GAMA Easy Spray Service Manual
Service Manual
Proportioning Unit
Easy Spray
Issue 3.1 15/02/19
Ref. NR-00019-ENG
Before installing the unit and starting it up, read all the technical and
safety documentation included in this manual carefully. Pay special
attention to the information to know and understand the operation and the
conditions of use of the unit. All of the information is aimed at enhancing
User Safety and avoiding possible breakdowns derived from the incorrect
use of the unit.
Service Manual
WARRANTY
HI-TECH SPRAY EQUIPMENT, S. A. (hereinafter “HI-TECH”) provides this LIMITED WARRANTY (hereinafter
“Warranty”) to the original purchaser (hereinafter “Customer”) covering this equipment and the original HI-TECH
manufactured accessories delivered with the equipment (hereinafter “Product”) against defects in material or
workmanship of the Product (hereinafter “Defect” or “Defective”) for a period of two (2) years from the date of first
purchase as shown on the original HI-TECH 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 HI-TECH and return the Product to HI-TECH as directed by HITECH, freight prepaid. If HI-TECH determines that the Product is Defective and that such Defect is covered by this
Warranty, HI-TECH will credit Customer for the reasonable freight charges incurred by Customer in returning the
Defective Product to HI-TECH, and HI-TECH (or its authorized agent) will, at HI-TECH’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-HI-TECH Components and Accessories: Non-HI-TECH 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 HI-TECH 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.
Improper or unauthorized installation, repair, alteration, adjustment or modification of the Product.
Use of heating devices, pumping equipment, dispensers, or other parts or accessories with the Product that
have not been approved or manufactured by HI-TECH.
Failure to follow the operating instructions and recommendations provided by HI-TECH.
Cosmetic damage.
Fire, flood, “acts of God,” or other contingencies beyond the control of HI-TECH.
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, HI-TECH 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 HI-TECH HAS BEEN ADVISED OF THE
POSSIBILITY OF SUCH LOSSES OR DAMAGES.
Non-Warranty Service by HI-TECH: If HI-TECH 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 HI-TECH’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 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 HI-TECH 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 HI-TECH 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 HI-TECH, 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 HI-TECH.
2/46 Issue 3.1 Ref. NR-00019-ENG
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Service Manual
SAFETY AND HANDLING
All information provided in this Service Manual is assumed to be correct; although this does not
constitute any implicit or explicit liability or guarantee. HI-TECH 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 errors, supplement the information
contained or insert changes predicated by the performance or use of the unit.
This chapter contains information on the safety, handling and use of the Easy Spray series
proportioning unit.
Before installing the unit and starting it up, read all the technical and
safety documentation included in this manual carefully. 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.
CAUTION! 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 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 HI-TECH local distributor or directly contact HI-TECH
SPRAY EQUIPMENT, S.A.
WARNING! The design of the Easy Spray 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.
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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 products to be
dispensed, the type of application and the working environment.
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.
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Service Manual
CHARACTERISTICS
The Easy Spray proportioning unit has been designed and built for the application of Polyureas,
chemical systems for polyurethane foaming, and some two-component Epoxy systems.
Its reduced size allows easy transport to site. Its easy operation (simply turn one switch and
push the START button) reverts into time saving during set up and application.
Principal Heating System
Consists of two independent heaters without seals. Each heater has two 900 W heating
elements, which give the unit a total power of 1800 W and the necessary control and safety
components for the precise operation of the system. Its peculiar configuration allows a
temperature differential (ΔT) of 30º C and application temperatures of up to 70º C under normal
conditions of ambient temperature.
Proportioning Pumps
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
difference between the upper and the lower side of the air motor, and the effect of the additional
pressure of the transfer pumps.
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Recirculation System
Allows keeping the products in temperature prior to start spraying and during breaks.
Proportioning System (OPTIONAL)
Designed with a 2000 W isolation transformer
that enables effective heating up to a total
hose length of 48 meters (165 feet). The
system includes an innovative hose heating
concept in which the copper heating element is
spread evenly around the circumference of the
hose, providing a uniform heating watt density
and precise control of the product application
temperature.
