PMC PH-2, PHX-2 User Manual
PH/PHX-2
Proportioner
For Professional Use Only
Not approved for use in European
explosive atmosphere locations
Manual
Ref. # MN-04009
REVISION 1.0
Polyurethane Machinery Corp.
Corporate: 1 KOMO Drive, Lakewood, NJ 08701
Manufacturing: 2 KOMO Drive, Lakewood, NJ 08701
Phone: 732-415-4400 Fax: 732-364-4025
http://www.polymac-usa.com
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Before installing the PH Series Proportioner and start-up, carefully
read all the technical and safety documentation included in this
manual. Pay special attention to the information in order to know
and understand the operation and the conditions of use of the PH
Series Proportioner. All of the information is aimed at improving
user safety and avoiding possible breakdowns from the incorrect use
of the PH Series Proportioner.
PH/PHX-2 Manual
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TABLE OF CONTENTS
WARRANTY ................................................................................................................... 4
SAFETY AND HANDLING ............................................................................................. 6
CHARACTERISTICS ...................................................................................................... 8
Principal Heating System ............................................................................................. 8
Hose Heating System .................................................................................................. 8
Double Acting Opposed Piston Metering Pumps ......................................................... 8
Pressure Balance Control System ............................................................................... 9
TECHNICAL SPECIFICATIONS .................................................................................. 10
Electrical .................................................................................................................... 10
Mechanical ................................................................................................................ 11
DESCRIPTION .............................................................................................................. 12
INSTALLATION ............................................................................................................ 17
PROPORTIONER PURGING ....................................................................................... 24
PRESSURE BALANCE CONTROL ............................................................................. 26
Operation ................................................................................................................... 26
DIGITAL TEMPERATURE CONTROLLER .................................................................. 27
START-UP .................................................................................................................... 28
SHUT-DOWN ................................................................................................................ 30
TROUBLESHOOTING .................................................................................................. 31
Heaters ...................................................................................................................... 32
Hydraulic Drive System ............................................................................................. 35
Metering Pump Line ................................................................................................... 37
Hose Heating ............................................................................................................. 41
Pressure Balance Control .......................................................................................... 44
MAINTENANCE ............................................................................................................ 45
Inlet Material Screens ................................................................................................ 46
Hydraulic Drive System ............................................................................................. 47
Metering Pump Line ................................................................................................... 48
Material Heater .......................................................................................................... 49
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HYDRAULIC OIL SPECIFICATIONS ........................................................................... 51
REPLACEMENT KITS .................................................................................................. 52
PARTS IDENTIFICATION ............................................................................................ 53
FRAME ASSEMBLY .................................................................................................. 53
HYDRAULIC MANIFOLD ASSEMBLY ...................................................................... 55
EXIT MANIFOLD ASSEMBLY ................................................................................... 56
HYDRAULIC SEAL ASSEMBLY ............................................................................... 57
HYDRAULIC PISTON ASSEMBLY ........................................................................... 58
HYDRAULIC CYLINDER ASSEMBLY ....................................................................... 59
A & R SINGLE PUMP ASSEMBLY (16:1) ................................................................. 61
PA-044 OUTLET BODY ASSEMBLY ........................................................................ 62
PA-044 PISTON ASSEMBLY .................................................................................... 63
PA-044 INLET BODY ASSEMBLY ............................................................................ 64
A & R SINGLE PUMP ASSEMBLY (30:1) ................................................................. 65
PAX-044 OUTLET BODY ASSEMBLY ...................................................................... 66
PAX-044 PISTON ASSEMBLY .................................................................................. 67
PAX-044 INLET BODY ASSEMBLY .......................................................................... 68
PUMPLINE ASSEMBLY ............................................................................................ 69
PUMPLINE ASSEMBLY ............................................................................................ 71
“A” INLET MANIFOLD ASSEMBLY ........................................................................... 73
“R” INLET MANIFOLD ASSEMBLY ........................................................................... 74
PREHEATER ASSEMBLY ........................................................................................ 75
MOTOR LINE ASSEMBLY (1 PHASE) ...................................................................... 78
MOTOR LINE ASSEMBLY (3 PHASE) ...................................................................... 80
FINAL ASSEMBLY .................................................................................................... 82
HOSES ...................................................................................................................... 87
EXIT MANIFOLD ACCESSORY ................................................................................ 88
MANUAL REVISIONS .................................................................................................. 89
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WARRANTY
Polyurethane Machinery Corporation (hereinafter “PMC”) provides this LIMITED WARRANTY
(hereinafter “Warranty”) to the original purchaser (hereinafter “Customer”) covering this
equipment and the original PMC 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 one (1) year from the date of first purchase as shown on
the original PMC 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 PMC and return
the Product to PMC as directed by PMC, freight prepaid. If PMC determines that the Product is
Defective and that such Defect is covered by this Warranty, PMC will credit Customer for the
reasonable freight charges incurred by Customer in returning the Defective Product to PMC,
and PMC (or its authorized agent) will, at PMC’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-PMC Components and Accessories: Non-PMC 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 PMC 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 PMC.
