Parts Manual. Spray Unit Easy Spray-H. Issue /07/17 Ref. NR ENG

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Parts Manual Spray Unit Easy Spray-H Issue 2.5 27/07/17 Ref.

the time to read all the technical and safety instructions in the Service

It is essential that you follow these instructions carefully so that you

1 Parts Manual Spray Unit Easy Spray-H Issue /07/17 Ref. NR ENG Before installing the unit and starting it up, please take the time to read all the technical and safety instructions in the Service 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 safety and avoid malfunctions deriving from the incorrect use of the unit.

2 WARRANTY GARRAF MAQUINARIA, S. A. ( GAMA ) provides this LIMITED WARRANTY ( Warranty ) to the original purchaser ( Customer ) covering the equipment and the original accessories delivered with the equipment ( Product ) against defects in the design, materials or manufacture of the Product from the moment of initial purchase by the user and for a period of two (2) years from this date. If during the Warranty Period and under conditions of normal use, the Product stops working correctly for reasons connected with its design, materials or manufacture, the authorized dealer for the country where the Product was purchased or the GAMA technical assistance service shall repair or replace the Product in accordance with the following CONDITIONS a) This Warranty is only valid if accompanied, on presentation of the Product for its repair or substitution, by the original invoice issued by a GAMA dealer authorized to sell the Product, and which should indicate the date of purchase and serial number. GAMA reserves the right to withhold the provision of Warranty where the aforementioned information does not appear on the invoice or has been altered after the purchase of the Product. b) The repaired or replaced Product shall be covered by the original Warranty for the time remaining until its expiry or for three (3) months subsequent to the repair date, where the remaining Warranty period is shorter. c) This warranty does not apply to Product malfunctions caused by: its defective installation, natural wear of parts, its use for purposes other than those considered normal for this Product or in a manner which does not strictly comply with the instructions for use provided by GAMA; accident, recklessness, or adjustments, alterations or modifications to the Product not authorized by GAMA; or the use of accessories, heating devices, pumping apparatus and/or dispensers not approved or manufactured by GAMA. d) Parts and accessories which are part of the Product and not manufactured by GAMA are covered by the Warranty offered by their original manufacturer. GAMA SHALL HONOUR NO VERBAL OR WRITTEN WARRANTY OTHER THAN THE PRESENT LIMITED WARRANTY IN ITS PRINTED FORM. ALL IMPLIED WARRANTIES, INCLUDING AND WITHOUT LIMIT FITNESS FOR A PARTICULAR PURPOSE, EXPIRE WHEN THIS WRITTEN GUARANTEE EXPIRES. GAMA SHALL NOT BE HELD LIABLE FOR ANY DAMAGE OR LOSSES CAUSED BY THE DEFECTIVE PERFORMANCE OR OPERATION OF THE PRODUCT, OR BY THE MATERIAL DISPENSED BY THE PRODUCT, INCLUDING ALL LOSSES DERIVING FROM DAMAGES TO PERSONS OR PROPERTY. GAMA SHALL NOT IN ANY CIRCUMSTANCES BE HELD LIABLE FOR LOSSES IN SPECULATIVE GAINS OR PROFITS. THE REPAIR OR REPLACEMENT OF THE DEFECTIVE PRODUCT SHALL CONSTITUTE THE FULL DISCHARGE OF GAMA S RESPONSIBILITIES TOWARDS THE CUSTOMER. GAMA CANNOT GUARANTEE THE SUITABILITY OR FITNESS FOR PURPOSE OF ITS PRODUCT FOR ANY GIVEN USE OR APPLICATION. All information on parts not manufactured by GAMA and based on the statements of the original manufacturer is given without warranty or liability of any kind, express or implied, even if considered accurate and reliable. Under no circumstances shall the transfer, sale or financial leasing of the Product by GAMA constitute express or implied authorization, assent or permission for the use of rights or patents, or provide grounds for, encourage or endorse their violation. Warranty restrictions do not limit the legal rights of the consumer as provided in applicable national legislation or affect the rights deriving from the purchase agreement between consumer and provider. 2/46 Issue 2.5 Ref. NR ENG

3 SPRAY UNIT MODEL easy spray - H Figure 1. Spray unit model easy spray - H Table 1. Spray unit parts list Model: easy spray - H Pos. Description Reference Qty 1 Frame assembly MQ Electrical console assembly See Table POL tank assembly MQ ISO tank assembly MQ Pump assembly ISO heater assembly CLH POL heater assembly CLH Tank mounting arms MQ ISO pump-heater hose MA POL pump-heater hose MA Hydraulic motor and pump assembly - 1 3/46 Issue 2.5 Ref. NR ENG

