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Service Manual G-125 A

1. k Press the RETRACT key Mount the gun on the coupling block 20 39 3 2 Issue Ref NR 00011 ENG http AWwww gamapur com Service Manual START UP PROCEDURES Follow the recommended procedure in the indicated order PRECAUTION The start up procedures assumes that all of the necessary adjustments have been correctly performed a Check the state of the DOP plasticizer in the Isocyanate pump e 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 Make sure that the chemical products to be processed are above the minimum temperature required to be supplied to the unit through the transfer pumps Ask your product supplier for information on the minimum supply temperature Check the inlet filters of the products Clean them if necessary Pressurize the two transfer pumps and open the inlet ball valves of the products to the unit Turn the general switch ON The top pilot light will come on Press the POWER CONTROL key The led will light Press the key under the HOSES display The led will light in the center of the key 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 heated hoses wait for the product in them to reach the required temperature before starting up the air motor system i j
2. 21 39 Press the NORMAL key The led will light One of the direction indicator lights will come on and the proportioning pumps will begin to move Using the air pressure regulators first of all select the pressure for the down stroke of the proportioning pumps and then adjust the pressure for the up stroke As a result of the difference in effective area between the lower face and the upper face of the plunger of the pneumatic cylinder and due to the effect of the additional pressure supplied by the transfer pumps there will be a small difference in pressure between the up and down stroke of the pumps To balance the pressures the value of the pneumatic pressure in the up stroke must be slightly lower between 3 and 6 psi than the value of the pneumatic pressure set for the down stroke of the pumps The pressures must be practically the same and remain constant The direction indicator lights must alternate with one on and the other out The light that is on indicates the direction of movement of the pumps If the pressures fluctuate on each stroke consult the fault section before continuing Connect the air supply to the gun open the manual valves of each product make a test projection and check the pressures on the product gages If the projection test is correct and the pressures remain equal proceed with the application 3 2 Issue Ref NR 00011 ENG http www gamapur com Manual de Servicio SHUTDOWN PROCEDURES Follow th
3. Follow the recommended procedure in the order indicated to try to solve the problem and avoid costly repairs Make sure all the automatic switches and control elements are in the correct working position before determining the existence of a fault PROBLEMS SOLUTIONS The hose is hot but fails to reach the selected temperature 1 2 7 The hose is not hot the pushbutton led is lit 2 3 4 5 Only the sections of the hose closest to the unit are heated 5 The hose display shows the symbol 6 The automatic switch is triggered 3 SOLUTIONS 1 Hose Length The evolution G 125 A has been designed to work with a maximum hose length of 93 metres 310 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 2 Hose Transformer The transformer offers the option of connecting to a 40 V output voltage valid for the connection of hose sections with a total length of up to 45 metres 160 t or an output voltage of 70 V for connecting hose lengths of over 45 metres 310 ft connect to one or the other position depending on the total hose length installed in the machine If the connection is performed incorrectly the hoses will not reach the required temperature 3 Automatic Switch This protects the secondary circuit of the transformer The switch is located on the front of the transformer make sure it is turne
4. The procedures recommended to determine the possible causes activating the alarms are indicated in the following 1 Maneuvering Voltage under 170 V e Check the electrical supply connections e Check the transformer thermal limit switch 2 Maneuvering Voltage over 270 V e Check the electrical supply connections 3 Excessive ISO Pressure deactivates the directional valve and the heating system e Check the product pressure e Check the number 10 led of the printed circuit it must be lit e Check the over pressure safety switch 4 Excessive POL Pressure deactivates the directional valve and the heating system e Check the product pressure e Check the number 11 led of the printed circuit it must be lit e Check the over pressure safety switch 5 Excessive ISO temperature deactivates the POWER CONTROL e Check the heater heating system e Check the connections of the safety thermostat and allow it to cool so that it makes an automatic reset e Check the number 12 led of the printed circuit it must be lit 6 Excessive POL temperature deactivates the POWER CONTROL e Check the heater heating system e Check the connections of the safety thermostat and allow it to cool so that it makes an automatic reset e Check the number 13 led of the printed circuit tt must be lit 7 Fault key it only turns on when the machine is connected to the main power supply e Check the keyboard 8 Fault in Hose Heating System deactivates the POWER
5. CHARACTERISTICS The evolution G 125 A G 200 A proportioning unit has been designed and built for the application of Polyureas chemical systems for polyurethane foaming and some two component epoxy systems Check with your chemical supplier for the recommended temperatures and pressures Principal Heating System Consists of two independent heaters without seals Each heater has four 1250 W 1500 W G 200 A heating elements that give the unit a total power of 5000 W 6000 W G 200 A and the necessary control and safety components for precise operation of the system Its singular configuration allows a temperature differential AT of 90 F and application temperatures of up to 194 F under normal conditions of ambient temperature Proportioning System Comprises two positive displacement piston pumps driven by a pneumatic motor The system includes two pressure regulators that allow the working pressures to be equalized in the two directions of pump movement compensating for the imbalance of pressure caused by the design of the design of the air motor and the effect of the additional pressure of the transfer pumps 7 i 5 39 3 2 Issue Ref NR 00011 ENG http www gamapur com KaLa Service Manual Hose Heating System Designed with a 3000 W isolation transformer that enables effective heating up to a total hose length of 94 meters 310 feet The system includes an innovative hose heating concept in which the copper
