 158 ft to 93 meters 305 ft Connect to one output voltage...

Page 25: ...of the cabinet f As soon as the connections were completed place the protections for the union fixing them with three plastic bridles Later cover the union with the ends of the cases NB To protect the...

Page 26: ...ce electrical discharges Purge method units with heated hose transformer Before using the unit the residual air and oil from factory testing must be eliminated To purge the whole circuit proceed as fo...

Page 27: ...essure 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 d Connect the recirculation hose...

Page 28: ...ing the hydraulic system h Press the MOTOR button The LED will light up Once the above operations have been completed you now must check the direction of rotation of the motor Proceed as follows to ma...

Page 29: ...k for any product leakage at any point in the circuit v Rotate the power switch to the OFF position All displays will switch off w Place the gun in the coupling block x Rotate the power switch to the...

Page 30: ...in the center of the key In machines fitted with two transformers the ISO and RESIN keys must be pressed The two leds will light i Press the ISO and RESIN keys under the HEATERS display when the produ...

Page 31: ...Recirculation of products enables heater temperature settings to be reached quicker heating both the hoses and the gun For more efficient heating during recirculation fill the tanks with the minimum...

Page 32: ...egulated to ensure that the unit s output pressure never exceeds the working pressure of the product hoses fitted to the unit p Set the isocyanate heater temperature q Set the polyol heater temperatur...

Page 33: ...keeping the system at a minimum pressure of 30 bars to prolong the life of the seal rings c Press the MOTOR button The LED will go out d Press the ISO and RESIN buttons located below the heater tempe...

Page 34: ...drums and place 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 b...

Page 35: ...d and press the CONTROL POWER MOTOR and NORMAL buttons to start the proportioning pumps i Check that the product pumps are working j Let the materials drain into the recipient from the recirculation h...

Page 36: ...aa Press the CONTROL POWER MOTOR and NORMAL buttons to start the proportioning pumps bb Check that the product pumps are working cc Let the cleaning agent drain from the recirculation tubes until the...

Page 37: ...e e Open the manual 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...

Page 38: ...umps to descend into the retract position h Press the RETRACT MOTOR and CONTROL POWER buttons to stop the proportioning pumps i Rotate the power switch to the OFF position j Reduce product pressure by...

Page 39: ...by the incorrect handling of the substances and solvents used in the spraying process read carefully the safety information provided by suppliers Dispose of waste as required by applicable legislation...

Page 40: ...ing again until the temperature of the heater falls below 120 C 248 F If the temperature of either heater isocyanate or polyol exceeds 90 C 194 F an alarm will activate and the corresponding number wi...

Page 41: ...177 2 88 2 44 2 29 2 1500 400 106 2 53 2 26 2 17 2 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 f...

Page 42: ...5 The hose display shows the symbol 6 The automatic switch is triggered 3 SOLUTIONS 1 Hose Length The easy spray H has been designed to work with a maximum hose length of 93 meters 310 ft A longer len...

Page 43: ...e 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 t...

Page 44: ...roke check the discharge upper ball valve If pressure is lost on the downward stroke check the intake lower ball valve Proceed as follows to check the ball valves a Disconnect the unit from the power...

Page 45: ...ction change sensor The metering pump system has a plate that activates the reversing switches to carry out the change of direction The most common cause of the fault is the entry of a foreign body pr...

Page 46: ...much current is delivered to the motor Disconnect the unit from the power supply and allow the motor to cool down Open the control panel and re prime the automatic switch The motor should now work nor...

Page 47: ...electrician To avoid exposure to pressurized fluids do not release any connectors or perform maintenance work on parts subjected to pressure until the pressure has been eliminated Use suitable protect...

Page 48: ...own in Table 2 on pag 41 d Apply PTFE or thread locking compound and screw the element into place in its housing e Re connect the cables in the terminal block make sure the connection is parallel and...

Page 49: ...hat if you reassemble an element that does not seem damaged it can cause premature wear in the remaining components the NR 00045 ENG Parts Manual includes the joint kits that correspond to each pump m...

Page 50: ...ee Table 3 on page 51 Once you have inserted the piston into the sleeve you must assemble the cylinder head seal First place the seal funnel tool 2 Next place the cylinder head seal with the lips faci...

Page 51: ...NR 000144 ENG http www gamapur com Table 3 List of Tools SIZE Tool 1 Tool 2 Tool 3 Tool 4 4 5 HT 00034 HT 00116 HT 00119 HT 00121 7 6 HT 00031 HT 00117 HT 00120 HT 00122 Note These tools are not suppl...

Page 52: ...f absorption of humidity and the possibility of contamination by reaction with the cleaning solvent begin spraying immediately after cleaning the filter To check the product intake filters proceed as...

Page 53: ...ump piston when the pump is operating The plasticizing oil needs to be changed less frequently if the seal rings and gaskets are in good condition To replace the plasticizing oil in the pump proceed a...

Page 54: ...cap of the hydraulic tank to prevent extraneous matter from falling into the tank during removal of the hydraulic components b Dismount and replace the tank s return filter c Inspect the bottom of the...

Page 55: ...Preparation units with heated hose transformer _______________________________ 24 Purge method units with heated hose transformer _____________________________ 26 Preparation only for units with tanks...

Page 56: ...____________________________________________ 55 List of illustrations ____________________________________________ 56 List of Tables ________________________________________________ 56 Figure 1 Genera...