GAMA evolution G-50 H User manual

Service Manual
Proportioning Unit
evolution G-50 H
Issue 3.2 3/21/2023
Ref. NR-00042-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.

evolution G-50 H
Service Manual
2/48 Issue 3.2 Ref. NR-00042-ENG
http://www.gamapur.com/
HI-TECH SPRAY EQUIPMENT, S. A. (hereinafter “HI-TECH”) grants this Limited Guarantee to the original
buyer (hereinafter the “Client”) for the unit and the original accessories given with the unit (hereinafter the
“Product”) against any fault in the design, materials or manufacture of the Product at the time of the first
purchase by the user and for a duration of two (2) years thereafter.
If during the guarantee period and under normal conditions of use, the Product should fail to work correctly
due to defects of design, material or manufacture, the authorised distributor of the country where the HI-
TECH Product or technical assistance service has been purchased shall repair or replace the Product in
accordance with what is established in the following:
CONDITIONS
a) The validity of this guarantee will be subject to the presentation of the original invoice issued by
the HI-TECH authorised distributor for the sale of the Product along with the Product handed over
for repair or replacement, which must show the date of purchase and the serial number. HI-TECH
reserves the right to refuse to give the guarantee service when the indicated data fail to appear
on the invoice or have been modified after the purchase of the Product.
b) The repaired or replaced Product will continue to maintain the original guarantee for the time
remaining until the end of the guarantee or for three (3) months from the repair date, if the
remaining period of the original guarantee were shorter.
c) This guarantee will not be applied to the faults in the Product caused by its faulty installation, the
natural wear and tear of the components, any use other than that considered normal for this
Product or which should fail to strictly comply with the instructions of use provided by HI-TECH;
due to accident, carelessness, adjustments, alterations or modifications of the Product not
authorised by HI-TECH or due to the use of accessories, heating devices, pumping equipment
and/or dispensers that have not been approved or manufactured by HI-TECH.
d) The guarantee applicable to the components and accessories forming part of the Product and
which have not been made by HI-TECH will be limited to the guarantee offered by the original
manufacturer thereof.
HI-TECH WILL NOT RECOGNISE ANY EXPRESS ORAL OR WRITTEN GUARANTEES OTHER THAN THIS
PRINTED LIMITED GUARANTEE. ALL IMPLICIT GUARANTEES, INCLUDING, WITHOUT LIMIT, ADAPTATION
FOR A SPECIFIC USE, ARE SUBJECT TO THE DURATION OF THIS WRITTEN GUARANTEE. HI-TECH DOES
NOT ASSUME ANY KIND OF COMMITMENT OR RESPONSIBILITY FOR ALL POSSIBLE DAMAGE OR EXPENSE
CAUSED BY FAULTS IN THE OUTPUT OF THE PRODUCT, ITS WORKING OR THE DISPENSING OF MATERIAL
THROUGH THE PRODUCT, INCLUDING, WITHOUT LIMITATION, ALL EXPENSES CAUSED BY DAMAGE TO
PEOPLE OR PROPERTY. EQUALLY, HI-TECH WILL IN NO CASE ACCEPT LIABILITY FOR THE LOSS OF
SPECULATIVE PROFITS OR COMMERCIAL LOSSES. ALL REPAIRS OR REPLACEMENT OF FAULTY
PRODUCTS WILL CONSTITUTE THE COMPREHENSIVE FULFILMENT OF HI-TECH'S OBLIGATIONS WITH
RESPECT TO THE CLIENT. HI-TECH DOES NOT IN ANY WAY GUARANTEE THE SUITABILITY OR APTITUDE OF
ITS PRODUCT FOR ANY PARTICULAR PURPOSE OR APPLICATION.
All information provided on components which have not been manufactured by HI-TECH and which is
based on reports received from the original manufacturer, though considered precise and reliable, is
provided without any guarantee or responsibility of any explicit or implicit kind.
All concession, sale or financial leasing of the Product by HI-TECH in no case explicitly or implicitly
constitutes any authorisation, acceptance or concession for the use of any rights or patents, nor does it
encourage, nurture or back their infringement.
The restrictions on the guarantee suppose no limitation on the legal rights of the consumer established in
applicable national legislation, nor do they affect any rights derived from the bargain and sale agreement
between the consumer and supplier.
All information provided in this manual has been included in the confidence that it is true, although it does
not constitute any responsibility or implicit or explicit guarantee. HI-TECH reserves the right at any time
and without prior warning to make all improvements and modifications necessary to this manual, in order
to rectify any possible typographical errors, increase the information contained or insert the changes
caused to the characteristics and performance of the unit.
WARRANTY