4 Table 2. Basic configurations Reference ES R15 ES H15 Description easy spray-h single-phase 230V Hoses with recirculation gun easy spray-h single-phase 230V Heated hoses 1.5kW Table 3. List of references for electrical console Reference EL EL Description Electrical console assy. (single-phase 230V) Gun recirculation Version 1 Electrical console assy. (single-phase 230V) Heated 15 m hose Version 2 4/46 Issue 2.5 Ref. NR ENG

5 ELECTRICAL CONSOLE Figure 2. Electrical console for Easy Spray - H Table 4. List of parts for electrical console for Easy Spray - H Pos. Description Reference Qty 1 Soldered cabinet assembly See Table Lower cabinet cover EL F 1 3 Cabinet back plate EL Cabinet lock assy. EL Face panel assembly See Table Rating plate MQ Internal reinforcement brace EL Brass nut EL /46 Issue 2.5 Ref. NR ENG

6 Pos. Description Reference Qty 9 Cable gland EL Brass nut EL Cable gland EL Cable gland EL Blind rivet TN Screw TN Hex nut TN Hex nut TN Brass nut EL Plastic cap EL Female connector assembly (*) EL / Screw (*) TN Note: (*) Parts valid only for the heated hose option. Table 5. List of cabinet variants Soldered cabinet assembly easy spray H Hoses with recirculation (version 1) EL easy spray H 15 m heated hoses (version 2) EL Table 6. List of parts for Face panel assembly GAMA face panel (standard) Face panel 1x Circuit 1x Switch 1x Spacer 9x EL EL EL EL /46 Issue 2.5 Ref. NR ENG

7 HYDRAULIC DRIVE WITH SINGLE-PHASE MOTOR 230V 50/60HZ (VK pump) Figure 3. Single-phase hydraulic drive 230V 50/60Hz (with VK pump) 7/46 Issue 2.5 Ref. NR ENG

8 HYDRAULIC DRIVE WITH SINGLE-PHASE MOTOR 230V 50/60HZ (BR pump) Figure 4. Single-phase hydraulic drive 230V 50/60Hz (with BR pump) 8/46 Issue 2.5 Ref. NR ENG

9 Table 7. List of parts for Hydraulic Drive with Single-phase Motor 230V 50/60Hz Pos. Description Reference Qty 1 Frame assembly with hydraulic tank MQ V single-phase electric motor EL Hood HI VK pump HI BR pump HI Spidex elastic coupler HI Fill cap assembly HI Return filter assembly HI Pressure gauge (included in POS 7) HI Elbow coupler 90º (VK) RA Elbow coupler 90º (BR) RA Elbow coupler 90º (VK) RA Elbow coupler 90º (BR) RA Elbow 90º (VK) RA Elbow 90º (BR) RA Thermometer HI Drain cap RA Bi-material gasket OR Nipple RA Intake hose (VK) HI Intake hose (BR) HI Pressure hose (VK) HI Pressure hose (BR) HI Return hose HI Drain hose (VK) HI Drain hose (BR) MA Hex screw TN Glower washer TN Flat washer TN Hex screw TN Cont. overleaf 9/46 Issue 2.5 Ref. NR ENG

10 / cont. Pos. Description Reference Qty 24 Glower washer TN Flat washer TN Allen Screw TN Glower washer TN Flat washer TN ULS screw TN Glower washer TN Allen screw TN Glower washer TN Flat washer TN /46 Issue 2.5 Ref. NR ENG

11 FRAMEWORK COMPONENTS Figure 5. Framework components 11/46 Issue 2.5 Ref. NR ENG

12 Table 8. List of framework components Pos. Description Reference Qty 1 POL tank assy. MQ ISO tank assy. MQ Bi-material gasket OR Wheel MQ Castor with lock MQ Ball valve RA Elbow coupler 90º RA Swivel nut RA Straight coupler with pin RA Handlebar cap MQ Dryer filter NE (*) 12 Silencer NE (#) 13 Flanged cap RA (*) 2 (#) 14 Flat washer TN Glower washer TN Hex screw TN Hex screw TN Hex screw TN Glower washer TN Allen screw TN Washer TN Locking nut TN Hose MA m 24 Mikalor clamp TN Hose reinforcement spring (not shown) SP m 26 Nut TN Hex. Screw TN Washer TN (*) Items included in ISO Tank Assy Ref. 2 (#) Items included in POL Tank Assy Ref. 1. Ref. Tank only with Cover; MQ (common for ISO & POL). 12/46 Issue 2.5 Ref. NR ENG