6. G 200 A Electrical Main voltage 230 400 V N Frequency 50 60 Hz Electrical consumption 26 A 3 x 400 V N Electrical consumption 52 A 3x 230 V Electrical consumption 67 A 1 x 400 V N Heater power 2 X 6 Kw 12 kW Hose Transformer Power 3 kW Total Active Power 15 kW Inside the console there is a terminal strip for connecting the main power wire not supplied to the unit The electrical connection of the unit must only be carried out by a qualified electrician Mechanical Maximum working pressure air supply 9 bar 200 kgf cm2 19 73 MPa 2840 psi Maximum production ratio 1 1 4 Kg min 9 Ib min Minimum production 1 kg min 2 2 lb min Maximum hose length 93 m Air consumption 6 bar 705 liters min Recommended compressor 7 5 HP three phase Approximate weight 125 Kg 275 lbs Dimensions H 1055 mm 42 W 540 mm 22 L 550 mm 23 8 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Annie Service Manual GENERAL DESCRIPTION Ar Sap Tiarafer Pegs for Tranfer Pumps Figure 1 General Description 9 39 3 2 Issue Ref NR 00011 ENG http www gamapur com Service Manual 1 Control Panel Controls and regulates the correct operation of the unit 2 isocyanate Proportioning Pump Meters the Isocyanate 3 Polyol Proportioning Pump Meters the Polyol 4 isocyanate Heater Heats the Isocyanate to the pre set temperature 5 Polyol Heater Heats the Polyol to the pre s
7. Isocyanate and 6 for Polyol Follow the recommended procedure in the order indicated to try to solve the problem and avoid costly repairs Make sure all the automatic switches and control elements are in the correct working position before determining the existence of a fault PROBLEMS SOLUTIONS The heater fails to heat the pushbutton led is lit 1 2 3 The heater display shows the symbol 4 SOLUTIONS 1 Static Relay This determines that the static relay is not working when all of the previous checks have been correct 26 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Service Manual 2 Heating Elements Each heater includes four 1250 W 1500 W G 200 A elements connected in parallel which give the system a total power of 5000 W 6000 W G 200 A If under normal conditions of room temperature it is not possible to reach the required temperature in two or three minutes it is possible that several heating elements are not working To check the state of the elements proceed as follows With the main switch off check with a tester that reading the total value of the heater resistance is indicated in the table according to the power voltage and number for each installed heater elements a higher value would indicate that one or more elements are faulty 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 Eleme
8. 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 3 x 400V NEUTRAL 50 60 Hz 1x 400V NEUTRAL 50 60 Hz li 2b ib N 2x 230 V 60 Hz USA CANADA li ke ib Make sure the power cable is disconnected from the main power supply before connecting it to the terminal in the console b Fill the Isocyanate pump lubricating cup with DOP plasticizer c Connect the hoses of the products to the outlets of the respective heaters the Isocyanate hose to the Isocyanate heater and the Polyol hose to the Polyol heater 17 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Anne Manual de Servicio Figure 3 Method of union of the Hoses WARNING To join the hoses together or to connect them to the heaters or the gun use two spanners to hold the parts to be joined 1 and a third spanner to tighten or loosen the connecting nut 2 as shown in the illustrations in Figure 3 The connections must be tightened to a torque of 20 Nm NOTE 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 be swapped The hoses receive vacuum 75v Tap Settings drying treatment and are 40v Tap Settings i supplied int
9. AiG Service Manual Proportioning Unit evolution G 125 A G 200 A Issue 3 2 10 10 14 Ref NR 00011 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 All of the information is aimed at enhancing User Safety and avoiding possible breakdowns derived from the incorrect use of the unit Service Manual WARRANTY GARRAF MAQUINARIA S A hereinafter GAMA provides this LIMITED WARRANTY hereinafter Warranty to the original purchaser hereinafter Customer covering this equipment and the original GAMA manufactured accessories delivered with the equipment hereinafter Product against defects in material or workmanship of the Product hereinafter Defect or Defective for a period of two 2 years from the date of first purchase as shown on the original GAMA invoice hereinafter Warranty Period If during the Warranty Period under normal use the Product is suspected by Customer to be Defective in material or workmanship it is Customer s responsibility to contact GAMA and return the Product to GAMA as directed by GAMA freight prepaid If GAMA determines that the Product is Defective and that such Defect is covered by this Warranty GAMA will credit Customer for the reasonable freight char
10. CONTROL e Replace the faulty triac 9 000000 Cycle Pre selection made deactivates the directional valve e Press the MODE key to reset the counter e 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 electrician 16 39 3 2 Issue Ref NR 00011 ENG http AWwww gamapur com Anni 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 GAMA provides a series of tools and accessories necessary for assembling the machine The kit is made up of the following elements 12 spanner 6 spanner universal pliers screwdriver allen keys socket oiling unit grease tube magnet holder gauge for magnetic position micro switches component manual and service manual Inside the console there is a terminal 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 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 Follow the recommended procedure in the indicated order to install the unit
11. Never handle the inside of the control panel with the unit connected to the power supply The proportioning pumps are components that work under pressure do not open any connection or perform repair or maintenance work on component subject to pressure until all of the pressures have been completely eliminated If excessive pressure is caused in the Ilsocyanate circuit or the Polyol circuit an alarm will be activated that will be shown on the control panel 3 for the Isocyanate and 4 for the Polyol Follow the recommended procedure in the order indicated to try to solve the problem and avoid costly repairs Make sure all the automatic switches and control elements 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 proportioning pumps 1 2 3 There is cavitation in the proportioning pump 1 2 3 The proportioning pumps do not change direction 4 6 The proportioning pumps fail to move and the direction indicator lights are 4 5 out The movement of the proportioning pumps is erratic 4 6 Difference in pressure or speed in the rising movement with respect to the T falling 31 39 3 2 Issue Ref NR 00011 ENG http www gamapur com Manual de Servicio SOLUTIONS 1 Loss in the Ball Checks Observe the manometers to identify which pump fails to maintain the pressure and check tha