evolution G-50 H
Service Manual
3/48 Issue 3.2 Ref. NR-00042-ENG
http://www.gamapur.com/
The equipment described in this manual has been designed
and manufactured in compliance with the following European
Directives, following as application guide the harmonized
standards detailed and in conformity with the relevant UK
Statutory Instruments (and their amendments):
Directive 2006/42/EC on machinery (UK Supply of Machinery (Safety) Regulations 2008)
UNE EN 12100:2012 (BS EN ISO 12100:2010)
Directive 2014/30/EU on electromagnetic compatibility (UK Electromagnetic Compatibility
Regulations 2016) (*)
UNE EN 55011 (BS UNE EN 55011)
UNE EN 55016-2-1 (BS UNE EN 55016-2-1); UNE EN 55016-2-3 (BS UNE EN 55016-2-3);
UNE EN 55032 (BS UNE EN 55032)
UNE EN 61000-3-2 (BS UNE EN 61000-3-2); UNE EN 61000-3-3 (BS UNE EN 61000-3-3);
UNE EN 61000-4-2 (BS UNE EN 61000-4-2); UNE EN 61000-4-3 (BS UNE EN 61000-4-3);
UNE EN 61000-4-4 (BS UNE EN 61000-4-4); UNE EN 61000-4-5 (BS UNE EN 61000-4-5);
UNE EN 6100-4-6 (BS UNE EN 6100-4-6); UNE EN 61000-4-8 (BS UNE EN 61000-4-8); UNE
EN 61000-4-11 (BS UNE EN 61000-4-11)
(*) The Unit may experience a degradation of its immunity in the presence of radiated
electromagnetic disturbances (IEC 61000-4-3) in the frequency range between 80MHz and
700MHz under an electric field level of 10 V / m, resulting in a temporary loss of function,
self-recoverable, according to performance criterion C of the Standard.
Directive 2014/68/EU on pressure equipment (UK Pressure Equipment (Safety)
Regulations 2016)
UNE EN 809:1999 +A1 (BS EN 809:1998 +A1:2009)
Directive 2014/35/EU on electrical safety (UK Electrical Equipment (Safety) Regulations
2016)
UNE EN 60204-1:2019 (BS EN 60204-1:2018)
Directive 2003/10/EC on noise level (UK The Control of Noise at Work Regulations 2005)
UNE EN ISO 3740 (BS EN ISO 3740:2019)
UNE EN ISO 3746 (BS EN ISO 3746:2010)
Directive 2011/65/EU on the restriction of the use of certain hazardous substances in
electrical and electronic equipment with amendment 2015/863/EU (UK The Restriction of
the Use of Certain Hazardous Substances in Electrical and Electronic Equipment
Regulations 2012)
Directive 2012/19/EU on waste electrical and electronic equipment (UK The Waste
Electrical and Electronic Equipment Regulations 2013)
SAFETY AND HANDLING