13 Pos. Description Reference Qty 29 Washer TN Washer TN Hex. Screw TN Hex. Screw TN Column MQ /46 Issue 2.5 Ref. NR ENG

14 PROPORTIONING PUMP ASSEMBLY Figure 6. Proportioning pump assembly 14/46 Issue 2.5 Ref. NR ENG

15 Table 9. List of parts for proportioning pump assembly Pos. Description Reference Qty 1 Hydraulic cylinder HI Hydraulic distributor block MQ A ISO proportioning pump See Table R POL proportioning pump See Table Guide column MQ Guide bush TN Seeger ring TN Flat washer TN Hex nut TN Countersunk screw TN Solenoid valve assy. NG4 C.A. HI O-ring (included in POS.10) OR /8 BSPP flanged cap RA O-ring OR O-ring (included in POS.10) OR Nipple RA Adapter RA Elbow 90º RA Pressure gauge 160 bar HI Flanged cap RA Adjustable elbow 90º RA Swivel nut adapter RA Washer TN mesh filter assy. RA Filter cap (Included in POS.23) (*) RA Filter spring (included in POS.23) (*) SP Mesh filter (included in POS.23) (*) RA Bi-material gasket (included in POS.23) (*) OR Bi-material gasket OR (*) Quantities per filter. Cont. overleaf. 15/46 Issue 2.5 Ref. NR ENG

16 / cont. Pos. Description Reference Qty 25 Pin DIN x30 TN Inductive sensor (included in POS.1) EL M12 4P connector EL Sensor nut (included in POS.26) (*) EL Polycarbonate protective casing MQ Upper Plate MQ Screw TN Screw TN Flat washer TN Glower washer TN Hex screw TN Serrated washer TN Allen screw TN Serrated washer TN Allen screw TN Flat washer TN Glower washer TN Hex screw TN Column base plate MQ Puma yoke MQ Spacer MQ Pump base plate MQ Bi-material gasket RA Extension nozzle RA Nipple RA Coupler with pin M3/4 BSPP-pin 19mm RA Hex. Spacer MQ Allen screw TN Hex. Screw TN Nipple RA (*) Quantities per assembly 16/46 Issue 2.5 Ref. NR ENG

17 Table10. List of parts per proportioning pump size, easy spray-h Size of proportioning pump Description Reference 4.5 ISO / POL proportioning pump PU AESH Note: The isocyanate and polyol pumps are identical. 17/46 Issue 2.5 Ref. NR ENG

18 PROPORTIONING PUMP Figure 7. Proportioning pump 18/46 Issue 2.5 Ref. NR ENG

19 Table11. List of parts for proportioning pump assembly Pos. Description Reference Qty 1 Pump and upper bushing assy. PU A Pump housing PU Ball seat bushing PU Chrome-plated steel ball TN Upper ball stopper PU Stopper gasket PU Shaft assy. See page Pump yoke PU Locking washer TN Hex head screw TN Packing nut PU Guide bush (#) PU O-ring (#) OR Retainer (#) OR Gasket OR Lower ball stopper PU O-ring OR O-ring OR Pin TN Base plate and bush assy. PU A Ball seat bushing PU Pump base plate PU Cylindrical head screw TN Gasket kit (not shown in drawing) See Table13 1 Notes: The isocyanate and polyol pumps are identical. The quantities indicated are for one pump. (#) Parts included in gasket kit Pos. 27. (Includes replacement parts for 1 pump). 19/46 Issue 2.5 Ref. NR ENG

20 PROPORTIONING PUMP PISTON Figure 8. Proportioning pump piston, exploded view 20/46 Issue 2.5 Ref. NR ENG

21 Table12. List of components of proportioning pump piston Pos. Description Reference Qty 1 Pump shank PU Washer PU Pump rod PU R 1 4 Rod guide (#) OR Rod gasket (#) OR Self-locking nut TN O-ring (#) OR Gasket kit See Table13 1 Note: Quantities per pump. (#) Parts included in gasket kit Pos. 9. (Includes replacement parts for 1 pump). Table13. Seal Kit, Parts List Reference KT Description #4.5 Pump Seal Kit 21/46 Issue 2.5 Ref. NR ENG

22 PRIMARY HEATER Figure 9. Primary heater Note: The heaters for isocyanate and polyol are the same, except for outlet coupling POS.22, cover POS.19 and the assembly of the parts. 22/46 Issue 2.5 Ref. NR ENG