Failure to follow the operating instructions and recommendations provided by PMC.
Cosmetic damage.
Fire, flood, “acts of God,” or other contingencies beyond the control of PMC.
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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, PMC 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 PMC HAS BEEN ADVISED OF
THE POSSIBILITY OF SUCH LOSSES OR DAMAGES.
Non-Warranty Service by PMC: If PMC 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 PMC’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 PMC 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 PMC 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 PMC, 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 PMC.
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SAFETY AND HANDLING
This chapter contains important information on the safety, handling, and use of your PH
Series Proportioner.
Before installing the PH Series Proportioner and start-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 PH Series Proportioner. All of the
information is aimed at enhancing User Safety and
avoiding possible breakdowns derived from the incorrect
use of the PH Series Proportioner.
WARNING! Symbol is presented in front of information to alert of a
situation that might cause serious injuries if the instructions are not
followed.
CAUTION! Symbol is presented in front of information that indicates how to
avoid damage to the Proportioner or how to avoid a situation that could
cause minor injuries.
NOTE! Symbol is presented in front of relevant information of a procedure
being carried out.
Careful study of this manual will enable the operator to know the characteristics of the
PH Series Proportioner and the operating procedures. By following the instructions and
recommendations contained herein, you will reduce the potential risk of accidents in the
installation, use, and maintenance of the PH Series Proportioner. You will provide a
better opportunity for greater output, incident-free operation for a longer time, and the
possibility of detecting and resolving problems quickly and simply.
Keep this Operations Manual for future consultation of useful information at all times. If
you lose this manual, ask for a new copy from your PMC Service Center or go on line at
our web site (www.polymac-usa.com).
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The PH Series Proportioner has been designed and built for the application of polyurea
chemical systems, polyurethane foam chemical systems, and some two-component epoxy
systems.
WARNING! The design and configuration of the PH Series Proportioner
does not allow its use in potentially explosive atmospheres or the pressure
and temperature limits described in the technical specifications of this
manual to be exceeded.
Always use liquids and solvents that are compatible with the unit. If in doubt, consult your
authorized PMC distributor.
When working with the PH Series Proportioner, 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 PH Series Proportioner 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 PH Series Proportioner, 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 possible injury caused by incorrect handling of the raw
materials and solvents used in the process, carefully read the
Material Safety Data Sheet (MSDS)provided by your supplier.
Deal with the waste caused according to current regulations.
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 being present
in the area where the equipment is functioning. This includes, but is
not limited to, the use of protective goggles, gloves, shoes and safety
clothing and breathing equipment.
The equipment includes components that reach high temperatures
and can cause burns. Hot parts of the equipment must not be
handled or touched until they have cooled completely.
To prevent serious injury through crushing or amputation, do not
work with the equipment without the safety guards installed on the
moving parts. Make sure that all the safety guards are correctly
reinstalled at the end of the repair or maintenance work of the
equipment.