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Electrical products cannot be thrown out with the rubbish. They must be taken to a
dedicated collection point for an environmentally sound disposal in accordance
with local regulations. You must contact your local collective or retailer for
information about recycling. Before leaving WEEE at appropriate collection
facilities, batteries must be removed and disposed of separately for proper
recycling. The packaging materials are recyclable. Dispose of packaging materials
in an environmentally sound manner and place them at the disposal of recycling
sectors.
TRANSPORT AND STORAGE
Proper precautions must be taken so that the equipment can withstand the effects of transport
and storage temperatures between -25°C and +55°C or up to +70°C for short periods that do
not exceed 24 hours. Also, appropriate means to prevent damage from moisture, vibrations or
shocks must be foreseen.
This chapter contains information on the safety, handling and use of the evolution G-50 H
series metering 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.
NB: 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 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 evolution G-50 H series metering 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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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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The evolution G-50 H metering unit has been designed and built for the application of
Polyureas, chemical systems for polyurethane foaming and some two-component epoxy
systems.
Principal Heating System
Consists of two independent heaters without seals. Each heater has six 1500 W heating
elements, that give the unit a total power of 9000 W, and the necessary control and safety
components for precise operation of the system. Its singular configuration allows a temperature
differential (ΔT) of 50º C (122º F) and application temperatures of up to 90º C (194º F) under
normal conditions of ambient temperature.
Hose Heating System
Designed with a 4000 W isolation transformer that
enables effective heating up to a total hose length of
93 meters (305 feet). The system includes an
innovative hose heating concept in which the
copper heating element is spread evenly around the
circumference of the hose, providing a uniform
heating watt density and precise control of the
product application temperature. This hose heating
element design is extremely resistant to fatigue
failure.
100% circumferential coverage produces the most homogenous distribution of heat available.
Double Acting Opposed Piston Metering Pumps
A pump line driven by a double rod hydraulic cylinder. The in line pump system with opposed
piston pumps provides a constant volume and guarantees uniform pressures in both directions
of pump movement. Different sized pumps allow for various volumetric ratios to be achieved
(1:4 to 4:1) between the chemical components used in the process.
CHARACTERISTICS

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Electrical
Main voltage: _________________________________________________________400/200 V
Frequency: ____________________________________________________________50/60 Hz
Electrical consumption: ________________________ 56 A @ 3PE~400V / 100 A @ 3PE~200V
Pre Heater power: _______________________________________________(2 x 9 kW) 18 kW
Hose Transformer Power: ___________________________________________________4 kW
Electrical Motor Power: ___________________________________________________ 5,5 kW
Total Active Power: _____________________________________________________ 27,5 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: _______________________________________ 240 bar (24 MPa)
Maximum production ratio 1:1:___________________________ 22 kg/min @ 110 bar (11 MPa)
17 kg/min @ 160 bar (16 Mpa)
12 kg/min @ 240 bar (24 Mpa)
Minimum production: ____________________________________________________ 1 kg/min
Maximum hose length: ______________________________________________________ 93 m
Recommended compressor: _________________________________________ 3 HP Triphasic
Acoustic
A-weighted sound pressure level: _______________________________________ 78,4 dB (A)
A-weighted sound power level: _________________________________________ 93,5 dB (A)
Values obtained according to UNE-EN ISO 3746:1995 standard.
Approximate weight (hydraulic tank empty): ____________________________________280 kg
Approximate weight (hydraulic tank full): _______________________________________360 kg
Dimensions: _________________________________ H: 1200 mm / W: 900 mm / L: 700 mm
TECHNICAL SPECIFICATIONS

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Figure 1. General Description.
GENERAL DESCRIPTION

evolution G-50 H
Service Manual
9/48 Issue 3.2 Ref. NR-00042-ENG
http://www.gamapur.com/
1. Control Panel
Controls and regulates the operation of the unit.
2. Isocyanate Metering Pump
Meters the Isocyanate.
3. Polyol Metering Pump
Meters the Polyol.
4. Isocyanate Pre Heater
Heats the Isocyanate to the pre-set temperature.
5. Polyol Pre Heater
Heats the Polyol to the pre-set temperature.
6. Hose Heating Transformer
Supplies the required voltage for heating the hoses.
7. Hydraulic Pressure Gage
Indicates the pressure in the hydraulic drive system.
8. Isocyanate Pressure Gage
Indicates the pressure in the Isocyanate system.
9. Isocyanate Safety Pressure Switch
Deactivates the directional valve in the event of excessive pressure in the Isocyanate system.
10. Isocyanate Temperature probe
Provides information on the temperature of the Isocyanate.
11. Polyol Pressure Gage
Indicates the pressure in the Polyol system.
12. Polyol Safety Pressure Switch
Deactivates the directional valve in the event of excessive pressure in the Polyol system.
13. Polyol Temperature Probe
Provides information on the temperature of the Polyol.
14. Recirculation Kit
15. Hydraulic Pressure Regulator
Allows the pressure of the hydraulic system to be increased
or decreased. Turn clockwise to increase the pressure and
counterclockwise to reduce it. In order to regulate the
pressure of the hydraulic system, the NORMAL or
RETRACT key must be activated.
The regulation mechanism has two configurations:
a) Limiting of pressure with pin, for low pressure
hoses (up to 155 bar).
b) Limiting of pressure without pin, for high pressure
hoses (up to 276 bar).
Regulate the hydraulic system so that the output pressure of the unit
never exceeds the pressure of work of the installed product hoses.