12. Warranty for the remainder of original Warranty Period or for three 3 months from the repair or replacement date whichever is longer No Rights Implied Nothing in the sale lease or rental of any Product by GAMA shall be construed to grant any right interest or license in or under any patent trademark copyright trade secret or other proprietary right or material owned by anyone nor does GAMA encourage the infringement of same Exclusive Warranty This writing is the final complete and exclusive expression of the Warranty covering the Product Any statements made by GAMA its employees or agents that differ from the terms of this Warranty shall have no effect It is expressly understood that Customer s acceptance of this Warranty by performance or otherwise is upon and subject solely to the terms and conditions hereof and any additional or different terms and conditions proposed or expressed by Customer or anyone whether in writing or otherwise are null and void unless specifically agreed to in writing by an Officer of GAMA 2 39 3 2 Issue Ref NR 00011 ENG http AWwww gamapur com Service Manual All information provided in this Service Manual is assumed to be correct although this does not constitute any implicit or explicit liability or guarantee GAMA reserves the right at any time and without prior warning to make all improvements and modifications necessary to this Service Manual in order to rectify any possible typographical
13. aware that after manipulating the DIP selector you should switch off the unit so the change in detected buy the board HOSE TEMP ON HOSE TEMP OFF with TCS probe in the ISO hose manual control HOSES MANGUERAS HOSES MANGUERAS a B To select the temperature when the unit is working in automatic control mode press the MODE key until the temperature flashes select the required temperature by pressing the UP DOWN keys and press the MODE key once more to enter the selected value into memory Do the same process to select the Amps When the unit is working in automatic mode the value of the power must be set between 45 and 50 Amps Hose temperature settings that are higher than the temperature settings of the heaters cannot be programmed If only one temperature control system is working ISO or POL the limiting temperature value will be the highest set in the heaters If both temperature control systems are working ISO and POL the limiting value will be related to each of their corresponding heaters Temperature settings are restricted to 80 C maximum for hoses and 90 C maximum for heaters 12 39 3 2 Issue Ref NR 00011 ENG http www gamapur com Service Manual To enter data the order will be as follows e The temperatures in ISO and POL heaters are set e The temperatures in ISO and POL hoses are set e Finally the settings of the rest of the data can be entered in the date range and cycle pre selector I
14. 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 DOP plasticizing agent Follow the recommended procedures in the order indicated a b 24 39 Place two drums of DOP cleaning agent close to the machine Dismantle the gun and leave the coupling block connected to the hoses Remove the transfer pumps of the product drums and place them in the drums of the DOP cleaning agent Place 2 separate vessels under the coupling block to gather up the products contained inside the machine Open the manual valves on the coupling block and press the NORMAL key to start up the proportioning pumps Allow the products to come out until you see that only DOP cleaning agent comes out free of impurities Deactivate the NORMAL key 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 proportioning pumps the heaters and the hoses must be full of DOP plasticizing oil Never leave the machine or the hoses empty of product or DOP plasticizing oil 3 2 Issue Ref NR 00011 ENG http www gamapur com Service Manual TROUBLESHOOTING The evolution G 125 A G 200 H unit has been designed and built to withstand severe working conditions with a hig
15. d on otherwise turn it on Replace it with one of an equal amperage if the switch fails to work correctly PRECAUTION The replacement of the automatic switch with another of different characteristics may cause damage to the equipment and put the operator at risk 29 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Manual de Servicio 4 Triac This determines that the triac is faulty when all of the previous checks have been correct Replace the triac if it fails to work correctly 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 Proceed as in the following a Disconnect the unit from the power supply by deactivating the general switch and start to check the hose section closest to the gun Remove the Fast Lock connector and make a bridge on the connection immediately before b Restore the power supply press the POWER CONTROL key and the key under the HOSES display If the heating works the problem will be in the last section of hose Replace it If not do the following c Disconnect the unit from the power supply remove the Fast Lock connector from the last section of hose and make a bridge on the connection immediately before d R
16. ducts to be dispensed the type of application and the working environment be Opp 4 39 To prevent all 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 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 pressure until the pressure has 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 masks protective goggles gloves shoes and safety clothing 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 prevent serious harm by crushing or loss of limbs do not work with the unit without the safety guards installed on all moving parts Make sure that all of the safety protections are correctly reinstalled after all repair or maintenance work is completed 3 2 Issue Ref NR 00011 ENG http www gamapur com Anni Service Manual
17. e Ref NR 00011 ENG http Wwww gamapur com Manual de Servicio a Connect the air hoses b Connect the hoses to the connectors of the coupling block of the gun making sure that the manual valves are closed c Insert a contact thermometer through the hose insulation so that the bottom of the thermometer is in contact with the hoses and the top is outside the insulation Fit the thermometer in such a way that the operators can see the temperature when they are spraying If the hoses have STC probes to automatically control the temperature the contact thermometer will not have to be installed Proceed to install the transfer pumps paying special attention to connect each pump to its product as changing the pumps would cause a reaction in the products inside them and make them useless Identify each pump with a tape of the same color as that of the hoses blue for the Polyol pump and red for the Isocyanate pump is a good method for avoiding errors in connection Do the following steps to install the pumps a Make sure that the inlet valves of the products to the unit are closed b Connect one end of the Polyol hose thread to the Polyol valve and the other end to the transfer pump of the same product c Connect one end of the Isocyanate hose 4 thread to the Isocyanate valve and the other end to the transfer pump of the same product d Connect the air hose to the transfer pumps NOTE To avoid errors in con