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100% circumferential coverage produces the
most uniform distribution of heat available.
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CHARACTERISTICS
The PH Series Proportioner has been designed and built for the application of polyurea
chemical systems, polyurethane foam chemical systems, and some specific twocomponent epoxy systems.
Principal Heating System
The Proportioner consists of one (1) Material Heater without internal seals. The Heater
has three (3) Heating Elements per fluid side rated at 1,250, 1,500, or 1750 watts, each
giving the Proportioner a total heat output of 7,500, 9,000, or 10,500 watts and the
necessary control and safety components for their precise operation. The Material
Heater design allows for a controlled and precise temperature differential (ΔT) and
material application temperatures of up to 190º F under ambient temperatures.
Hose Heating System
The system is designed with a 3 KVA Isolation Transformer that enables effective
heating of up to a total hose length of 310 feet (also available with a 2KVA transformer
and a 5 KVA transformer for maximum hose lengths of 210 and 410, respectively). The
system includes an innovative hose heating concept in which the continuous braid
tinned-copper jacket is distributed evenly around the circumference of the hose
providing a uniform heating watt density and precise control of the material application
temperature. This hose heating element design is extremely resistant to fatigue failure.
Double Acting Opposed Piston Metering Pumps
The opposed double acting Pump Line is driven by a double ended 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.
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1. Power supply
2. “A” side pressure reading
3. “R” side pressure reading
4. Maximum pressure
5. Maximum allowable
pressure differential
Logic Box
1. Continue pumping material
OR
2. Shut off pumps
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Pressure Balance Control System
The Pressure Balance Control (PBC) system performs an automatic shutdown when a chemical
imbalance occurs. When the system is turned off, the Proportioner will perform as if there is no PBC
system and will continue pumping material. When the system is turned on, it will continually monitor the
pressure between the two chemicals (known as the pressure differential). If the pressure differential
becomes equal to or greater than the maximum allowable pressure differential, the pumps will be shut
off.
The Pressure Balance Control system can be simplified into a logic box diagram with inputs and outputs.
There are five inputs: the power supply from the main console, the pressure readings from each
chemical, the maximum pressure, and the maximum allowable pressure differential. Inside the logic box,
the actual pressure differential of the chemicals is compared to the maximum allowable pressure
differential. Depending on the circumstances of all five inputs, there are only two possible outputs: either
the pumps will continue to pressurize and move material, or the pumps will shut off and flow will be lost.
Logic Box Representation
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TECHNICAL SPECIFICATIONS
Electrical
Main Voltage: __________________________________________3 x 208-230V, 50/60Hz
Electrical Consumption: PH-2, 2000 PSI (2 x 3.75 kW Heaters) _______ 40 A @ 3 x 230V
Electrical Consumption: PH-2, 2000 PSI (2 x 4.50 kW Heaters) _______ 46 A @ 3 x 230V
Electrical Consumption: PH-2, 2000 PSI (2 x 5.25 kW Heaters) _______ 51 A @ 3 x 230V
Electrical Consumption: PHX-2, 3000 PSI (2 x 5.25 kW Heaters) _______ 51 A @ 3 x 230V
Main Voltage: __________________________________________1 x 208-230V, 50/60Hz
Electrical Consumption: PH-2, 2000 PSI (2 x 3.75 kW Heaters) _______ 61 A @ 1 x 230V
Electrical Consumption: PH-2, 2000 PSI (2 x 4.50 kW Heaters) _______ 67 A @ 1 x 230V