23 Table14. List of parts Primary heater Pos. Description Reference Qty 1 Heater block CLH Bottom insulating plate CL Top insulating plate CL Thermocouple EL Thermal limit switch EL Gasket OR Cap RA Gasket OR Extension nozzle RA Straight coupler RA Male extension nozzle RA T connector RA Pressure gauge HI Straight coupler for tube RA Screw TN Screw TN Grommet EL Heater casing CL Heater cap See Table Element EL Elbow coupler for tube EL º elbow coupler See Table Screw TN Nut EL Spring SP Cap RA Washer TN Screw TN Nipple RA T connector RA Pressure switch HI Note: The heaters for isocyanate and polyol are the same, except for outlet coupling POS.22, cover POS.19 and the assembly of the parts. 23/46 Issue 2.5 Ref. NR ENG

24 Table15. List of parts specific to heater models Reference Description POS. 19 POS. 22 CLH Isocyanate heater CL RA CLH Polyol heater CL RA /46 Issue 2.5 Ref. NR ENG

INLET BYPASS KIT REF. KT-00119 Figure 10.

25 INLET BYPASS KIT REF. KT Figure 10. Inlet Bypass kit Ref. KT /46 Issue 2.5 Ref. NR ENG

26 Table16. List of components of Inlet Bypass kit Pos. Description Reference Qty 1 3 Way L Ball Valve RA Nipple RA Swivel nut adapter RA Elbow 90º Swivel nut RA Metal-Ring OR Other parts of the drawing according to standard assembly. The quantities reflected in the table correspond to the total units included in the kit for two Product Pumps. 26/46 Issue 2.5 Ref. NR ENG

27 RECIRCULATION KIT REF. KT Figure 11. Recirculation kit Ref. KT /46 Issue 2.5 Ref. NR ENG

28 Table17. List of components of recirculation kit Item. Description Part Number Qty. 1 Nipple RA Elbow RA Manifold RA Nipple RA Nipple RA Swivel (*) RA Swivel (*) RA Flex mm Supply ISO MA Flex mm Recirculation ISO MA Flex mm Supply POL MA Flex mm Recirculation POL MA Air Hose MA Air Coupler RA Flex 1000 mm Recirculation Extended ISO MA Flex 1000 mm Recirculation Extended POL MA Nipple RA Nipple RA Ball Valve RA Swivel RA Tube MQ Hose Cover mm Insulating Cover mm Insulating Cover 8000 mm MA MA MA This kit is included with the standard unit version 1. 28/46 Issue 2.5 Ref. NR ENG

29 ADDITIONAL TRANSFORMER (OPTIONAL) For heated hoses of 38 to 48 m Figure 12. Additional transformer (optional) Ref. MQ /46 Issue 2.5 Ref. NR ENG

30 Table18. List of components of additional transformer (optional) Ref. MQ Pos. Description Reference Qty 1 Transformer cart MQ Transformer EL Castor MQ Glower washer TN Allen screw TN Tube cap Glower washer TN Allen screw TN For heated hoses of 38 to 48 m 30/46 Issue 2.5 Ref. NR ENG

31 CIRCUIT DIAGRAM: SINGLE-PHASE 230V 50/60HZ Figure 13. Circuit diagram: single-phase 230V 50/60Hz standard version (page 1/7) 31/46 Issue 2.5 Ref. NR ENG

32 Figure 14. Circuit diagram: single-phase 230V 50/60Hz standard version (page 2/7) 32/46 Issue 2.5 Ref. NR ENG

33 Figure 15. Circuit diagram: single-phase 230V 50/60Hz standard version (page 3/7) 33/46 Issue 2.5 Ref. NR ENG

34 Figure 16. Circuit diagram: single-phase 230V 50/60Hz standard version (page 4/7) 34/46 Issue 2.5 Ref. NR ENG

35 Figure 17. Circuit diagram: single-phase 230V 50/60Hz standard version (page 5/7) 35/46 Issue 2.5 Ref. NR ENG

36 Figure 18. Circuit diagram: single-phase 230V 50/60Hz standard version (page 6/7) 36/46 Issue 2.5 Ref. NR ENG

37 Figure 19. Circuit diagram: single-phase 230V 50/60Hz standard version (page 7/7) 37/46 Issue 2.5 Ref. NR ENG

38 Table19. List of parts for single-phase distribution board 230V 50/60Hz version 1, hoses with recirculation. Pos. Description Reference Qty Terminal block EL A differential circuit breaker EL A switch EL Fuse terminal EL P 63A switch EL Control switch EL Auto 2P 12A switch EL Auto switch base EL Contactor 7.5 kw EL Transformer 63VA EL Fuse 3.15A EL Relay EL Circuit EL Automatic switch 2P 10A EL Fourth pole EL Table20. List of parts for variant single-phase distribution board 230V 50/60Hz version 2, heated hoses. Pos. Description Reference Qty Triac EL Current transformer EL /46 Issue 2.5 Ref. NR ENG