18. e 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 proportioning pump is in the retract position and the pressure begins to fall PRECAUTION To avoid possible seal weepage and the early failure of the pump seals the pressure must not be reduced to zero It is recommended to keep the system with a minimum pressure of 30 bar 400 psi to extend the life of the seals c Press the ISO and RESIN keys under the heater temperature display The two leds will go out d Press the key under the HOSES display The led will go out e Press the POWER CONTROL key The led will go out f Turn the general switch OFF The top pilot light will go out g Close the inlet ball valves h Close the supply to the transfer pumps i Disconnect the air supply to the transfer pumps j Remove the contact thermometer and roll up the heated hoses k Close the manual valves on the coupling block and remove the gun to perform the corresponding maintenance 22 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com 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 be flushed clean
19. en the Socket Head Set Screw of the NYLON SAFETY A SOCKET HEAD terminals and place the Nylon Safety PLUG SET SCREW Plugs NB A good practice is to add some dielectric grease to the ID of the connector Repeat the same steps to connect the fast lock that you will find in the middle hose connections e Connect the rest of the product hoses to complete the required length Remember that the hoses are identified with red lsocyanate and blue Polyol NB Assure the proper mechanical and electrical connection of the hoses to avoid possible product leakage and hose heat problems f 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 g Wind the connector of the probes to the connector of the hose Realize so many connections as stretches of 15 m hose you have h Realize the connections between the connector of exit of the probe TCS of the first stretch of hose and the connector proceeding from the machine i 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 NOTE Having fitted the TCS 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 4ft 19 39 3 2 Issu
20. er parts or accessories with the Product that have not been approved or manufactured by GAMA Failure to follow the operating instructions and recommendations provided by GAMA e Cosmetic damage e Fire flood acts of God or other contingencies beyond the control of GAMA THE WARRANTY DESCRIBED HEREIN IS THE EXCLUSIVE REMEDY FOR THE CUSTOMER AND IS IN LIEU OF ALL OTHER WARRANTIES EXPRESS IMPLIED STATUTORY OR OTHERWISE AND THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND ALL OTHER WARRANTIES ARE HEREBY DISCLAIMED TO THE FULLEST EXTENT PERMITTED BY LAW GAMA SHALL NOT BE RESPONSIBLE WHETHER BASED IN CONTRACT TORT INCLUDING WITHOUT LIMITATION NEGLIGENCE WARRANTY OR ANY OTHER LEGAL OR EQUITABLE GROUNDS FOR ANY CONSEQUENTIAL INDIRECT INCIDENTAL LOST PROFITS SPECIAL PUNITIVE OR EXEMPLARY DAMAGES WHETHER TO PERSON OR PROPERTY ARISING FROM OR RELATING TO THE PRODUCT EVEN IF GAMA HAS BEEN ADVISED OF THE POSSIBILITY OF SUCH LOSSES OR DAMAGES Non Warranty Service by GAMA If GAMA determines that the suspected Defect of the Product is not covered by this Warranty disposition of the Product will be made pursuant to the terms and conditions of GAMA s written estimate on a time and materials basis Continuing Warranty for Products Repaired or Replaced under Warranty Following the repair or replacement of a Product covered by this Warranty such Product will continue to be subject to the original
21. erconnected at the E ends to prevent them from absorbing moisture Do not separate them until they are going to be installed in the unit The hose connection system includes special terminals fast lock to facilitate the electrical connection to the transformer and between the different sections installed in the unit The transformer offers the option of connecting to 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 of over 48 meters 158 ft Connect to one output voltage or the other depending on the total hose length installed Before starting up the unit make sure that the connection made in the factory matches the total length of hose installed If you add or eliminate sections of hose make sure the output voltage of the transformer to which it is connected is suitable for the resulting total length Otherwise change the connection ge Move black wire to the correct tap setting 18 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Ane Service Manual d 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 into the fast lock connector body d Tight
22. errors supplement the information contained or insert changes predicated by the performance or use of the unit SAFETY AND HANDLING The evolution G 125 A evolution G 200 A series proportioning unit has been designed and manufactured in full compliance to the provisions of Machine Directive 89 392 CEE in its modified form and the National Regulations that transpose it It also meets all European Directives concerning electromagnetic compatibility and electrical safety and the provisions of the Harmonised Norms that are applicable This chapter contains information on the safety handling and use of the evolution G 125 A evolution G 200 A series 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 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 avoid damage to the unit or how to avoid a situation that could cause minor injuries NOTE is relevant information on a procedure being carried out Careful study of this manual will enable the operator to know
23. es 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 required number of working cycles so that the unit will automatically stop when it reaches this number To enter the number of cycles to reach automatic shutdown press the MODE key until the cycle meter flashes select the number of cycles with the UP DOWN keys and press the MODE key to enter the value into memory When the unit starts the cycles used will be deducted from the pre selected cycles until the total number of cycles requested is completed Once completed the display will show zero and the unit will automatically stop The cycle meter display will alternate every two or three seconds to show the cycles used totalizer and the cycles remaining pre set The cycles remaining will be shown by the Minus sign XXXXX The counter display will also show any alarm warnings resulting from faults 7 Power Control Key Pushbutton turns on and off the control voltage to the electrical circuit of the heaters and hoses When the key is on the led in its center will come on It may be turned off at will by pressing the key once more or automatically if an alarm is caused due to excessive temperature in the heaters alarms 6 and 7 or due to excessive current in the heating system of the hoses alarm 9 8 Motor Key Pushbutton turns on and off the hydraulic motor When the