Electrical Consumption: PH-2, 2000 PSI (2 x 5.25 kW Heaters) _______ 72 A @ 1 x 230V
Electrical Consumption: PHX-2, 3000 PSI (2 x 5.25 kW Heaters) _______ 72 A @ 1 x 230V
Main Voltage: _____________________________________________ 3 x 380V, 50/60Hz
Electrical Consumption: PH-2, 2000 PSI (2 x 3.75 kW Heaters) _______ 40 A @ 3 x 380V
Electrical Consumption: PH-2, 2000 PSI (2 x 4.50 kW Heaters) _______ 46 A @ 3 x 380V
Electrical Consumption: PH-2, 2000 PSI (2 x 5.25 kW Heaters) _______ 51 A @ 3 x 380V
Electrical Consumption: PHX-2, 3000 PSI (2 x 5.25 kW Heaters) _______ 51 A @ 3 x 380V
Material Heater Power: PH-2 (2 x 3.75 kW)________________________________ 7.5 kW
Material Heater Power: PH-2 (2 x 4.50 kW)________________________________ 9.0 kW
Material Heater Power: PH-2 (2 x 5.25 kW)_______________________________ 10.5 kW
Material Heater Power: PHX-2 (2 x 5.25 kW) _____________________________ 10.5 kW
Hose Transformer Power: (70 V) _________________________________________ 2 KVA
Hose Transformer Power: (90 V) _________________________________________ 3 KVA
Hose Transformer Power: (120 V) ________________________________________ 5 KVA
Electrical Motor Power: PH-2 _____________________________________________ 3 hp
Electrical Motor Power: PHX-2 ___________________________________________ 5 hp
CAUTION! Inside the console is a Terminal Strip for
connecting the main power (wire not supplied) to the PH
Series Proportioner. This electrical connection must be
made only by a qualified electrician.
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Mechanical
Maximum working pressure PH-2 (123 pumps): ___________ 2,000 psi (14 MPa, 138 bar)
Maximum working pressure PHX-2 (61 pumps): ____________ 3,000 psi (21 MPa, 207 bar)
Maximum production ratio 1:1 PH-2 (123 pumps): _______________ 31 lb/min (14 kg/min)
Maximum production ratio 1:1 PHX-2 (61 pumps): ________________ 2.3 gpm (10.5 Lpm)
Minimum production: ________________________________________ 2 lb/min (1 kg/min)
Gallons per stroke PH-2 (123 pumps): ___________________ .01859 gal/stroke (.07037 L)
Gallons per stroke PHX-2 (61 pumps): ___________________ .00911 gal/stroke (.03449 L)
Strokes per 55 gal (200 L) drum PH-2 (123 pumps): _____________________ 2958 strokes
Strokes per 55 gal (200 L) drum PHX-2 (61 pumps): ____________________ 6037 strokes
Maximum hose length (2 KVA Transformer): ___________________________ 210 ft (64 m)
Maximum hose length (3 KVA Transformer): ___________________________ 310 ft (95 m)
Maximum hose length (5 KVA Transformer): __________________________ 410 ft (125 m)
Approximate weight (Hydraulic Tank empty): _______________________ 415 lbs (166 kg)
Approximate weight (Hydraulic Tank full @ 12 gal): __________________ 450 lbs (197 kg)
Dimensions: __________________________________________ 44in W x 22in D x 52in H
_____________________________________________ (111cm W x 55cm D x 132cm H)
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DESCRIPTION
PH-2/PHX-2 Proportioners
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PH-2/PHX-2 Proportioners
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A. Control Panel
Controls and regulates the operation of the PH Series Proportioner.
B. Isocyanate (Iso, A) Metering Pump
Meters the Isocyanate material.
C. Polyol (Poly, R) Metering Pump
Meters the Polyol material.
D. Hydraulic Cylinder Assembly
Transfers power from hydraulic pump to material pumps.
E. Isocyanate (Iso, A) Inlet Manifold Assembly
Provides Isocyanate temperature and pressure readings prior to heating and
pressurizing
F. Polyol (Poly, R) Inlet Manifold Assembly
Provides Polyol temperature and pressure readings prior to heating and pressurizing
G. Exit Manifold Assembly
Provides pressure reading of material after heating and pressurizing
H. Isocyanate (Iso, A) Lube Reservoir
Provides lube to the Isocyanate pump shaft
I. Hydraulic Manifold Assembly
Provides pressure reading of hydraulic fluid and controls direction of flow
J. Motor
Provides power for hydraulic pump.