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16. DIP S1 Selector TPC Probes
This sets the hose heating control mode
to be selected, depending on whether
the system includes a single
Temperature Control Sensor (TCS) for
automatic temperature control or no
TCS for manual temperature control.
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 S2 Selector Control Units
This sets the pressure and temperature
units that will be shown on the control
panel displays to Metric or English. Set
to EU for the pressure to be shown in
bar and the temperature to be shown in
degrees Celsius. Set to USA for the
pressure to be shown in psi and the
temperature to be shown in degrees
Fahrenheit. Please be aware that after
manipulating the DIP selector you
should switch off the unit so the
change. (in detected buy the board).
18. DIP S3 selector –Input Voltage selector
It allows selecting the input voltage. Moving the 1 switch to ON for 230V with neutral and to OFF
for 400V without neutral. Selection is factory set and cannot be modified without HI-TECH
technical service authorization. Please be aware that after manipulating the DIP selector
you should switch off the unit so the change (in detected buy the board).

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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 to select the
next parameter for setting.
The modification mode will be interrupted automatically after 3 seconds without activity on the
keyboard.
The parameters that may be selected and displayed are the following:
•Hose temperature in automatic control mode (maximum 80º C / 176º F)
•Hose heating power (maximum 50 Amps)
•Isocyanate heater temperature (maximum 90ºC / 194º F)
•Polyol heater temperature (maximum 90ºC / 194º F)
•Total number of cycles to be made
•Number of cycles made
CONTROL PANEL

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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 display shows the temperature of the Isocyanate hose
(ISO) and the temperature of the Polyol hose (RESIN).
The hose heating control may be automatic (optional) if using
a Temperature Control Sensor (TCS) or manual. The control
mode must be established with the two DIP selectors on the printed circuit board.
If the TCS is located in the ISO hose (the recommended placement), then set the Isocyanate
DIP selector to ON and the Polyol DIP selector to OFF. In this setup, the Isocyanate
temperature will show on the indicator and the Polyol indicator will be blank. If the hose heat
system does not include a TCS or the sensor is inoperative, then set both DIP selectors to OFF.
In this setup, both temperature indicators will be blank. In the units equipped with two hose
transformer power, locate the DIP “Hose ISO” and the DIP “Hose RESIN” to ON position if the
hoses have TCS for the temperature control system, or OFF position if the hoses not have
TCS.
Please be aware that after manipulating the DIP selector you should switch off the unit so
the change. (in detected buy the board).
ISO on / RESIN off
w/TCS
ISO off / RESIN off
manual control
Dual Hose Heat
(optional)
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. Repeat the
process to select the Amps. When the unit is 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 80ºC maximum for hoses and 90ºC maximum for
heaters.

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For the data input, the order will be as follows:
•Temperature set-point for A(ISO) heater and B or R (POL).
•Temperature set-point for A(ISO) hose and B or R (POL).
•Amps set-point for A (ISO) and B or R (POL).
•Ratio adjustment.
•Cycles pre-selection.
•Date input
If the TCS stops working, the temperature display will show the symbol (---)and the heating will
be automatically turned off.
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:
30 A 38º C 100º F
35 A 48º C 118º F
40 A 60º C 140º F
45 A 75º C 167º F
50 A 80º C 176º F
Select the required amps for a quick pre-heating.
NOTA:
The 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.
The settings programmed by the machine operator will be stored for the next time the
heating is switched on.