24. estore the power supply press the POWER CONTROL key and the key under the HOSES display If the heating works the problem will be in the last but one section of hose Replace it If not repeat steps c and d until you find the point of the fault 6 TCS Temperature Control Sensor The control panel automatically detects any fault in the operation of the temperature sensor To determine if the mistake is caused by the proper probe or by a defective electrical connection realize the following cross check dismantling the electrical connector of the probe TCS of the last stretch of hose and without dismantling any other connection connect it straight to the electrical capture of the exit of the machine if the control is restored check the electrical connections of the probe existing TCS in the intermediate stretches of the hoses in the opposite case replace the probe TCS 7 Hose Heating Temperature Adjustment The hose heating system has the function of maintaining the temperature of the products proceeding from the heaters which is why the value set for the temperature of the hoses must be the same as that selected on the heater display 30 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Ane 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
25. et temperature 6 Hose Heating Transformer Supplies the required voltage for heating the hoses 7 isocyanate Pressure Gage Indicates the pressure in the Ilsocyanate circuit 8 Isocyanate Safety Pressure Gauge Deactivates the directional valve in the event of excessive pressure in the Isocyanate circuit 9 lIsocyanate Heater Probe Provides information on the temperature of the Isocyanate 10 A Recirculation Valve 11 Polyol Pressure Manometer Indicates the pressure in the Polyol circuit 12 Safety Pressure Gauge of the Polyol Circuit Deactivates the directional valve in the event of excessive pressure in the Polyol circuit 13 Polyol Heater Probe Provides information on the temperature of the Polyol 14 R Recirculation Valve 15 Pneumatic Pressure Regulators The unit has two pressure regulators that allow independent adjustment of the air pressure for the advance cycle and the return cycle of the pneumatic cylinder 16 DIP Selectors TCS Probes This allows the hose heating control mode to be selected depending on whether they include a TCS probe for direct temperature control or not To make a correct selection of the control mode consult page 10 point 2 of this manual Please be aware that after manipulating the DIP selector you should switch off the unit so the change in detected buy the board 17 DIP Selector Control Units This allows the temperature units to be selected that will be shown on the displa
26. f the control probe is not operative the temperature display will show the symbol and the heating will be turned off The lower pushbutton activates turn on or off the heating of the hose of the product The pushbutton has a led that lights when the heating is working if the led flashes it indicates that the heating is activated but fails to heat If excessive pressure is Caused in the circuit of any of the products the heating will stop working momentarily until the problem disappears AT start up the hose heat set point is not maintained in memory and must be reset after each activation of the CONTROL POWER key To select the hose power when the unit is working in manual heating control mode press the MODE key until the 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 30A 38 C 100 F 35A 48 C 118 F 40A 60 C 140 F 45A 75 C 167 F 50A 90 C 194 F Select the required amps for a quick pre heating NOTE The circuit breaker software of the transformer has a safety system to prevent the hoses from being exposed to high temperatures during long periods of time If you have selected a potential over 35 amperes after 20 minutes the potential will automatically regulate to 35 amperes This potential cannot be set ab
27. g System Hose Heating System Technical Specifications evolution G 125 A Electrical Mechanical Technical Specifications evolution G 200 A Electrical Mechanical General Description Control panel Alarms Installation Start up procedures Shutdown procedures Cleaning long term shutdown procedures Troubleshooting Heaters Hose Heating Proportioning Pumps Maintenance Heaters Proportioning Pumps Inlet supply filters lsocyanate pump lubrication system Content List of Illustrations 38 39 3 2 Issue http www gamapur com Service Manual o o O NAN N awa OT W N N N NY NY NO NYO O O A WAN NO O W W R oourzseseBeaBs Bes Ref NR 00011 ENG Service Manual LIST OF ILLUSTRATIONS Figure 1 General Description Figure 2 Control Panel Figure 3 Method of union of the Hoses 39 39 3 2 Issue http Wwww gamapur com 11 18 Ref NR 00011 ENG
28. ges incurred by Customer in returning the Defective Product to GAMA and GAMA or its authorized agent will at GAMA s option repair or replace the Product subject to the following Original Invoice The original invoice must be kept as proof of the date of first sale and the Product serial number The Warranty does not cover any Product if the Original Invoice appears to have been modified or altered or when the serial number on the Product appears to have been altered or defaced Product Maintenance It is the Customer s responsibility to maintain the Product properly See your maintenance schedule and owner s manual for details The Warranty does not cover an improperly maintained Product Non GAMA Components and Accessories Non GAMA manufactured components and accessories that are used in the operation of the Product are not covered by this Warranty Such components and accessories shall be subject to the warranty offered to the Customer if any by the original manufacturer of such component or accessory Other Warranty Exclusions The Warranty does not cover any Product that GAMA determines has been damaged or fails to operate properly due to misuse negligence abuse carelessness neglect or accident By way of example only this includes Normal wear and tear e Improper or unauthorized installation repair alteration adjustment or modification of the Product e Use of heating devices pumping equipment dispensers or oth
29. h 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 GAMA technical service In any case feel free to contact the technical assistance service of Garraf Maquinaria S A where a qualified technician will advise you on whatever you may need All repairs performed by unqualified personnel or the use of spares other than originals may cause damage to the unit and put the operator at risk gt Popp 25 39 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 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 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
30. 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 extremely resistant to fatigue failure 100 circumferential coverage produces the most homogenous distribution of heat available 6 39 3 2 Issue Ref NR 00011 ENG http www gamapur com Service Manual TECHNICAL SPECIFICATIONS evolution G 125 A Electrical Main voltage 230 400 V N Frequency 50 60 Hz Electrical consumption 22 A 3 x 400 V N Electrical consumption 43 5 A 3 x 230 V Electrical consumption 58 A 1 x 400 V N Heater power 2 X 5 Kw 10 kW Hose Transformer Power 3 kW Total Active Power 13 kW Inside the console there is a terminal strip for connecting the main power wire not supplied to the unit The electrical connection of the unit must only be carried out by a qualified electrician Mechanical Maximum working pressure air supply 9 bar 145 kgf cm2 14 3 MPa 2065 psi Maximum production ratio 1 1 9 Kg min 20 Ib min Minimum production 1 kg min 2 2 lb min Maximum hose length 93 m Air consumption 6 bar 705 liters min Recommended compressor 7 5 HP three phase Approximate weight 125 Kg 275 lbs Dimensions H 1055 mm 42 W 540 mm 22 L 550 mm 23 7 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Service Manual TECHNICAL SPECIFICATIONS evolution