K. Hose Heating Transformer – Right side, inside of hydraulic tank
Supplies the required voltage for material Heated Hoses
L. Hydraulic Pressure Control
Allows the pressure of the hydraulic system to be increased or decreased. Turn
clockwise to increase the pressure and counterclockwise to decrease. To regulate the
pressure of the hydraulic system, the NORMAL or RETRACT Pump Switch position
must be selected,
M. Inlet Material Strainer
Screens (60 mesh) material from bulk supply.
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MODEL
PUMP SIZE
CYCLES PER GALLON
PH-2, 2000 PSI
123
27
PHX-2, 3000 PSI
61
55
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N. Main Power - Turns ON and OFF main power to the control panel. It must be turned
ON for any operation to be performed with the unit. When turned ON, the red pilot will
light.
O. Emergency Stop - Interrupts the PH- Series control power circuit to stop all motion
and heating.
P. Pump Switch
Off - Removes power from the pump circuit. The directional indicator lights will not be
lit.
Normal - Activates the normal operation of the machine. When the switch is ON, the
directional light corresponding to the stroke direction will light.
Retract - Sets the Piston Rod of the Iso (A) metering pump into the pump to prevent
crystallization of Iso (A) on the Piston Rod. Press the RETRACT key every time the
unit is stopped by the operator (see Shut-Down, page 30).
Q. Direction Indicator Lights - Indicates the movement direction of the Metering Pumps.
If excessive pressure is caused in the system, the pump circuit will be disabled and the
directional lights will be OFF.
R. Control Power - Turns ON and OFF the control power to the complete electrical
circuit including Heaters and Hose Heater.
S. Heater Temperature Switch – A (Iso), R (Poly), HOSE – Turns ON and OFF power
to the specific Heaters and Hose.
T. Temperature Controllers – Displays the temperature of the chemicals. See page 27
for detailed Temperature Controller instructions.
U. Totalizer – Indicates the number of pump cycles to calculate material usage.
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V. Auto Shut Down Switch - Turns ON and OFF power to the Auto Shut Down unit.
W. Auto Shut Down Counter – Used to set the amount of cycles required to prevent the
chemical drums from running dry, the machine will shut down when the preset cycles
expire. There is an on/off switch to activate this feature or deactivate and not use it,
see page 29.
X. Motor Switch - Turns ON and OFF the Electric/Hydraulic Motor. When turned ON,
the pilot will light. In the event of an overload of the Motor, pilot light will turn OFF and
Motor will stop.
Y. Pressure Balance Control Knob – Used to set the maximum allowable pressure
differential (in PSI) between the A (Iso) and R (Poly) pumps. See page 26 for more
information.
Z. Pressure Balance Control “ON” Light – Indicates that the Pressure Balance Control
system is on and functioning.
AA. Pressure Balance Control “FAULT” Light – Indicates that the pressure differential is
equal to or greater than the maximum allowable pressure differential.
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L1
L2
1 phase x 230 Volt
L3
L2
L1
3 phase x 230 Volt
3 phase x 380 Volt
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INSTALLATION
WARNING! Use suitable protection and follow the recommendations in the
Safety Information enclosed and provided by material suppliers when installing
or working with the Proportioner.
Inside the console is a Terminal Strip for connecting the
incoming power cable (not supplied). The electrical connection
of the Proportioner must be performed by a qualified electrician.
NOTE! To ensure the PH Series Proportioner works correctly, the electrical
supply must meet the specifications indicated on the Serial Number Placard
affixed to the Electrical Console.
CAUTION! Make sure the power cable is disconnected from the main power
source before connecting to the Terminal Strip in the Console.
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Follow the recommended procedure in the indicated order to install the Proportioner:
1. 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 above.
2. Fill the Hydraulic Reservoir with 10 gallons (37 Liters) of approved hydraulic fluid. See
page 51 for oil specifications.