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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 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. Pressure
Indicator displays the Isocyanate pressure (ISO) and the Polyol (RESIN)
Using the DIP S2 selector labeled USA and EU, the units of
pressure and temperature can be set. Set the switch 1 of DIP
S2 selector to EU (ON) for the pressure to be displayed in bar
and the temperature in degrees Celsius; set the switch 1 of DIP
S2 selector to USA (OFF) for the pressure to be displayed in psi and the temperature in
degrees Fahrenheit. Please be aware that after manipulating the DIP selector you should
switch off the unit so the change. (in detected buy the board).
7. Counter
Indicator displays the cycles used and the cycles remaining from the preset. The cycle counter
is incremental and may be reset by simultaneously pressing the UP / DOWN keys.
The system allows pre-selecting the 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.
8. 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 nº 6 and nº 7) or due to excessive current in the heating system of the hoses
(alarm nº 9).

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9. Motor Key
Pushbutton turns on and off the hydraulic motor. When the key is active, the led in its centre 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).
10. Ratio Key
Controls that the pressure difference between the two components will not be higher than the
programmed (between a 5 and a 25%), if the difference is greater than, the alarm number 10
will be activated. The system to monitor the pressure differential is activated five seconds after
pressing the NORMAL key and allows the differential to be exceeded for two seconds before
the alarm is set off. The ratio control parameters are factory set. When the key is active, the led
in its center will come on.
11. Normal Key
Activates the normal operation of the machine. When the key is active, the led in its center will
come on.
12. Retract Key
Sets the piston rod of the Isocyanate metering pump to the retract position and prevents the
crystallization of Isocyanate on 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.
13. Direction Indicator Pilot Lights
Indicates the direction of movement of the metering pumps. If excessive pressure is caused in
the system, the pilot lights will be turned off and alarms 3 and 4 will be set off. The functions of
the NORMAL and RETRACT keys will remain active
14. USB Port
Standard connector to insert device of massive storage for capture of data.

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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.
The procedures recommended to determine the possible causes activating the alarms are
indicated in the following:
1. Maneuvering Voltage under 170 V
•Check the electrical supply connections.
•Check the transformer thermal limit switch.
2. Maneuvering Voltage over 270 V
•Check the electrical supply connections.
3. Excessive ISO Pressure (deactivates the directional valve and the heating system)
•Check the product pressure.
•Check the number 10 led of the printed circuit: it must be lit.
•Check the over pressure safety switch.
4. Excessive POL Pressure (deactivates the directional valve and the heating system)
•Check the product pressure.
•Check the number 11 led of the printed circuit: it must be lit.
•Check the over pressure safety switch.
5. Excessive ISO temperature (deactivates the POWER CONTROL)
•Check the heater heating system.
•Check the connections of the safety thermostat and allow it to cool so that it makes an
automatic reset.
•Check the number 12 led of the printed circuit: it must be lit.
6. Excessive POL temperature (deactivates the POWER CONTROL)
•Check the heater heating system.
•Check the connections of the safety thermostat and allow it to cool so that it makes an
automatic reset.
•Check the number 13 led of the printed circuit: it must be lit.
7. Fault key (it only turns on when the machine is connected to the mains)
•Check the keyboard.
8. Motor fault (the motor stops)
•Check the amperage draw on the hydraulic motor.
•Check the electrical connection of the hydraulic motor.
•Check the number 15 led of the printed circuit: it must be turned off.
9. Fault in Hose Heating System (deactivates the POWER CONTROL)
•Replace the faulty triac.
ALARMS

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10. Fault Ratio Off Tolerance (deactivates the directional valve)
•Check the product pressures.
•Replace the pressure transducer if there is no reading.
•Press the ratio key to cancel the function.
11. 000000 Cycle Pre-selection made (deactivates the directional valve)
•Press the MODE key to reset the counter
•Set the cycle selector to zero.
Disconnect the unit from the main power supply before working on the
inside of the electrical console. The electrical maintenance of the
machine must only be performed by a qualified electrician.