31. ical supply to the directional valve thus stopping the pumps When the pumps stop the direction indicator lights will go out and an alarm will be activated that will be shown on the control panel 3 if the excess pressure is caused in the Ilsocyanate circuit or 4 if it is caused in the Polyol circuit When the pressure reaches lower values than the established limit the proportioning pumps will start To avoid the incident from reoccurring the causes of the surplus pressure must be determined and corrected 6 Guiding Rollers The guiding rollers may sometimes be blocked due to dirt caused by remain power supply of crystallized Isocyanate Change the rollers if they fail to turn freely 7 Rising Movement Pressure Regulator During the up stroke the proportioning pumps receive additional pressure through the effect of the supply of products through the transfer pumps Adjust the up stroke regulator so that the pressure of the proportioning pumps is the same in both directions 33 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Manual de Servicio MAINTENANCE To achieve maximum output from the evolution G 125 A G 200 A unit certain daily or regular maintenance operations are needed 34 39 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 Deal with the waste caused according to current
32. is not limited to the use of face masks protective goggles gloves shoes and safety clothing 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 To prevent serious harm by crushing or loss of limbs do not work with the unit without the safety duly installed on all moving parts Make sure that all of the safety protections are correctly fitted after all repair or maintenance work 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Annie 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 The heaters are components that reach high temperatures wait until they have cooled before handling NOTE The thermostat is a safety element in contact with the heater If the temperature exceeds 120 C 248 F the thermostat will cut off the electric supply by deactivating the POWER CONTROL The thermostat will not reset until the temperature in the heater is below 120 C 248 F lf the temperature in the Ilsocyanate heater or the Polyol heater is over 120 C 248 F an alarm will be activated and the corresponding number will be shown on the control panel 5 for
33. key is active the led in its center 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 The function of the Motor Key selector is only active in the units with hydraulic actuation 9 Normal Key Activates the normal operation of the machine When the key is active the led in its center will come on 14 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Service Manual 10 Retract Key Sets the piston rod of the Isocyanate proportioning pump to the retract position and prevents the crystallization of Isocyanate on the piston rod Press the RETRACT key every time the unit is stopped by the operator When the key is active the led in its center will come on 11 Direction Indicator Pilot Light Indicates the direction of movement of the proportioning pumps If excessive pressure is caused in the system the pilot lights will be turned off and alarms 3 and 4 will be active The functions of the NORMAL and RETRACT keys will remain active 15 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com 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
34. nection the coupling connectors of the Isocyanate and Polyol hoses are a different size that makes it impossible to swap connections Only USA version e Perform the unit ground connection The speed of the product inside the hose can cause Static electricity and produce electrical discharges Before using the unit the retained air and the residual oil from the operating tests made in the factory must be eliminated To purge the whole circuit proceed as follows a Pressurize the transfer pumps and open the inlet ball valves Make sure there are no leaks b Turn the pneumatic pressure regulator counter clockwise as far as it will go c Turn the general switch ON The top pilot light will come on d Press the POWER CONTROL key e Keep the coupling block with the outlet of each product in separate vessels and open the manual valves of each product f Press the NORMAL key The led will light g If necessary increase the pneumatic pressure by turning the regulator clockwise until the product pumps begin to slowly move h Allow the materials to come out of the coupling block until the residual oil and the air bubbling has disappeared completely i Close the manual valves of each product and clean the coupling block of the remaining supply of product j Slowly increase the pneumatic pressure to check for product leaks in the hose connections Retighten if necessary and tape the connectors to protect them from possible damage
35. nts Values List w v xt oy 2a x4 0 o ee ee ee ee 400 440 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 favourable place or use an auxiliary heating system 27 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Manual de Servicio 3 Automatic Switch This protects the elements against any possible change in voltage With the general switch turned off open the control panel and make sure the switch is activated see electrical diagram otherwise activate it 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 28 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Service Manual Hose Heating 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 The hoses can reach high temperatures wait until they have cooled before handling If a fault occurs in the heating system of the hoses an alarm will be activated and the number 9 will be shown on the control panel
36. o 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 11 39 Hose temperature in automatic control mode maximum 90 C 194 F Hose heating power maximum 50 Amps Isocyanate heater temperature maximum 90 C 194 F Polyol heater temperature maximum 90 C 194 F Total number of cycles to be made Number of cycles made 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com KaLa Service Manual 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 When turned ON the green pilot at the top of the switch will come on 2 Hoses The hose heating control may be automatic optional when using the TCS probe for direct temperature control or manual when not using the TCS probe The control mode must be established with two DIP selectors in the printed circuit Set the HOSE TEMP DIP to ON if the Isocyanate hose includes a TCS probe or set the one DIP selector to OFF if the Isocyanate hose does not have a TCS probe or if this is not operative due to breakdown or for any other reason The automatic control mode will show the temperature of the Isocyanate hose ISO on the corresponding display In manual control mode only the selected amps will be shown Please be