NOTE! Do not fill the tank to maximum capacity; use the Visual Level
Indicator on the tank to make sure the amount of hydraulic fluid is not
more than 10 gal (37 L) or 80% of the tank maximum capacity.
3. Check the level of the hydraulic fluid in the Hydraulic Pump Case: Disconnect the
Hydraulic Hose from the 90 fitting and remove Fitting from Hydraulic Case. Add fluid
as required. Reattach Fitting and Hydraulic Hose. Turn the hydraulic pressure control
knob counter clockwise until it stops, that is the lowest hydraulic pressure setting.
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ENSURE THAT THE EMERGENCY STOP IS NOT ENGAGED
4. Three-phase Proportioner Only: Check the Electric Motor to ensure rotation is
clockwise when viewing the end of the Electric Motor. A counter clockwise rotation
indicates two of the incoming power leads need to be reversed.
CAUTION! Ensure Main Power Switch is OFF and incoming power is locked
OFF before reversing power leads.
Recheck rotation before proceeding with Installation.
5. Fill the Lube Reservoir with PMC Pump Lube or suitable diluents. It is not necessary
to prime the system.
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Heated Hose Installation
CAUTION! The material delivery Heated Hoses are color coded Red and
Blue allowing the user to recognize them. The Red corresponds to the
Isocyanate (Iso, A) and the Blue to the Polyol (Poly, R). To avoid connection
errors, the Coupling Connections of the Iso (A) and Poly (R) Heated Hoses
are also different sizes to ensure correct orientation.
NOTE! The material delivery Heated Hoses are capped at the ends to
prevent absorbing moisture. Do not remove caps until the Heated Hoses are
going to be installed on the Proportioner.
1. Lay out all the Heated Hose assemblies end to end aligning the Iso “A” (red) and Poly
“R” (blue) and connect the respective Coupling Connections using the appropriate
sized open-end wrench after ensuring Heated Hose assemblies lay flat.
CAUTION! Take care to not cross-thread or over-tighten the Coupling
Connections. Thread seal tape or compound is not recommended for this
tapered seat Coupling Connections.
2. Connect the material Heated Hoses to the outlets of the respective Heaters i.e. Iso (A)
Heated Hose to the Iso (A) Heater and the Poly (R) Heated Hose to the Poly (R)
Heater ensuring Heated Hose assemblies lay flat.
3. Connect Air Hose Coupling Connections.
4. Connect the Heated Hose power wires to the “Fast-Lock” Connector (Part # KT00029A) coming from the Hose Heat Transformer as follows:
a. Loosen the Socket Head Set Screw to allow
insertion of the Heated Hose electrical wire
Terminal.
b. Insert the Terminal into the “Fast-Lock”
Connector Body.
c. Securely tighten the Socket Head Set Screw.
d. Install electrical tape around Connector Body.
NOTE! A good practice is to add some
dielectric grease (Permatex 67VR or equivalent) to the outside of the
Terminal, where the electrical connection is made, prior to insertion.
Repeat the above steps to connect the “Fast-Lock” Connectors that you will find on all
Heated Hose power wire.
CAUTION! Ensure the proper mechanical and electrical connections of the
Heated Hoses are made to avoid possible material leakage and Hose heat
problems.
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5. It is recommended the TSU be installed between the last section of Heated Hose and
the Gun Whip. Carefully straighten the sensing wire, inserting it in the Iso (A) Heated
Hose and tighten fluid fittings with appropriate sized open-end wrenches.
CAUTION! To protect the TSU sensor, you must pay special attention not to
kink or excessively bend the Heated Hoses. Do not coil the Heated Hoses
with a diameter of less than 4 feet (1.22 Meters).
Temperature Sensing Unit
(TSU) Part # EL-51A
Replacement Sensor Part # EL-51A-2
CAUTION! Connecting the TSU between the first and second section of
Heated Hose results in the TSU sensing the material temperature exiting the
Heater and not the inside of the Heated Hose near the Spray Gun.