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Service Manual
TECHNICAL SPECIFICATIONS EASY SPRAY-100
Electrical
Main Voltage: ____________________________________________________________ 230 V
Frequency: ____________________________________________________________ 50/60 Hz
Electrical Consumption: ______________________________________ 16 amp @ 1 x 400 V+ N
@ 2x 230 V
Total Active Power: ______________________________________________________ 3.6 Kw
Heater Power:_________________________________________________ (2 x 1.8 Kw) 3.6 Kw
Transformer Frequency (Optional): _________________________________________ 50/60 Hz
Transformer Active Power (Optional): ________________________________________ 1,6 Kw
Transformer Electrical Consumption (Optional): ____________________ 9 amp @ 1 x 400 V+ N
@ 2 x 230 V
Mechanical
Maximum Working Pressure (air supply 9 bar): ________________ 100 bar (10 MPa) / 1450 psi
Maximum Production Ratio 1:1: ___________________________________ 4 kg/min / 8,8 lb/min
Minimum Production: ___________________________________________ 1 kg/min / 2,2 lb/min
Recirculation Hose Length: _____________________________________________ 11 m / 36 ft
Maximum Heated Hose Length (Optional): ______________________________ 48 m / 157,5 ft
Approximate Air Consumption @ 6 bar: _____________________________________ 550 l/min
Recommended Compressor: _____________________________________ 5,5 HP three-phase
Approximate weight without Transformer (standard version): _________________ 92 kg /203 lbs
Approximate weight with Transformer (optional version): ___________________ 112 kg /247 lbs
Dimensions: ____________________________________ H: 1000 mm / A: 610 mm / L: 700 mm
____________________________________________________ H: 39,4 in / A: 24 in / L: 27,6 in
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Manual de Servicio
TECHNICAL SPECIFICATIONS EASY SPRAY-200
Electrical
Main Voltage: ____________________________________________________________ 230 V
Frequency: ____________________________________________________________ 50/60 Hz
Electrical Consumption: ______________________________________ 16 amp @ 1 x 400 V+ N
@ 2x 230 V
Total Active Power: ______________________________________________________ 3.6 Kw
Heater Power:_________________________________________________ (2 x 1.8 Kw) 3.6 Kw
Transformer Frequency (Optional): _________________________________________ 50/60 Hz
Transformer Active Power (Optional): ________________________________________ 1,6 Kw
Transformer Electrical Consumption (Optional): ____________________ 9 amp @ 1 x 400 V+ N
@ 2 x 230 V
Mechanical
Maximum Working Pressure (air supply 9 bar): ________________ 200 bar (20 MPa) / 2900 psi
Maximum Production Ratio 1:1: ___________________________________ 4 kg/min / 8,8 lb/min
Minimum Production: ___________________________________________ 1 kg/min / 2,2 lb/min
Recirculation Hose Length: _____________________________________________ 11 m / 36 ft
Maximum Heated Hose Length (Optional): ______________________________ 48 m / 157,5 ft
Approximate Air Consumption @ 6 bar: _____________________________________ 550 l/min
Recommended Compressor: _____________________________________ 7,5 HP three-phase
Approximate weight without Transformer (standard version): _________________ 92 kg /203 lbs
Approximate weight with Transformer (optional version): ___________________ 112 kg /247 lbs
Dimensions: ____________________________________ H: 1000 mm / A: 610 mm / L: 700 mm
____________________________________________________ H: 39,4 in / A: 24 in / L: 27,6 in
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Service Manual
GENERAL DESCRIPTION
Figure 1. General Description Easy Spray
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1. Isocyanate Tank
Contains the A chemical element. Capacity 30 liters.
2. Polyol Tank
Contains the R chemical element. Capacity 30 liters.
3. Isocyanate Recirculation Valve
Allows selecting recirculation or spraying in the Isocyanate circuit.
4. Polyol Recirculation Valve
Allows selecting recirculation or spraying in the Polyol circuit.
5. Control Panel
Controls and regulates the correct operation of the unit.
6. Isocyanate Proportioning Pump
Meters the Isocyanate.
7. Polyol Proportioning Pump
Meters the Polyol.
8. Isocyanate Heater
Heats the Isocyanate to the pre-set temperature.
9. Polyol Heater
Heats the Polyol to the pre-set temperature.
10. Hose Heating Transformer (Optional)
Supplies the required voltage for heating the hoses.
11. Hose Electrical Regulator (Optional)
Set the electric power desired for heating the hoses.
12. Isocyanate Pressure Gage
Indicates the pressure in the Isocyanate circuit.
13. Polyol Pressure Manometer
Indicates the pressure in the Polyol circuit.
14. Isocyanate Heater Probe
Provides information on the temperature of the Isocyanate
15. Polyol Heater Probe
Provides information on the temperature of the Polyol.
16. Isocyanate Inlet Filter
Avoids the penetration of solid particles inside the Isocyanate pump of the unit.
17. Polyol Inlet Filter
Avoids the penetration of solid particles inside the Polyol pump of the unit.
18. Main Pneumatic Valve
It opens and closes the flow of air coming into the pneumatic system.
19. Retract Valve
Sets the piston rod of the Isocyanate proportioning pump to the retract position and prevents the
crystallization of Isocyanate on the piston rod. Close the RETRACT valve every time the unit is
stopped by the operator.
20. Pressure Regulators
Using the two air pressure regulators, select the pressure for the down stroke and the up stroke
of the pneumatic cylinder.
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Service Manual
CONTROL PANEL AND HOSE HEATED SYSTEM
Figure 2. Control Panel and Hose Heating
Comprises two electrical components for an accurate working of the unit.
1. Main Power Switch
Turns the electric supply to the control panel on and off. It must be turned ON for any operation
to be performed with the unit.
2. Start Button
This pushbutton turns the circuit control on.
3. ISO/POL Temperature Regulator
Establishes the temperature needed for every
product.
Note:
To manipulate the device, refer to the specific
chapter “Regulator of Temperature Heaters”.
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4. Hoses (OPTIONAL)
Hose heating is activated and deactivated by
the orange pushbutton located at the front of
the transformer. It will lit up when heating is
activated.
Turn the potentiometer clockwise to increase
amps, and anti-clockwise if you wish to
decrease amps. Adjustment ranges from 0 to
50 amps.
Take the values below as an approximate
reference to select the intensity that allows
reaching the requested 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
Turn the potentiometer clockwise until the screen shows the required amps for a quick preheating.
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 above 35 amperes until the heater is disconnected from the
hoses and reconnected.
5. Heaters Switch
Turns the electric supply to the control heaters unit ON and OFF.
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REGULATOR OF TEMPERATURE HEATERS
This machine equips each heater with separate temperature regulators.
Instructions
When the power is connected to the machine, the displays will show the current temperature
values.
To modify the values press or as required.
For more details about the settings, follow the instructions from the manufacturer's manual
attached.
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