37. ove 35 amperes until the heater is disconnected from the hoses and reconnected The settings programmed by the machine operator will be stored for the next time the heating is switched on 13 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Service Manual 3 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 The pushbuttons turn on or off the heater of each product Each pushbutton has a led that lights steady when the heater is on if the led flashes it indicates that the heater is at the preset temperature If excessive pressure is caused in the circuit of either product the heating will stop working momentarily until the excessive pressure disappears lf the temperature control probe stops working the temperature display will show the symbol and the heater will automatically be turned off AT start up the heater set point is not maintained in memory and must be reset after each activation of the CONTROL POWER key 4 Mode Key Allows access to change the different control parameters 5 UP Down Keys Allows the value of each of the parameters to be increased or decreased 6 Counter Indicator displays the cycles used and the cycl
38. peration 36 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Service Manual Isocyanate pump lubrication system Each day inspect the lubrication cup of the Isocyanate pump and check the state of the DOP plasticizing oil Replace the oil when it shows changes in color or signs of solidification The DOP oil solidifies as a result of the absorption of moisture and the maintenance interval will depend on the working conditions The oil discoloration is due to the small film of Isocyanate that lies on the pump shaft during the pumping operation If the gaskets and the seals are in a good state the plasticizing oil will not have to be changed so frequently To replace the plasticizing oil of the pump proceed as follows a Use the gun to project until the Isocyanate proportioning pump is at the highest point of the rising run Press the NORMAL key to interrupt the working cycle The pushbutton led will go out b Press the POWER CONTROL key and turn the general switch to OFF Disconnect the machine from the power supply c Remove the existing DOP oil from the cup clean the cup and the shaft of the pump eliminating any remain power supply of polluted oil or crystallized material Use a wooden or plastic tool to clean the shaft Fill the cup with new DOP plasticizing oil 37 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com CONTENT Warranty Safety and Handling Characteristics Principal Heating System Proportionin
39. pumping more difficult When the ambient conditions prevent the products from being maintained at a minimum temperature of 12 C auxiliary heating elements must be used to condition the products as the minimum temperature required for the transfer 32 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Service Manual c The product inlet filter is obstructed see Maintenance d The inlet ball valve has leaks as a result of wear or possible faults in the ball or the closing surface of the bushing which means that part of the material supplied returns to the supply tank and that the proportioning pump supplies a smaller volume of material in the discharge cycle causing an incorrect ratio 4 Fault in the Direction Change Micro The pneumatic cylinder that drives the supply pumps has two magnetic position detectors for making the change of direction Each detector includes an led to indicate when it is active Any accidental movement of the detection position will prevent the pumps from making the change in direction which will oblige the detector to be put back into the correct position by using the gauge supplied with all of the accessories 5 Safety Pressure Gauges The proportioning pumps are protected by safety pressure gauges adjusted in factory to a pressure of 125 bar 1800 psi on the evolution G 125 A Model and 210 bar 2980 psi on the evolution G 200 A When the limit pressure is exceeded the pressure gauge cuts the electr
40. pumps heaters and hoses whenever applications have to be made that require a change of components Follow the recommended procedures in the order indicated to perform the cleaning a b 23 39 Place two drums of DOP cleaning agent close to the machine Dismantle the gun and leave the coupling block connected to the hoses Remove the transfer pumps of the product drums and place them in the drums of the DOP cleaning agent Place 2 separate vessels under the coupling block to gather up the products contained inside the machine Open the manual valves on the coupling block and press NORMAL key to start up the proportioning pumps Allow the products to come out until you see that only DOP cleaning agent comes out free of impurities Close the valves on the coupling block and deactivate the NORMAL key Place the transfer pumps in the drums of the new products Place 2 separate vessels under the coupling block to collect the DOP cleaning agent Open the valves on the coupling block and press NORMAL key to start up the proportioning pumps Allow the DOP cleaning agent to come out until you see that only the new products come out When the products come out without the contamination produced by the effect of the DOP cleaning agent the cleaning process is complete and you can proceed as normal 3 2 Issue Ref NR 00011 ENG http www gamapur com Manual de Servicio LONG TERM SHUTDOWN PROCEDURES PRECAUTION The unit includes
41. 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 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 masks protective goggles gloves shoes and safety clothing 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 To prevent serious harm by crushing or loss of limbs do not work with the unit without the safety duly installed on all moving parts Make sure that all of the safety protections are correctly fitted after all repair or maintenance work 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com 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 The heater is a component that reaches high temperature
42. s wait until it has cooled before handling 1 Heating Elements To replace a faulty element proceed as followings a Depressurize the unit disconnect it from the power supply and remove the cover on the heater b Disconnect the element from the terminal block with an appropriate spanner loosen the element and remove it from its housing Inspect the element it must be smooth and shiny in appearance If it is blackened or has material adhered to it replace the element c Check the new element with a tester the reading of the value of the resistance must be as shown in Table 1 on pag 27 d Apply Teflon or sealing paste to the thread and screw the element into its housing e Reconnect the wires to the connection block make sure the connection is in parallel and fit the heater cover NOTE If the element that has to be replaced is the one in contact with the temperature probe first remove the probe 2 Temperature Probe The temperature probe is fixed to the connector with a ferule and a torque nut Once inserted in its housing the ferule forms part of the probe and does not allow it to be relocated or moved The location of the probe is very important and must be done correctly before fitting the torque nut a Depressurize the unit and disconnect it from the power supply Check the torque of the body of the connector inserted in the heater to prevent leaks b Install the heating element c Insert the torque nut and