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HOSE TAP TO LENGTH CHART*
Tap
Feet
Meters
90v
310
94.5
75v
260
79.5
60v
210
64.0
45v
160
48.8
30v
110
33.5
18v
60
18.3
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6. Hose Heat Transformer
The Hose Heat Transformer offers the ability of connecting to different output voltages
depending on the total length of the Heated Hose in use, maximizing the heating ability of
the Heated Hose. The factory setting is 18 volts for use with 60 feet of Heated Hose.
Before starting the Proportioner, ensure the setting matches the Heated Hose length
installed. If Heated Hose sections are added or removed, the Tap setting should be
changed to a setting which will limit the maximum amperage in the Heated Hose to 52
amps. The suggested settings are tabled below:
*Note: Only the 3KVA transformer is shown above. The 2 KVA and 5 KVA transformers
are also available. See page 10 for technical specifications.
6. Ensure the Manual Valves are CLOSED and connect the Coupling Block to the Heated
Gun Whip.
CAUTION! Excessive force closing or opening the Manual Valves may result
in damage to the Manual Valves and/or Coupling Block.
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7. Connect the Transfer Pump/ Heated Hose Assemblies/ Air Supply and Air Dryer
systems as required. Review the Installation Instructions for each to ensure proper setup and operation.
8. Install the Material Transfer Pumps as follows:
WARNING! If Transfer Pumps have been previously used, pay
special attention to connect each Pump to “its” specific material.
Inadvertently changing the Transfer Pumps will cause a
chemical reaction rendering them useless.
NOTE! Placing a tape of the same color as of the Material
Delivery Hoses (red for the Iso (A), blue for the Poly (R)) on
each Transfer Pump would be a good method for minimizing
errors in connection.
a. Make sure that the Inlet Valves on the Proportioner are closed.
b. Connect one end of the Polyol (R) Material Delivery Hose (¾”
thread) to the Proportioner Polyol (R) Inlet Valve and the other end
to the Polyol (R) Transfer Pump.
c. Connect one end of the Iso (A) Material Delivery Hose (½” thread) to
the Proportioner Iso (A) Inlet Valve and the other end to the Iso
Transfer Pump.
d. Connect the air hose to the Transfer Pumps after ensuring each
Transfer Pump Shut-Off Valve is CLOSED.
NOTE! To avoid errors in connection, the Coupling connections
of the Iso (A) and Poly (R) Material Delivery Hoses are different
sizes, making it difficult to swap connections.
e. Ground the Transfer Pump as recommend by the material supplier.
The movement of product inside the Hoses can cause static
electricity and produce electrical discharges.
f. Connect air to the air line coming off the first section of hose (90-110
psi, 6-8 bar)
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PROPORTIONER PURGING
WARNING! Use suitable Personal Protection Equipment (PPE) and follow
the recommendations in the Safety Information provided by product
suppliers when installing or working with the unit.
WARNING! Do not turn the Temperature Controllers ON until the
Proportioner purging procedure is complete and the Primary Heaters and
Heated Hoses are filled with material.
NOTE! Before using the Proportioner it is necessary to purge the entire
system, including Heated Hoses of mineral oil left over from Quality Control
testing and air. The following procedure is also followed to purge air
entrapped by running out of material in the supply Drum/Reservoirs resulting
in a significant indicated material pressure imbalance as indicated by the
Pressure Gauges and sprayed material.
1. Ensure the following before proceeding:
a. Air supply to Transfer Pumps is 90 - 110 psi (6 - 8 bar)
b. Proportioner Inlet ball Valves are CLOSED.
c. All connections are tight.
d. Material should be stored to the material suppliers' recommended temperatures.
e. Spray gun coupling block is installed and manual valves are closed.
2. Slowly OPEN the Poly (R) Transfer Pump Air Shut-Off Valve allowing Pump to cycle
slowly as it fills the Material Delivery Hose to the Proportioner. Check for leaks.