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Service Manual
18/48 Issue 3.2 Ref. NR-00042-ENG
http://www.gamapur.com/
Follow the torques for threaded joints listed in Table 1
according to thread sizes of hose fittings to ensure
their proper assembly.
There is also an alternative procedure to obtain an
equivalent torque without using special tools: joint both
ends of the hoses to be connected, tighten a swivel nut
by hand (without using spanner) until there is
resistance on the nut. Fit two spanners (1) on the fixed
ends of the hoses and turn the swivel nut with a third
spanner (2) as many flats from wrench resistance
(FFWR) as indicated in Table 1.
Table 1. Tightening Threaded Joints
THREAD
SIZE
TORQUE
Nm
FFWR
1/2”-20
23
2 (or 120º)
9/16”-18
30
1-1/2 (or 90º)
NOTE: 1 FFWR corresponds to one complete shear of a flat marked with red between
swivel and fitting or else 60º.
METHOD OF THREADED UNION OF THE HOSES

evolution G-50 H
Service Manual
19/48 Issue 3.2 Ref. NR-00042-ENG
http://www.gamapur.com/
PRECAUTION! Use suitable protection and follow the recommendations in the safety
information provided by product suppliers when installing or working with the unit.
HI-TECH provides a series of tools and accessories necessary for assembling the machine. The
kit is made up of the following elements:
REFERENCE
DESCRIPTION
QTY.
BI-00009
Tube of grease Lubriplate 1.75 oz./ 49 gr
1x
NR-00041
NR-00042
NR-00065
Parts Identification Manual
Service Manual
Monobloc Pumps Parts Manual
1x
1x
1x
HT-00001
Magnet holder tools
1x
HT-00003
Pin extractor
1x
MA-00102
12” Hoses Connection Cover
2x
EL-00051-00E
ISO TCS Assy with POL hose extension (For units with TCS)
1x ①
EM-00012
Hose TCS packaging
1x ①
EL-00093-01
White Flange 300 x 4.8
3x
HT-00045
Allen key 1/8”
1x
EL-00100-06
Blue Terminal for Cable 16 mm2L=12mm
2x ①
TN-00242
Threaded Rod 1/4”-20 UNC x 14” nylon
2x ①
OPTIONALS
EL-00052-00E
ISO –POL TCS Assy (For units with 2 Transformers)
1x ②
MA-00102
12" Hose Connections Protector
2x ②
EL-00093-01
White Flange 300 x 4.8
3x ②
EM-00012
Hose TCS packaging
1x ②
EL-00100-06
Blue Terminal for Cable 16 mm2L=12mm
4x ②
TN-00242
Threaded Rod 1/4”-20 UNC x 14” nylon
4x ②
NR-00093
Recirculation kit Parts Manual
1x
① For Units with 1 transformer & TCS (standard version)
② For Units with 2 transformers & individual TCS each hose of product (optional versions).
INSTALLATION

evolution G-50 H
Service Manual
20/48 Issue 3.2 Ref. NR-00042-ENG
http://www.gamapur.com/
Inside the console there is a terminal strip 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.
NB: 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:
a) Insert the main power cable by passing it through the wire stop at the bottom of the
electrical console and connect as shown in the diagram.
Use the proper size of cable according to the voltage, current and maximum power required by
the Unit.
The sizing of the cable is calculated for a length of 25m, for longer lengths you must
recalculate the appropriate section.
56,0 A @ 3PE~400V
100 A @ 3PE~230V
Cable Section 10 mm2
Cable Section 16 mm2
Make sure the power cable is disconnected from the mains source before connecting it
to the terminal strip in the console.
b) Load 63 liters (16.6 gal) of hydraulic fluid into
the tank of the unit. The oil must be of the
characteristics and specifications of DIN
51524 standard, sections 1 and 2 (for
example. ISO VG 46).