43. t the direction indicator light is lit to determine in which direction the pump fails to maintain the pressure If the light on the left is on check the ball in the aspiration valve lower valve of the isocyanate or polyol pump depending on which pump is losing pressure If the right light is on check the ball in the discharge valve upper valve of the isocyanate or polyol pump depending on which pump is losing pressure Proceed as follows to check the ball checks a Disconnect the machine from the power supply and close all supply valves and the supply system to the transfer pumps b Depressurise the proportioning pump and remove the corresponding ball check c The loss from the ball checks is usually caused by foreign particles that prevent the perfect coupling of the ball in the housing at the top of the closing bushing Clean the ball and the seat of the bushing and make sure there are no faults from nicks marks or scratches to the bushing or the ball If cleaning fails to resolve the problem or any fault is observed replace the bushing and the ball 2 Unbalanced Pressures Pressures are unbalanced when there is an obstruction in the hose or in the gun that prevents one of the components from leaving freely through the gun chamber when it is projected or when a problem in the pumping system prevents one of the components reaching the gun in the required amount To identify which component is relatively easy if we bear in mind
44. that the chemical components used in the polyurethane foaming are of a different color By observing the color of the material that leaves the gun we can determine which component is missing 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 3 Cavitation Cavitation occurs when the proportioning pump requires a larger volume of material than that supplied by the feeding system causing the formation of a vacuum in the proportioning pump The causes of cavitation are the following a The transfer pump fails to supply the necessary volume The problem might be in the pump not meeting the required specifications in the lack of air supply to the pump or that the pump is faulty A pump is recommended with a ratio of 2 1 for transferring the lsocyanate and a supply hose with an interior diameter of at least 20 mm b High viscosity the polyurethane foaming systems normally require a minimum transfer temperature of 12 C at lower temperatures the product increases in viscosity making the
45. the characteristics of the unit and the operating procedures By following the instructions and recommendations contained herein you will reduce the potential risk of accidents in the installation use or maintenance of the unit you will provide a better opportunity for incident free operation for a longer time greater output and the possibility of detecting and resolving problems fast and simply Keep this Service Manual for future consultation of useful information at all times If you lose this manual ask for a new copy from your GAMA local distributor or directly contact Garraf Maquinaria S A WARNING The design of the evolution G 125 A G 200 A series proportioning unit does not allow its use in potentially explosive atmospheres or to exceed the pressure and temperature limits described in the technical specifications of this manual 3 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com 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 The introduction and follow up of safety measures must not be limited to those described in this manual Before starting up the machine a comprehensive analysis must be made of the risks derived from the pro
46. the ferule in the probe and insert this in the connector body until it comes into positive contact with the heating element Make sure the spring does not prevent the probe from making contact with the element d Fix the probe in place and fit the torque nut 35 39 3 2 Issue Ref NR 00011 ENG http Wwww gamapur com Manual de Servicio Proportioning Pumps 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 The proportioning pumps are components that work under pressure do not open any connection or perform repair or maintenance work on component subject to pressure until all of the pressures have been completely eliminated The proportioning pumps require specific annual maintenance they must be completely removed and inspected for damage which may cause the pump seals to fail All wear components mainly o rings and seals must be changed as a measure of preventive maintenance The pump base must also be inspected to ensure that the valve balls show no sign of wear knocks or marks that affect the correct operation of the pump 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
47. up and clean them Replace the filter screen if necessary lsocyanate is a product that crystallizes with ambient moisture or freezing If the storage and transfer is correct and the operating procedures are respected the risk of contamination of the lsocyanate filter will be minimized NOTE Clean the Isocyanate inlet filter before the daily start up it should not be cleaned after the machine has been stopped for the day Immediately beginning to project after cleaning the filter reduces the risk of absorption of moisture and the possibility of 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 stopper to allow the product to be emptied into the vessel below Completely unscrew the stopper c Remove the seal the spring and the mesh and clean it all with the solvent used for cleaning the gun Dry it all and check that the mesh is not obstructed The holes in the mesh must be completely free Replace the mesh if more than 10 of the surface is obstructed d Refit the mesh the spring and the seal Screw on the stopper e Open the product entry valve of the filter make sure there are no leaks and proceed with the normal o
48. ys of the control panel Set to EU for the temperature MIS Val qn Bz P to be shown in degrees Celsius C or to USA for 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 Motor Selector This allows the operation of the hydraulic system to be activated or deactivated The adjustment is carried out in factory depending on the machine model The function of the DIP Motor selector is HY PNEU 4 gt A O p only active in the units with hydraulic actuation Please be aware that after manipulating the DIP selector you should switch off the unit so the change in detected buy the board 10 39 3 2 Issue Ref NR 00011 ENG http www gamapur com Service Manual CONTROL PANEL PLURAL COMPONENT PROPORTIONER COUNTLA COmianen arsos Gap mii Oe naa i bepa fa p memp i 1 fetecemee 19 i tebrep paee IELA CRE TETEE Figure 2 Control Panel 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 The parameter display will flash for a few seconds to allow the change of this 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 t

Service Manual G-125 A

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