39 Figure 20. Distribution board 39/46 Issue 2.5 Ref. NR ENG

40 PNEUMATIC CIRCUIT Figure 21. Pneumatic circuit 40/46 Issue 2.5 Ref. NR ENG

41 HYDRAULIC CIRCUIT Figure 22. Hydraulic circuit 41/46 Issue 2.5 Ref. NR ENG

42 FUNCTIONAL DIAGRAM STANDARD MODEL Figure 23. Functional diagram standard model 42/46 Issue 2.5 Ref. NR ENG

43 FUNCTIONAL DIAGRAM HEATED HOSE MODEL Figure 24. Functional diagram heated hose model 43/46 Issue 2.5 Ref. NR ENG

44 CONTENTS Warranty 2 Spray unit model easy spray - H 3 Electrical console 5 Hydraulic drive with single-phase motor 230V 50/60Hz (VK pump) 7 Hydraulic drive with single-phase motor 230V 50/60Hz (BR pump) 8 Framework components 11 Proportioning pump assembly 14 Proportioning pump 18 Proportioning pump piston 20 Primary heater 22 Inlet Bypass kit Ref. KT Recirculation kit Ref. KT Additional transformer (optional) 29 Circuit diagram: single-phase 230V 50/60Hz 31 Pneumatic circuit 40 Hydraulic circuit 41 Functional diagram standard model 42 Functional diagram heated hose model 43 Contents 44 List of illustrations 45 List of tables 46 44/46 Issue 2.5 Ref. NR ENG

45 LIST OF ILLUSTRATIONS Figure 1. Spray unit model easy spray - H 3 Figure 2. Electrical console for Easy Spray - H 5 Figure 3. Single-phase hydraulic drive 230V 50/60Hz (with VK pump) 7 Figure 4. Single-phase hydraulic drive 230V 50/60Hz (with BR pump) 8 Figure 5. Framework components 11 Figure 6. Proportioning pump assembly 14 Figure 7. Proportioning pump 18 Figure 8. Proportioning pump piston, exploded view 20 Figure 9. Primary heater 22 Figure 10. Inlet Bypass kit Ref. KT Figure 11. Recirculation kit Ref. KT Figure 12. Additional transformer (optional) 29 Figure 13. Circuit diagram: single-phase 230V 50/60Hz standard version (page 1/7) 31 Figure 14. Circuit diagram: single-phase 230V 50/60Hz standard version (page 2/7) 32 Figure 15. Circuit diagram: single-phase 230V 50/60Hz standard version (page 3/7) 33 Figure 16. Circuit diagram: single-phase 230V 50/60Hz standard version (page 4/7) 34 Figure 17. Circuit diagram: single-phase 230V 50/60Hz standard version (page 5/7) 35 Figure 18. Circuit diagram: single-phase 230V 50/60Hz standard version (page 6/7) 36 Figure 19. Circuit diagram: single-phase 230V 50/60Hz standard version (page 7/7) 37 Figure 20. Distribution board 39 Figure 21. Pneumatic circuit 40 Figure 22. Hydraulic circuit 41 Figure 23. Functional diagram standard model 42 Figure 24. Functional diagram heated hose model 43 45/46 Issue 2.5 Ref. NR ENG

46 LIST OF TABLES Table 1. Spray unit parts list 3 Table 2. Basic configurations 4 Table 3. List of references for electrical console 4 Table 4. List of parts for electrical console for Easy Spray - H 5 Table 5. List of cabinet variants 6 Table 6. List of parts for Face panel assembly 6 Table 7. List of parts for Hydraulic Drive with Single-phase Motor 230V 50/60Hz 9 Table 8. List of framework components 12 Table 9. List of parts for proportioning pump assembly 15 Table10. List of parts per proportioning pump size, easy spray-h 17 Table11. List of parts for proportioning pump assembly 19 Table12. List of components of proportioning pump piston 21 Table13. Seal Kit, Parts List 21 Table14. List of parts Primary heater 23 Table15. List of parts specific to heater models 24 Table16. List of components of Inlet Bypass kit 26 Table17. List of components of recirculation kit 28 Table18. List of components of additional transformer (optional) 30 Table19. List of parts for single-phase distribution board 230V 50/60Hz version 1, hoses with recirculation. 38 Table20. List of parts for variant single-phase distribution board 230V 50/60Hz version 2, heated hoses /46 Issue 2.5 Ref. NR ENG

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