3. OPEN Poly (R) Coupling Block Manual Valve over a waste container.
4. Slowly OPEN Proportioner Poly (R) Inlet Valve allowing Transfer Pump to move material
through the system. When all spitting of air stops and all traces of mineral oil have
disappeared, CLOSE Poly (R) Coupling Block Manual Valve. Clean Coupling Block.
5. Repeat steps 2 to 4 for Iso (A) side.
CAUTION! Properly dispose of all waste chemicals in accordance with all
applicable local, state and federal codes. DO NOT turn on the Auto
Countdown Switch or the Pressure Balance Control Switch.
6. Turn Hydraulic Pressure Control (L, page 14) full COUNTERCLOCKWISE.
7. Turn ON Main Power (N, page 15). Green pilot will light.
8. Turn ON Control Power (R15, page 15). Switch will light.
9. Turn ON Motor Power (X, page 16). Switch will light.
10. Set Pump Switch (P, page 15) to NORMAL. Turn Hydraulic Pressure Control
CLOCKWISE increasing material pressure to 400 psi (28 bar). Both Material Pressure
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Gauges (E, F, page 14) should approximately read the same. Check all Heated Hose
Coupling connections for leakage.
11. Check all TSU and “Fast-Lock” connections for leaks.
12. Bundle all Heated Hose Connections ensuring that there are NO kinks in the TSU
Cable or Air Hose. Wrap with Electrical Tape to securely hold all components in place
and minimize places for bundle to snag onto job site protrusions.
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PRESSURE BALANCE CONTROL
The PH Series Proportioner has been designed with a pressure balance control system. This
system will give the operator of this machine the ability to control a pressure imbalance within
certain predetermined parameters.
The system consists of:
Selector Switch
Fault Light
On Light
Control Unit
Pressure Transducers
Relay
Operation
Position the selector switch on one of the three options:
Pressure differential number – these consist of 300, 400, 500, 600, and 700 PSI.
Selecting any of these numbers with the switch will activate the green ON light. While
the pressure differential numbers are selected, the control box will continually monitor
pressure on both sides of the Proportioner. In the event that the pressure differential
between both sides of the Proportioner is equal to or larger than the selected number,
a fault is given (the red fault light is turned on and the active green light is turned off)
and shuts down.
Off – if the selector switch is placed in this position, the Proportioner will operate as
though there is NO PRESSURE BALANCE CONTROL SYSTEM (neither the red fault
light nor the active green light will be lit). The over pressure system will remain active
for the machine and personnel protection.
Reset – in the event of a pressure imbalance, resolve the Proportioner imbalance,
position the selector switch on reset to clear the fault light and restore power to the
Proportioner. After the fault has been cleared, position the switch in either a Pressure
Differential number or in the Off Position to continue operations.
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DIGITAL TEMPERATURE CONTROLLER
The PH Series has three (3) Digital Temperature Controllers to manage the temperatures
for the Primary Heaters and the Heated Hose. The Hose Heater Controller is
programmed differently from the heater Controllers and therefore not interchangeable with
them.
WARNING! Do not turn the Temperature Controllers ON until the
Proportioner Purging procedure is complete and the Primary Heaters
and Heated Hoses are filled with material.
1. Ensure Main Power (N, page 15) and Control Power (R, page 15) is ON.
2. Press and release or button. The display will flash and indicate its current
set point.
3. Press and hold the or to increase or decrease the material temperature
set-point to the desired value as determined by the material supplier or application
conditions.
4. Once the set point is entered the controller will go back to ambient temperature on its
own.(5-8 seconds)
WARNING! The Controllers are factory programmed and are not field re-
programmable. If a problem is encountered, contact your authorized
distributor. Do not attempt to change any of the programmed parameters. Do
not substitute a Controller from an alternate supplier as its use may result in
equipment damage and/or bodily injury.
NOTE! The Temperature Controller normally displays the actual material
temperature. When lit, the red “OUT” display in the upper left indicates power
is being sent to the Heater. The “OUT” display goes out when the material
temperature has reached its set-point. The “OUT” display will continue to
cycle on and off indicating the Controller is maintaining the material
temperature set-point.
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